NUMERIK JENA’s non-magnetic LIK linear series has a 20 micron graduation on glass and digital versions can output resolutions to 50 nanometers, where the digitizing electronics reside in the connector. With loose mounting tolerances of the scanning unit in relation to the 20 micron scale, and three configurations of mounting the scanning unit, the LIK series provides excellent motion feedback for high magnetic environments.

The RIK rotary series is a kit-style bearingless rotary encoder including a disk with various diameters and line counts, and non-magnetic scanning units to match those diameters.  The various sized aluminum disks containing a 20 micron graduation are epoxied to the customer’s hub design. NUMERIK JENA can also adhere the disks to custom hub designs at the factory with exact specifications and lowest runout errors.

Both encoder systems use the Epiflex Adjustment Tool to enhance the signal margin during installation on the machine. Long cable extensions are also possible for high magnetic field environments.

For more information, visit www.numerikjena.de.

Motion Control Tips

1. Networks

Perhaps the most significant and ongoing trend is the rise of Ethernet-based control networks. You see this with Rockwell’s Integrated Motion over Ethernet/IP as well as network standards based on Ethernet protocols such as Beckhoff’s EtherCAT standard. And a major reason for this trend is that using an Ethernet-based standard allows the manufacturing floor to more readily coordinate with other areas of an organization, most significantly with the larger enterprise resource planning, or ERP, functions within a company. But it also lets you integrate motion control with process and discrete machine control and even safety control.

2. Software

Specifically, simulation and modeling software. The relative ease of simulation and modeling is growing, with the benefits including the ability to slash design time and effort by doing increasingly sophisticated real-world modeling simulation of complex control systems and getting useful results from which to tweak the model before investing substantial time and material in building a prototype.

Another trend with software is the increased integration of what were once separate software packages. So for instance, many companies are offering software packages that integrate modeling and simulation functions with the motion controller, allowing an entire design to be done within one common software environment.

3. Controllers

Last but certainly not least is the area of motion controllers, the hardware itself. The general trend here is for manufacturers to add features, such as support for Ethernet-based network protocols and other more sophisticated features such as diagnostics and programming capabilities. And this trend of more features is common across the full spectrum of controllers, from stand-alone controllers for simple single-axis applications to powerful multi-axis controllers.

Summary

Of course, the motion control industry isn’t an island but is integrated with the larger world of global politics and economics. As just one example, this is why the supply of neodymium in China, used in the manufacture of rare-earth permanent magnets, is watched so closely, as China is the main exporter of neodymium at this time. So the price and availability of the material can easily affect the supply chain for motor manufacturers around the world. In addition, as the direction of the world economy remains uncertain and the world now more interconnected than ever before, recessions or upheavals in one part of the world can have a significant impact elsewhere.

It’s these global factors as well as technological ones that will make for an intriguing and anything-but-dull 2012.

Motion Control Tips

The certified plastic parts in the new ball rail system are even resistant to weak acids, lyes, organic solvents, oils and alcohols. They are strong and possess good sliding properties. Contrary to systems made from coated non-corrosion resistant steels, NRFG ball rail systems are not affected by surface damage and any resultant corrosion, increasing service life significantly. The ball rail systems are corrosion resistance Class 2 and hygiene Class 3 compliant.

The profiled rail can be mounted from the top, using the clip-on stainless steel cover strip to create a smooth surface. Alternatively, the mounting holes can be covered with white caps, or mount the profiled rail from underneath. The fully integrated sealing results in longer lubrication intervals, which means less maintenance. The ball runner blocks are not pre-lubricated so that users can fill in the proper lubricant recommended for their specific applications. Lube ports with metal threads are provided on all sides to give engineers a greater degree of freedom when space is tight.

NRFG ball rail systems are perfect in dry working zones such as primary packaging, even in environments where there is a combination of high humidity and high temperatures. Combined with screens or other protective barriers, they’re also suitable for splash areas and wet working zones in food processing, where liquid, moist or sticky foods stick to machine parts, or which are wet-cleaned and disinfected. Using FDA-certified plastics throughout eliminates the risk of unacceptable contamination during processing.

The ball runner blocks, which come in a flange version or a narrow version, are available in accuracy class H and in three preload classes. The O configuration of the balls ensures that the system has the required rigidity and equally high load capacities in all four main loading directions. Users can mount parts onto the runner blocks from the top or from underneath.

For more information, visit www.boschrexroth-us.com.

Motion Control Tips

LVDTs designed with a radially mounted electrical connector are shorter than those with axial connectors. In addition, the bending radius of the mating cable doesn’t add to the length. As a result, the installed length of the LVDT linear position sensors is at least 2 in. shorter than comparable units with an axially mounted connector for easier installation in tight spaces.

A radially mounted electrical connector also permits through-bore operation that makes the right angle LVDT accessible from both ends for better mechanical support and core guidance than with blind-bore units. In addition, through-bore design stops debris from getting trapped inside the LVDT body for longer, more accurate operation. Open at both ends, LVDTs can be easily cleaned of grit, dirt, dust or other contaminants for greater reliability and longer life.

Macro Sensors right angle LVDT linear position sensors are rated for operation in temperatures up to 220°F (105°C). Hermetically sealed versions, constructed entirely of stainless steel with coil windings sealed against hostile environments to IEC standard IP-68, are able to withstand pressures up to 1000psi. Available in both AC and DC configurations, DC-operated units use built-in electronics to provide the desirable features of an LVDT, such as frictionless operation and dynamic response, with the added convenience and simplicity of DC input and pre-calibrated DC output.

The combination of shortened installed length, environmental resistance and long-term operation make the right angle LVDT position sensors ideal for position measurement in hostile environments containing caustic/corrosive materials or with extreme temperature variations. Many can be found providing displacement measurement in applications for automotive factories, forges and foundries, metal fabricating machinery, paper and plastic film plants, sawmills, process automation applications, hydraulic cylinder and all types of motion control systems.

For more information, email positionsensors@macrosensors.com or visit Macro Sensors at http://www.macrosensors.com/index.html.

Motion Control Tips

Zero-Max Crown gear drives feature long-life, precision hardened and ground ball bearings handling speeds up to 2,000 rpm in most operating environments. The internal gears are permanently mounted to the shafts with locking pins. This provides a resilient and durable connection for use in heavy load applications while requiring no maintenance.

Zero-Max ensures their drives are predictably smooth operating, and similar model sizes have identical performance characteristics when designed into multiple drive setups. To accomplish this, Zero-Max drives are hand-shimmed and hand-assembled for perfect bearing and gear alignment. The drives are pre-lubricated during assembly, then completely enclosed in a heavy-duty anodized aluminum housing.  This design ensures that internal gears stay permanently aligned, lubricated and free of contamination from outside debris.

Zero-Max Crown drives are ideal for a wide range of machine applications including food processing, packaging and material handling systems. Available in many sizes and models, they are ideal for a wide range of horsepower, torque and shaft speed requirements. Standard two and three way models are available with 1:1 and 2:1 speed ratios in shaft diameter combinations of 3/8, 1/2, 5/8 and 3/4 inch.

For more information, visit www.zero-max.com.

Motion Control Tips

The hollow-shaft direct drive wing motor has two swinging stator halves that feature a mounting concept for unique integration and operating scenarios where axial installation and removal in or from a machine are not possible. The split stator contains two parallel, three-phase systems which allow for the stator to be joined together in a controlled way. Each stator half contains a water-cooling pipe system made from stainless steel. It prevents damage to the drive due to intense heat stemming from the roll. It can be retrofitted or dismantled at any time for maintenance, and is designed to withstand the harshest of operating environments.

This motor operates the same way as a classic, one-piece direct drive with impressive performance.

For more information, visit www.wittenstein-us.com.

Motion Control Tips

Whether a system needs special mechanical requirements, special sealing, Autoclave heat cycles, or the ability to withstand a harsh environment, Applimotion can create a solution with one of its frameless motor kits. Applimotion engineers will guide you through the selection of feedback, bearings and precision mechanical attributes.

Direct drive motors are finding their way into many new applications as designers see the advantages in reliability, precision and performance compared to traditional solutions. If you know it is the right solution, but do not have the resources in house, Applimotion can create an affordable direct drive solution that fits your application.

For more information, visit www.applimotion.com.

Motion Control Tips

HM series hybrid stepper motors, as drop-in replacements in most industrial and medical hybrid applications, allow machine builders to reduce the ownership cost of their machine with no noticeable sacrifice in performance.  As a result, these RoHS-compliant hybrid step motors are an ideal solution in life sciences, fluid handling, industrial automation equipment, medical devices and vending/ticketing applications.

For more information, email sales.america@portescap.com or visit www.portescap.com.

Motion Control Tips

With 8 gear ratios available (16:1 to 643:1), the brushed DC MG16B gear motor series develops a range of rated torques from 1.42 oz-in. at 800 rpm to 42.5 oz-in. at 17 rpm.  Using the same gearboxes, the brushless DC LB16MG gear motor series (with integrated driver) generates 1.42 oz-in. at 710 rpm to 42.5 oz-in. at 18 rpm.

Available input voltages for the MG16B include 6, 12 and 24 VDC and 6 and 12 VDC for the brushless LB16MG version. Nidec Copal also provides a lower cost HG16 series of 16mm gear motors using resin planetary gears.

For more information, email info@nidec-copal-usa.com or visit www.nidec-copal-usa.com.

Motion Control Tips

The DMC-300xx is higher speed than Galil’s prior generation single-axis controllers; The 125 microsecond servo loop update time is twice as fast and the 15MHz encoder frequency and 3 MHz stepper pulse output are 25% faster.

The DMC-30012 model is packaged with an 800W amplifier for driving brushless servo motors at 20-80 VDC, up to 10A continuous, 15A peak. The fully digital, transconductance amplifier is a sinusoidally commutated brushless motor amplifier that minimizes torque ripple compared to drives using trapezoidal commutation. This is especially important for applications using low friction linear motors. The amplifier provides commands for initialization of the brushless motor using either hall sensors or encoder feedback.

Other features of the DMC-300xx motion controller include PID compensation with velocity and acceleration feedforward, non-volatile memory for user programs, multitasking for simultaneously running up to four programs, and I/O processing for synchronizing motion with external events. Modes of motion include point-to-point positioning, position tracking, jogging, contouring, electronic gearing, ECAM, and PVT.

The DMC-300xx provides optically isolated inputs and outputs as a standard feature. It also provides two 100Base-T Ethernet ports that can be daisy-chained, allowing multiple units to be connected without the use of an Ethernet hub. I/O includes forward and reverse limit inputs, homing input, 8 uncommitted digital inputs, 4 uncommitted digital outputs, 2 uncommitted analog inputs and 1 uncommitted analog output. The DMC-300xx accepts position feedback from both a main and auxiliary encoder. Quadrature encoder feedback is standard with BiSS and SSI formats available as an option. A 115 kb RS232 port is also provided.

Visit www.galilmc.com/products/dmc-300xx.php for more information.

www.galilmc.com

Motion Control Tips

The DMC-1417 can handle the most demanding applications with features such as an extra encoder input for electronic gearing, program memory with multitasking, uncommitted I/O and user-selectable stepper or servo motor control. Modes of motion include point-to-point positioning, jogging, contouring, electronic gearing and e-cam.

Programming the DMC-1417 is simple using two-letter, intuitive commands and a full set of software tools such as WSDK for servo tuning and analysis, ActiveX Tool Kit for Visual Basic users and a C-Programmers Tool Kit. Econo Series controllers do not include uncommitted analog inputs and are not optoisolated.

The DMC-1417 can accept up to 8 MHz encoder frequencies for servos and 2 MHz for steppers and can accept inputs from two encoders for gearing or dual-loop applications. It also features advanced PID compensation with velocity and acceleration feed forward and integration limits as well as modes of motion including jogging, point-to-point positioning, contouring, electronic gearing and ECAM with multitasking for concurrent execution of two application programs.

The DMC-1417 also features sinusoidal commutation for brushless servo motors, memory for application programs, variables and arrays, as well as 7 uncommitted digital inputs, 3 digital outputs, and forward and reverse limits and home input. A 37-Pin D-type connector is standard with custom hardware and firmware options available as well.

www.servo2go.com

www.galilmc.com

Motion Control Tips

Maximum permissible torque is increased by up to two times the level of conventional AC motor gearheads. If the load condition changes, the gearhead’s strength can easily accommodate it and there is no need to increase the size of the motor or gearhead. Specific torque is dependent on frame size.

The motor’s strength is due to its rigid case, a proprietary side-panel construction and an optimized gear design. The larger diameter bearing serves to extend its useful life.

For more information about the V-Series, visit: http://www.orientalmotor.com/products/ac-motors/v-series.html

Motion Control Tips

Some of the benefits of Balluff’s UHF system include the enabling of real-time visibility for logistics and manufacturing, needing no batteries for long-range transmission and unlike bar codes, UHF does not require “line-of-sight.” Other features include RS232 serial or Ethernet TCP/IP interface options and the ability to detect and process multiple RFID tags at once.

Applications include asset tracking, logistics tracking, closed-loop and supply chain logistics and production tracking.

Balluff can combine the new UHF system with our other passive RFID technologies, including high frequency ISO15693 systems to provide greater flexibility with the highest reliability. Balluff can also provide the necessary services for site surveys, hardware and even software integration to create a fully integrated, cost effective and reliable manufacturing and logistics solution.

For more information on Balluff’s UHF systems, visit: www.balluff.com/UHF

www.balluff.com

Motion Control Tips

Designed to meet the needs of machine manufacturers, value-added resellers and end-user service organizations, Support Connect enables cost effective administration, predictive maintenance and remediation of remotely managed assets without an upfront investment in datacenter hardware, and ongoing infrastructure maintenance.  Support Connect allows service/support resources to concentrate on serving their customers instead of managing the connectivity between companies.

Learn more about Support Connect by visiting http://www.meau.com.

Motion Control Tips

Simotion D motion control systems are ideal for production machines covering all levels of performance; from simple single-axis positioning tasks to complex synchronous applications, with extremely short cycle times on a large number of axes. Thanks to its scalability, Simotion D offers users a high degree of flexibility for the ever-changing demands of machine automation. The Simotion D drive-based multi-axis control system not only offers PLC, motion control and advanced technology functions, but also an integrated drive control based upon Siemens Sinamics S120 drives.

With the new Simotion D445-2 DP/PN and D455-2 DP/PN versions, the performance range has been extended even higher. Compared to the previous generation, the maximum quantity has been doubled to 128 axes and the memory capacity significantly expanded. This has increased the PLC and motion control performance by a factor of three. With Simotion D445-2 DP/PN and D455-2 DP/PN, the previously optional Profinet I/O interface has now been integrated on the modules as standard. This frees up the option slot for other expansion cards. The onboard interface is equipped with an integrated three-port switch and facilitates different network topologies such as line, star or tree structures, without the need for additional external switches. The interface not only supports real-time (RT), but also isochronous real-time (IRT) data exchange and can be operated as a controller and/or device of another controller.

In addition to the Profinet interface, Simotion D445-2 DP/PN and D455-2 DP/PN also have two Profibus and two Ethernet interfaces, as well as 28 digital I/Os, of which 16 can be used for technology tasks such as output cams and measuring inputs with microsecond resolution.

For more information, visit www.usa.siemens.com/motioncontrol.

Motion Control Tips

The BIP is non-contact and linear travel of up to 40mm can be reliably detected.  The Balluff BIP has a resolution of 14 microns, high repeat accuracy of +/- 80 microns and non linearity of +/- 250 microns for optimal process quality. Available outputs include 0…10V and 4…20mA.  The sensor’s high degree of repeat accuracy guarantees excellent process quality, even in cramped locations with temperatures up to 85°C.

Mechanical adjustments are not necessary as the sensor is teachable on site, allowing the measuring range to be adapted to the application. With the IO-Link Variant this is also possible via the control system.

For more information on Balluff’s BIP linear inductive positioning sensors, visit www.balluff.com/BIP.

Motion Control Tips

Cicoil’s exclusive crystal-clear silicone encapsulation is tear-resistant, needs no external “armor” or conduit for protection, and will not deform or wear during a lifetime of more than 10 million cycles, even under tight bending radius and high speed flexing conditions. These halogen-free cables are an excellent alternative to bulky round and stiff PTFE, Polyurethane & PVC jacketed flat cables.

Cicoil’s UL recognized, RoHS compliant & CE conforming wire is manufactured in an automated, climate-controlled environment, and exceeds the NASA 1124 outgassing specifications for space use and vacuum requirements. The cable is also 100% contaminant-free, as it is rated for Class 1 clean room use.

Standard “off the shelf” High Flex Unshielded Cable (4 AWG to 30 AWG) is available from stock in continuous lengths, cut to order, or as assemblies, complete with connectors of your choice, 100% tested and inspected.  For additional abrasion resistance, Cicoil offers anti-friction coating options by request.

Visit www.cicoil.com for more information.

Motion Control Tips

Whether you’re looking for split bearing solutions, trying to determine why a bearing failed or trying to learn more about bearing types and the numbering system, Emerson Bearing’s selection of videos will impart all the information desired and more. Looking to learn about the history of bearings? Or perhaps learn more about Emerson and sister company Action Bearing which have become Boston’s industrial cornerstone for bearings? Simply log on to their website and visit the Video Tutorials page.

The average video duration is 4:40 minutes, with the shortest video being “Optimum Sealing” for challenging environments (1:09) and Bearing Types and Numbering (10:38) being the longest.

Visit http://www.emersonbearing.com/video-tutorials.html to view the videos.

Motion Control Tips

The motors are ideal for many applications in self-contained drive systems as well as industrial automation applications. Designed as internal or external rotor motors, they are often the ideal solution when space is limited.

For more information, visit www.maxonmotorusa.com or email info@maxonmotorusa.com.

Motion Control Tips

When compared with the conventional STOBER K1 helical bevel gear unit version, the new KL1 supplies increased torque density of well over 100 percent. The size reduction for the KL was achieved by a newly designed, 2-stage gear set geometry. The housing dimensions of the two sizes illustrate the new shape factor. In the KL1 version, the length is 113.5 mm, the width 81mm and the depth 90 mm; this represents a volume of only 0.83 liters.

The KL2 is 143.5 mm long, 98 mm wide and 108 mm deep, which makes its volume only 1.52 liters. This compact housing also gives a significant weight reduction, which is an advantage for drive dynamics, particularly on traveling axes.

Input speeds of up to 6,000 rpm are possible in cyclic operation with a torque range up to 65 Nm. The highly stiff, compact and symmetrical design requires no offset because the unit looks virtually the same on either side. On the output side, the new right-angle gear unit offers various options for output shafts and mounting methods, including solid shafts with and without keys, and hollow output shafts with and without keys. Output shafts are available in carbon and stainless steel.

Motors from other suppliers can be fitted using an adapter with a backlash-free coupling that features thermal length compensation. Both sizes are available in all the different versions.

www.stober.com

Motion Control Tips

The new STM line is designed to enable the control of up to 127 motors over a 5,000 meter (16,400 feet) bus length using the motors’ integral CANopen interface with a single economic, off-the-shelf PLC having a solar tracking function block. The STM integral control brushless motors can also be used with industrial PCs as well as Profibus and Modbus networks. The embedded intelligence of the STM motors’ integral controls, which are designed with up to 650,000 hour MTTF, dramatically reduces bus traffic by running complex routines onboard, such as homing and closing the position loop with an attached absolute encoder or inclinometer. In addition, the motors’ embedded intelligence can also take over mission critical functions, like returning to a safe position, when the network is down.

The low-voltage brushless dc STM motors are available in three millimeter frame sizes (45, 65, 75) with powers up to 530W (0.7 hp) and can be easily integrated with existing design slew drives, pan and tilt mechanisms and linear actuators used in the solar industry. Where additional gear reduction is required, the STM motors can be mated to Dunkermotor’s own modular planetary or worm reducers offering up to 678 Nm (6,000 in-lb) peak torques.

The standard STM motors are designed to be maintenance free for life. They are rated for IP65 environmental protection, employ special venting devices to prevent condensation, as well as proprietary lubrication techniques for the low speed, high torque and wide temperature ranges found in solar applications. The STM’s integral control also features speed and torque regulation capability to prevent mechanical damage.

http://www.dunkermotor.com

Motion Control Tips

Using Baumer’s patent-pending HDMag MSGP sensor technology, the series consists of a magnetic encoder attached using flexible magnetic tape. The customized tape can be easily buckled onto the drive or generator shaft, just like a belt. With the help of the welded fastener, the tape is tightened on the shaft and can be quickly exchanged when required. The narrow read-head incorporates an integrated dual sensor head that is mounted to a frame over the flexible tape. This takes up minimal space on the shaft and operates without interruption over the fastening gap in the tape ends, and has no effect on the encoder output signal.

The unit can be installed and removed repeatedly without affecting performance, and offers wear-free speed and position feedback with a nearly unlimited service life.

For uninterrupted sensing across the fastening gap, the flexible magnetic tape encoder features an integrated dual sensor head and a signal processing unit (patent pending). The large permissible tolerances on axial displacement (+/- 5 mm) and air gap (up to 3 mm) ease alignment of the sensor head and also ensure  reliable detection unaffected by mechanical backlash and vibrations. The fully encapsulated electronics integrated in the sensor head are protected against soiling, shocks and vibrations. The integrated FPGA-based signal processing allows for high angular resolutions, better than 0.003°, more than 100,000 ppr, and will remain unaffected by thermal shaft expansion.

For more information on Baumer’s HDMag line, visit www.baumer.com.

Motion Control Tips

The 4mm Linear Shaft Motor is quiet due to the absence of friction because the only mechanical contact section is the linear guide. The coreless construction of the Linear Shaft Motor also eliminates cogging and due to its design it also has no backlash.

The motor’s high stiffness allows it to be used in high precision positioning applications where a resolution of 0.09 nanometers is achievable. The motor also boasts virtually no fluctuation in speed.

Durable construction makes it possible to operate the Linear Shaft Motor in harsh conditions, including a vacuum situation and underwater.

www.nipponpulse.com

Motion Control Tips

The new NI cRIO-908x systems feature an Intel® Core™ i7 dual-core processor for increased processing power, Xilinx Spartan-6 field-programmable gate arrays (FPGAs) and the option of a Windows Embedded Standard 7 (WES7) OS configuration for monitoring and control applications that require exceptional performance and the ruggedness of CompactRIO. For high-volume and OEM applications, the new NI sbRIO-9605/06 devices are sized from less than 102.87 mm x 96.52 mm and offer greater customization and I/O support than previous versions.

With the Intel Core i7 dual-core 1.33 GHz processor and up to a Xilinx Spartan-6 LX150 FPGA, the cRIO-908x systems deliver the highest processing power of any CompactRIO product and are ideal for performing complex signal processing and control within applications such as rapid control prototyping, advanced motion control and machine vision. The controllers can be configured with a WES7 OS, which gives engineers access to a broad ecosystem of Windows-based software and integrated graphics, or a real-time OS for reliable, deterministic performance. The systems provide a variety of high-performance peripheral connectivity including two Gigabit Ethernet ports, a MXI Express port, four USB ports, RS232 and RS485 serial ports and a new CPU eXpansion Module (CXM) that makes it possible to add custom connectivity and expansion to CompactRIO using industry standard protocols.

The new NI Single-Board RIO devices provide a small and cost-optimized form factor for the NI RIO platform and are ideal for embedded monitoring and control applications in industries such as energy and medical. The devices feature a 400 MHz processor and Xilinx Spartan-6 FPGA to provide reliability and performance at a low price point for OEMs. The devices also offer built-in peripherals such as RS232, CAN, USB and Ethernet. Additionally, the new devices feature a high-density and high-bandwidth connecter that gives engineers direct access to the FPGA and processor as well as the ability to add peripherals for further customization.

An integral part of the NI graphical system design approach, NI RIO technology combines NI LabVIEW system design software with commercial off-the-shelf hardware to simplify development and shorten time to market when designing advanced control, monitoring and test systems. NI RIO hardware, which includes CompactRIO, NI Single-Board RIO, R Series boards and PXI-based NI FlexRIO, features an architecture with powerful floating-point processors, reconfigurable FPGAs and modular I/O. All NI RIO hardware components are programmed with LabVIEW to give engineers the ability to rapidly create custom timing, signal processing and control for I/O without requiring expertise in low-level hardware description languages or board-level design.

Learn more at www.ni.com/compactrio and www.ni.com/singleboard.

www.ni.com

Motion Control Tips

With a unipolar winding, the PF55 stepper offers a holding torque of 120N, while a bipolar winding provides 150N of holding torque. In a full-step (2-2) excitation mode, the PF55 has 48 steps per revolution, a rated voltage of 5 and 12V, inductance between 12 and 37mH, and resistance between 5 and 36 ohms.

The PF55 stepper motor also comes in a gearhead model with 20 different ratio options, ranging from 6/25 to 1/300. These gearhead motors provide maximum torques of 400, 700, and 1000mN·m. All variations of the PF55 motor are also available with a connector.

Nippon Pulse PF55 motors are ideally suited for liquid dispensing devices, valve control machines, torque metrology instruments, printing machines, and medical diagnostic systems.

For more information, visit www.nipponpulse.com

www.nipponpulse.com

Motion Control Tips

The SPK+ 210 / 240 hypoid gear has an output shaft and offers:

- Torques up to 4500 Nm

- Ratios up to i=10000

The TPK+ 300 / 500 hypoid gear has an output flange and offers:

- Torques up to 4500 Nm

- Ratios up to i=10000

www.wittenstein-us.com

Motion Control Tips

Two versions of the new control are available in the same compact, power-dense package size of 51.7cc, slightly larger than a matchbox. The BGE 3508 model is designed for 10-30V input with 75W of continuous and 225W peak power, while the BGE 6005 model can produce 120W continuous and 300 W of peak power with 60V input.

These new controllers are suitable for use with brushless or conventional brushed DC motors similar to Dunkermotoren’s BG and GR/G ranges. Information about the motor’s rotor position can be supplied to the positioning controller either by the voltage or by an encoder in the case of commutator motors or, for brushless motors, by Hall sensors or an incremental encoder. The controls incorporate protection against over-voltage, low voltage and excessive temperature.

If 4-quadrant digital speed control is desired, the control can be commanded to run in either direction, stop and hold with torque, and stop without torque (coast) through digital inputs. Other inputs can switch between programmed speeds or allow for a variable analog speed reference. Accel/decal ramps for the motor can also be programmed. The control offers the capability for a motor to function as a stand-alone, programmed servo which interfaces to the rest of the machine via digital and analog IO.

The new BGE 3508/6005 controllers offer many different modes of operation to choose from, such as analog or digital torque control, analog or digital speed control and digitally selectable position control (relative, absolute, and modulo).

Designed for volume OEM applications, the Dunkermotoren BGE 3508/6005 controllers offer a design alternative for restricted space applications where the additional length of an integral control motor may not be feasible. They can also be encapsulated to provide additional protection in extreme environmental conditions.

CANopen is the most widespread application layer in non-automotive control applications and market researchers predict that by 2015 some 400 million CAN chips will be used annually in a wide range of applications such as medical equipment, heavy vehicles, door control systems and throughout commercial and industrial automation systems.

Visit www.dunkermotoren.com to find out more.

www.dunkermotoren.com

Motion Control Tips

The High Performance Servo Motors have all the necessary characteristics to optimize productivity and efficiency for your processes. With a compact design and reduced inertia for high dynamic performance, these servo motors offer unexcelled efficiency with high continuous power.

High Performance Servo Motor frame sizes and corresponding lengths are:

Servo Motor MRSH049A (available in lengths of 15mm, 30mm, 45mm, 60mm)

Servo Motor MRSH064A (available in lengths of 15mm, 30mm, 45mm, 60mm)

Servo Motor MRSH130A (available in lengths of 30mm, 60mm, 120mm, 230mm)

Servo Motor MRSH178A (available in lengths of 135mm, 195mm)

Servo Motor MRSH178C (available in lengths of 135mm, 195mm)

www.wittenstein-us.com

Motion Control Tips

The FSBR brakes are designed for applications requiring minimum space (short axial length) or on motors with short shaft extensions. When mounted, the armature hub is installed on the shaft first, then the brake is installed over the hub and attached to the motor.

The FSBR brakes are rated up to 100 lb-in static torque, and fit motors up to 5.3 in. outside diameter.

For more information, visit http://www.servo2go.com/product.php?ID=100509&cat=10019

Motion Control Tips

The new EC 16 is available with up to five winding types as well as with hall sensors or sensorless. Four high-power motors are available; 30W or 60W and sterilizable or non-sterilizable.

The new design features a torque/speed gradient reduced by approximately 60% and maximum continuous torque increased approximately by 80%. Other key improvements include higher stability, quiet running, larger bearings, higher forces, improved performance and higher torque. Coupled with gearheads that are also sterilizable, this drive is ideally suited for the most demanding medical and hand tool applications.

Visit www.maxonmotorusa.com for more information.

Motion Control Tips

The SCR100 stage is a moving magnet design, which locates all cables and connectors in the stationary base. The absence of any moving cable means a clean and compact design and eliminates motion errors due to cable forces. The precision ground cross roller way provides high stiffness and smooth motion. Together they are capable of supporting higher torque levels due to offset loads with travels from 50mm to 300mm. The non-contact Linear Shaft Motor and optical linear encoders are self-contained inside the stage, making it a low-profile compact solution. The built-in non-contact optical linear encoder is available with resolutions from 1 micron to 10 nm with digital output. The sub-micron resolution results in a high accuracy stage, which is laser tested for optimum performance.

The SCR100 stage has the added benefit that any standard digital servo driver can drive the SCR100 stage. Any two SCR stages will bolt directly together to form a very stiff, compact X-Y stage. Two SCR stages can be supplied compounded as an X-Y stage to insure true orthogonal orientation.

www.nipponpulse.com

Motion Control Tips

Continuous torque for the smaller size 17 brushless PM motor starts at 35 oz-in at 900RPM (3W) duty up to 700 oz-in at 1500RPM (770W) for the size 34 brushless servo motor. Maximum speeds are 4000RPM. The SilverDust controls product line has RS232, RS435 and CANopen protocols with Ethernet and Modbus TCP as an option. Currents range from 3.5A in the smaller size 17 and 23 SilverDust drives and up to 10A in the larger size 34. Typical input voltages are 12 to 48VDC.

The SilverDust controller uses sophisticated motion control algorithms to maximize the high torque capability and properly handle very high load inertias reaching a 100:1 inertia mismatch.

For more information contact QuickSilver Controls Inc. at www.quicksilvercontrols.com.

Motion Control Tips

The miniature brushless actuator is able to adjust its vibrating force without changing the vibration frequency. This surface mount device (SMD) provides high acceleration, superior reliability, and quick signal response for a wide range of mobile communication and safety devices. New applications involve devices and machines that use touch or tactile (haptic) motion and are used in video game and computer controllers, touch pads, robots and medical instruments.

For more information, visit www.nidec-copal-usa.com or email info@nidec-copal-usa.com.

Motion Control Tips

All input and output functions of the ServoNOW™ are programmed into the set-up feature through a simplified indexing type command structure making it able to interface to nearly any logic input and output. Analog inputs can be selected and set-up to control the position or velocity of the system. All set-up and installation can be accomplished with any standard PC with a built-in USB port. Free, downloadable host software called QuickLaunch is available with the package and loads on any Windows PC.

The ServoNOW™ incorporates an inclusive closed loop brushless servo motor with built-in driver, controller, magnetic encoder and 110/230VAC universal power supply all in one complete, compact package. Four programmable digital inputs and outputs, analog I/O (0 to 10VDC or 4 to 20MA, 12 bit) and position resolution of 4096 counts per revolution is included.

There are 5 standard, 34 frame models with different variations of high speed (6900 rpm) and high torque (310 in-lbs) features which can be customized to meet application specific requirements.

ServoNOW™ products are part of Bison’s In-Stock, Instant-Ship (ISIS) program that supports Bison’s distribution partners and web customers offering same day shipment for orders received before noon (Central Time).

www.bisongear.com

Motion Control Tips

The R325 microstepping driver is capable of output currents ranging from 0.3 to 3.0A peak while handling +15 to 48VDC of input voltage. Selectable step resolutions from Full, 2x, 4x, 8x, 16x, 32x, 64x, 128x, and 256x microstepping are also available. The R325 has hold current reduction capability with adjustable current and timeout settings. It also features three optically isolated inputs and one optically isolated control output that can be used for step, direction, disable/enable, and fault detection.

The R325 features Pole Damping Technology™ (PDT) which enhances a step motor’s performance by creating a more accurate and smooth motion profile. PDT optimizes the microstepping performance of the step motor by outputting the correct amount of run and hold current to the motor, at the right time. Thus, each step will overcome the motor’s natural tendency to want to “jump” towards the full step ON position.

www.linengineering.com

Motion Control Tips

The AC201 Digital Autocollimator is ideal for instrumentation, tooling, and OEM manufacturers with requirements for high precision alignment, flatness, squareness of surfaces in relation to each other, detection of angular movement, shaft straightness, motion control, and other orientation measurements. This rugged and compact 1.0 in. x 1.1 in. x 1.3 in. (2.5 cm x 2.8 cm x 3.3 cm), low-cost digital autocollimator can also interface with a PC.

The AC201 Digital Autocollimator has an optical angular range of ±344 arc sec (±100 mrad), and a sensitivity of 0.2 arc sec (1.0 µrad). The laser has a beam diameter of < 0.125 in. (<3 mm) and requiring only a slightly larger reflection surface.  Electrical requirements are: +5.0 VDC @ 30 mA. It can be factory configured with one of several different interfaces including analog, USB, SPI, or quadrature encoder. The black anodized (per MIL-A-8625C) 6061-T6 Aluminum body has 2x 4-40 mounting holes and integral electronics and connections are via a Nano D9 or USB connector.

Supplied with a Windows® application software and more than 24 ASCII commands for control and operation, the AC201 Digital Autocollimators can perform complex data collection and analysis. They are ideal for vibration analysis, mechanical and optical alignments, servo control feedback, tip & tilt measurements, settling time and stage damping analysis, and measurements needed in the manufacturing and testing of miniature mirrors and lenses, linear and rotary stages, fiber optic components, robotic components, and medical analytical devices.

For more information, email info@equipsolutions.com or visit www.equipsolutions.com.

Motion Control Tips

The module processes signals to and from the drive, mounts on 35mm DIN rail, and connects the drive to an Ethernet hub or PC. It formats drive signals to conform with the Ethernet standard and transmits these signals to the H2-ERM or H4-ERM, Productivity3000, KEPDirect OPC Server, KEPDirect EBC I/O Server, or independent controllers with a Modbus TCP/IP driver. This allows for greater connectivity to many control system architectures. The GS-EDRV100 is equipped with a serial and an Ethernet communication port and LED activity indicators.  The module ($185) features a built-in Web browser which allows users to configure and control the drive from any Web browser via the IP address of the GS-EDRV100 module.

AutomationDirect has also added the H2-SERIO-4 serial communications model to its line of communication devices for WinPLC and PC-based control systems. The H2-SERIO-4 module has two RS-232C ports and one RS-422/485 terminal. Each port on the module is capable of full hardware handshaking. The H2-SERIO-4 communications module is priced at $165.

For more information, visit www.automationdirect.com.

Motion Control Tips

Ranging from 2 to 12 poles, 2706 Series provides a lever for each pole. Lifting each opens a CAGE CLAMP Spring Pressure unit that remains open for conveniently terminating multi-conductor cables into the terminal strip. Lowering the levers creates an audible click, signaling that the units are secured. 2706 Series resists thermal-, vibration- and current-induced loosening common to screw-style terminations, eliminating preventive maintenance.

Pin spacing ranges from 7.5, 10 to 12.5mm; the 12.5mm variant achieves UL 600V certification. 2706 Series is available with jumper slots for potential commoning via optional comb-style jumper bars; additional accessories include test plugs and marker strips.

For additional information, visit www.wago.us.

Motion Control Tips

Whether you require special mechanical requirements, high accuracy for precision positioning, or a harsh environment, Applimotion can create a solution for you. The process is straight forward. An Applimotion motor kit is selected based on performance needs. Then Applimotion engineers guide you through the selection of feedback and precision mechanical attributes. Finally, a complete custom direct-drive motor solution is fabricated and delivered, including unique testing if required.

Direct drive motors are finding their way into many new applications as the advantages in reliability, precision and performance are realized. Applimotion has supplied their motors to a wide range of industries including energy, medical, unmanned-vehicles, inspection, metrology and military/defense. Unfortunately, standard off-the-shelf solutions currently available often don’t have the right features and can be too expensive.

For more information, visit http://applimotion.com.

Motion Control Tips

The latest MOFSET technology is more efficient and robust than its predecessors.  Greater efficiency leads to a more compact ACS controller that reduces the requisite number of mechanical components. Greater robustness and fewer components maximizes reliability, while smaller size lets OEMs place the controller more freely within the vehicle to reduce cabling and mounting costs. The net impact for OEMs who use ACS GEN6 motor controllers is maximum reliability with lower total cost of ownership.

ACS GEN6 is the first Kollmorgen product released with Kollmorgen’s new software platform for vehicle motor controllers. The software lets Kollmorgen customize software to meet specific customer requirements, while crucial firmware functionality remains untouched. Improved granularity and adjustability of the event log, as well as advanced logging, are firmware features that bring value to both OEMs and end-users by allowing detailed and accurate troubleshooting information to shorten vehicle downtime and minimize service costs. Additionally, the software is designed to meet the high quality standards of the automotive and hybrid markets, and Kollmorgen’s software development process is regularly audited for conformance to Automotive SPICE©.

The design and manufacturing process of ACS GEN6 controllers ensures maximum product quality. ACS GEN6 has gone through repeated Design For Manufacture (DFM) analyses during the design process to ensure that the product is optimized for stable and consistent manufacturing at high volume. Specialized production equipment tailored to manufacturing ACS GEN6 was developed alongside the actual products to ensure that the production equipment and processes, as well as the product itself, enable low variance production.

For more information visit www.kollmorgen.com.

Motion Control Tips

Extreme temperature motors are used in the most demanding of environments – from space to the ocean floor. These servo motors are small but designed to handle conditions where extreme temperature is a demanding requirement. Reliable systems will operate at temperatures ranging from -70°C to 210°C.

Radiation-hardened motors are custom designed to their own unique specifications. With the latest FEM-development software and proprietary motor programs, rad-hard servo motors are suited for applications in military and aerospace due to their highly accurate positioning, dynamic acceleration and high constant stability.

Ultra high vacuum (UHV) motors require the use of special materials and extreme cleanliness due to their environmental restrictions. These servo motors offer a range of vacuum levels for a variety of applications. Time and cost savings are significant due to high reliability and faster system pump-down.

For more information, contact WITTENSTEIN at info@wittenstein-us.com.

www.wittenstein-us.com

Motion Control Tips

The Siemens line of XP100 motors are UL® and CSA listed for gas and dust ignition-proof environments and are suitable for Division 1, Class I, Groups C & D, Class II, Groups F & G, hazardous area classifications. They are also available for drill rig duty in Division 1, Class I, Group D hazardous locations. Their advanced electrical design meets or exceeds the requirements of the Energy Independence & Security Act of 2007 (NEMA MG1 – table 12-12). Siemens is a NEMA Premium® licensee.  Therefore, all XP100 motors bear the prestigious NEMA Premium® logo.

Available from stock with ratings from 1 hp through 300 hp and modifiable to specific application needs, the XP100 motors combine durability, superior operating performance and energy efficiency into a single package.

The Siemens XP100 explosion proof motor features a cast iron frame and bearing housings that provide high structural strength. In addition to the all cast iron construction, the XP100 features epoxy enamel paint, polycarbonate cooling fan, non-hygroscopic insulation, corrosion resistant hardware and stainless steel nameplate to reduce the effects of industrial contaminants, moisture and extreme weather conditions.

The stator insulation system design and components result in an anti-corona system that can withstand voltage spikes caused by fast switching IGBTs from adjustable speed drives.  Each die cast aluminum rotor assembly is balanced for extended bearing life and includes a high strength carbon steel (C1045) shaft for maximum performance.

Siemens XP100 motors are available with a wide range of options such as QuikMOD modifications (2 days or less) and customer specific designs.

For more information about the XP100 visit http://www.sea.siemens.com/us/Products/Electric-Motors/NEMA-AC-Motors/Pages/Hazardous-Duty.aspx

Motion Control Tips

RFID with cloud computing leverages shared IT infrastructure and standard software to collect and present tracking data without having to develop, maintain and most importantly, finance a redundant and load balanced infrastructure internally. Cloud applications also provide visibility and access anytime, anywhere, and on any web-enabled device.

By using cloud computing from Balluff and provider partners like IGear, the burden and cost of the IT infrastructure can be greatly reduced or even eliminated.

For example, building an on-premise application for a single machine or work cell would typically require an upfront investment of $30K for hardware, software, and integration services. The ongoing cost of support and maintenance requires an additional $10K investment. Additional challenges with on-premise applications include remote access and keeping up with the latest devices and web browser development.

In contrast, a comparable cloud application would involve an annual subscription of $1K with the potential need for one-time configuration services of $10K; a savings over $20K the first year and as much as $9K every year thereafter. With cloud applications, updates and enhancements are instantly rolled out to all users and the infrastructure is secure, redundant, and load balanced. Using Balluff RFID with cloud computing provides cutting edge visibility and visualization of your data while significantly lowering the cost of ownership.

For more information visit www.balluff.com/RFID.

Motion Control Tips

In the High Speed Reversing Drive (HSRvD) the input to the two clutches rotate in opposite directions. Force Control High Speed Reversing Drives are ideal for higher horsepower applications (up to 75 hp) that require reversing often, such as automotive production machines, machine tools, mineral processing, loading machines, and many more.

Several versions are available to suit many industrial applications. In the Type II HSRvD one motor rotating in the forward direction is connected through a primary clutch and a second motor running in a reverse direction is connected through the secondary clutch. By actuating the proper clutch and brake, the reversing is handled within the Posidyne® while the motor runs continuously.

In the Type I HSRvD there is only one input motor. The input to the two clutches rotates in opposite direction by means of a jack shaft through a reversing gear set.

The Force Control High Speed Reversing Drive uses less power than traditional start/stop systems, generating much less motor heat. Traditional systems reverse the drive motor each cycle, so the major inertia load is typically the motor rotor itself, degrading the motor’s service life. With Force Control, the motor runs continuously while the reversing is accomplished with the Posidyne® resulting in significantly longer service life for motors.

Oil Shear Technology is the reason that brakes by Force Control do not need constant maintenance, adjustment, disc replacement, and last up to 10 times longer than standard dry friction brakes. Oil Shear Technology is the function of a boundary layer of transmission fluid in shear between the friction disc and drive plate. As the parts come together the fluid under shear will transmit torque between the two parts as well as absorb heat. This eliminates direct contact of the friction discs and drive plates during high speed slip. Heat from the friction surface is dissipated as the fluid circulates to the housing.

For more information, visit www.forcecontrol.com.

Motion Control Tips

The guide is available as a free download at www.boschrexroth-us.com/linearmotion. The 88-page guide provides information about the applications, performance capabilities and energy efficiency of linear motion technology.

It also contains an overview of the structural design, operating principles and characteristics of Bosch Rexroth’s linear motion products, including precision modules, profiled rail, ball screw drives, miniature components, electromechanical actuators and completely preconfigured linear motion systems with matching motors and controls.

The selection guide also offers engineers example applications and technical drawings to illustrate, for instance, how reducing friction can dramatically lower energy consumption without sacrificing machine performance or capacity.  Other examples illustrate how precision-engineering and manufacturing of profiled rail systems can minimize downtime during changeovers, provide cost–efficiency in logistics and installation, and lower the overall cost of ownership.

The new guide is part of the recently created Bosch Rexroth Linear Motion Resource Center online, which offers easy access to Rexroth’s most popular linear motion resources, including interactive tools for system design, product configuration tools, technical documents, product updates, and other useful information.

www.boschrexroth-us.com

Motion Control Tips

The PFL35T features an outer diameter of 35mm and features neodymium magnets, which allow for a high driving force. Its sturdy design and construction and its ball bearing support makes the PFL35T durable and gives it a long life cycle.

The PFL35T is available with three lead screw pitches (0.48mm, 0.96mm, and 1.2mm), both bipolar and unipolar windings, a force rating up to 39.5N (at 200pps), rated voltages of 5V and 12V, and 48 steps per revolution.

Applications for the PFL35T include XY stages, liquid dispensing devices, medical pumps, semiconductor wafer handling machines, and data storage recorders.

For more information, visit www.nipponpulse.com.

Motion Control Tips

Engineers are no longer boxed in with a particular motion control format and interface. With the Power PMAC operating as a hub to their overall system, they are able to interface with almost any remote device via the Power PMAC’s open hardware and software architecture. This results in a compact and powerful solution for commercial, industrial, and military applications.

The unit can be used anywhere along the spectrum of applications from dedicated controller to general-purpose computer that provides built-in routines to command the occasional move easily through the use of most popular programming languages. This gives machine control designers the best of both worlds. The controller can be programmed in several languages simultaneously, including the Power PMAC’s built-in Script Language that can handle motion sequences as well as general machine and I/O logic; industry standard graphical programming in any of five formats specified in IEC-61131 including ladder logic and sequential function charts; and in C for advanced programmers who wish to write servo, phase, PLC and general-purpose applications. Other languages accepted include G-Code, MatLab^™/Simulink, LabVIEW^™ and EPICS.

Features of the Power PMAC include an 800 MHz or 1 GHz RISC processor with hardware floating-point engine; up to 4 Gbytes of error-correcting RAM; 100-Base-T and 1000-Base T Ethernet TCP/IP communications; standard interfaces to support keyboards, video cameras, disk drives, and other peripherals; built-in web server to support direct browser access for development and maintenance; the ability to control up to 256 motors in up to 128 independent coordinate systems simultaneously; and the ability to accept RS-274 G-code programs.

For more information, contact Delta Tau Data Systems at sales@deltatau.com or visit www.deltatau.com.

Motion Control Tips

As debris accumulates at either end of the shaft it can be wiped away with a cloth. In most applications the shaft scrapers may be used without the grease fittings to clean the shaft while the drive runs. The grease fitting combination is recommended, however, in heavy usage applications and also when shaft RPMs exceed rated speeds (1,000 RPM for Model RG drives; 1,500 RPM for Model RS drives).

The shaft scraper is an O-ring made of specially formulated rubber which is mounted in a Delrin® brand plastic fitting. One shaft scraper is attached to each of the end bushings on the drive unit. When equipped with the grease fitting, the plastic fitting is made larger to accommodate the addition of a felt wiper ring which wicks oil out of the grease and applies a thin oil film to the shaft as the drive runs. Most standard grease gun nozzles fit the Uhing grease fittings. Note that special, molybdenum disulfide-free grease must be used. If attached in the field, users must also note that the addition of the shaft scraper with or without the grease fitting will slightly reduce the travel distance of the linear drive, which for most applications this is less than 1 in.

Amacoil-Uhing RG linear drives are used in equipment requiring a reciprocating or positioning linear motion component such as material handling systems, winding machines, spraying assemblies, converting equipment and metrology systems.

For more information, email amacoil@amacoil.com or visit www.amacoil.com.

Motion Control Tips

The new BLDC motors feature a wide selection range for power, speed, torque and size. Motors include continuous power up to 400W, speeds between 1,500 and 6,100 RPM, and motor constants up to 15 ounce per square root Watt (103 mNm per square root Watt). Maximum torque constants feature up to 198 oz.-in./A (1400 mNm/A). The six new models include two round and four square designs with lengths ranging from 41 to 114mm. Motors can be ordered with a factory-mounted optical or magnetic encoder and can also be fitted with electro-mechanical fail-safe power off brakes.

Compatible gearboxes feature Spur, Planetary and Worm styles with torques from 0.4 to 120 Nm. The BDE30 and BDE40 external drives are offered in 6A or 14A max respectively. Internal drives are offered on BLDC motors that feature power ranges from 40 to 100W. A wide range of accessories are also available.

The new motor control solution is suitable for a wide range of applications in the medical and industrial markets. Specific uses include automation for endoscopy, x-ray and dental equipment, robotic pool equipment, peristaltic pumps, access control, printing and bill boards.

For more information, visit www.crouzet.com.

Motion Control Tips

The combination of gearbox, pinion and rack represents intelligent integration of specifically developed drive components. The rack assembly of the RP+ is the alpha high performance rack which is characterized by high precision and optimal power transmission. Using this rack results in a quiet-running solution which is weight- and noise-optimized. The gearbox and pinion components of the RP+ system are unique to the design, significantly increasing allowable torques. The high forces produced by the meshing of rack and pinion teeth are controlled more effectively, improving system rigidity and positioning accuracy.

To learn more about the new RP+ system, email info@wittenstein-us.com or visit www.wittenstein-us.com.

Motion Control Tips