MA - Motion Control 2015

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

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.

T h e P l a n a r DL- 2 0 0 X Y a n d -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 crossed-roller 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 Phone: +1-412-963-7470 Fax: +1-412-963-7459 Email: sales@aerotech.com www.aerotech.com

2 MA • Technology Handbook Motion Control

For further information, please contact Aerotech at 412-963-7470, or via e-mail at sales@aerotech.com. In addition, more information on the PlanarDL is available at: http://www.aerotech.com/product-catalog/ stages/linear-x-y-stages/planardl.aspx

Rugged...Smooth...Fast...Accurate Aerotech PRO-LM Linear-Motor Stages PRO280LM: 8 Models

PRO560LM: 8 Models

560 mm

280 mm

225 mm

165 mm

PRO225LM: 12 Models

PRO165LM: 10 Models

Add an Aerotech awardwinning single- or multiaxis control system for a complete motion solution.

The vertical side-seal design provides superior protection from debris.

PRO-LM Series Linear Motor Stages Aerotech’s PRO-LM series linear-motor stages offer a cost-effective, high-performance solution for positioning applications that require smooth, precise motion. A linear motion guide bearing system, high-performance brushless linear servomotor, protective hard cover and side seals make the PRO-LM series ideal for applications such as laser machining, medical component manufacturing, and other applications requiring high accuracy and extremely smooth motion in a production environment. With a wide variety of sizes and load capacities, there is a PRO-LM stage to match your needs and exceed your expectations.

Contact Aerotech today to learn how a PRO-LM stage can improve your up-time and application throughput.

Dedicated to the Science of Motion

• Direct-drive linear motor for smooth, precise motion and high speed.

• Linear motion guide bearing system means long life and minimal downtime.

• Thirty-eight different models with travels ranging from 100 mm to 1.5 m to ideally match almost any application.

• Unique side-seal design provides superior debris protection increasing up-time and keeping your process moving.

The PRO series is also available with a rotary motor and high-speed ball screw!

Ph: 412-963-7470 Email: sales@aerotech.com www.aerotech.com AF1114G-LPM

TECHNOLOGY HANDBOOK

Motion Control

Scalable and Modular Motion Control

B

&R’s motion control technology melds seamlessly into its overall automation system – along with machine control, HMI and safety technology – to create a complete system solution for machines and equipment. B&R’s motion control components are fully interoperable, so individual devices can be swapped out at any time to adapt to any changes in the machine’s configuration or requirements.

Safety and flexibility are B&R’s guiding principles: B&R servo drives and inverter modules are equipped with hardwired or integrated safety technology that allow for intelligent reactions to hazardous situations. In addition to minimizing downtime, this also boosts machine output substantially. B&R servo technology is perfectly suited to both centralized and distributed architectures.

The portfolio includes a drive solution for any situation, whether inside the control cabinet or mounted directly on the machine. "$0104 1 BYJT TFSWP ESJWF High performance with a compact design More than ever before, machine and system manufacturers are being bombarded with demands for increased productivity and availability. At the same time, pressure is constantly building to reduce the manufacturing costs for production machines. The new servo drive generation from B&R was designed to meet these challenges.

With the ACOPOS P3, B&R is setting new standards for motion control. This 3-axis servo drive offers a power density of 4 A per liter, making it one of the most efficient servo drives with integrated safety functions on the market. It also provides previously unmatched dynamics and precision, with a minimum sampling time of 50 μs for the entire controller cascade.

No loss of energy When using an ACOPOS P3 together with an ACOPOSmulti drive, it is also possible to take advantage of the power regeneration capabilities of the ACOPOSmulti.

Braking energy from the ACOPOS P3 is not converted to heat using braking resistors; instead, it is passed on to an ACOPOSmulti via the DC bus, which can feed the energy back into the power grid.

Learn more about B&R’s new ACOPOS P3. "$0104NPUPS .PUPS JOUFHSBUFE ESJWF TZTUFN B&R’s ACOPOSmulti has always been an extremely modular drive system, and it was the next logical step to merge inverters with the motor to create 8DI ACOPOSmotor modules that can deliver power directly where it is needed. This allows configurable modules to become easily connected mechatronic devices. It also makes it possible to reduce delivery times, free up valuable floor space and simplify commissioning.

Compact and safe ACOPOSmotor modules combine the following important components in a compact unit: r 5IF TFSWP ESJWF JODMVEJOH PQUJPOBM TBGFUZ UFDIOPMPHZ r 5IF TFSWP NPUPS BT B QPXFS DPOWFSUFS r 5IF CVJMU JO QPTJUJPO TFOTPS r 5IF DIPJDF PG BO PQUJPOBM HFBSCPY The ACOPOSmotor module delivers maximum performance by using the latest technology for power devices with minimal power loss as well as a motor series that is optimized for this application.

Safety included It is even possible to integrate a complete safety solution in a minimized system of this type. The SafeLOGIC-X virtual safety controller runs on an ordinary PLC and offers the reliability B&R customers have come to expect without requiring a dedicated safety controller.

Learn more about ACOPOSmotor.

Completely compatible The ACOPOS P3 can be combined with all of B&R’s ACOPOSmulti family products. Additional space can be saved in the control cabinet, for example, by using the motor-mounted ACOPOSmotor servo drive or the distributed ACOPOSremote drive system.

B&R Industrial Automation Inc. 3VUIFSGPSE 3PBE 6OJU $PODPSE 0/ - , / $"/"%" 5FM &NBJM PGGJDF DB!CS BVUPNBUJPO DPN

4 MA t 5FDIOPMPHZ )BOECPPL Motion Control

www.br-automation.com

STREAMLINE YOUR CABINET. UNLEASH THE SERVO. www.br-automation.com/ACOPOSmotor

< 1 cable for a modular machine design < Integrated safety technology CAT 4 / PL e / SIL 3 < STO, STO1, SBC, SOS, SS1, SS2, SLS, SDI, SLI, SMS, SLP, SMP, Safe Homing, Safe Robotics < Local I/O < 500 W up to 4 kW < CNC, robotics, motion control < reACTION Technology with 1 µs response time

Technology handbook

Motion control

Simon says “CleverLevel is a switch for all media”

L

evel detection is of great importance in many industries.

The demands on level switches can vary considerably, from monitoring maximum and minimum levels in tanks, to protection against overflow or running dry. Until now, engineers have needed to specify from a wide assortment of different sensors, depending on the specific application. It was simply not possible to cover all applications with one type of level switch. The CleverLevel has changed all of that, allowing just one sensor to be used for almost any point level application.

There are many factors to consider in level applications, such as foam presence, viscosity, stickiness, and the aggressiveness of the media. The commonly used vibrating fork level sensor does not offer great performance in all of these situations. Measuring errors can arise, since high viscosity materials tend to stick to these forks. Coarse granular media can easily become lodged between the forks and also cause measuring errors. The forks are difficult to clean. Also, liquid and powder substances required different fork sensor versions.

Versatile sensor with easy configuration The CleverLevel sensor is able to reliably detect levels in virtually any media. Based on frequency sweep technology, the sensor continuously analyses the resonant frequency around the sensor tip. All materials have a die-electric value. The dieelectric value directly affects the resonant frequency, allowing the sensor to reliably detect the presence of the material. High sensitivity for dielectric constants from 1.5 to over 100 enables limit detection for all sorts of powders, granulates and liquids.

Out of the box, the CleverLevel factory default setting can already detect most media. A Teach-in function can be used to further customize the sensor for trickier applications, such as ignoring foam, sticky residue or other material stuck to the tip. Tanks with liquid chocolate are a typical example. Even when empty, the sensor and container walls are coated with chocolate. When configured accordingly, the CleverLevel still switches only when the tank is really full or empty. A sim-

6 MA • Technology Handbook Motion Control

ple configuration software shows the user a clear graphical representation of what the sensor sees, and makes setting the sensor easy, even for difficult applications.

CleverLevel can be installed in any orientation. A bright blue signal LED is highly visible from all directions. The sensor housing is IP67 as standard, and it is suitable for ambient temperatures between -40°C and +200°C. The small mounting depth of only 15 mm is a plus for many applications. In addition to the industrial process connections, there are also versions with EHEDG approval for food areas and other areas with strict hygiene requirements. The PEEK sensing tip is compatible with most solid materials, oils, chemicals, and solutions.

See why Simon says “CleverLevel is a switch for all media”.

Click the link for more information or call Baumer for a demonstration of this game-changing new technology.

Baumer Inc. 4046 Mainway Drive, Burlington, Ontario L7M 4B9 Phone: 1-905-335-8444 Fax: 1-905-335-8320

www.baumer.com/cleverlevel

Times are changing.

CleverLevel LBFS/ LFFS switch – The really clever alternative to vibrating forks.

Inaccurate readings because something is sticking to the vibrating fork are a thing of the past. We took this to the next level: Safe monitoring of filling level thanks to Baumer’s new CleverLevel series. Reliable differentiation of media that might be electrostatic, sticky, pasty, or have a high or low viscosity.

Bring yourself up-to-date on the latest in filling level measurement at www.baumer.com/CleverLevel

TECHNOLOGY HANDBOOK

Motion Control

Function integration streamlines machine design, assembly costs

O

ften, when electrical and pneumatic subsystems are designed and incorporated separately into a new machine, it takes more time than it should to get both technologies and all related sensor and safety hardware and software to work smoothly as one system. It’s a well-accepted but sub-optimal approach to machine-building that adds to project costs in several ways.

There is the added labor associated with all the puttering around to get things that were conceived of in separate silos to harmonize. Late deliveries tax customer goodwill and can even trigger extra charges. Potential integration synergies are missed, which can lead to higher than necessary component usage. Electrical and pneumatic components may be ordered separately from different vendors, reducing the OEM’s negotiating leverage. During assembly, superfluous componentry and haphazard placement adds to the job of labeling and wiring, with a greater risk of errors that may only be discovered during testing or commissioning, where they are more expensive to fix.

That’s why a new trend is gaining wide acceptance in machine-building: function integration – incorporating both electrical and pneumatic systems via the medium of a valve terminal, which serves as an integrated automation platform.

This simplifies design and assembly and offers cost savings along the entire value chain.

Project benchmarking with Festo customers has confirmed significant time savings offered by function integration. A typical project using a valve terminal to integrate both functions for the automated manufacturing of fuel cells was shown to achieve over 14 hours of net labor savings, from design through commissioning. Over half of the savings were in the engineering phase. In practice, time savings will differ with the project, but in almost all cases will be enough to cover the extra cost of the valve terminal and then some.

Other benefits of function integration include increased system functionality, reliability, machine diagnostics, material savings from fewer interfaces and the possible sole-sourcing of components. In some cases, function integration at an onboard valve terminal can reduce a machine’s footprint by eliminating the need for an external electrical cabinet.

8 MA t 5FDIOPMPHZ )BOECPPL Motion Control

Click here to read our Festo white paper on function integration using valve terminals Click here to read about the benefits for actual customers Function integration using state of the art, modular valve terminal encourages designers to think outside the box. Instead of working separately, the machine designer and electrical engineer work collaboratively to optimize the integration of electrical and pneumatic subassemblies in any machine, simple or complex. Small changes can be made far more quickly.

Festo valve terminals are remarkably versatile. What was once a group of simple valves has evolved into a decentralized control system for the entire machine cell – including motion control! Festo valve terminals can be precisely configured to suit the application, supporting all needs for digital/analog I/ O, sensors monitoring temperature or pressure, safety modules, servo electric and pneumatic control, pneumatic valves with electrical zoning, and directly mounted proportional pressure regulation.

Even in applications where mounting space is limited the Festo valve terminal solution can be configured to be very compact in size. This is achieved by adding a scanner module to the main Festo network node and decentralizing the location of some or all of the I/O and valves using compact components. All features come standard with protection class IP65. Festo Canada technical support can help you determine which valve terminal is right for your project, and provide advice on configuring it for optimal function integration.

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www.festo.ca

Management level Control level

This is the future!

Field level Sensor/actuator level

Setting your sights high?

Want to achieve more?

We show you new ways forward.

WE ARE THE ENGINEERS OF PRODUCTIVITY. Festo CPX: the star of electric & pneumatic control Ideal as an automation platform, valve terminal partner or remote I/O, open and direct. The unique function integration features and diagnostics will increase your productivity significantly. Exactly what you need when you demand the best from your automation solution.

www.festo.ca

Technology handbook

Motion control

Incremental rotary Sensors: Versatility, Variety and Programmability!

I

ndustrial motion control systems come in all shapes and sizes.

POSITAL-FRABA, a leading supplier of position and motion sensors, has responded to the challenges of this diverse market by offering buyers an extraordinarily wide range of choices.

POSITAL rotary encoders are offered in a wide variety of mechanical features, connector types and connection interface options. POSITAL recognizes regional differences and offers mounting and connector options that address European, Asian and North American standards and practices. With more than a million choices overall, buyers can find variants that will fit directly into their equipment, usually without the need for special adaptors or modifications. An online product finder – accessible through www.posital.com - enables customers to browse through the full range of options and retrieve the model numbers, specification datasheets and CAD drawings they need, in 11 different languages. Order fulfilment is usually within two weeks, virtually anywhere in the world.

Programmable Performance POSITAL’s new programmable incremental rotary encoders take versatility to a new level. Resolution can be set anywhere from one to 16,384 pulses per turn in software, without changing the mechanical properties of the devices. Similarly, pulse direction and the output driver – either Push-Pull (HTL) or RS422 (TTL) – can be defined through software parameters.

Changes can be made quickly using POSITAL’s easy-to-use UBIFAST programming tool.

Reducing Inventories, Retaining Flexibility Device programmability is very significant for distributors, system integrators or machine builders since it helps them reduce inventories. Now, they can hold a relatively small stock of ‘standard’ models and set them up for specific applications on an as-needed basis.

10 MA • Technology Handbook Motion Control

Configuration Management Made Easy POSITAL has also introduced a unique Internetenabled configuration management system for IXARC programmable encoders.

Whenever a device is reconfigured, the operator can register the changes with POSITAL through an automatic email interface. POSITAL will update the configuration history of the device in a database maintained by the company. If a replacement part is required, this record can be accessed and used to manufacture an encoder with an identical performance profile. It could also be provided to a distributor or system integrator who could take a mechanically compatible device from their stock, enter the appropriate software parameters and deliver the completed unit directly to the end user.

Download our white paper Programmable Encoder 2.0

Follow POSITAL on Social Media

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: 905-850-7447 Email: sales@electromate.com www.electromate.com

IXARC PROGRAMMABLE INCREMENTAL ENCODERS

Smart Phone Meets the Smart Encoder!

www.posital.com

TECHNOLOGY HANDBOOK

Motion Control

Harmonic Drive LLC /FX TFSJFT BEEFE UP PVS 2VJDL $POOFDU¡ HFBSIFBE MJOF 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 CSF-GH Series

NEW

Price

HPGP Series HPG Series

NEW HPN Series

High Precision Low Backlash Standard Torque

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 Harmonic Planetary® 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 Harmonic Drive® 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.

12 MA t 5FDIOPMPHZ )BOECPPL Motion Control

%FTJHO 'FBUVSFT r 5ISPVHI )PMF %FTJHO m 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. r 'MBOHFE 0VUQVU m 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. r $SPTT 3PMMFS 0VUQVU #FBSJOHT 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. r /P $IBOHF JO 4J[F PS 8FJHIU XJUI (FBS 3BUJP m Harmonic Drive gears have the same size, weight, and form factor regardless of gear ratio. )BSNPOJD %SJWF HFBST BOE BDUVBUPST BSF VTFE JO B XJEF SBOHF PG BQ QMJDBUJPOT FBDI UBLJOH BEWBOUBHF PG UIF QSPEVDUT IJHI QFSGPSNBODF 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 the Province of Alberta) )BSNPOJD %SJWF BOE )BSNPOJD 1MBOFUBSZ BSF SFHJTUFSFE USBEFNBSLT PG )BSNPOJD %SJWF --$

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ELECTROMATE INDUSTRIAL SALES LTD. )JHIXBZ 6OJU 7BVHIBO 0OUBSJP $BOBEB - ) , 1IPOF 4&370 &NBJM TBMFT!FMFDUSPNBUF DPN 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

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Harmonic Drive LLC 247 Lynnfield Street Peabody, MA 01960 800-921-3332 www.HarmonicDrive.net

Harmonic Drive®, Harmonic Planetary® and Quick Connect® are registered trademarks of Harmonic Drive LLC. * Electromate Industrial Sales is the exclusive Canadian distributor of Harmonic Drive® products (except the Province of Alberta).

Electromate Industrial* 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 www.electromate.com

Technology handbook

Motion control

SAVE TIME, INCREASE PROFITS, IMPROVE PERFORMANCE….SAVE YOUR MONEY

T

VFD-C2000/CP2000 Series Powerful Features, High Efficiency

The VFD-C2000 Series is a high level field Devicenet, MODBUS TCP and EtherNet/IP. oriented control AC motor drive with a high performance variableAlong with the traditional drive frequency Technology, system offered in the C2000 FOC control. It features versatile series to target traditional driving controls, modular design, applications, Delta has also wide variety of applications, easy released the CP2000 with maintenance, self diagnosis and incorporates the benefits of the competitive market price.

It C2000 and more! The CP2000 brings customers not only highincludes a realtime clock and 10k efficiency construction but also step PLC programming capacity, the most economic solution to it is designed for the building compete with the global market. automation sector with built in BACnet and MODBUS RS-485.

The CP2000 has a quick settings The VFD-C2000 series AC function to allow for fast and easy motor drive provides the most setup for functions such as efficient and cost-effective sleep/wake , flying start and skip solution for many types of drive frequency. The CP2000 also applications including printing offers a fire mode and by pass machines, extruders, calendar mode: continuous pressure and paper machines, output to extract smoke when fire compressor, wire drawing accident or other emergency machines, mixers, conveyors, occurs. and more. It features precise speed, torque and position control functions that are suitable Rated up to 690VAC 745HP for both sensor and sensorless types of synchronous and asynchronous motors.

The C2000 series is also equipped with built-in PLC functions and supports the CANopen Master/Slave extension for the ultimate in system flexibility and • PLC’s fast data exchange as well as MODBUS (built-in • Power Capacitor Banks standard).

The Advanced Drive controls • Vision Systems incorporate door width auto-tuning, environmental • Temperature controllers compensation, safe stop, built in brake and • Servo motors and drives synchronous point to point control. The C2000 has • CNC solutions been designed as a modular solution to allow you to • HMI get only the components you need! Expanded I/O, • Power supplies hot pluggable LCD screen, a variety of encoder • Protocol Modules and Converters feedback and network cards including Profibus-DP,

Can we help you with other Delta Product:

Manufacturers Automation Inc. 1-800-387-6268 • www.manuauto.com 14 MA • Technology Handbook Motion Control

Automation for a Changing World

Leading the Future of Drive Technology

Smarter • Greener • Together How May We Help You?

Manufacturers Automation Inc. 1600 King Street North, St. Jacobs, ON N0B 2N0 - 1-800-387-6268 - www.manuauto.com

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rd

Technology handbook

Motion control

A Perfect Blend of Quality, Performance and exceptional Value

N

OARK Electric is a global manufacturer of electrical distribution and control products that address a variety of customer needs, ranging from components to intelligent system solutions. Our global product lines include: circuit breakers, contactors, relays and intelligent control. NOARK Electric was established in 2007 and covers the globe with regional headquarters in North America, Latin America, Europe and Middle East/Africa.

NOARK Electric is backed by a two billion dollar organization and serves the manufacturing, industrial, commercial, residential, utility and renewable energy markets. In North America, NOARK Electric focuses primarily on industrial OEMs, users and associated channel partners. Our motto is “Excellent product. Exceptional value.” NOARK Electric delivers this to our customer with a perfect blend of quality products backed by a five-year limited warranty; exceptional values that reduce the cost of products, improve profitability and increase margins; and local support and local inventory with superb customer service, a knowledgeable technical support, dedicated sales force, wellstocked inventory and a North American headquarters.

NOARK Electric’s top-selling products are: • Ex9 Series M: Molded Case Circuit Breakers and Switches that offer a complete range of UL 489 2 and 3 poles in four frame sizes: 100 A, 225 A, 400 A and 600 A. Each frame offers a choice of interrupting ratings at voltages ranging from 240~690 Vac and 250~600 Vdc. • Ex9 Series – B1: Miniature Circuit Breakers that offer a complete range of UL 489 and UL 489A listed 35 mm DIN rail miniature circuit breakers up to a 63 A current rating with a red/green contact position indicator.

• Ex9 Series – B1: Supplementary Protectors that offer a complete range of UL 1077 listed 35 mm DIN rail miniature circuit breakers up to a 125 A current rating with a red/green contact position indicator.

16 MA • Technology Handbook Motion Control

• Ex9C & Ex9R Series: IEC Contactors and Thermal Overload Relays with four frame sizes that bring optimization of electrical parameters and mechanical dimensions.

All frame sizes share accessory auxiliary contacts. Overload relays differ with frame sizes and fit the respective contactor of a given rated current.

• Ex9CD & Ex9RD Series: IEC Contactors and Thermal Overload Relays with four frame sizes that these contactors have a refined appearance, a compact structure and ease of installation. All frame sizes share accessory auxiliary contacts. Overload relays differ with frame sizes and fit the respective contactor of a given rated current.

• Ex9CK Series: Definite Purpose Contactors, these UL 508 rated definite purpose contactors have a rated current from 20 to 90 A with 1, 2, 3 and 4 pole configurations.

• Ex9SN Series: Manual Motor Starters are electromechanical protection devices for the main circuit and used mainly to switch motors manually ON/OFF and protect them fuse less against short circuit and loss-phase. None-fuss protection with a manual motor starter saves costs, space and ensures a quick reaction under short-circuit condition, by switching off the motor within milliseconds. Manual motor starter combinations are setup together with contactors and overload relays.

Contact NOARK Electric today to see how we can help you!

noArK electric north America 2188 Ponoma Blvd. • Ponoma, CA 91768 (626) 330-7007 nasales@noark-electric.com

na.noark-electric.com

Quality Performance Small Panel Solutions Ex9 Minature Circuit Breakers DIN mounted devices for branch circuit & supplemental protection

Broad product range • Amperage ratings: 0.5 A - 63 A Global acceptance • Certified to UL 489/489A and 1077, CSA C22.2 and IEC 60947-2 Flexible terminals • Less physical demand • Detachable shield makes it faster and easier for installer Three terminal options • Lug terminal • Box terminal • Quick connect Multiple accessories • Extended rotary handle* • Electrical auxiliaries • Locking device* * only available for 489/489A

Ex9C/CS Series AC Contactors & Ex9R Overload Relays

Ex9CD/CM Series AC Contactors & Ex9RD Overload Relays

Ex9CK Definite Purpose Contactors

Ex9SN Manual Motor Starters

NT

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Ex9 Series - B1 Miniature Circuit Breakers UL 1077 & 489

A

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Ex9 Series - M Molded Case Circuit Breakers & Switches

Y

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WAR

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Ex9 Series Push Buttons & Indicator Lights

Contact NOARK Sales for more information at: (626) 330-7007 • nasales@noark-electric.com • na.noark-electric.com

Technology handbook

Motion control

Grab Control of the Programming Process from Day one Integrated simulation tests the whole system, not individual logic, motion and safety programs from the start of a machine build.

C

ontrols engineers know the stress of the last-minute crunch to finish program development, testing and debugging the system to meet a promised delivery date. If only they could start working out the whole program from the start of the machine build instead of waiting until the very end. An integrated development environment (IDE) with program simulation provides a tool to let controls engineers control their destiny.

Integrated programming and simulation at Omron Automation and Safety means that a single software package, Sysmac Studio, can be used for logic, motion, safety and vision system development as well as HMI. Using simple drag-and-drop configuration, all hardware can be seamlessly integrated without cumbersome handshaking protocols and timing issues. Typically, each of these systems is developed separately, using software specific for the functionality.

Each one has its own programming environment. The Sysmac integrated programming environment reduces time lost creating multi variables to pass information back and forth. With all these under one environment variables are common to them all. The complex motion capabilities are further simplified by integrated cam editors. This facilitates easy cam integration that can be graphically displayed to show position, velocity, etc.. All applications are in one software, with one application version to control.

Parameters for all devices are in a single file for easy loading compared to several separate ones based on functionality.

Programming the System Typical simulation software often only lets the engineer check just the PLC program or motion program in isolation with no way to verify interaction between controlled devices. The early integrated simulators showed the interaction between PLC and HMI, and eventually general motion—defined here as point-topoint control, gearing and camming. High end motion control for robotic kinematics was kept separate due to the programming and timing complexities. Integrated configuration software like Omron’s Sysmac Studio automatically creates a single data table that can be referenced by all our connected control systems. This

18 MA • Technology Handbook Motion Control

provides the basis for extensive trace functionality within the simulator.

One Button Simulation Test the whole system, from PLC logic and motion to robotic kinematics without creating separate configurations for simulation and real world operation.

Sysmac Studio displays operation with a built-in, high-powered oscilloscope.

All sections of code work together as they would in the real machine, whose hardware may not be available for 12 to 14 weeks. The simulation allows the verification that motion processes complete their cycles where and when expected. Large simulation capacity lets engineers see more machine interaction instead of piecing together multiple traces to get a general sense of what is happening. A typical simulation offers 8 variables in a single trace—such as speed, acceleration, deceleration, and position. The simulator in Sysmac Studio provides 4 simultaneous traces with up to 192 variables that can be divided among the traces whether testing in simulation or with actual hardware.

Reward: One Golden Program File On-time machine delivery can be achieved with less stress using the integrated development environment and program simulation in Sysmac Studio. The comprehensive integrated view provides a practical basis to start developing the whole machine program starting week one and refining and debugging as the machine comes together, incorporating parts that get changed out along the way.

omron Automation & Safety 885 Milner Avenue Toronto ON M1B 5V8 Toll Free: 1-866-986-6766 Email: askomron@omron.com

www.industrial.omron.ca

Increase Throughput with Precise, High-Speed Motion

One unified platform controls your entire machine At Omron, we deliver a comprehensive range of products and services designed to increase the speed, versatility, and safety of your machines.

Our Sysmac automation controllers deliver ultra-synchronized performance

for up to 256 axes that lets you turn up the speed and maintain the quality level.

If you are developing a new machine or upgrading an existing model, look to Omron as your knowledgeable partner for superior automation.

Discover how we can overcome your machine’s throughput barriers.

OMRON AUTOMATION AND SAFETY • Canada toll free: 866.986.6766 • www.omron247.com

Technology handbook

Motion control

The laTesT generaTion

ThermoplasTic racks open up new moTion conTrol applicaTions

By DAvID HEIn

R

ack and pinions are linear actuators that play a critical role in a wide range of linear motion control applications. While rack and pinions are commonly thought of as a timeless technology, several new developments have helped provide significant performance improvements in specific applications.

One new approach — the roller pinion system — replaces the traditional rack and pinion with bearing supported rollers, increasing positional accuracy, speed and durability. The latest development goes one step further by constructing the rack from thermoplastic, which provides corrosion resistance, eliminates the need for lubrication, and reduces weight and cost. The latest generation of rack and pinion gears helps adapt this tried-andtrue technology for dusty environments, food industry applications that require 20 MA • Technology Handbook Motion Control

washdown, outdoor equipment, and many other applications that are not well served by traditional metal gears.

Conventional metal rack and pinion systems

Conventional rack and pinion gears consist of a circular gear, called a pinion, that engages the teeth of a linear gear, called a rack, to convert rotational motion to linear motion. Rack and pinion gears are commonly used as linear actuators in a wide range of machinery.

For example, they are used to move the axes of CNC machine tools, such as machining centres. They are also widely used to position robots used in assembly, welding, painting and other operations. Rack and pinion actuators are also suitable for controlling valves in pipeline transport applications.

Roller pinion systems

Traditional metal rack and pinion gears are less than ideal for many applications due to shortcomings such as backlash, cumulative error, thermal creep, vibration, noise, and particle emissions. A new design addresses these shortcomings by replacing the spur gear teeth with bearing supported rollers that engage a unique rack tooth profile. This approach replaces the sliding friction of conventional rack and pinion systems with smooth rolling friction that provides 99 per cent efficient rotary to linear motion conversion. Due to the smooth way the rollers engage the rack teeth, the new approach generates very low noise and vibration. It also does not suffer from noise caused by tooth slap or recirculating balls that can occur with other linear drive systems.

Technology handbook

Motion control

Characteristics of thermoplastic rack and pinion systems

Steel rack and pinion systems are ideally suited for clean operating environments, but applications involving corrosive fluids, washdown applications where the equipment is sprayed with water, outdoor applications, etc., are likely to substantially reduce the life of a metal rack and pinion. Most metal rack and pinion systems require lubrication, so they are not well suited to applications that generate considerable contaminants such as wood, fiberglass routing, or other applications that produce dust and debris.

Thermoplastic racks provide an alternative that delivers very high corrosion resistance, high durability and low maintenance requirements at a relatively low cost point.

Thermoplastic racks are impervious to corrosion. They are made of a self-lubricating polymer so they can withstand dirty environments and outdoor operation without concern over failure due to the loss of lubricant.

Their ability to run at full speed without lubrication reduces maintenance requirements and means that these systems can easily withstand washdown, outdoors operations, operation in coastal climates with salty air, etc. A related development is a new generation of value-oriented roller pinions that can also withstand dirty and harsh environments while providing good accuracy, good speed and good flexibility at an economical price point.

Typical applications for thermoplastic racks

There are many very high precision applications where steel racks will

continue to provide the best fit such as CNC machine tools, waterjet cutting systems, and robot transfer applications. Many other applications are well suited for thermoplastic racks as well like CNC routers, and are generally used for cutting wood, composites and plastic. Routing operations generate large volumes of chips that can interfere with lubrication of steel racks. Thermoplastic racks provide a good fit in most cases because they do not require lubrication and provide sufficient accuracy. Material handling applications such as conveyors and picking systems typically require high durability and low maintenance, while high levels of accuracy are not.

Thermoplastic racks provide a very good fit for this application, primarily because of their low maintenance requirements and low cost. They also provide a good fit for part marking systems, another application where low maintenance and durability are important but accuracy is not as critical. Many gantry-based automation systems are another good candidate for thermoplastic racks, as a typical gantry stacking system does not have high accuracy requirements so the low maintenance, durability and simplicity provide major benefits.

Conventional steel racks and pinions have been a mainstay of machine design for more than a century and are well positioned to maintain their leading role for many years to come.

Yet there are many applications that can benefit from a simple and durable alternative that offers high levels of corrosion resistance, reduced maintenance requirements and lower cost, while still providing accuracy and are load bearing. Thermoplastic racks deliver all these benefits and are destined to play an ever-increasing role in the industrial machinery of the future. • David Hein is the vice-president of engineering for Nexen Group, where he has managed worldwide new product development for more than 10 years. He also serves on several non-profit advisory boards.

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 lowestpriced 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 inhouse might seem to be the best option for companies with plenty of time, resources, product demand and money. > Motion Control Technology Handbook • MA 21

Technology handbook

Motion control

Unfortunately, engineers typically learn whether building inhouse 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.

Risk of ownership – When building a positioner, a company assumes every risk — from concept to product launch. When buying a positioner, a company should choose a reputable supplier that has already thoroughly tested the product to help reduce risk.

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 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.

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 22 MA • Technology Handbook Motion Control

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.

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.

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