Featuring a very compact design, the new controller has also been fitted with a microSD card that offers a large storage capacity. Its Embedded PC features a CPU, a number of IT connectivity solutions and optional interfaces, a direct I/O interface and power supply for Beckhoff I/O systems. It also automatically detects the connected EtherCAT Terminals (E-bus) or Bus Terminals (K-bus) as well as switches to the corresponding mode for convenient system management.

Its CPU has access to 1 GB internal DDR3 RAM and a 256 MB microSD card for its operating system. For additional operator data, the controller also offers a free microSD card slot.

The CX9020’s basic version offers two 10/100 Mbit/s Ethernet ports, a DVI-D interface and four USB 2.0 connections. Its multi-optional interface allows integration of added interface that includes PROFINET, PROFIBUS, Ethernet/IP, DeviceNet, CANopen, audio or serial interface (RS232/RS422/RS485).

Unlike the current ARM9 architecture, the controller’s ARM Cortex A8 processor features a hardware-based floating point unit, which makes floating point operations (LREAL, REAL) faster. When combined with Beckhoff’s TwinCAT automation software platform, the CX9020 system turns into a high-performance PLC and Motion Controller that can be utilized with or without visualization. The operating system of the CX9020 is Microsoft Windows Embedded Compact 7.

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The Kinetis K70 family is suitable for applications requiring advanced connectivity, a graphic LCD user interface and security functionality, without the increased power consumption and cost related to multi-chip designs.

The high-performance Kinetis K70 family allow graphics LCD displays with its one MB of flash memory, integrated graphics LCD controller and 128KB of SCRAM that drive LCD panels at eight bit QVGA resolution without the complexity and costs of adding frame buffer memory and external program.

It also allows users to conveniently manage graphics processing’s performance demands, while simultaneously managing real-time communication, control and connectivity functions commonly required by HMI applications.

Freescale’s PEG development suite enables designer’s to create multi-layered, high-color-depth GUIs that operate tightly with the real-time operating system of applications. In fact, they can even move current PEG applications to the Kinetis K70 family from a different architecture.

To enhance computing throughput, the 120/150 MHz MCUs deliver increased cache responsibilities and up to 150 MHz CPU speed.

The floating point unit of MCUs extend the range of data-acquisition-intensive applications such as audio processing, motor drive and digital filtering by increasing system accuracy and reducing computation time.

Featuring dedicated motor control peripherals, the MCUs also offer BLDC, fast 16-bit ADCs with programmable delay lock and fault control for driving stepper, multiple timers and PMAC motors with sensorless or sensor algorithms.

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The module supports circular interpolation of two axes, linear interpolation of up to four axes, continuous orbit control and fixed feed control. Users only have to set the speeds as well as the positioning addresses from within a sequence program.

The auxiliary functions of the Melsec L series positioning module feature step operation, M codes, skip and target position change. Featuring a built-in mark detection interface, the series’ cam control and synchronous control can also be combined.

The module has been specifically designed to match a library of function blocks that are based on PLCopen motion control specifications. Offering single- and multi-axis functions, the library delivers a standard command set that effectively enhances the set-up, despite the complexity of motion tasks, leading to reduced maintenance, development and support costs.

Instead of using motion programming, the motion module employs parameter settings to simplify the system set-ups. A data table is used to execute the positioning control, while the positioning data is set with the help of functions such as offline simulation, automatic calculation of auxiliary arcs and speed simulation. Synchronous control can be implemented using parameter settings, while cams can be easily set without worrying of electronic cam controls.

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It also offers more powerful communication, fault-tolerant and redundancy-related functions to its controllers as well as extended functionalities for the software tools.

In this latest version of the Simatic PCS 7, the data exchange between the PCS 7 engineering tools and the COMOS plant management software has been optimized while the engineering workflow was simplified. This provides users enhanced planning quality, and allows them to easily document the tracking of changes. Its built-in, scalable long-term archiving system, Process Historian, is now ideally suited for real time central archiving of process data from various projects.

Users can now quickly access reports and archive data for the purpose of enhancing assets and production. The standard Microsoft Reporting Service tool enables users to easily create and modify reports.

With regards to Profibus and Profinet communication, the PCS 7 Version 8 has also been improved in the areas of redundancy and fault tolerance, as well as for the controllers. The high-performance, fault-tolerant Simatic S7-400H controllers have been enhanced to offer not only new functions but greater performance as well. They feature an integrated two-port switch Profinet interface and an increased range of I/Os.

Meanwhile, the software tools’ functionality has also been extended in this version. The Simatic PDM has been supplemented with new export/import functions, while the Advanced Process Library now offers new blocks for starters and compact drives as well as motor management. In addition, its AdvES advanced engineering system now comes with an ISA 88 compliant concept.

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Compliant with PLCopen and IEC 61131-3, the MotionPAC can be used in conjunction with AeroBasic programs or independently for full machine control. It also allows users to program in Function Block Diagrams (FBD), Ladder Diagrams (LD) or Structured Text (ST). Its integrated automation reduces commissioning and programming time by 30 percent to 50 percent, making it ideal for use in machine control program development.

Since it is integrated with the company’s A3200 motion controller, users can directly command coordinated, asynchronous, geared, blended or cammed motion from FBD, LD and ST. MotionPAC also allows users to specify moves as absolute or relative either in English or metric units.

Meanwhile, programmers can create shared Tags and variables that are referenced by Name in the A3200 tools, AeroBasic, Operator Interface, C or .NET programs. MotionPAC automatically handles memory management for all variables and Tags.

Its tools, which include user definable libraries (FBD, LD, ST or .NET), global Tag database, integrated axis manager for manual control and readout, virtual execution of the PLC and automatic memory management effectively increases programming quality and efficiency. Through MotionPAC, PLC and .NET programmers can collaborate seamlessly to deploy machine control applications. MotionPAC comes with standard fieldbuses, high-end data acquisition and drive I/O, which can also be shared with applications by Name.

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Offering 32-bit Stellaris LM3S818 microcontroller, the new motor control kit also comes with DRV8312 motor driver to spin 6.5A, sub-50V three-phase brushless DC (BLDC) motors in just a few minutes. A low-cost solution, the Stellaris ARM Cortex-M microcontroller motor control kit is ideally suited for high-volume motor control applications, such as low-voltage fans, pumps, blowers, compressors and tools.

The motor control kit includes a Stellaris LM3S818 controlCARD module, which features a pre-programmed firmware required in flash memory to operate the company’s InstaSPIN-BLDC solution, together with other customer-developed applications, when connected into the DRV8312 motor driver base board.

Its controlCard module offers 64 KB flash, 50 MHz performance, eight KB SCRAM and six PWM generators, enabling developers to make complex motion control designs with a small footprint.

The Stellaris motor control kit’s DRV8312 motor driver eliminates the need for expensive external heat sink and deliver up to 6.5A. The fully-protected motor driver is reliable featuring cycle-by-cycle over-current, cross-conduction, over-temperature and under-voltage protection, reducing board space and design complexity while ensuring higher system reliability.

In addition, the kit’s 24V three-phase BLDC motor can continuously operate at up to 3.5A. Its supporting software includes InstaSPIN-BLDC software for reliable and fast motor start-up on any motor and StellarisWare® software with TI’s IQmath Library for fixed to floating point conversion.

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All of Tolomatic’s electric actuators feature built-in configurations that enable the ACS with Ethernet to simplify the creation of linear motion. Paired with Tolomatic’s ERD low-cost rod-style electric actuators, the ACS offers cost-efficient solutions for automation applications such as product diverting, sorting, pick-and-place, pressing and changeovers.

“The ACS Stepper Drive/Controller with Ethernet completes the actuation solution,” said Aaron Dietrich, Marketing Manager at Tolomatic.

“With Ethernet, the ACS is a unique entry-level automation solution that brings connectivity to the control systems that customers already have in place. This reduces costs and greatly simplifies the integration of low-cost electric actuators into the motion system.”

For infinite position capability, the ACS with Ethernet is capable of preconfigured moves or immediate move command. Each move features configurable motion profile parameters such as force, position, velocity, and acceleration/deceleration that are independent for every move. For better fault recovery and monitoring, the Ethernet connectivity also provides the control system with additional diagnostic and status information.

“With Ethernet connectivity, the ACS has a lot more flexibility in operating the motion control system. Additionally, Ethernet allows more information such as better diagnostics compared to digital I/O control schemes found in many low cost actuator applications. With Ethernet, faults are easily indicated and identified,” he added.

The ACS with Ethernet is available with a starter kit that includes two set-up manuals and configuration software.

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“The Atmel AVR UC3 C series delivers more processing power—in a smaller footprint—than any other microcontroller in our line card,” remarked Haakon Skar, Marketing Director of AVR UC3 Products, Atmel Corporation.

“The new series offers better performance and enables us to include this new FPU without negatively impacting the microcontroller power consumption. These new 32-bit AVR microcontrollers complement our already-strong line card of 8-bit AVR MCUs targeting the industrial control.”

Built specifically for high-speed communication with a true 5V operation, the Atmel UC3 C series comes with 64 + 4KB high-speed SRAM, a nine-layer databus and various high-speed communication peripherals that include dual CAN ports, a 100 Mbps Ethernet and a full-speed USB interface. In addition, an SDRAM interface in fitted in larger devices. Together with the layered databus, the split SRAM architecture enables the system designer to avoid clashes on high-speed communications.

Featuring the Atmel Peripheral Event System, the Atmel UC3 C series also comes with FlashVault code protection, which is a flash security technology that partially programs and locks the on-chip flash to create secure on-chip storage for software intellectual property and secret code.

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Featuring a real time channel with a single input and output connection, the EasySlave can support cycle times as low as 31.25 usec.

Meanwhile, an IP core serves as a netlist for the Xilinx Spartan-6 FPGA family. The core contains all of the Sercos slave connection’s functions, including the related software library for I/O devices.

“Sercos EasySlave can be integrated in an application with minimal effort in order to achieve various I/O activations,” said Peter Lutz, Managing Director of Sercos International.

EasySlave’s technical support is provided bySteinbeisTransferCenterfor Systems Technology (TZS). In addition, TZS provides an EasySlave evaluation kit that offers customers an easy and quick introduction to the Sercos slave development. The kit comes with a development board based on a Xilinx Spartan-6 XC6SLX9 FPGA. Using plug-in modules, the evaluation kit, which includes all other required documents and materials (power supply, Ethernet cable and documentation), can also be extended.

“The EasySlave evaluation kit makes Sercos III slave development easy. Steinbeis-TZS will be happy to provide assistance in the integration and commissioning of EasySlave,” noted Professor Reinhard Keller of Steinbeis-TZS.

Sercos International offers various EasySlave licensing models. Aside from the special prizes provided to Sercos member companies, a license-free bitstream IP core version with a limited functionality is also offered, under the product name EasySlave-IO.

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Completing the platform’s power range, the PCM7539X allows the IDEA system to be utilized with any stepper motor product offered by the company. In particular, the PCM7539X programmable stepper motor is designed to control the bigger size 23 stepper motor units as well as size 34 stepper motor units.

Similar to all Haydon IDEA Drives, the compact PCM7539X is a fully programmable control unit that is easy to use. Featuring a patent-pending graphic user interface, the stepper motor drive can be programmed using on-screen buttons instead of other proprietary programming languages or complex command sets. The software enables the system designer to troubleshoot programs that use multiple line or line-by-line program execution through interactive debug feature. The software also has the ability to simulate inputs and outputs prior to connecting in actual I/O hardware.

The PCM7539X IDEA programmable stepper motor drive’s technical specifications include 12VDC to 75VDC input voltage, programmable current control, eight digital I/O points, memory for up to 75 stored motion control programs and drive current per phase of 3.85A RMS plus a 30 percent “current boost” function that can be used during ramping.

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Based on the 533 MHz ARM11 processor, the MC403 and MC405 controllers offers a vast array of performance enhancements enabled by the ARM11 core. With an optimized selectable servo update rate from 125 microseconds to 2000 microseconds, up to 512K data table size and over four times the clock frequency at 533 MHz, the double floating point precision processor offers an outstanding servo loop accuracy with fast 64 bit integer position and 64 bit real-number mathematics registers.

The MC403 can control three stepper axes or two servo axes plus a master encoder input, while the MC405 can control five step and direction axes or four servos with a master encoder. Offering a maximum stepper output frequency of two MHz, the controllers’ servo encoder ports are selectable for rotary feedback or incremental linear. The ports can also be configured for Tamagawa, SSI and EnDat absolute types.

Aside from the encoder provision and the axis count, the evident differences between the two models relate to the number of virtual exes offered, the multitasking ability and the physical variations such as the status display, I/O count and size. The MC403 features eight axes in software and can simultaneously operate six tasks, while the four-servo/five-stepper MC405 has sixteen axes in software and can run ten simultaneous tasks.

Although both controllers provide two 12-bit analog inputs and eight 24 VDC inputs, the physical layer of MC405 has ten registration inputs compared to MC403’s six. MC405 also offers eight 24V bidirectional I/O channels rather than four.

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The QLX controller works with the armature controller to deliver the required field control functions including field reversal. With currents ranging between 12 Amps and 2250 Amps, the new product utilizes three phase power supply to offer a controlled DC field current. Featuring full digital control and the usual communications facilities, QLX is ideally suited for use in various applications such as in steel handling and hot rolling mill.

With digital functions similar to the company’s PLX range of DC drives, the QLX 3 phase field controller comprise five frame sizes, with up to 2250 Amps current capability. It also offers Field Reversal as well as Auto Field Weakening for high power fields. It also features an integrated Standby Field mode. The QLX interfaces directly with the main armature controller for start and stop functions. The controller cost-effectively includes reversing to big DC motors where the facility exists only with contractors, or when it no longer exists.

Offering a vast array of DC motor control, Sprint Electric has more than 150 models covering both three phase and one phase, non-regenerative and regenerative DC motor applications, which come with digital slip ring motor controllers.

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The new series does not only increase the amount of information exchanged between the supervisory layers and the control, but it also boost system performance and improve productivity by enhancing access to real-time information.

Ideally suited for synchronizing complex motion applications, the ControlLogix 5570 Series offers high-speed axis and trajectory planning. With two to three times quicker scan times, the new controllers feature memory options ranging from 2 MB to 32 MB.

The new series includes the ControlLogix 5571, 5572S, 5572, 5573S, 5573, 5574 and 5575 controllers. In December, it will be expanded to include the GuardLogix 5573S and 5572S controllers, which are designed to provide similar automation capabilities as the ControlLogix platform and safety-rated control for safety-related functions.

The controllers are fitted with on-board display features that offer improved diagnostics as well as run-time information to increase uptime and help ease troubleshooting. Its improved security features includes optimized data integrity and quicker data transference with its 1-GB secure digital card.

It will again be expanded in January with the addition of the ControlLogix 5573XT PAC. Suitable for extreme environments and rated for extended temperatures ranging from -25°C to 70°C, this soon-to-be addition is coated for use in corrosive and high-humidity environments.

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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

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A part of the Allen-Bradley Micro800 range, the component-class micro programmable controllers provides machine manufactures a cost-effective control solution, making them suitable for standalone machine applications with less than 48 I/O.

“With this new line, Rockwell Automation is delivering the functionality and flexibility of a micro programmable logic controller for the price of a smart relay. Yet, the greatest value of the new Micro800 range is the simplicity and convenience it provides, with the right amount of control, so customers only pay for what they need,” said Adrian van Wyk, Business Manager at Rockwell Automation.

The Micro800 controllers feature a vast array of plug-in modules for communications, analogue/digital I/O and expanded memory. The range’s plug-in modules allow machine manufacturers to customize the controllers to optimize functionality without increasing the product footprint. Aside form providing removable terminal blocks, the new range also simplifies communication through point-to-point data exchange.

The smallest of the Allen-Bradley Micro800 family, the Micro810 programmable logic controller comes with embedded smart relay function blocks, which can be configured from the keypad and LCD. These function blocks include time of day, delay OFF/ON timer, time of week as well as time of year for applications demanding a programmable lighting and timer control.

Offering flexible communications, the Allen-Bradley Micro830 programmable logic controllers offers up to six high-speed counter inputs. These off-the-shelf controllers have been specifically designed to allow easy integration of up to five plug-in modules on the 48pt variants. They are fully customizable and carry global certifications and support.

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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

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The new Simotion D445-2 multi-axis controllers offer high-speed I/O, onboard Profinet interfaces and with thrice the performance, a single controller can support a maximum of 128 axes of motion.

Suitable for production machines, Simotion D motion control systems provide high degree of flexibility for the machine automation’s ever-changing needs. Offering motion control, PLC and advanced technology functions, the Simotion D drive-based multi-axis control systems also provide an integrated drive control that is based on Siemens Sinamics S120 drives.

The new Simotion D445-2 DP/PN and D455-2 DP/PN provide expanded memory capacity while doubling the maximum quantity to 128 axes than the previous generation. The new versions have also integrated the previously optional Profinet I/O interface into the modules as standard. Equipped with an integrated three-port switch, the controllers’ onboard interface facilitates various network topologies such as star, tree or line structures, without adding external switches. The interface, which can be used as a controller or as a device of another controller, also has the capability of supporting real-time (RT) and isochronous real-time (IRT) data exchange.

Aside from the Profinet interface, the new controllers also feature two Ethernet and two Profibus interfaces. Of the 28 digital I/Os of the Simotion D445-2 DP/PN and D455-2 DP/PN, 16 can be utilized for technology tasks such as measuring inputs and output cams with micro-second resolution.

Motion Control Tips

A servo controller is the heart of a servo system. A typical servo system consists of a motor, feedback device, and the controller. The control circuitry typically involves a motion controller, which generates the motion profile for the motor, and a motor drive which supplies power to the motor based on the commands from the motion controller. Servo systems are closed-loop systems which have some benefits over open-loop systems including the fact that they improve transient response times, reduce steady state errors and reduce system sensitivity to load parameters.

Servo controllers perform two types of tasks; tracking some commanded input and improving a system’s disturbance rejection. One of the most powerful methods of control is PID control, which stands for proportional-integral-derivative control. PID control is a combination of proportional control, integral control and derivative control. A PID control method works on the error signal which is the difference between a commanded value and the actual value of an output variable, and driving the error to zero. The proportional value can be thought of as a simple gain value. The integral value integrates the error over a period of time and helps to drive the error to zero. The derivative value helps to stabilize a system that uses an integral and proportional term only.

There are a few important factors to consider when selecting a servo controller for an application. The first thing is knowing which type of motor is to be controlled. Is the servomotor an ac or dc motor? If dc, is it brushless or brushed? This will help in determining the kind of commutation the motor needs and if the controller can accommodate it.

How many axes of motion does the application have? Is it a single axis of control or are there multiple axes? Servo controllers are available to control simple single axis applications as well as more complex motion such as robotics applications involving multiple axes.

Next, how many channels of I/O are needed? Are special input types needed beyond inputs for feedback signals such as speed and position? Be sure that the controller can accommodate the appropriate feedback device, such as incremental encoder signals, resolver signals, SSI, Hall sensor signals, or tachometer inputs.

Another important factor that is sometimes overlooked is the controller set up. Is the controller easy to set up and program? Is programming done via keypad or can it be programmed from a computer screen? Also consider the available communication links. Are there basic RS232 or RS485 links? Does the controller include bus interfaces for common networks such as CAN, DeviceNet, Sercos or Ethernet?

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The earliest PLCs came along to replace large cabinets of electromechanical relays which were used to control machine processes. Cabinet-based control systems were big and bulky and required an enormous amount of wiring. And when a change in the control system was desired, the only way to do so was to go into the cabinet and rewire connections, which was costly and took up a lot of time.

The introduction of PLCs meant that the same control functions could be accomplished in a fraction of the space of a traditional control cabinet with far less wiring and complexity. Also, if a change in control was desired, the change could be handled via simple ladder-logic programming, eliminating the need to rewire large portions of a control cabinet.

The basic parts of any PLC system include the processor, I/O modules to handle inputs to the controller and outputs to the controlled devices, and some type of user interface which could be as simple as a keypad or a touchscreen interface or a programming link via a PC. The PLC’s processor is programmed via the user interface. The I/O modules are used to bring input signals into the PLC’s CPU and output control signals to controlled devices such as motors, valves, sensors and actuators, among others.

Individual PLC manufacturers may have different programming languages, but most are still based on the fundamental ladder logic programming structure. Although now, they can be programmed in higher-level languages such as C and BASIC. Communication options may include simple RS-232 serial communications to more advanced Ethernet protocols.

One of the most important considerations for any PLC is the scan time. Basically, this is the time in which the PLC runs through the program taking in data and updating outputs. This is typically a few milliseconds but can be much longer depending on the program length and the speed of the processor. Higher scan times can accommodate processes with more real-time demands than traditional slower applications where scan speed is not as critical.

Other points to consider include the I/O count and the ability to expand I/O if needed. This can range from a handful of I/O for simple applications to hundreds in more complex machinery. The type of I/O, whether analog or digital, is also important. It’s common for manufacturers to supply modules designed for unique input types, such as counting encoder inputs.

Another point to consider is the level of customization needed. For instance, PLCs can be set up with individual web pages where operators can go to view system parameters and machine conditions. They can also be programmed to send alerts and condition status updates to mobile devices such as cell phones to keep operators and engineers abreast of machinery and processes.

More recently, some manufacturers have introduced so-called PACs (programmable automation controllers). A PAC is similar to a PLC but denotes a controller that accommodates better real-time control needed in some automation applications. Also, special PLCs can include dedicated safety PLCs which monitor machine inputs such as photoelectric sensors, light curtains, magnetically operated sensors, emergency stop buttons, and safety mats.

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A motion controller also creates the trajectories that the motors follow in order to meet the desired commands. Also called motion profiles, a profile is a sequence of position commands vs. time. This tells the motor where to position the load and how fast it must do so. The motion controller uses the trajectories it creates to generate the proper torque commands. These torque commands are then sent to the drive, which powers the motor and creates motion.

Because of the large amount of signal processing required for these actions, motion controllers typically use digital signal processers (or DSPs) for this task. DSPs are specifically designed to perform mathematical operations quickly and efficiently, and can handle the algorithmic processing better than standard microcontrollers which aren’t designed to handle large amounts of mathematical processing.

There are a number of common motion profiles including trapezoidal, ramp, triangular, and complex polynomial profiles. Each of them is used in certain conditions and situations where that type of motion is desired. For instance, a trapezoidal profile is characterized by constant velocity and acceleration and a graph of the velocity vs. time profile is in the shape of a trapezoid.

Motion controllers also use some of the basic control laws to implement motion. The simplest of these is called proportional (P) control, which represents a constant integer gain. This is the simplest type of control to implement. From P controllers, one can add either a derivative gain (known as D) or an integral gain (or I). The combination of these three, known as PID, represents one of the most common and most powerful types of control algorithms.

Practically speaking, motion controllers come in a variety of sizes and types. In general, motion controllers fall into one of three categories; stand-alone, PC-based, and individual microcontrollers.

Stand-alone controllers are entire systems typically mounted in one physical enclosure that includes all of the necessary electronics, power supply, and external connections. These types of controllers can be built into a machine and are dedicated to one motion control application that could involve controlling a single axis of motion or multiple axes.

PC-based controllers are mounted onto the motherboard of a basic PC or industrial PC. These types of controllers are mainly processing boards that may generate and execute motion profiles. The advantage of PC-based controllers is that they provide a ready-made graphical user interface that makes programming and tuning the control much easier.

Lastly, there are individual microcontrollers. These are individual ICs that are often designed onto a printed circuit board along with feedback inputs and outputs to drivers to control a motor. While these controllers are relatively inexpensive and have the advantage of giving designers chip-level access to their systems, the drawback is that they require good programming skills to configure and implement.

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The machine controller’s primary operations include scanning I/O, updating output and process control. After an initialization phase, the controller will continuously read inputs, calculate control parameters for the machine process using application-specific logic based on the input data, and then update outputs to the machine. If the controller is turned off, some shutdown process may be completed.

The central part of a machine controller is the controller itself, which can take on several forms. For single machine control, a programmable logic controller (PLC) or a programmable automation controller (PAC) is usually sufficient to handle the job. PLCs are usually programmed using ladder logic or sequential function charts. The controller receives various sensor data, processes this information and executes controls via some combination of digital and/or analog I/O signals to turn on or off processes, actuate or stop movement, and take user or environmental input and make decisions based on these inputs. Machine controllers will generally work together with some type of human-machine interface (HMI). These can be either integrated with the controller as one piece or can be stand-alone units that communicate with the controller.

More recently, machine control has seen a move to PACs because they can offer better performance and a wider range of functions than traditional PLCs. For instance, PACs can support high-speed data acquisition and processing, as well as motion control and vision functions.

In order to take advantage of all the features and capabilities of a PAC, the application code must be well designed, balancing and coordinating various controller processes such as I/O, process control logic, communication to an HMI unit and other tasks.

There are a number of considerations to keep in mind when selecting a machine controller. One of the most important is the number and type (i.e. analog or digital) of I/O the controller will have to handle. Also, do the speed requirements of the machine match up with the controller’s capabilities? For instance, some machine controllers may be tasked with closing servo loops and thus must be capable of handling such a task.

Another consideration is the type of communication link needed. The machine may have special demands or may be wired to accommodate a specific networking protocol, so ensure that the controller can communicate with the machine. Related to the communication link is the programming environment. Is the controller simple to program? Can programs be edited quickly and easily? Lastly, consider any environmental factors in which the machine will have to operate such as shock and vibration, extreme temperatures, and moisture or humidity.

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The STM line has been specifically designed to control a maximum of 127 motors across a bus length of 5000 meter (16,400 ft) using the integral CANopen interface of the motor with one economic, off-the-shelf PLC that features a solar tracking function block. The brushless dc motors can also be utilized with industrial PCs as well as Modbus and Profibus networks. The integral control’s embedded intelligence offers up to 650,000 hour MTTF, significantly reducing bus traffic by performing complex routines on board, such as closing and homing the position loop with a connected inclinometer or absolute encoder. Meanwhile, the embedded intelligence of the motors can take over mission critical functions, such as reverting back to a safe position, whenever the network is down.

Offered in frame sizes 45, 65 and 75, with powers up to 0.7 HP (530W), the low voltage brushless dc STM motors can be integrated with current design slew drives, linear actuators as well as pan and tilt mechanisms utilized in the solar industry. When added gear reduction is needed, the brushless motors can also be mated with the company’s modular worm or planetary reducers that provide up to 678 Nm (6000 in-lb) peak torques.

Rated IP65 environmental protection, the STM motors are maintenance free for live as its integral control features torque and speed regulation that prevent mechanical damage.

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The new PLC offers extremely fast I/O update, user defined web pages, various field-bus options (Profibus / Modbus), redundancy features, hot swappable I/O modules, enhanced diagnosis, flexible architecture, easy installation and maintenance design, special modules and wide I/O. Aside from having a life span of approximately 10 to 15 years, the PLC is also IEC 61131-3 compliant and can support up to 32 expansion racks.

The new PLC also offers other latest user friendly features in mechanical structure such as special diagnostic push button for field diagnostics, diagnostic LCD on each module, huge memory for data storage, dynamically updated diagnostic Web pages, remote monitoring, application event logging, road map towards hot-standby redundancy and hot plugging of all modules.

Its unique design allows it to be utilized in various applications including machinery automation, infrastructure, utility sectors and water management. With the product design focused on controller for process automation, much attention has been placed on its ability to handle numerous analog I/Os and other related processing.

“NX7 PLC series is another step by Messung to provide path breaking automation technology to the industrial segment in India. The engineers involved in the development of this product have ensured that the product is not only best in terms of quality but also fulfills all the automation needs of its users,” said Mr. Farook Merchant, Chairman and MD of Messung Group.

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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.

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Featuring color touch screen control panels, this Siemens-based PLC can support polymer-conveying systems with up to 120 stations and 20 pumps. Its base panel can control up to 25 purge valves, 32 material receivers with proportioning capability and five vacuum pumps, while its icon-driven graphic display offers an easy-to-learn user interface.

With Ethernet connection capability, the PLC can be controlled from any remote personal computer. It is also designed with Profinet communications to allow the PLC to remotely add more components. Expansion is achieved through FlexXpand FXMS modules that automatically connect to the main control through Profinet communications network. The modules, which control additional pumps, receivers, material-selection stations and purge valves, can be arranged in such a way to minimize wiring to system components.

Every FXS control features a three-port Ethernet connection for added FXS modules or remote or local human-machine interface (HMI) modules. Expansion requires no additional programming, since all modules are automatically recognized by the FXS control.

Moreover, both visual and audible parameters are integrated on the control face. With assignable levels of security, various changes to operating parameters can be easily made. Likewise, the Ethernet capability of FlexXpand allows the advanced, intuitive interface to monitor as well as control other Novatec ColorNet-compatible HMI’s integrated on the local network.

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“Utility and industrial companies around the world depend on SEL automation and integration solutions,” noted David Whitehead, Vice President of Research and Development at SEL.

“The Axion is a key new product to help our customers solve tough control system and substation automation problems.”

An Axion system can be developed with up to six nodes or units connected to a network utilizing the EtherCAT protocol. Every node can accommodate ten modules, which includes one or two power supplies, a processor module, and a user-determined mix of I/O modules ideally suited for the application.

Featuring a complete IEC 61131 logic processor, the Axion also comes with an advanced data concentration, secure communications, protocol conversion capabilities between multiple integrated client/server protocols as well as local and remote I/O. The IEC 61131 logic processor allows engineers to operate their custom control logic at two varying rates. The solution also offers integrators the necessary tools to easily concentrate and integrate information from various microprocessor-based devices.

Each Axion provides an ACSELERATOR RTAC SEL-5033 configuration software for no extra cost. The software provides everything the users need to set up I/O, security, communications and programmable logic in a single easy-to-use package.

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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

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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

Based on the next generation dsPIC DSC/PIC24 MCU core, the new dsPIC33 and PIC24 “E” devices provide larger Flash memory (536 KB), a USB 2.0 OTG interface, greater I/O capability with 144-pin packages, more RAM (52 KB), and expanded graphics, audio, motor-control, and real-time embedded-control capabilities compared to the previous-generation dsPIC DSC/PIC24 MCU core.

Offering customers a solid growth path, the company’s dsPIC33E DSCs and PIC24E MCUs are fully compatible with the current lineup of dsPIC33F DSCs and PIC24H/PIC24F MCUs, software libraries and tools. Its USB 2.0 On-The-Go (OTG) peripheral offers easy connection to a Flash drive, PC and other USB-enabled devices, while its 60 MIPS performance allows new devices to support high-end commercial and industrial applications such as solar inverters, Servo motor control and running dual three-phase motors in parallel. Its independent Pulse Width Modulation (PWM) mode reduces software overhead since it supports dead-time compensation and multiple stepper motors. Aside from reducing system cost, its three on-chip analog comparators also reduce the required number of external components.

“Microchip continues to invest in its 16-bit product lines,” remarked Sumit Mitra, Vice President of Microchip’s High-Performance Microcontroller Division.

“Building upon the success of previous-generation dsPIC DSCs and PIC24 MCUs, the new ‘E’ core devices, and their extensive support resources, provide the increased performance, integration, and whole-product solution that customers need for their increasingly complex designs.”

Featuring enhanced timer capabilities, the new dsPIC33 and PIC24 “E” devices deliver more flexible and powerful Input-Capture and Output-Compare modules.

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Designed for harsh industrial applications, the optional SD card of 750-880 has been specifically covered with gold-plating. With the SLC-technology (Single-Level-Cell), the SD Card can last around 10 times longer as compared to MLC (Multi-Level-Cell) cards. The card offers ESD stability up to 15 kV, Power-Loss Protection and a -20°C to +60°C temperature rating.

With the SD card, the 750-880 speeds up large-scale programming while enhancing capabilities by transferring boot files, device parameters and other file types between controllers. It also provides one MB of both data memory and program, featuring a maximum supplemental memory of eight GB from the SD card. Accessible through the FTP, the card also serves as data backup or as an additional drive.

The 750-880 utilizes new function libraries as well as an optimized two MB Fast File System that comes with an integrated Web server for status information, configuration options and Web pages. It relies on a strong, industry-approved TCP/IP stack and IEC61131-3 friendly environment. The featured protocols include HTTP, MODBUS, DHCP, ETHERNET/IP BootP, SNTP, DNS, SNMP and FTP.

Featuring two internet interfaces, 750-880 also has a built-in switch blend PLC-like functionality with the flexibility of IT networking. Through line topology, the switch can effectively eliminate redundant hubs and switches. Its IP20 housing enhances cooling, while meeting stringent EMV standards and carrying UL 508.

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.

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Together with the Portable Test Controller, the Modular Test Controller is the company’s newest addition to its product portfolio that includes larger units dedicated to automotive and aerospace testing. The controllers offer efficient operation in a range testing applications such as single-axis test systems, shock absorber tests, vibration and performance evaluation tests.

Adept at handling complex and simple tests, the controller is specifically designed to make it easily accessible from the desktop of the operator while enabling easy integration into a network’s test machines. The new controller can also interface with commonly used sensors utilized for a single axis movement.

Aside from being reliable, the new controller also comes with a Software Development Kit (SDK), which can be used to connect to existing software or to develop customized user interfaces, and an integrated advanced safety checks to ensure that the test data and test article are always protected.

With its control loop technology, the new controller effectively reduces the amount of time spent on set-up and testing. It can also interface with any electric, hydraulic or pneumatic actuator. Powered by EtherCAT, the new connector allows immediate integration with various test systems. Its embedded disk card feature offers integrated data storage, while its “plug and play” feature allows for immediate integration.

The new Modular Test Controller supports the company’s newest Integrated Test Suite software, which allows engineers to set up and run tests efficiently anywhere in the world.

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

The company’s new ECS servo system offers the servo drives high dynamic performance, which is vital in motion tasks requiring the highest precision and speed. Specifically engineered for multi-axis applications in central control architecture, the new system, when combined with new L-force Controller 3200 C, effectively and economically solves even the most demanding and complex motion tasks in terms of precision and the number of axis required.

The versatile system also provides a vast array of axis and power supply modules which can be easily connected to produce an integrated unit, while the ECS drives are compatible with the MCS range’s highly dynamic motors. The drives can be also combined with asynchronous and synchronous motors.

Based on the energy-efficient Intel Atom processor, the L-force Controller 3200 C has been specifically developed for use in the control cabinet. The integrated 48 MBit/s backplane bus enables I/O modules from the I/O system 1000 to be side-mounted to the controller. A combination of the time stamp with the short cycle time and the minimum jitter ensures that the motion system conforms to speed and synchronism requirements.

“With our combination of Controller 3200 C and ECS servo system, we offer the optimum solution for tasks with a large proportion of motion,” said Sören Mirbach from Control Technology Product Management at Lenze.

“And integration of the ECS in the EtherCAT-based control environment rounds off our uniform, end-to-end portfolio for setting up central control architectures.”

Motion Control Tips

Rockwell Automation provided the control solution that would enhance the flexibility and performance of Thiele’s Nigrelli Envoy Tray Former Packer, a continuous-motion, high-speed packaging system specifically designed for loading cartons, bottles and cans onto corrugated trays, pads or U-board. Processing up to 3,600 containers per minute with exceptionally accurate positioning and versatility, the heart of the Envoy features Rockwell Automation Kinetix Integrated Motion solution that includes an Allen-Bradley ControlLogix controller, Allen-Bradley MP-Series servo motors and Allen-Bradley Kinetix 6000 multi-axis servo drives. Together they control and coordinate all major machine functions, such as placing and carrying the trays through the machine, and control of the rotary tray and feeding system.

Rockwell Automation’s ControlLogix controller eliminates the need for multiple programming packages and controllers, conveniently tying all control functionality into one, multitasking controller platform. Motion functions of the Envoy are incorporated in both the Rockwell Software RSLogix 5000 programming software and the ControlLogix controller. To reduce time spent on wiring, engineers utilized a SERCOS interface module for integration with the Kinetix 6000 servo drives. Operators of the Envoy can view the status and performance parameters of the machine through an Allen-Bradley PanelView Plus 1000 touch-screen human-machine interface.

The RSLogix 5000 software’s motion instructions reduce the need to coordinate and write two programs in separate controllers.

“With the need for high reliability and fast changeovers, the servo control technology from Rockwell Automation provided the best option,” said Stephen Kaye, Rigid Product Line Manager at Thiele Technologies.

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

The new PLC controllers provide standardized functions for planning, programming, configuration and diagnostic in one single engineering environment. It also features flexible motion control functions. Using SERCOS III and other communication interfaces, IndraLogic XLC can be connected into various communication networks.

Rexroth’s new range of PLC enables controller-based, scalable and embedded PC solutions in relation with the company’s newest IndraControl device platform.

Using state-of-the-art PLC kernel, IndraLogic 2G, the company has enhanced the PLC programming of the latest IndraLogic XLC PLC and integrated it into the multitasking runtime system and the company’s IndraWorks software tool. This enables users to take advantage of the various functions of the IndraLogic XLC PLC for developing modular software projects in an end-to-end overall system quickly.

The new range of PLC features functions such as comprehensive function libraries, object orientation as an extension to IEC 61131-3, convenient editor tools and fast compilers for efficient production of machine codes. Simplifying the process of designing new machines with improved software quality, the modular GATcompact (Generic Application Template) project template also reduces effort considerably.

Ethernet SERCOS III provides end-to-end communication between the decentralized system peripherals, such as drives or I/O, and the controller. The controller’s fast PLC cycles of up to 250 µs offer excellent response times in handling time-critical process signals. To enhance the company’s previous IndraLogic system, the new controllers have integrated into its run system versatile motion control functions.

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Integrated with configurations for the ERD, Tolomatic’s rod-style electric actuator linear motion is easily and automatically created in the desired linear units (inch or mm).

The ERD range of actuators, which has been originally developed as an economical replacement for pneumatic cylinders, has become an affordable solution for applications such as pick-and-place, heat-staking, sorting and diverting, changeovers and more.

“The primary goal in designing the ACS Stepper Drive/Controller for the ERD product family was to create a low-cost, extremely easy-to-use drive and control product intended for single-axis actuator solutions,” said Aaron Dietrich, Electric Products Manager at Tolomatic.

“What makes creating motion so easy is that through two simple configuration steps, the ACS drive knows everything about the axis of motion. Combined with any of Tolomatic’s electric actuator products, the entire axis of motion is available from one supplier.”

For infinite position capability, the ACS provides four, eight or 16 move command modes (incremental, absolute or jog). This range of command modes is flexible enough for a vast array of single-axis actuator solutions. It also features adjustable motion profile parameters (velocity, position, force, acceleration/deceleration) that are configurable separately for each move.

To save energy, the ACS reduces holding current when not in motion. Aside from its force-limiting capacity, the ACS is also capable of zone output based on the position of the actuator. Its digital I/O can be configured in either 24 VDC Opto-Isolated, NPN or PNP, while its drive/controller is suitable for use with most brands of 24 VDC stepper motors.

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With the enhancements on its programmable automation controllers (PACs) portfolio, the company now offers Integrated Motion over EtherNet/IP technology. This new technology helps companies optimize their machine design flexibility, reduce overall system costs and improve their systems performance.

“This really is an important evolution in machine control; what we have done is close the loop,” said Haïthem Mansouri, European Product Manager, Motion Control, Rockwell Automation.

“By introducing motion over EtherNet/IP we have given engineers the ability to side step their reliance on specialist motion protocols, such as SERCOS. This has removed the final remaining barrier that was preventing the adoption of a complete, single, integrated network that is already capable of undertaking safety, process and discrete control.”

“EtherNet/IP is, to all intents and purposes, identical to standard Ethernet; the only change being in the Application Layer,” explained Mansouri. “It uses standard, unmodified Ethernet, and allows users to effectively manage real-time control and information flow for improved plant-wide optimization; ultimately resulting in more informed decision-making and better business performance.”

He added that although other vendors use Ethernet “but they just use the first physical layer – the actual protocol is proprietary and specialist. This means that although they can claim ‘Ethernet compatibility’, it is, in fact, just as closed as any other proprietary protocol.”

With this latest innovation, machine builders can now program, commission, configure and maintain PowerFlex 755 AC drives and Kinetix 6500 servo drives with the outstanding processing capabilities of Allen-Bradley ControlLogix 557X PACs – all over EtherNet/IP.

Motion Control Tips

IndraLogic XLC (eXtended Logic Control) PLC controllers feature capabilities go beyond standard PLC functions. Users can leverage a wide range of new functions that achieve modular software projects quicker than before. All planning, configuration, programming and diagnostic functions are standardized in one single engineering environment, with flexible motion control functions fully integrated. IndraLogic XLC can be connected into different communication networks thanks to real-time communication via SERCOS III and other common communication interfaces.

A state-of-the-art PLC kernel, IndraLogic 2G, is integrated into the company’s IndraWorks software tool and the multitasking runtime system. This lets users take advantage of many new functions for creating modular software projects in an end-to-end overall system in less time than before. Functions include convenient editor tools, object orientation as an extension to IEC 61131-3, and comprehensive function libraries as well as fast compilers for efficient generation of machine codes. The modular GATcompact (Generic Application Template) project template simplifies the process of designing new machines with enhanced software quality while reducing effort considerably.

End-to-end communication between the controller and decentralized system peripherals, such as inputs and outputs or drives, takes place via real-time Ethernet SERCOS III. Fast PLC cycles to 250µs enable optimum response times for handling time-critical process signals. IndraLogic XLC controllers come with versatile motion control functions, integrated into the run-time systems, to enhance the previous IndraLogic systems.

With its motion control functionality, the XLC handles machine applications ranging from simple point-to-point motion to the synchronization of multiple axes that use Rexroth’s FlexProfile to integrate complex motion sequences. The graphical profile editor in the Rexroth IndraWorks software tool offers numerous offline and online functions for this purpose. Master and slave interfaces for PROFINET RT, PROFIBUS and EtherNet/IP are also available, in addition to SERCOS III, for integrating into a wide range of communication networks.

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

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Even when processing thin gage materials at extremely high speeds, the new Series 30i/31i-L MODEL B CNCs can provide seamless choreography between power modulation and axes motion. It offers technological features that translate to superior accuracy and cut quality, which enables it to deliver premium quality parts.

It comes with an Ethernet interface that allows users to conveniently integrate the CNC control system into a network. This allows it to deliver high-speed part program transfers or easier data collection. Remote maintenance, diagnosis and online training are now possible, since the Series 30i/31i-L MODEL B CNCs also has the capability to set up worldwide links via the internet. Its integrated Ethernet interface does not utilize a public operating system, which makes it immune to viruses and “hacker-free”.

The new Series 30i/31i-L MODEL B CNCs offer superior technology, outstanding performance, and impressive gains in power modulation and processing speeds that translates to increased edge quality and shorter cycle times. With an update rate of 125 microseconds, it is 40 times faster than the rate which a neuron can travel within the human brain.

The Series 30i/31i-L MODEL B offers a maximum internal memory of 8 MB. This allows users to store constant inventory nests, without the need of a network access to activate during surplus machine availability.

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Certified by the FDT Group, Emerson’s Valvelink software has complied with FDT standards and has been certified for use with other FDT compliant host system producers such as Invensys, Honeywell and Yokogawa.

The digital valve controllers have been utilizing the AMS ValveLink SNAP-ON to integrate into FOUNDATION and HART fieldbus host systems, such as Ovation digital automation and Emerson’s DeltaV systems. The addition of DTM technology has allowed the company to continue its strong integration tradition for FIELDFVUE instrument clients.

Known for its reliability and performance, FIELDVUE’s digital valve controllers diagnose the assembly, maintain valve performance and allow predictive maintenance. Logging in millions of operating hours, Emerson’s FIELDVUE digital valve controllers have earned the respect of companies that uses their technology to upgrade plant availability. Specifically designed for extreme conditions, the controllers have survived harsh environments in chemical, pulp and paper, refining, oil and gas, nuclear and power industries.

The company’s Process Management sales office offers additional information regarding the FIELDVUE digital valve controllers or ValveLink DTM software.

Motion Control Tips

These new FMD PLCs complete Triangle Research’s lineup of highly integrated “Super PLCs”, which starts from the small Nano-10 to the F-series. The super PLC series blends the easy-to-use and powerful i-TRILOGI Ladder+BASIC software with a vast array of features, such as PWM, PID, built-in analog and digital I/Os, stepper controls, encoders, and on-board communication ports which enables connection to other devices.

The FMD models allow Nano-10 PLC users easy creation of graphic web page without the need of writing any Internet program. For remote interaction with the controlled device, users simply have to define a background image and modify significant variables that define the location and I/O labels over the image on a browser screen.

Aside from making the FMD model PLCs remotely accessible for OEM troubleshooting and machine monitoring, the company’s iTRILOGI client/server software also allows easy integration into mixed-brand PLC networks and environments.

As implied by the model name, the FMD88-10 comes with eight digital inputs and outputs, and 10 analog I/Os while the FMD1616-10 features 16 digital inputs and outputs, and 10 analog I/Os. Specially designed with an I/O expansion port, both models also offers RS485 and RS232 serial ports, LCD display interface and an Ethernet port which has become quite indispensable.

The FMD1616-10 and FMD88-10 are available at $295 and $229 respectively.

Motion Control Tips

Cognex Connect enables users to easily monitor and configure a network of vision systems and Cognex ID readers through its open standard industrial Ethernet communications protocols. Since In-Sight and DataMan are network devices, the protocols enable the devices to be easily accessed from any terminal connected to the network. Thus, they eliminate the need for a host PC that will translate USB or RS 232 communication to a central or PLC network. Images and data files can be archived using the Cognex Connect’s FTP support. This capability allows later analysis and review of files. DataMan ID readers also allow users to customize terminal interfaces and GUI through a NET based command library. Its simple command line interface provides users control over the ID readers.

“By adding industrial protocols, the DataMan 8000 series is the first and only hand held ID reader to allow a direct connection to a PLC-acting as a node on the factory network,” Senior Vice President, International Sales and Marketing Didier Lacroix said. “DataMan readers with Cognex Connect completely eliminate the need for a PC and simplify the integration into the factory network, reducing costs and downtime.”

Motion Control Tips

Galil Motion Control recently released the CDS-3310 single-axis controller and drive system designed to provide high performance and precise control of a single brush or brushless servomotor. According to the company, it combines a programmable motion controller and 500W drive in a single, compact package that eliminates the external wiring between the controller and drive.

The CDS-3310 includes PID compensation with notch filter and velocity/acceleration feedforward, non-volatile program memory with multitasking, uncommitted digital and analog I/O, and advanced modes of motion such as electronic gearing and teach-and-playback. It also accepts differential encoder inputs up to 12 MHz, and provides dual encoder inputs that let it accommodate electronic gearing or dual-loop applications.

www.servo2go.com

Motion Control Tips

Housed in an IP66-rated enclosure, the Exlar EXP-24 Positioner integrates a fully featured 24VDC motion controller and brushless servo motor amplifier, and is able to power most resolver feedback brushless motors on the market. With an operating temperature range of -29 to 82°C, the EXP-24 is ideal for process control applications and provides the functionality to position a valve or damper by following an analog input signal and providing position feedback via an analog output. For other applications, additional motion modes are available to accommodate the widest possible range of motion control applications.

Designed for analog control, the EXP-24 also includes an isolated RS485 Modbus serial interface for easy integration into factory-wide process systems. Several diagnostics features are available including real time monitoring, following error, position error, input and output status, communication diagnostics, a multi-channel oscilloscope and data logger.

The EXP-24 is set up via Windows-based software. The software lets users select all aspects of configuration and control required for operation. Tabbed pages provide access to input all of the parameters necessary for configuration of valve control or general motion control applications and further simplify the set-up process.

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“Combining this feature-rich industrial fieldbus adapter with the ACS355 and ACS850 drives will make available a great drive solution for OEM’s or system integrators who are focused on the packaging, material handling, printing, rubber & plastics, and machine tool industries,” said ABB LVD Senior Platform Solutions engineer Chris Stamas.

The adapter’s flexibility offers easy and fast connectivity to major programmable automation interfaces/controllers that support Ethercat protocol including ABB AC500 programmable logic controller (PLC). Some of the applications for coupling with this advanced drive adapter are high-speed presses, packaging machines, injection molding machines, machine tooling (CNC), robotics, test beds, woodworking machines, high speed bottling lines (food and beverage) and materials handling / logistics.

EtherCAT is an Ethernet technology aimed at maximizing the capability of full duplex Ethernet bandwidth. It exceeds the overhead usually associated with Ethernet by using “on the fly” processing hardware. An EtherCAT bus comprises up to 65535 slave devices and a master system, linked together with standard Ethernet cabling. The incoming data are processed by the slave devices, which insert or extract them and shift the message to the next slave device, creating a loop.

Various protocols can be utilized as the application layer. ABB’s drive adapter uses the CANopen over EtherCAT (CoE) technology. Customers can create a robust solution out of the combination of this data infused protocol with the company’s ACS850 and ACS355 drives. It does not only provide real time control but also the capability to extract data in order to optimize applications.

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“Our HVAC/R OEM and end user customers face a unique set of challenges when it comes to designing machines that are efficient, productive and reliable while also being cost effective,” said General Manager – OEM Business, Industry Business, Schneider Electric Ian Hitchins. “Automation solutions are a driving force behind controlling costs, reducing design time, and continuing to deliver innovative products, so we’re proud to deliver an HVAC/R-tailored solution that will also enable a value-add through decreased energy costs.”

The Modicon M168 PLC is part of the company’s automation solution that uses new equipment platforms and a single software suite to help OEMs design machines that are optimized for energy efficiency, performance and cost.

The Modicon M168 PLC features web-enabled capabilities, which allow end users and machine OEMs to monitor machine shutdowns, energy consumption and other problems remotely. Communications protocol such as BACnet allows the controller to easily integrate into Building Management System platforms, savings up to 30 percent of energy. These unique products are powerful enough to control various building functions: electrical and mechanical equipment for heating, air conditioning, ventilation, shutters/blinds, lighting and power distribution, including security functions as CCTV and access control.

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Lenze’s I/O System 1000 is integrated with a 136mm-wide DIN-rail-mounting controller to create a single station with a 1µs time stamp and a 48MHz backplane bus. Up to 64 I/O modules can be combined to offer analog and digital I/O, counters and encoder evaluation, and temperature measurement.

To avoid moving parts, the 3200C makes use of Intel Atom processors, which operate without fans, and flash memory storage. It also features a built-in UPS to save variables in case of power interruptions. The controller has two USB ports and a SD memory card slot.

The controller also has two 100Mbit Ethernet interfaces. A third Ethernet interface is also provided to allow real-time communication with drives. Users can also add further communication buses, while the controller’s two synchronized CAN buses can support CANopen. The 3200C controller can also serve as a gateway between supervisory-level computers and field devices.

The Windows CE 6.0 based controller is complete with Lenze’s PLC Designer software, which allows programming compliant with IEC61131-3. The PLC Designer software is based on the CoDeSys3 programming system, which has been upgraded for the controller. The controller also features an integrated Web server, which provides access to all control parameters and to any Web browser’s logbook.

Individual System 1000 I/O modules can also be added as elements in the PLC Designer’s project tree. The I/O systems are integrated in the controllers mechanically and in the programming software.

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The latest PIFOC system packages are developed to improve results in lens positioning and fast focusing including deconvolution / 3D imaging, as well as to minimize costs.

The PIFOC piezo objective scanner system packages comprise custom-tuned compact digital servo controller / driver units and closed-loop piezomechanic objective positioners. The duo provides reduced costs with higher performance. The frictionless and high-stiffness piezo flexure drive integrated in the system ensures short settling times and quick response, as well as outstanding guiding accuracy. The settling time of not more than 10ms increases throughput and allows for fast Z-stack acquisition.

The digital controller delivers several advantages than the fast focusing systems of conventional analog controllers currently available. These include improved settling performance, higher linearity, access to advanced automation features and quick adaptation to varying motion requirements.

The integrated software allows switching of various sets of parameters on-the-fly and facilitates system setup. For the user, this means always getting the maximum performance from the piezo focusing mechanism. System integration becomes much more straightforward without the need of accessing trim pots and jumpers to make changes.

System setup with the integrated user-interface software is easy and fast, and interfacing to the customers’ software is made easier with the DLLs and LabVIEW drivers. Drivers for image acquisition software packages such as µManager and MetaMorph are also available.

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