Design and Manufacture a Power Distribution Module
PROBLEM DIFFICULTY GETTING POWER TO MULTIPLE MOTORS WITHOUT COMPLEX WIRE HARNESSNG
Motion systems are critical components to most applications whether in aerospace, medical, automotive, or industrial automation. As motion components and systems become more complex, companies struggle with a variety of concerns, including a safe method for running power to devices with-out having to come up with multiple cable and wiring strategies that not only complicate installation but also maintenance and repair down the line.
Both source and auxiliary power needed for many integrated devices in a motion system typically run from 24 VDC to 60 VDC with current ratings up to 4 amps per device. Until recently, the current architecture for power, communications, and I/O for motion systems required a wire harness bundle for each motor/device (see Fig. 1). This configuration increased the need for additional wiring, adding complexity to an application’s design, and posed safety issues along the way.
SOLUTION DESIGN AND MANUFACTURE A POWER DISTRIBUTION MODEL
Increased motion system complexity due to networking capabilities has created a greater need for a well-designed power distribution module. Novanta IMS has Developed and manufactured its PDM-60 primarily to provide simpler and cleaner cable management strategies inside a motion system application (see Fig. 2). Each module can be located next to up to four LMD motors and requires only one power cable to run back to the control panel rather than four separate cables.
The power cables—also available from Novanta IMS—handle the 24 VDC to 60 VDC input voltage with current ratings up to 16 amps (4 amps per channel). The main input connection to the power distribution module uses an L-coded M12 connector, while each channel connection on the power block uses an A-coded M12 connector. For applications where power must be delivered over longer distances, this solution is of particular interest as this design takes advantage of the higher current-carrying capability of the L-coded input cable while still providing a smaller, more flexible output cable that connects to each LMD in the group (see Fig. 3).
The PDM-60 was also designed to provide valuable input power diagnostics using a series of LEDs located on each output channel of the PDM-60 for both main and auxiliary power to each connection point. The overall structure of the power block carries a minimum ingress protection (IP) rating of IP67. Unused channels on the power module should be protected through the use of IP67 rated plug covers. This approach eliminates the need for coming up with complex wiring strategies and allows customers to easily drop power into an existing application for greater capabilities.
The PDM-60 power distribution modules are compact devices that provide an excellent range of input voltage and current supply capabilities. They are made of durable plastic, with rugged M12 industrial connectors, designed to reside right next to the devices they supply power to on the application itself. The power blocks are CE rated as well as RoHS and REACH compliant. Multiple variations of cables are avail-able based on the application considerations needed to be met.
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