Pacific Scientific 6410-024-N-N-N DC Servo Motor

Technical Specifications:

• Model Number: 6410-024-N-N-N
• Manufacturer: Pacific Scientific (Altra Industrial Motion)
• Motor Type: Brushless DC Servo Motor (BLDC)
• Frame Size: 40 mm (1.57 in) square flange
• Rated Voltage: 24 VDC
• Continuous Torque: 0.28 Nm (2.5 lb-in)
• Peak Torque: 0.84 Nm (7.4 lb-in)
• Rated Speed: 3000 RPM (no-load)
• Maximum Speed: 5000 RPM
• Power Rating: 75 W continuous, 225 W peak
• Feedback Device: Resolver (12-bit resolution)
• Winding Configuration: Standard (N)
• Gear Ratio: 1:1 (Direct Drive, no gearbox)
• Phase: 3-phase
• Commutation: Electronic (Hall sensor or resolver-based)
• Insulation Class: Class H (180°C)
• Protection Rating: IP40 (dust protected, no water ingress)

Functional Features:

• Resolver Feedback: Provides absolute position data at all times; no homing required after power loss
• Brushless Construction: Eliminates brush wear; delivers >10,000 hours MTBF
• Low Cogging Torque: Smooth rotation at low speeds; ideal for precision positioning
• High Torque-to-Inertia Ratio: Fast acceleration and deceleration for dynamic motion profiles
• Wide Speed Range: Operates from 0 to 5000 RPM with constant torque up to 3000 RPM
• Overload Capability: Sustains 3× rated torque for 60 seconds without damage
• Thermal Protection: Internal PTC thermistor triggers motor shutdown at 155°C winding temperature
• EMI Shielding: Built-in EMI filter reduces electromagnetic interference to compliant levels
• Multiple Feedback Options: Resolver standard; encoder variants available in series
• Standard Connector: MIL-DTL-5015 connector for power and feedback signals

Performance Parameters:

Material Composition:

• Stator Laminations: M19 silicon steel (0.35 mm thick) for low core loss and high permeability
• Stator Windings: Class H (180°C) magnet wire (polyimide-coated copper)
• Rotor Magnets: Samarium Cobalt (SmCo) sintered magnets for high-temperature stability
• Rotor Core: High-strength carbon steel with epoxy bond for mechanical integrity at high speed
• Housing: 6061-T6 aluminum alloy with anodized finish for corrosion resistance
• Shaft: AISI 4140 alloy steel, ground and polished, with keyway
• Bearings: Sealed ball bearings (608ZZ, 8 mm bore) rated for 10,000 hours L10 life at 5000 RPM
• Resolver: Copper windings on silicon steel laminations with stainless steel housing
• Connector: MIL-DTL-5015 stainless steel shell connector with gold-plated contacts
• Thermal Sensor: PTC ceramic thermistor embedded in stator winding
• Seals: Nitrile rubber (NBR) shaft seal and housing gasket

Structural Features:

• Square Flange Design: 40 mm × 40 mm mounting flange with 4 threaded mounting holes (M4 × 0.7, 32 mm BCD)
• Hollow Shaft Option: Available with 8 mm bore through shaft for cable routing (variant dependent)
• Keyed Shaft: 2 mm × 2 mm keyway on 8 mm diameter shaft for coupling attachment
• MIL Connector: 10-pin MIL-DTL-5015 connector on rear end for power (3 wires) and resolver feedback (4 wires)
• End Bell: Aluminum end bell with integrated bearing housing on both drive and resolver ends
• Ventilation: External cooling fan mount on non-drive end for forced air cooling at high duty cycles
• Labeling: Nameplate riveted to housing with model number, serial number, and rating data
• Balancing: Dynamic balanced to G2.5 (ISO 1940) for smooth operation at 5000 RPM
• Surface Finish: Military-spec anodized coating (Type III hardcoat, 25–50 µm)

Working Principle:
The Pacific Scientific 6410-024-N-N-N operates on the principle of electronic commutation of a 3-phase brushless DC motor. The stator contains 3 sets of windings energized sequentially by an external servo drive. The Samarium Cobalt permanent magnets on the rotor interact with the stator’s rotating magnetic field to produce torque. Rotor position is detected by the integrated resolver, which outputs sine and cosine signals proportional to shaft angle. The resolver signals are processed by the servo drive to determine the exact rotor position at all times, enabling precise commutation timing. The drive applies PWM (Pulse Width Modulation) voltage to the stator windings, controlling average current and thus torque. The PTC thermistor monitors winding temperature; if temperature exceeds 155°C, the drive reduces current or shuts down the motor to prevent insulation damage. The resolver provides absolute position feedback without requiring a homing sequence, as the resolver outputs the exact angular position at power-on.

Advantages and Highlights:

• Absolute Position via Resolver: No homing required after power loss; position is known immediately at startup
• Brushless Design: Zero brush wear; MTBF >10,000 hours; maintenance-free operation
• Samarium Cobalt Magnets: Superior high-temperature performance compared to Neodymium; stable up to 300°C
• High Torque Density: 0.28 Nm in a 40 mm frame; excellent power-to-size ratio
• Low Cogging Torque: Smooth motion at low speeds; ideal for precision positioning and scanning applications
• Wide Speed Range: 0–5000 RPM with constant torque to 3000 RPM
• 3× Overload Capacity: Handles 0.84 Nm peak torque for 60 seconds for dynamic load conditions
• IP40 Rating: Dust-protected; suitable for clean industrial environments
• MIL-Spec Connector: Rugged, lockable connector for harsh industrial environments
• Class H Insulation: Operates reliably at elevated temperatures up to 180°C winding temperature
• Dynamic Balancing: G2.5 balance grade ensures smooth operation at maximum speed

Applicable Industries:

• Robotics: Joint actuators, end-effector drives, mobile robot wheel motors
• CNC Machining: Spindle drives, axis feed motors, tool changer actuators
• Semiconductor Equipment: Wafer handling, die bonding, inspection stage drives
• Medical Devices: Surgical robots, CT gantry drives, lab automation
• Aerospace and Defense: Gimbal actuators, antenna positioning, UAV motor drives
• Packaging Machinery: High-speed labelers, filling machines, conveyor drives
• Printing and Converting: Web tension control, registration drives, cutter motors
• Textile Machinery: Yarn feeders, loom drives, winding motors
• Automated Guided Vehicles (AGV): Wheel drive motors for warehouse logistics
• Optical Equipment: Lens positioning, mirror galvanometer replacement drives

Model Series:

Installation Requirements:

• Mounting Orientation: Any orientation (horizontal, vertical, shaft-up, shaft-down); bearings support all positions
• Mounting Flange: 40 mm square flange with 4× M4 mounting holes on 32 mm BCD; use M4 × 12 mm socket head cap screws with 8 Nm torque
• Coupling: Use flexible coupling (jaw or bellows type) to accommodate ±0.1 mm misalignment; rigid coupling requires <0.02 mm alignment tolerance
• Shaft Key: Install 2 mm × 2 mm × 6 mm key in shaft keyway; use keyway locking compound (Loctite 641)
• Cable Routing: Route cables through hollow shaft (if equipped) or external cable carrier; minimum bend radius 5× cable diameter
• Connector Mating: Mate MIL-DTL-5015 connector fully until bayonet lock engages; do not force connection
• Grounding: Connect motor housing to equipment grounding conductor; ground resistance <0.1 Ω
• Ambient Conditions: Install in environment <40°C (104°F) for continuous operation; derate above 40°C
• Ventilation: Ensure minimum 50 mm (2 in) clearance around motor for airflow if using external fan
• Torque on Fasteners: Tighten mounting screws to 8 Nm (71 in-lb); re-torque after 24 hours of operation

Usage Precautions:

• Do not exceed 5000 RPM maximum speed: Overspeed will cause bearing failure and rotor disintegration
• Do not apply radial load exceeding 50 N (11.2 lbs): Excessive radial load damages bearings and reduces MTBF
• Do not apply axial load exceeding 25 N (5.6 lbs): Axial thrust beyond rating destroys bearing preload
• Do not operate without servo drive: The motor requires an external 3-phase PWM servo drive; do not connect directly to DC power supply
• Do not disassemble the resolver: The resolver is sealed; opening it voids calibration and accuracy
• Do not exceed 155°C winding temperature: The PTC thermistor triggers shutdown at this threshold; repeated thermal trips degrade insulation
• Do not use compressed air to clean: Blowing debris into bearings causes premature failure; use lint-free cloth with isopropyl alcohol
• Do not submerge in liquid: The motor is rated IP40 (dust protected, no water); liquid ingress destroys windings
• Do not paint the housing: Paint covers ventilation slots and increases operating temperature; voids warranty
• Lubricate bearings only if specified: Bearings are sealed for life (608ZZ); do not re-lubricate
• Verify phase sequence before first run: Incorrect phase sequence causes reverse rotation; correct sequence per drive manual
• Perform insulation test before first use: Measure >100 MΩ at 500 VDC between windings and frame; replace motor if below threshold
• Derate torque by 15% at 40°C ambient: Above 40°C, continuous torque must be reduced to prevent overheating
• Store with shaft protected: Install protective cap on shaft during storage to prevent bearing contamination and corrosion
• Replace after 10,000 hours or 5 years: Even if functional, bearing life and magnet stability degrade over time; replace per preventive maintenance schedule