Z5MJ-150 5 Pole Pairs Series

Servo Control Systems for High Speed Rapid Roll Door

 

TONGHANG Industrial fast door servo control system has significant advantages. It uses advanced servo drive technology, and the door opening and closing speed reaches 1-2.5m/s, which is more than 30% higher than the traditional system. It supports high-frequency use and runs stably more than 500 times a day, effectively improving work efficiency. Its high-precision position control function has a positioning error of less than ±5mm. With the encoder, it can flexibly adjust the operation curve to ensure stable operation. It is also equipped with multiple protection devices such as infrared sensors and airbags, combined with fault diagnosis functions, to protect operational safety in all directions. It can also be seamlessly connected with PLC and Internet of Things platforms, realize intelligent control and data management through multiple terminals, store multiple operation modes, and meet the needs of multiple scenarios.

Z5MJ-150 Series Specifications/Application Guide
Technical description/Parameter values
Specifications	Z5MJ-150	Power output	1.5kW
Input Voltage	220V±10%	Input Frequency	50Hz
Motor Rated Current	9.0A	Motor Rated Torque (N·m) (Motor with 5 pole pairs)	5.4 N·m (1.7x Overload Capacity)
Motor Rated Maximum Speed (RPM) (Motor with 5 pole pairs)	3000rpm	Motor Protection Rating	IP65
Standard Power Line/ Encoder Cable Length (m)	3.5m	Limit Switch (Encoder) (Magnetic Encoder Bit)	2500-line Optical Absolute Encoder
Self-locking Method	Electronic mechanical brake	Ambient Temperature (℃)	(-20~50)℃
Control Box Dimensions (mm)	362mm(L)*251mm(W)*110mm(H)	Motor size	Refer to Dimensional Drawing for Accuracy
Reducer	RV63
Control Panel Functions
Display Screen	4.3-inch Programmable Touchscreen	Door Opening/Closing Speed Setting (RPM)	Motor Rated Speed
Door Opening/Closing Acceleration/Deceleration Setting (ms)	/	Automatic Door Closing Delay Time (s)	0-300秒(s)
Partial Door Opening Height (%)	Customizable Height within Limit Range	Operation Status Display Selection	Main Interface
Control Panel Expansion Functions
Language Display	Chinese & English Chinese & English (Other languages customizable)	Jog Mode	(√)
Historical Fault Inquiry	(√)	Interface Logic Switching (NC/NO)	(√)
Motor Forward/Reverse Operation	(√)	Low Temperature Anti-freeze Function	(√)
Control Box Interfaces
Network Communication Interface	RS485	Safety Protection Signal Input	Emergency Stop Action
Automatic Full Opening Signal Input	(√)	Partial Open Signal Input	(√)
Single-button Cycle Control	(√)	Interlock Input	(√)
Programmable Relay Output	2 Sets (Expandable)	Programmable Diode Output	2 Sets (Expandable)
Manual/Automatic Switching Input	Touchscreen Switching	Emergency Stop Input	(√)
Supported limit types	Motor with Built-in Multi-turn Absolute Encoder

 

As an industrial fast door servo system manufacturer, what solutions can we bring to you?

 

High Precision

 

Traditional servo control systems often cause cumulative errors in door operation due to insufficient encoder accuracy or algorithm lag, and frequently cause problems such as deviation and positioning offset. Especially in high-frequency switching scenarios, regular shutdown and debugging are required. We have improved positioning accuracy to the industry-leading level through triple technological innovation. ​

Equipped with a 24-bit absolute encoder, the resolution is 256 times higher than the 16-bit encoder commonly used by peers. It can capture the angle change of 0.001° of the motor in real time. With the self-developed "dynamic error compensation algorithm", it can automatically correct the slight deviation caused by track friction and temperature changes, ensuring that the positioning error of the door is still controlled within ±1mm after 100,000 operations.​

 

The dual closed-loop control architecture is adopted, and the position loop redundancy check is added on the basis of the current loop and speed loop. The motor feedback signal and the theoretical trajectory are compared in real time through a high-speed chip (operating frequency of 1MHz). When encountering interference, the correction can be completed within 0.1 seconds, completely eliminating the hidden danger of "power failure and loss of position" - even if the power is off for 72 hours, the door position memory accuracy remains 100%, and no recalibration is required after power is turned on. ​

 

Safety protection

 

In industrial scenarios, safety accidents often originate from control system response delays or protection logic loopholes. We build a closed-loop protection system from the three links of "prevention - monitoring - emergency", which is a full-scale upgrade compared to the single safety function of peers. ​

 

At the prevention level, the system has a built-in AI behavior prediction module. By analyzing the door running speed and obstacle movement trajectory (such as sudden intrusion of personnel and emergency stop of vehicles), the deceleration command is triggered 50ms in advance, which is twice the 100ms response speed of traditional infrared sensing.​

 

The monitoring link innovatively adopts multi-sensor fusion technology. In addition to the standard infrared photoelectric and airbag, the new "sound wave vibration monitoring" function is added. When the door body encounters an abnormal impact (such as cargo scratches), it can instantly identify the difference in vibration frequency and trigger a protective door stop. However, peer products mostly rely on a single sensor and are easily interfered by dust and strong light. ​

 

In terms of emergency mechanism, it is equipped with a dual-channel independent brake system. When the main brake fails, the backup mechanism starts within 0.05 seconds, and the braking force reaches 150N (the average of peers is 80N), ensuring that the 3-meter-high door body is completely braked within a 1-meter fall distance. It has passed the EU EN 13241-1 highest safety level certification. ​

 

High adaptability, solving complex scene problems ​

 

Different industrial scenarios have different requirements for fast doors. Traditional control systems often have insufficient adaptability, resulting in the embarrassment of "big horses pulling small carts" or "small horses pulling big carts". We achieve accurate matching of all scenarios through modular design and intelligent adaptation algorithms.​

 

For ultra-wide and ultra-heavy doors (such as 8-meter-wide, 50kg/m² door curtains), we developed a "heavy-duty drive module" that uses an 11kW high-torque servo motor (the mainstream in the industry is 7.5kW) and a reinforced gearbox (transmission efficiency 98%) to ensure that the door body still runs at a speed of 1.8m/s, 40% faster than the same specification products in the industry. ​

 

In extreme environments such as low temperature (-30℃) and high temperature (60℃), the system uses wide-temperature electronic components and special grease, and the motor temperature rise is controlled within 40K (the average of the industry is 60K). It can run continuously for 1,000 hours without failure, and is perfectly suitable for cold chain warehouses, metallurgical workshops and other scenarios. ​

 

In addition, it supports compatibility with all brands of door bodies. Through the "parameter self-learning" function, it can adapt to door curtains of different materials such as stainless steel, PVC, and aluminum alloy without modifying the mechanical structure of the door body, and the installation and debugging time is shortened to 2 hours (the average of the industry is 4 hours).​

 

Intelligent management

 

We not only provide control equipment, but also build an intelligent management ecosystem of "operation-maintenance-optimization" to help customers reduce comprehensive costs.

 

The system has a built-in energy consumption monitoring chip, which can record motor power, operating time and other data in real time, and generate energy consumption reports through the supporting cloud platform. Compared with traditional systems, it saves an average of 30% of electricity. Calculated based on 100 door openings and closings per day, the annual electricity bill for a single door is more than 1,200 yuan. ​

 

At the maintenance level, it is equipped with a fault self-diagnosis system, which can accurately locate more than 80% of common faults (such as motor overload and encoder disconnection), and push maintenance instructions through display screens and mobile phone APPs, compressing the mean time to repair (MTTR) to 15 minutes, which is 60% shorter than that of peers. ​

For multi-door linkage scenarios, a distributed control network is developed to support the synchronous operation of 100 doors, with a response time difference of ≤50ms, meeting the efficient passage needs of large logistics parks and vehicle workshops, while similar systems in the same industry only support linkage within 30 doors.​

 

Service system

 

We firmly believe that high-quality products require perfect service support. Compared with the "sold out" model of our peers, we have established a full life cycle service system: ​

 

7×24 hours technical response: equipped with a 50-person professional technical team, quickly solve problems through telephone and video guidance, and provide on-site support within 4 hours in emergency situations (covering 90% of prefecture-level cities across the country). ​

Free upgrade service: The system software is updated free of charge for life, and 2-3 functional iterations are launched every year (such as adding face recognition interfaces and energy consumption optimization algorithms) to ensure the long-term leadership of the product. ​
Customized solutions: For special industries (such as pharmaceutical clean workshops and explosion-proof chemical areas), we provide full-process customized services from selection, installation to acceptance, and have created exclusive solutions for 300+ companies.