F3Studio for Physis New Energy Technology
Operating manual for electric motors.
Physis new energy technology.
360° engineering of a motor: hardware, mechanics, layout and software.
Physis new energy technology, based in Genoa, provides solutions for the automation sector.
One of the company’s strengths is its integral approach to the design of their products.
Physis, in fact, manages all phases of product development. From the design of the hardware and firmware, through to component selection, product layout design, mechanical component dimensioning and even software development.
In the development of the IML electric motor range, Physis partnered with F3Studio for the operating manuals.
We are very satisfied with F3Studio’s professional attitude and ability to work independently.
Physis New Energy Technology
Independent electric motors that can be connected in a series circuit
High performance at low cost.
To achieve this, the Physis R&D team designed a motor capable of operating at lower voltages than usual, at 400V DC. This solution makes it possible to limit costs (especially on the power supply system) and also provides better insulation against electromagnetic interference.
With the decentralisation of the drive system, now located directly on the motor, the system architecture has been simplified: we therefore have reduced wiring, and a more linear motor design.
Although each motor is independent, including its own encoder and servo control, the hardware and software architecture allows up to 5 motors to be connected in series, using a single power supply.
In this way, systems capable of operating on multiple axes can be easily created.
The electric motors in the IML line are designed for use in various industrial sectors, such as glass, stone, wood and sheet metal processing, packaging, food and beverage packaging, through to robotics and aerospace.
Two wiring solutions.
The motors are controlled via an EtherCAT field bus, and an external battery stores the position of the various motors even in the event of a power failure.
It is possible to wire the system in two different ways:
– Hybrid Cable technology. A single cable transmits the signals and simultaneously powers the device.
– Near-by solution. The power cable goes to the motor, while the signal cable goes to the control unit.
In the latter case, the cable connectors are marked in different colours to prevent incorrect connection.
What F3Studio did.
Called upon by Physis to produce the user and maintenance manuals for the IML series of electric motors, F3Studio began its work by identifying, and studying, the applicable regulations.
In addition to producing the user and maintenance manual, F3Studio prepared the certificate of incorporation, as these motors are considered by the regulations as ‘partly-completed-machine‘.
F3Studio’s work culminated in the creation of nameplates, compliant with current regulations, to be affixed to the motor encoder batteries.
Objective 1: Easy-to-understand manual
When creating this manual, F3Studio set itself two main objectives.
The first challenge was to create a manual that would be easy to read even for an operator without the knowledge of the team that designed the engine.
Despite its small size, this is a product whose creation requires multidisciplinary skills. The principles of operation and design of an electric motor are spread across various fields of engineering: electromagnetics, mechanics, electronics, the mechanical and technological properties of the materials chosen, through to the connections and software/hardware computer interfaces that enable these motors to be programmed.
Objective 2: A single manual for various configurations.
The other challenge was to create a single manual covering the various possible configurations. In this case, the motors of the IML series are available
– either as stand-alone motors, or connected in series.
– with, or without, a brake.
– in two different wiring configurations.
F3Studio has therefore optimised the manual modules in order to cover all cases in a streamlined manner, without duplicating parts or creating redundancies that would complicate finding information and reading the manual.
Of course, connection and installation procedures for mechanical and electrical parts have been included, as well as cable descriptions, including cutaways identifying the function of each pin.
Even for the connection ports, some drawings guide the operator in correctly understanding the function of each port.
Safety and operating conditions.
If the two points seen above were the objectives F3Studio had set for this manual, the safety aspect is a basic prerequisite on which F3Studio pays particular care and attention in every manual it produces.
Good drafting of the safety-related sections and procedures is a prerequisite for a good manual that complies with regulations.
In this manual, the risks connected with the use of these motors have been explained, both those due to voltage and the risks connected with the high temperatures to which the motor could reach during use.
Given the presence of certain residual risks, danger and warning signs have been placed in a visible position on the components.
The manual gives a description of the pictograms, indicating which prescriptions and procedures to follow to limit the residual risks.
The manual also indicates the operating conditions, such as temperature and humidity, under which the engines can be safely operated, stored and transported.
The description of the interface between the user and the machine is always an important point in any manual, as it is necessary to know both how to connect to the machine and how to interpret the various error signals.
In this case, F3Studio has listed the possible error codes that the motor can return, indicating with a legend what they mean and how to solve the fault.
The IML motors designed and built by Physis can be connected either via USB or via Ethernet over EtherCAT, using a standard communication protocol widely used in the field of industrial automation.
By consulting the manual, you can easily update the firmware, perform real-time diagnostics, read the various motor parameters and program them.
F3Studio has more than 20 years of experience gained in various sectors: from the luxury sector to the mechanical industry, from the railway sector to the lighting industry, from packaging to machine tools, from automotive to marine.
Having worked with numerous realities, F3Studio is able to adapt to its clients’ methodology in a non-invasive manner, operating in extreme autonomy.