Aerotech Ndrive HLe maintenance replacement

The feedback connector also includes motor over temperature input, encoder fault input, 5V encoder and limit power supply, and brake output. A thermistor with a normal resistance of about 100 Ω triggers an over temperature fault when it exceeds about 1 k Ω. Encoder fault input is used for encoders with fault output, and the effective state can be parameterized. The brake output can be connected to the brake power supply and brake coil. The brake coil must be equipped with a suppression circuit to avoid high-voltage transient damage to relays or solid-state switches.

PSO, MXH and multi axis laser triggering

PSO position synchronization output is a key function of HLe in laser processing, visual inspection, and aerial photography. HLe standard supports single axis PSO, with optional dual axis and three-axis PSO. The trigger signal can come from the autoencoder, auxiliary encoder, SSI Net, or software trigger. The maximum single axis tracking rate can reach 20 MHz, with a trigger delay of about 200 ns; the dual axis and three-axis PSO delay is about 275 ns, and the multi axis tracking rate is limited to 5 MHz. The PSO hardware uses FIFO queues internally, programmable pulse configuration, window mode, data capture, and data update modes.

The MXH encoder has a maximum multiplier of x65536 and supports real-time orthogonal output, making it suitable for systems that require high resolution and encoder cascading. When using a dual axis or three-axis PSO, if the encoder data rate is too high, the PSO tracking rate should be limited to 5 MHz through parameters while maintaining full resolution of the servo loop. The MXH programming and erasing cycle is about a few minutes, during which the LED will flash and the axis cannot be enabled. After changing the multiplication parameter, you must wait for the cycle to complete.

HLe also supports SSI Net for daisy chain encoder signals, which sends the second/third axis encoder to drivers with dual/three-axis PSO. SSI Net has a maximum data rate of 20 MHz and requires the use of dedicated cables and parameter configuration. If the original device uses multi axis laser triggering, these cables and parameter configurations must be retained during replacement. PSO and MXU are mutually exclusive on some models, while HLe is compatible with PSO and real-time output when using MXH.

Rotary, Absolute Encoder, and I/O Expansion

HLe optional rotary interface, providing 1 or 2 channels, 16 bit resolution, and carrier frequency options of 10 kHz, 7.5 kHz, or 5 kHz. Rotary feedback is suitable for harsh environments, high vibration, or high-temperature situations. When using spinors, Sine and Cosine signals should be adjusted to 2 V RMS (2.8 V peak) and gain, offset, and phase should be optimized through parameter optimization. The commutation initialization of brushless motor rotary feedback can be achieved through R/D automatic configuration or Hall initialization. R/D automatic configuration is usually not suitable for Inductosyn because it has multiple electrical cycles per revolution. In dual loop mode, the position source generates commutation initialization, while the speed source maintains commutation position.

In terms of absolute encoders, HLe supports Renishaw Resolute BiSS, EnDat 2.1, and EnDat 2.2. The absolute encoder can directly read the position after power on without returning to zero, making it suitable for devices that cannot be moved or require quick startup. When replacing, it is necessary to confirm that the original encoder protocol matches the HLe option.

In terms of I/O expansion, HLe's expansion board provides 16 digital inputs, 16 digital outputs, 3 16 bit analog inputs, and 3 16 bit analog outputs. Digital I/O optical isolation, can be sourced or sung, but the same group must be configured uniformly. Analog input ± 10 V, 16 bit differential, analog output ± 10 V, 16 bit. The high-speed data capture delay is about 50 ns, suitable for high-speed sampling and position locking. HLe can choose Ethernet and supports Modbus TCP and Ethernet/IP for connecting third-party I/O modules. ML does not provide Ethernet, but both support FireWire network with a speed of 400 Mbps. Star daisy chain is recommended, with a maximum of 32 axes and a maximum of 16 drivers per chain.

Engineering process for replacing discontinued modules

When replacing discontinued Ndrive HLe or other brands of linear servo modules, it is recommended to follow the following sequence:

Record the original module parameters: model, peak/continuous current, bus voltage, motor power supply, control power supply, feedback type, communication interface, I/O quantity, PSO axis number, encoder multiplier, brake output, ESTOP logic, size, and heat dissipation.

Match motor: confirm brushless, brushed, stepper or voice coil; Confirm pole pairs Hall、 Encoder resolution, rotary or absolute encoder. If the original system uses a rotary converter, HLe needs to choose RDP; If using an analog sine encoder, choose MXH.

Confirm power supply: HLe uses 115/230 VAC motor power supply and 85-240 VAC control power supply; ML uses DC motor power supply and 18-36 VDC control power supply. If the original system is powered by AC and requires a rotary converter, multi axis PSO, or Ethernet, HLe is more direct.