TECHNOLOGY HANDBOOK
MOTION CONTROL
A LOOK INTO THE PRODUCTS, TECHNOLOGIES AND SOLUTIONS SHAPING THE MARKET
DIGITAL
SUPPLEMENT TO
MACHINE DESIGN • SYSTEMS • TECHNOLOGY
TECHNOLOGY HANDBOOK
Motion Control
New motion control system options utilizing EtherCAT® technology
S
ervo-based motion control systems have traditionally been categorized into two types: centralized or distributed. Centralized systems use dedicated motion control cards that account for all aspects of the system including servo commands, motor feedback and I/O to close all control loops while simultaneously running complex programs that plan motion profiles and maintain machine operations. Increasing the number of axes involved places an ever increasing burden on the processing power of the DSP quickly making the system unmanageable simply due to scalability. In distributed systems, motion commands are less complicated since the drives close the velocity and/or position loops internally leaving the controller to focus on motion profiling, planning and associated I/O. However, limitations arise as communications speed may be the limiter of some specific motion and machine requirements. Even though systems can be made to be deterministic, the ability to keep up with demand can also be a challenge, even for simple machine tools. Is there a solution that combines the speed of centralized control with the scalability of distributed systems? ...Enter the Age of Motion Control via EtherCAT. The latest evolution in motion and machine control is EtherCAT, taking into account centralizing machine control but leaving motion control distributed. This brings together the best of both worlds. In fact, CANopen over EtherCAT is easily implemented and is gaining more and more traction every day. EtherCAT overcomes Ethernet’s system limitations by processing frames ‘on the fly’ so data packets are no longer delayed at every node. Packets are processed in each slave node addressed to it while being forwarded to the next device. Similarly, input data is inserted while the frame passes through and therefore only delayed by a few nanoseconds. Data transfer to the master controller is via direct memory access (DMA) so no processor capacity is consumed for network access. EtherCAT network configurations support almost any topology while being completely flexible - line, tree, star or variations of each are not a problem. In fact, provision for cable lengths of up to 100m between devices is possible
2 MA • Technology Handbook Motion Control
and network size is almost unlimited (up to 65,535 devices can be connected). Given this, EtherCAT achieves performance not realized by other networks. The update time for 1,000 distributed I/O points is only 30 µs. Almost 12,000 digital inputs and outputs can be updated with a single Ethernet frame and only take 300 µs for data transfer. If that wasn’t fast enough, now comes the amazing part communication with 100 servo axes only takes 100 µs, faster than most centralized control systems for a single axis! As amazing as EtherCAT is, ADVANCED Motion Controls has taken further steps to achieve yet new levels of capabilities. By leveraging the system’s overall flexibility and maximizing potential performance, recently introduced are DxM™ and DxI/O™ (Demultiplexed Motion and I/O) technologies by the company. Now a single EtherCAT node can accommodate a combination of up to 4 axes of motion, 128 digital inputs, 128 digital outputs, 16 analog inputs, and 8 analog outputs or 70 I/O points per axis! Typically, EtherCAT systems have been on larger machines such as printing presses, packaging lines and large in-place robotic systems that can accommodate sizeable control systems enclosures. With ADVANCED Motion Controls’ DxM™ and DxI/O™ technologies, application solutions are now available for smaller machinery and desktop equipment like water jet cutters, routers, lab automation equipment, biotech processing equipment, smaller mobile robots etc. where panel space is a premium or not at all available.
ELECTROMATE INDUSTRIAL SALES LTD. 4300 Steeles Ave West, Unit #39 Woodbridge, Ontario L4L 4C2 Phone: 877-SERVO98 Email: sales@electromate.com www.electromate.com
ADVANCED MOTION CONTROLS 3805 Calle Tecate Camarillo, CA 93012 USA Phone: 1-805-389-1935 Email: a-m-c.com www.a-m-c.com
TECHNOLOGY HANDBOOK
Motion Control
Integrated XY Linear Motor Stage for Unparalleled Geometric Performance • Integrated, low-profile, XY, linear-motor stage • Excellent geometric performance (straightness to ±0.4 µm; flatness to ±1 µm) • Anti-creep, precision crossed-roller bearings • Large selection – nine models in travel and accuracy Aerotech’s PlanarDL-series stages offer excellent geometric and dynamic performance in a compact, low-profile and cost-effective package. Available in nine different travel and performance configurations, this stage is the ideal solution for applications ranging from high-accuracy surface profilometry to high-speed semiconductor and LED wafer scribing.
The PlanarDL-200XY and -300XY stages are both available with one or two motors per axis, allowing optimization of each individual axis for the specific application and process parameters. Regardless of the number of motors selected, the resulting drive force acts through the centers of friction and stiffness resulting in superior geometric performance and accuracy. Integrated Cable Management The cable management system on the PlanarDL is integrated into the stage and optimized for long life and performance. Additional standard options are available for extra servo axes or air/vacuum lines for vacuum chucks or other process pneumatics.
Superior Stage Design With an optimized structure, components with exacting precision, Aerotech’s own direct-drive motor technology and an integrated cable management system, the PlanarDL debuts as an industry leader in planar performance. The PlanarDL XY design allows for unparalleled planar geometric performance in applications where straightness and flatness of motion are critical. High-precision, anti-creep crossedroller bearings, precision-machined surfaces and Aerotech linear motors driving through the axes’ center-of-stiffness result in exceptional geometric tolerances. PlanarDL structural elements are optimized for high-dynamics and high-stiffness for the most demanding dynamic applications. Capable of achieving 1 m/s velocities and 1.5 g accelerations, the PlanarDL enables high-throughput, high-accuracy processing resulting in superior process yield and a low total cost of ownership. Unlike competitive products using recirculating bearings, the anti-creep crossed-roller bearings used in this design provide the smooth motion ideal for the most challenging scanning applications.
Extreme Positioning Performance The PlanarDL is available in three positioning performance options: -BASE, -PLUS and -ULTRA. Relying upon decades of experience in system-level design including not only positioning mechanics, but also software and electronics, Aerotech has developed advanced technologies to push the envelope of precision. High-performance -PLUS and -ULTRA options are available to enable accuracies and straightness values down to ±400 nm and orthogonality down to 1 arc second.
Noncontact Direct-Drive Technology Only noncontact, direct-drive technology offers high-speed and accurate positioning coupled with maintenance-free operation and long service life. At the heart of the PlanarDL is Aerotech’s proprietary direct-drive technology. This drive technology allows for unmatched performance compared to other competitive screw-based and linear-motor designs.
AEROTECH, INC. 101 Zeta Drive Pittsburgh, PA 15238-2897 Phone: +1-412-963-7470 Fax: +1-412-963-7459 Email: sales@aerotech.com www.aerotech.com
4 MA • Technology Handbook Motion Control
For further information, please contact Aerotech at 412-963-7470 or sales@aerotech.com. In addition, more information on the PlanarDL is available at www.aerotech.com.
Linear Stages
Integrated Servo/ Scanner Systems
• Models with travels from 50 mm to 1.5 m • Speeds up to 2 m/s • Side-seal design with hard-cover • Low cost; high performance • Ball-screw or linearmotor-driven models
• Wide range of focal lengths and apertures • Industry best accuracy and thermal stability • Laser firing based on real-time scanner/servo position
PRO and PRO-LM Series
Nmark AGV-HP
Micromachining shouldn’t be a giant task
Let Aerotech Cut Your Micromachining System Down to Size
Cylindrical Laser Machining Systems
Nmark CLS
Get our FREE brochure Capabilities in Laser Processing and Micromachining at www.aerotech.com/ about-us/brochures.aspx
Linear Motor Gantry Systems • Velocity to 3 m/s and acceleration to 5 g • Exceptional accuracy and performance for improved throughput and yield • “Sealed” versions and custom options to suit your application
• Integrated linear/rotary motion platform • Advanced control architecture • Single- or dual-spindle configurations VascuLathe® DS
AGS Series
Dedicated to the Science of Motion
Ph: 412-963-7470 Email: sales@aerotech.com www.aerotech.com
A e r o t e c h Wo r l d w i d e United States • France • Germany • United Kingdom China • Japan • Taiwan
AF1212D_LM
TECHNOLOGY HANDBOOK
Motion Control
Your Sensor Supplier Doesn’t Want You To Read This Ad… …especially if you are a food or beverage producer concerned with food safety. That’s because our sensors are easy to clean and can thrive in harsh wash-down conditions. You do not have to cover our sensors with a bag or glove or remove them during a wash cycle. This saves you valuable production time and also ensures your machinery can be completely cleaned, including the sensor, without worrying about sensor fogging or leak induced failures. Baumer sensors also survive well in many aggressive environments where other sensors get ‘eaten up’. One poultry producer’s maintenance department has even dubbed our sensor the ‘Super Sensor’ since it has survived in applications where the competitors’ sensors previously were replaced monthly. Along with the extremely well sealed and hygienic housing designs, our customers also appreciate our superior sensor performance. From our extended sensing range proximity sensors, to our background suppression and SmartReflectTM photoelectric sensors, to several high precision measurement technologies, tough applications are just plain easier to solve. For example, Baumer offers the UNAR 18 series of ultrasonic sensors in digital and analog versions. Both versions feature stainless steel housing and a special Parylene coating on the sensing face. The digital version reliably detects the presence of many objects, including clear cups, bottles, or even liquids. The measuring version of the UNAR 18 is particularly well-suited for the contactless level control in filling machines. For volume measurement, such as used in meat and cheese processing, Baumer provides the OADR 20 series of laser sensors. The OADR 20 uses laser triangulation to provide a high degree of accuracy and a resolution down to 5µm. Baumer laser distance sensors are designed to provide 4-20mA or 0-10v signal directly from the sensor - no separate amplifier; just a single housing with IP69K rating. The IFBR and IFRR series of inductive sensors are available in both hygienic and wash-down designs. These prod-
6 MA • Technology Handbook Motion Control
ucts feature smooth, continuous or sealed surfaces, corrosion-resistant materials as well as flush and hygienic connections. The sensor is able to withstand frequent and intense (100deg C) cleaning and disinfection cycles. The Ecolabtested and EHEDG-certified inductive sensors are particularly well-suited for presence detection in food processing machinery. Series 14 photoelectric sensors, which are used to detect food or packages on conveyor belts, feature the hygienic and wash-down designs as well. This feature is also present in a version of the SmartReflectTM, an awardwinning light barrier without a reflector that has a sensing distance of 800 mm. The photoelectric sensors feature an anti-fog lense to increase reliability in high humidity and varying temperatures. Baumer is already well known in many industries for offering high performance sensors with high quality standards. We have seen the needs of the food and beverage industries and have incorporated our proven technologies into these products. We have designed our sensors to live up to the industry’s IP68 and IP69K standards, even after many wash-down and high temperature cycles. Baumer products are designed and manufactured in Switzerland, with Canadian sales and service support in Burlington, Ontario. Please contact us for more information or a product demonstration.
BAUMER INC. 4046 Mainway Drive, Burlington, Ontario L7M 4B9 Phone: 1-905-335-8444 Fax: 1-905-335-8320 www.baumer.ca/food-beverage-industry/
A new member of the family. O300 – The latest addition to the new performance class for optical sensors.
While the O500 is perfect for long ranges, the O300 is the new member of the family in the 1-inch class, ideal for confined spaces. Baumer gives you safety, ease-of-use and reduced operating costs in all performance classes. To learn more about all the advantages of this series, visit www.baumer.com/O300
TECHNOLOGY HANDBOOK
Motion Control
The No-Compromise IXARC Rotary Sensor from POSITAL
W
hen designers of motion control systems need to measure the rotation of shafts or other mechanical components, they have had two types of rotary encoders to choose from. Encoders based on optical measurement technologies provide high levels of precision and dynamic response, but are relatively bulky and can be unreliable in damp or dusty conditions. Magnetic encoders are typically more compact and rugged, but with lower levels of precision and dynamic response. POSITAL has eliminated the need for compromise by developing a new generation of magnetic absolute and incremental encoders that match the performance of optical shaft-mounted encoders in all but the most demanding applications.
The Secret is in the Signal Processing POSITAL’s new magnetic encoders feature highly-optimized signal processing software running on powerful 32-bit microprocessors. This combination improves on earlier-generation magnetic encoders with a four-fold improvement in measurement accuracy and a reduction of latency by a factor of over 100. These new devices offer the best of both worlds: accuracy and dynamic response that rivals high-quality optical encoders combined with the ruggedness and compact form-factor of magnetic encoders. The new POSITAL encoders provide up to 12-bit accuracy (0.09 degrees) and a multi-turn capability with a range of over four billion rotations. The multi-turn capability is based on an all-electronic rotation counter system that is powered by energy harvested from the rotary motion of the device’s shaft. This counter keeps track of the total number of turns that the encoder shaft has experienced, even if these occur while system power is unavailable, As a result, there is no need to re-zero the control system – even when movements take place while the control system is powered down. Versatility by Design Thanks to the improved dynamic response of the new technology, it is also possible to build high-performance incremental encoders based on magnetic sensors. The advantage here is
8 MA • Technology Handbook Motion Control
that magnetic encoders offer exceptional reliability and long service life when compared to traditional mechanical or optical designs. Also, with a microprocessor-centered design, operational characteristics – such as the number of pulses per revolution – can be changed with a simple software update. An offthe-shelf encoder can be programmed to emulate an older unit, then used as a drop-in replacement. POSITAL has adopted a highly modular approach to the mechanical construction of the devices. Customers can specify exactly what they need in terms of housing materials, mounting flange, shaft configuration, electrical connector type etc. and the factory will assemble the appropriate product from standardized sub-components. The interval between order acceptance and product delivery is typically within 2 weeks.
Download our white paper describing the technology behind the new IXARC encoders
POSITAL-FRABA CEO Christian Leeser describes the performance of the new generation IXARC rotary encoders.
POSITAL-FRABA Inc. 1800 East State Street, Suite 148 Hamilton, NJ 08609, USA Phone: 609-750-8705 info@fraba.com www.posital.com
ELECTROMATE INDUSTRIAL SALES LTD. 4300 Steeles Ave West, Unit #39 Woodbridge, Ontario L4L 4C2 Phone: 877-SERVO98 Email: sales@electromate.com www.electromate.com
LOOKING FOR ROTARY ENCODERS?
Find What You Need at www.posital.com
TECHNOLOGY HANDBOOK
Motion Control
Evolution of Ethernet in Control Systems
E
thernet was developed in the 1970’s and was started being used commercially in the 1980’s. By the end of the 1980’s it was the dominant network technology. It was initially used to connect computer systems and peripherals in a Local Area Network (LAN) and quickly evolved to be the protocol used for Wide Area Networks (WAN). Then came the world-wide web and the incorporation of the internet into every aspect of communication. In the mid to late 1990’s, Ethernet’s popularity spread to control systems. The engineering team here at Galil Motion Control determined Ethernet was a viable protocol in 1999 and introduced its first Ethernet Motion Controller. Even today, Ethernet is the most popular method of network communication in control systems. Before Ethernet Before Ethernet was considered viable for control systems, several other communication protocols were popular. • Bus-based communication was used when the controller lived within the computer. This solution was often cumbersome because the computer had to be large enough to house the motion controller, and the computer had to be and very close to the often noisy, dirty machine. • Daisy-Chain serial communication allows for distributed systems. The network was a series of controllers with a master. The master transmitted packets to the first device. The first device read the packet address, kept the packet if appropriate, or sent it on if it was addressed to another controller. This solution was very slow at the typical 9600 baud rate. • RS-485 multi-drop allowed data to be received by multiple motion controllers at the same time, but the speed was also slow, and the packet size was small. • Various proprietary serial communication networks became popular. These protocols were useful when data was short, repetitive and simple. Some of them are still used in some control systems today. Proprietary serial communication protocols such as CANOpen, Profibus, MultiNet and DeviceNet were developed because motion control systems needed more intelligence than bus-based and primitive serial networks could provide. The protocols needed to be able to take advantage of increasingly capable motion system hardware. Because these protocols were proprietary and part of a ‘turn-key’ solution, they were also expensive and created a barrier to migration. Customers were locked into a single hardware and software vendor and support for these solutions had to come straight from the supplier. By the 1990’s, Ethernet provided an alternative to proprietary bus communication because it was scalable, affordable, and flex-
10 MA • Technology Handbook Motion Control
ible. Ethernet became ubiquitous. Compatible hardware was easy to source and relatively inexpensive so it proliferated quickly. But there were still some questions whether a non-deterministic protocol like Ethernet was viable for motion control systems. Non-Deterministic and Deterministic Networks What is the difference between a non-deterministic and a deterministic network? A Non-deterministic network allows any device on the network to transmit at any time. Many masters and many slaves can exist, the network can be closed (not connected to the outside) or open (connected to the outside like the Internet). The drawback to a non-deterministic network is the possibility of packet collisions. Collisions occur if more than one device transmits at the same time. TCP/IP over Ethernet is an example of a non-deterministic network protocol. A Deterministic network has a guaranteed ‘same time’ delay for data transfer. A deterministic network has one master and many slaves. A drawback to a deterministic network is if the given time to transmit isn’t used, it is lost. CanOpen and EtherCAT are examples of deterministic protocols. The real question is: Are collisions in a closed, non-deterministic network relevant to control systems? Collisions occur if two devices transmit at exactly the same time, which is uncommon even on open networks where there are an indefinite number of devices and data being transmitted. So it is extremely unlikely that collisions will cause problematic delays for control systems when they are non-deterministic closed networks. There are some instances when a deterministic network is important for transmitting data in control systems. A good example is closing a servo loop across the wire. In this case it’s very important for the data to arrive at the same time, every time. Some motion controller vendors, like Galil, design their motion controllers so they close the servo loop inside the controller. This is one reason why a deterministic network is not vital to applications using Galil’s motion controls.
ELECTROMATE 4300 Steeles Ave West, Unit #39 Woodbridge, Ontario L4L 4C2 Phone: 877-SERVO98 Email: sales@electromate.com www.electromate.com
GALIL MOTION CONTROL 270 Technology Way, Rocklin, California 95765 Toll-free: 800-377-6329 (US Only) Email: galil@galilmc.com www.galil.com
TECHNOLOGY HANDBOOK
Motion Control
Harmonic Drive LLC New series added to our Quick Connect™ gearhead line Building a high precision actuator is easily achieved by coupling any servomotor to one of our precision Quick Connect™ gearheads. Harmonic Planetary® and Harmonic Drive® gearheads are available with a wide range of gear ratios and torque capacities.
NEW CSG-GH Series
NEW
Price
HPGP Series
NEW
HPN Series
HPG Series
High Precision Low Backlash Standard Torque
CSF-GH Series High Precision Zero-Backlash Standard Torque
High Precision Zero- Backlash High Torque
High Precision Low Backlash High Torque
Exceptional Price for Performance Quiet Quick Delivery Low Cost
Performance Performance
New HPN Planetary gearheads feature a robust design utilizing helical gears for quiet performance and long life. These gearheads are available with short lead times and are designed to couple to any servo motor with our Quick-Connect™ coupling. This new value series of planetary gears carry the reputation for quality and reliability for which Harmonic Drive® products are known throughout the world. HPN Harmonic Planetary® gears are available in 5 sizes, with reduction ratios ranging from 3:1 to 31:1. HPG and HPGP Quick Connect™ gearheads offer high precision and low backlash (standard: < 3-arc-min, optional: <1 arc-min). Innovative ring gear automatically adjusts for backlash, ensuring consistent, low backlash for the life of the gearhead. Standard (HPG) and high torque (HPGP) versions are available. With reduction ratios ranging from 3:1 to 50:1, HPG and HPGP HarmonicPlanetary® gears are each available in 6 frame sizes. HPG is also available in 3 sizes as a right angle configuration. CSF-GH and CSG-GH Quick Connect™ gearheads with zero-backlash Harmonic Drive® gearing are available with high reduction ratios, 50:1 to 160:1. CSF-GH and CSGGH utilize our proprietary S tooth profile and provide high precision positioning (repeatability ±4 to ±10 arc-sec). The greatest benefit of HarmonicDrive® gearing is the weight and space savings compared to other gearheads because it consists of only three basic parts. Harmonic Drive® Precision Gearheads and Actuators provide exceptional positioning accuracy and repeatability within a few arc-seconds and offer a wide range of reduction ratios in a single stage. Harmonic Drive gears provide zero backlash and have a long, maintenance free life. See a video explaining the technology.
12 MA • Technology Handbook Motion Control
Design Features • Through-Hole Design – Many Harmonic Drive gearheads and actuators feature a large hollow shaft allowing cables, pipes, or shafts to pass through the axis of rotation. This can greatly simplify a design and improve reliability. • Flanged Output – Many Harmonic Drive gear and actuator products feature a flanged output for direct mounting of the load. A large bolt circle diameter ensures secure mounting without the need for an additional support bearing. • Cross Roller Output Bearings are commonly used in our gearheads and provide high axial, radial, and moment load capacities, and in most cases eliminate the need for an additional support bearing. • No Change in Size or Weight with Gear Ratio – Harmonic Drive gears have the same size, weight, and form factor regardless of gear ratio. Harmonic Drive gears and actuators are used in a wide range of applications, each taking advantage of the products high performance. Industrial Robotics These applications require zero-backlash with high torque, high torsional stiffness, and excellent repeatability. Harmonic Drive gears also feature hollow shaft designs, for easy, neat, and reliable cable routing. Medical Equipment Surgical robots require high-precision motion control. Harmonic Drive gears provide exceptional positioning accuracy. Other medical applications include CT machines, active prosthetics, laboratory automation and therapeutic equipment. Machine Tool Features valued by tooling manufactures are high-accuracy, compact form, and hollow shaft design. For example, CNC grinding machines require precision, repeatability, and zero backlash with superior dynamic transmission accuracy for smooth motion. Common applications for Harmonic Drive products include fourth and fifth axes of milling heads of machining centers and routers. Electromate Industrial Sales is the exclusive Canadian distributor of Harmonic Drive products (except Alberta Province) Harmonic Drive and Harmonic Planetary are registered trademarks of Harmonic Drive LLC.
HARMONIC DRIVE LLC 247 Lynnfield Street, Peabody, MA 01960 Toll Free: 800-921-3332 Phone: 978-532-1800 www.HarmonicDrive.net
ELECTROMATE INDUSTRIAL SALES LTD. 4300 Steeles Ave West, Unit #39 Woodbridge, Ontario L4L 4C2 Phone: 877-SERVO98 Email: sales@electromate.com www.electromate.com
Building a high-precision actuator is easy! Simply couple any servomotor to one of our precision Quick Connect™ gearheads! • Complete line of gearheads now available • Harmonic Drive® or Harmonic Planetary® gearheads • Zero backlash and low backlash versions • Ratios: 3:1 - 160:1 • Peak Torque: 3.9 N•m - 3940 N•m • Sizes: 40mm - 230mm • Output Configurations: Hollow Shaft, Flange, Keyed Shaft
Harmonic Drive LLC 247 Lynnfield Street Peabody, MA 01960 800-921-3332 www.HarmonicDrive.net
Electromate Industrial 4300 Steeles Avenue West, Unit #39 Woodbridge, Ontario, Canada L4L 4C2 877-SERVO98 (737-8698) www.electromate.com
TECHNOLOGY HANDBOOK
Motion Control
DRIVE-BASED INTEGRATED SAFETY How advanced drive designs can be used to better implement mandated safety functions on production machines BY JOHN KRASNOKUTSKY
W
hile safety functions have been integrated into drives packages for some years now, the current trends are very exciting, from many angles. Today, a full complement of safety functions can be implemented at the front-end of a system design on all types of production machines. This can be accomplished in full compliance with all the current regulations for machines used worldwide. Furthermore, machine designers can look to a drive-based safety integrated protocol that has greater flexibility than ever before, both in terms of its mechanical footprint and component savings, owing to the various ancillary devices such as external contactors and redundant electromechanical safety devices, with all their inherent wiring, cabinet space and related costs. Lastly, and perhaps most important to the designers working on that factory of the future with an eye on lean, green and expandability, the safety-integrated features on today’s drives allow additional functionality to be included without excessive rework. Combined with the current state of safety communication capabilities over protocols such as Ethernet/ Profinet and Profibus, plus the rapidly emerging and already utilized automation platforms of wireless communication of critical safety function data in a manner isolated from nondeterministic information, these are not your father’s drives, to put it mildly. In the past, the common practise for monitoring drive reaction to shutdown requests came through the machine controller, be it a PLC, CNC or other motion controller hardware. Current safety requirements — especially Category 3 of NFPA 79 and the corresponding category of EN 954-1 and its recently implemented upgrade, ISO 13849-1 — allow drive-based safety functions to be utilized independently. Drives are now performing the continuous safety monitoring with control-reliable safety action inside the drive, through dual-channel safety inputs. Coupled with a safety controller, safety monitoring in a drive must be continuous and integral, so the drive no longer needs to “wait” for a periodic signal from the machine controller to detect, for example, an over speed condition, a break in a light curtain, or even improper inputs that may have resulted from welded contacts or other off-normal conditions. In this manner, the loss of productivity to your machine is radically reduced, while the drive can also send a signal directly to an HMI screen, identifying the fault, in sharp contrast to bygone days when this was not possible without lengthy breakdown and analysis. Troubleshooting and maintenance costs are further reduced by the safety-integrated drives. 14 MA • Technology Handbook Motion Control
Safety concerns on many types of machinery vary considerably, and today’s advanced safety-integrated drives can accommodate.
Drives can now accept inputs directly from various safety devices such as e-stops, laser scanners and light curtains, without need of external devices or a PLC.
Dual benefits derive from these drives for the practical execution of machine control, as well. First, safe stop of the drive without disconnecting the low-voltage power means faster restart and less degradation of the drive over time. Additionally, motion safety is achieved by monitoring drive speed through functions such as safety limiting speed, safe brake control and safe speed monitoring functions, which in some drives can be achieved without encoder feedback. These are the more recent advancements beyond the basic safe stop, torque off and safe operating stop functions. These drives are typically available in variable frequency, vector and servo control models to accommodate induction, servo, linear and torque motors from the subfractionals to the megawatt variety. For inputs, safety incidents from light curtains, laser scanners, position switches and other machine hardware are routinely accepted. Output signals
TECHNOLOGY HANDBOOK
Motion Control
processed in the drive CPU are sent via wire or bus to higherlevel safety controls or available upgrade modules that activate the drive functions. During commissioning, the safety functions are set by the password-protected relevant parameters in the drive architecture protocol and triggered for single or multi-axis groups. Therefore, these drives are finding applications in every type of basic point-to-point linear or rotary motion scheme from a pump or fan to a packaging line up to the highly sophisticated interpolation of multiple axes on machine tools. Highly reliable circuitry controls the output of the low-voltage power that runs the rotational speed output of the drives, so the machine can retain drive power without shutdown to remain more productive. This contrasts sharply with the old three-phase contactor technology of the past. For installation simplicity, many of these drives also feature plug-and-play connectivity for implementing all functions, either at startup or, subsequently,
as the manufacturing protocols or monitoring requirements change in the field. The new thought process for engineers in this area must now be to build monitoring of safety functions into their systems at the front end, knowing they can add I/O with more design work done in the software than the hardware without redundant external devices and custom safety wiring on every job. Machine designers will realize substantial engineering savings, component cost reductions and improvements in footprint configuration through the use of these safety-integrated drives, while building compliant machines for use worldwide to protect equipment, manufacturing integrity and, most importantly, workers in the process.
Manufacturing revival drives investment in automation technologies: report
Power transmission/motion control industry shows growth in second quarter
R
John Krasnokutsky is the marketing manager in the Motion Control Business of Siemens Industry, Inc.
ising capital investments in both process and discrete industries, a declining workforce, global competitive pressures, and the convergence of operational technologies (OT) with IT have given a boost to the global automation market, according to new analysis from Frost & Sullivan. The report, “2013 Global Automation Market Factbook,” states that North American shale gas and tight oil boom, and its ripple effect in the rest of the oil and gas as well as chemical industries, have further strengthened global demand for automation solutions. In fact, the report finds that the deployment of new infrastructure projects in response to rapid urbanization, especially in Asia-Pacific, will trigger adoption of automation solutions. Particularly, projects in the power, water and wastewater industries in emerging economies, such as China, India, Brazil and the Middle East, will contribute to market revenues. “Modernization efforts influenced by recovering economies in Europe will aid the uptake of automation systems,” noted Frost & Sullivan industrial automation and process control senior industry analyst Naveen Kumar Ramasamy. “Increasing capex in the Middle East industrialization and the industrial revival in emerging Africa will also spur the need for automation.” However, market participants are unlikely to fully capitalize on this potential, as many critical automation product solutions are still proprietary and remain tied to legacy architecture or to certain standards, the report states. Developing collaborative solutions that synchronize seamlessly with existing legacy systems will be vital to encourage the move from legacy platforms. “Raising awareness on the benefits of automation, such as reduced operational expenditures, increased efficiency and higher profitability, will be crucial,” advised Ramasamy. “Coupled with penetration of industrial Internet of Things and stronger convergence between IT and OT, this will aid the expansion of the global automation system market.” The “2013 Global Automation Market Factbook” is part of the Industrial Automation & Process Control Growth Partnership Service program. The report includes product analysis by total market size in 2013, by region, by end-user industries, and finally by key trends.
T
he PTDA Business Index for the second quarter of 2014 indicates strong growth in both business activity and new orders. Business activity increased 12.7 per cent (from 67.7 to 76.3) and new orders improved 14.5 per cent (from 67.7 to 77.5) from the first quarter to the second quarter this year. This quarterly survey of PTDA’s distributor and manufacturer members continues to point to growth, with the second quarter Business Index at 68.7, up from the first quarter reading of 63.6. However, when asked about their outlook for the entire year, survey participants’ expectations remained the same from the previous quarter at six per cent growth. (Note: The index reading indicates the rate of change compared with the previous period. For example, a reading of 50 indicates no change from the prior period, while readings above 50 indicate growth and below 50 indicate contraction. The further the index is above or below 50 suggests a faster or slower rate of change.) The entire 2Q2014 PTDA Business Index report is available through PTDA’s website at www.ptda.org.
Motion Control Technology Handbook • MA 15
TECHNOLOGY HANDBOOK
Motion Control
BUILD OR BUY? Important factors to consider when deciding between building a linear positioner in-house or purchasing an existing technology BY BEN FURNISH
T
ypically, a manufacturer’s main goal in developing or implementing an innovative automation technology is to speed production and boost the bottom line. In this endeavour, it almost always pays to keep an eye on the basics. For example, in applications involving high-volume, single-axis positioning systems, how does a company decide whether it makes sense to build a potentially more innovative linear actuator in-house or purchase an existing off-the-shelf technology? Many companies assume that building a linear positioner from scratch and producing the high volumes needed for an application makes for the lowest-priced approach. That’s because at its most basic level, designing or building a positioner in-house versus buying an off-the-shelf unit seems purely a function of cost and volume. The approach seems simple and straightforward because cost and volume directly relate. The cost for building in-house will be higher initially than the cost for buying, but the cost will level over time. Therefore, producing a positioner in-house might seem to be the best option for companies with plenty of time, resources, product demand and money. Unfortunately, engineers typically learn whether building in-house was the correct decision only after they are well into the development process and have invested heavily in time and money. Engineering decisions are rarely this easy and usually require considering many factors. 16 MA • Technology Handbook Motion Control
conditions and analyse projected sales. Because demand determines volume, analyze whether your facility is equipped to sustain production demands or whether outsourcing is a more efficient option.
Making versus buying guidelines
Following this checklist can help ensure you make the right decision for your organization. Materials – Make sure that the bill of materials (BOM) is complete, including hardware, bolts, fasteners, bearings, motors, drive mechanisms and other components. Account for all the materials needed to build the positioner in-house and find the suppliers that can deliver the desired quality and quantity. Volume – Another significant factor for cost comparison is the actual volume of positioners needed over a given period of time. At higher volumes, it might be worth the effort to build the positioner in-house to ensure integration and quality. On the other hand, spending the required time and labour may not be worthwhile when it detracts from a company’s core competency and more pressing priorities that are critical to the business. When the positioner is being used as a new product, consider market
Labour – Don’t forget to factor in time to market and lead times. Time to market includes the time it takes to design and develop prototypes. It also includes the months of work necessary to build a reliable, validated and verified positioner. Also, don’t forget to factor in machining time and labour times for assembly. Support – Consider support costs and study them. When a unit fails, what are the implications? How long will it take to replace or repair the unit? Application – The positioner must work well in varied applications, such as a lab instrument, small diagnostic device and semiconductor. Deciding to make or buy can depend on finding a supplier with a compatible product that is customizable to your needs. Expertise – Is your time best spent designing positioners or focusing on your expertise? It is sometimes tempting to keep engineering in-house, but in some cases, partnering with a company that specializes in positioners reduces risk, costs and frustrations. Risk of ownership – When building a positioner, a company assumes every risk — from concept to product launch. When buying a positioner, a
TECHNOLOGY HANDBOOK
Motion Control
Emerging regions prove profitable for the industrial valves and actuators market
company should choose a reputable supplier that has already thoroughly tested the product to help reduce risk. Within these guidelines, be sure to consider hidden costs that are often overlooked. For example, companies usually consider design costs, but fail to note that a larger inventory and higher overhead can also keep lead times short. Labour costs should include the times an employee must touch an order to expedite, track or receive it. They should also include the time it takes for employees to inventory, pick or inspect parts. The issue might not seem significant, but for positioner assemblies that include 30 components, time can quickly become a production concern. Likewise, companies sometimes estimate business risks too optimistically, which can be a disaster. It is necessary to spend a lot of time early in the design process using concept feasibility and performance tests to build a reliable product.
Coming to a conclusion
The decision between building and purchasing a linear positioner is easier to calculate and quantify when all the considerations have been accounted for. Tools are available and experienced suppliers can help with a discussion to reveal hidden costs. When building in-house, companies should use concept feasibility and performance testing early in the design process. When purchasing a technology, companies must ensure the vendor has application experience and can provide good customer support. Ben Furnish is a market development manager for Parker Hannifin Corporation’s Automation Group.
A
n increase in oil exploration activities, investments in new refineries, and the modernization of existing facilities will spur the uptake of valves and actuators, particularly in emerging markets such as Africa and Latin America, according to new analysis from Frost & Sullivan. In Latin America, demand from the offshore oil and gas industry is expected to fuel the valves and actuators market. In addition to demand from emerging economies, control valve manufacturers will find growth opportunities in North America and Europe due to end-user preference for greater process automation. Frost & Sullivan’s report, “Strategic Analysis of the Global Industrial Valves and Actuators Market,” finds that the market earned revenues of US$19.51 billion in 2013 and estimates this to reach $25.95 billion in 2018. The study covers the oil and gas, power generation, chemical processing, mining and metallurgy, and water and wastewater end-user industries. “The water and wastewater industry will offer significant growth potential for valve and actuator manufacturers in Asia-Pacific, Africa and Latin America,” said Frost & Sullivan Industrial Automation and Process Control research analyst Niranjan Paul. “Due to the burgeoning population and rapid urbanization in these regions, water scarcity and the need to provide purified and portable water for human consumption have led to the setting up of desalination plants, boosting the use of valves and actuators.” Despite this demand, valve and actuator manufacturers are likely to witness a loss of potential revenues due to politics in countries such as Iran, Sudan and Syria. In addition, the global financial downturn has compelled end-users to defer projects and focus on the maintenance of existing equipment rather than the purchase of new valves and actuators. The adoption of aggressive pricing strategies in Asia-Pacific, too, will reduce the sale of new valves. Vendors must enhance their aftermarket capability to sustain profits and meet wide-ranging consumer requirements. “Valve and actuator manufacturers need to invest in R&D to deliver a comprehensive solution complete with wireless monitoring and advanced valve-condition monitoring capabilities,” recommended Paul. “With subsea exploration in Europe and Latin America projected to rise, widening product portfolios to include double-expanding gate valves will help vendors appeal to a larger consumer base in this high-potential market.” www.frost.com Motion Control Technology Handbook • MA 17
DON’T MISS OUT on your next issue of
IT’S FAST, IT’S EASY AND IT’S FREE! FOR FASTEST SERVICE VISIT
www.automationmag.com
HERE’S
HOW:
FINDING FUNDS
Government funding that supports HR and training
MACHINE SAFETY
The challenge of developing a custom guarding solution for a sterile environment
and click the subscription button
ROBOTIC SIMULATION Software helps build advanced assembly systems for an Ontario manufacturer
AUTOMATION TRENDS
The top technologies that will impact the plant floor in 2014
INVESTING IN ERP Food manufacturer optimizes business processes with ERP software
FUNDING NEWS Feds invest in Centre for Smart Manufacturing in Ontario
J U N E 2 014
J A N . / F E B. 2 014
www.AutomationMag.com
M AC H I N E D E S I G N • S YS T E M S • T E C H N O L O G Y
CYBERSECURITY Three common cybersecurity issues in industrial control systems and how to manage them
2014 SOFTWARE CASE STUDY GUIDE The latest software solutions help manufacturers solve their biggest challenges
AUTOMATION UPFRONT Inside Mohawk College’s new Additive Manufacturing Resource Centre
Finding Funds Five steps to improved energy efficiency
S E P T E M B E R 2 014
www.AutomationMag.com
the Future oF sensors harnessing technology to www.AutomationMag.com create smarter plant floors
M AC H I N E D E S I G N • S YS T E M S • T E C H N O L O G Y
M A r C H / A p r I L 2 014
M AC H I N E D E S I G N • S YS T E M S • T E C H N O L O G Y
CYBER WARFARE Manufacturers arm themselves for battle
demand management automation puts manufacturers in control of energy costs
www.AutomationMag.com
SAFETY Q&A Important questions to ask machine builders when buying new equipment
M AC H I N E D E S I G N • S YS T E M S • T E C H N O L O G Y
AUTOMATION UPFRONT Ontario unveils new vision for education
M AY 2 014
www.AutomationMag.com
EMPLOYEE EDUCATION Ottawa-based manufacturer launches work-supported apprenticeship program
M AC H I N E D E S I G N • S YS T E M S • T E C H N O L O G Y
THE
The
SECRET to my SUCCESS How one manufacturer experienced substantial growth during the industry’s most difficult years
energy
BRIGHT SIDE
Our editorial advisory board discusses positive trends in the manufacturing industry, and where we go from here
well spent
PM #40065710
PM #40065710
Investing in
Cement manufacturer sees huge savings with automation strategy SubScriber action required pg. 25
MA_MArApr2014.indd 1
2014-02-26 1:27 PM
www.automationmag.com