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Kollmorgen XPL-230-40
Product Series: XPL Series — Ultra-High-Performance AC Servo Motor
Product Introduction:
The XPL-230-40 represents the pinnacle of Kollmorgen’s AC servo motor technology in the 230mm frame class. Delivering 40 Nm continuous torque with extraordinary dynamic response, this motor is designed for the most demanding high-speed, high-acceleration motion control applications where every millisecond counts.
Detailed content
Model Designation Breakdown:
- XPL = XPL Series (Ultra-Performance AC Servo)
- 230 = Frame Size 230
- 40 = Continuous Torque Rating 40 Nm
Technical Specifications:
| Parameter | Value |
|---|---|
| Frame Size | 230 mm |
| Continuous Torque | 40 Nm |
| Peak Torque | 120 Nm (3× rated, 10s) |
| Rated Speed | 2500 RPM |
| Rated Power | 10.5 kW (14.1 HP) |
| Supply Voltage | 480 VAC (3-Phase) |
| Frequency Range | 0 – 500 Hz |
| Motor Type | AC Synchronous (Permanent Magnet) |
| Cooling Method | Liquid Cooled (standard) |
| Encoder Type | Multi-Turn Absolute, EnDat 2.2 |
| Encoder Resolution | 2048 lines (8192 counts/rev) |
| Protection Class | IP65 (with connector) / IP44 (standalone) |
| Insulation Class | Class F (155°C) |
| Weight (approx.) | 30 kg |
Material Composition:
- Stator Core: Ultra-low-loss amorphous metal or premium silicon steel (0.2mm laminations)
- Stator Windings: Litz wire construction for reduced eddy current losses at high frequency
- Rotor: High-temperature NdFeB magnets (180°C class, Dy-enriched for coercivity)
- Housing: High-pressure die-cast aluminum with internal cooling channels
- Shaft: Forged 42CrMo4 alloy steel, nitrided surface (HRC 60+), super-finished (Ra < 0.4μm)
- Bearings: Ceramic hybrid bearings (Si3N4 balls) for high-speed capability
- Seals: Double-lip Viton seals with labyrinth design
Structural Features:
- Optimized electromagnetic design — minimized iron losses at 500 Hz
- Hollow shaft standard — bore diameter 80mm for direct-drive integration
- Dual feedback system ready — primary + Hiperface safety encoder
- Integrated motor temperature monitoring — 3× PTC sensors (U/V/W phases + bearing)
- Compact terminal box — 2× M20 + 1× M16 cable entries
Working Principle:
The XPL-230-40 operates as a high-frequency permanent magnet synchronous motor. The servo drive outputs sinusoidal three-phase currents up to 500 Hz, enabling the motor to reach speeds far beyond the rated 2500 RPM through field weakening. The EnDat 2.2 encoder provides deterministic, high-resolution position data with CRC error checking. The liquid cooling system actively removes heat from both stator windings and rotor, enabling sustained 40 Nm output without derating. The ceramic hybrid bearings reduce friction and heat generation at high speeds, extending service life.
Key Advantages:
- Highest torque in 230mm class — 40 Nm continuous, 120 Nm peak
- 500 Hz operation — extended speed range for high-speed machining
- Ceramic hybrid bearings — 50% longer life vs. steel bearings at high speed
- Hollow shaft standard — eliminates backlash from gearboxes
- Litz wire windings — superior efficiency at high frequencies (>95% at rated point)
- Deterministic EnDat 2.2 — cycle time < 1μs, zero position loss
Applicable Industries:
- Ultra-High-Speed CNC Spindles (>40,000 RPM equivalent)
- High-Acceleration Pick-and-Place Robots
- Semiconductor Wafer Handling
- Aerospace Test Equipment
- High-Speed Printing & Coating Lines
Installation Requirements:
- Mount on vibration-damped base — resonance frequency > 2× operating frequency
- Hollow shaft coupling: Use shrink-fit or clamping hub, concentricity < 0.02mm
- Cooling system: Glycol-water (40% glycol), flow min. 5 L/min, pressure 2.0 bar ± 0.5 bar
- Encoder cable: Use Kollmorgen shielded EnDat cable, max length 10m (extend with repeater if needed)
- Torque arm required for hollow shaft to react torque
Usage Precautions:
- Do not exceed 500 Hz input frequency — core saturation causes overheating
- Coolant flow is mandatory — motor will fault within 30 seconds without flow
- Do not use V/Hz drives — requires true sinusoidal servo drive (AKD/AKM compatible)
- Bearing replacement interval: 10,000 hours (with proper lubrication and alignment)
- Store in dry environment — NdFeB magnets corrode if exposed to moisture
