­Iron Core and Coiling Technology

To improve motor performance and efficiency, it is important to develop materials and use technology for iron cores and coils that affect performance. In motors, iron and copper loss decrease efficiency. The optimization of the iron core shape, the selection of the plate thickness, and the adoption of low-loss materials are effective ways of reducing iron loss.
High-density coiling technology can reduce copper loss; hence, we have pioneered the split iron core technology and applied high-density coiling to our products. For that purpose, we are working on the development of higher-performance coilings, such as pressurized coiling technology, a high-density coiling technology that improves the occupancy rate by press-forming copper wires after being wound into coils.

­Simulation Technology

In the development of motor technology and products, optimal design techniques are applied, using magnetic field, heat, and structure simulations. For example, in magnetic field analysis, the motor’s magnetic circuit is optimized to increase torque and reduce loss. Thermal analysis can lead to smaller motors by optimizing the motor’s cooling structure. In addition, the motor can be highly accurate and efficient by adopting a design that incorporates coupled simulation technology where data is exchanged between various analyses for optimization.

Control technology is used to precisely control three elements of an object – position, speed, and torque – in response to commands received from the controller. This technology is built into the servo amplifiers and AC Drives/inverters, making it the basic technology for rotating objects in motor drives

­Sensorless Control

FA (factory automation) equipment is frequently installed in environments that harm its operation, such as dust and high temperatures. Sensorless control technology, which can estimate the magnetic pole position without using a position or speed sensor, prevents equipment failure and operates equipment normally even in harsh conditions. Sensorless position estimation methods include estimating the current and terminal voltage flowing through the motor based on a mathematical model of the motor and superimposing the sensing signals on the current driving the motor.

­Auto-Tuning Technology

Auto-tuning technology is applied to adjust the motion control automatically without manual intervention. It automatically measures the operating constants, such as the motor’s coiling or the load’s inertia, and adjusts them to the optimum constant to obtain a stable response, thus, greatly reducing the process required to set up equipment.

In absolute encoders that can detect the absolute value of the rotation angle by the optical slit’s pattern, a battery is used to guarantee operation even when the power is turned off. However, battery usage is subject to maintenance requirements and rising costs. To solve this situation, we develop a batteryless technology that allows us to detect multiple revolutions without batteries, rather through magnets and coils in the encoder, and store them in non-volatile memory, even when the power is off.

­Batteryless Encoder

In absolute encoders that can detect the absolute value of the rotation angle by the optical slit’s pattern, a battery is used to guarantee operation even when the power is turned off. However, battery usage is subject to maintenance requirements and rising costs. To solve this situation, we develop a batteryless technology that allows us to detect multiple revolutions without batteries, rather through magnets and coils in the encoder, and store them in non-volatile memory, even when the power is off.

When using the Internet in an office, communication speed is important. However, FA requires speed and reliable communication at regular intervals without delay. The requirements for FA equipment are to be fulfilled by a system including software and hardware. Therefore, we develop design and verification technology for ASIC (Application Specific Integrated Circuit), which is an IC chip for specific applications, to bring out the performance of FA devices for motion control and FA communication.

­MECHATROLINK

MECHATROLINK, one of the communication networks (field networks) for FA equipment developed by Yaskawa, is an international standard for industrial communication networks. Its main feature is the synchronous control of multiple motors from the controller, thanks to the technology that ensures the synchronicity of all connected devices. In addition, the transmission reliability in FA is improved by the retransmission processing technology that automatically performs retransmission without losing synchronization even if a communication error occurs due to noise or other factors. We develop an ASIC for motion control that achieves these features, and thereby ensure the performance of MECHATROLINK.

­Σ-LINK II

The encoder, which is mounted on the other side of the motor shaft, is a sensor type that is connected to the amplifier in pairs using cables. Conventionally, a system with multiple motors, such as robotics, requires as many cables as motors. However, the Σ-LINK II represents a communication technology that connects multiple motors in multiple stages (cascade connection) while maintaining highly functional and reliable communication. The Σ-LINK II can be connected in multiple stages by mixing motors and sensors, I/O devices, and other equipment installed on the machine side. This enables the system to achieve high performance, high functionality, and minimal wiring.