The feature-rich MicroFlex e150 drive is expected to be popular among OEM machine builders as it offers a remarkably flexible platform for making new machinery designs.

“Machinery OEMs need versatile products, and these new drives have versatility in abundance – without needing to add hardware or choose configuration options,” said David Greensmith of ABB.

“The multi-protocol Ethernet capability and local intelligence mean that the applications potential is truly broad. And the processing performance is spectacular too – offering some 20 times the speed of one of our popular existing generations of smart drives – making it ideal for performance intensive applications such as high-speed labeling.”

ABB said that the new MicroFlex e150 drives are ideally suited for numerous machine automation applications, such as grinding or glue laying, metal cutting machinery (plasma/waterjet) and various common packaging automations that include form/fill/seal. The drives also feature multi-tasking programmability and two high speed registration inputs, making it suitable for speed-intensive applications like labeling.

In addition, the drives can also be fitted with a scalable PLC platform for automation applications, the AC500 PLC. The PLC communicates using a wide range of standard fieldbuses such as EtherCAT, which is an Ethernet based protocol.

Motion Control Tips

The axis’ main head moves left to right and up and down on the cross beam to make the table turn front to rear. All of the axes are driven by double-nut ball screws of high precision to stop thermal increase while machining. Offering an outstanding repeatability and positioning, the double pretension design also provides practically no thermal increase. Reducing any backlash, all ball screws are directly linked to the servo drive motors avoiding the need for belts or gears.

The linear motion guideways help achieve fast axis movement trimming on machining time and non-cutting time. The spindle traverse for the A/C axes is 70/150 rpm while for the X/Y/Z axes is 50/50/50 m/min.

Hi-Mold VMC’s main spindle is engineered for precision machining delivering 24,000 rpm, geared with precision-class angular bearings offering fast acceleration or deceleration. Even at the greatest rotation levels, the spindle maintains low vibration, reducing thermal transmission to the main spindle and therefore, promoting stability.

An optional 40,000-rpm main spindle is offered for high-quality machining of mold cavities and bases. To ensure that oil temperature remains constant and to reduce the growth in the spindle caused by heat distortion, it also gets a spindle oil chiller that can control the spindle temperature.

Motion Control Tips

Measuring 55 mm x 26 mm x 13 mm, this compact plug-in module seamlessly integrates the basic motor control functions with PLC and motion control features. Offering CAN/CANopen and an optional EtherCAT interfaces, the iPOS3602 MX offers a flexible solution ideal for decentralized/coordinated control of any linear or rotary brushless, step or DC motor.

The µ-sized pluggable servo drive can work in multi-axis, single axis or stand-alone configurations, while performing speed, position or torque control. Technosoft Motion Language (TML) and EasyMotion Studio makes tuning, drive setup and motion programming easy and simple, while its embedded intelligence eliminates the need for an external motion controller when executing complex motion.

In addition, the iPOS3602 MX can operate in different communication modes, such as TMLCAN, CANopen and EtherCAT (when offered with an EtherCAT interface board). This implies that it can be controlled through the appropriate masters when the CANopen/EtherCAT mode is chosen. If the TMLCAN mode is employed, the iPOS3602 MX operates like the usual Technosoft intelligent drive, which conforms to Technosoft protocol when exchanging TML commands through CAN-bus.

When operating as a standalone, the iPOS3602 MX plays the role of a master, coordinating both the motion application and the network communication/synchronization. However, if a higher level of coordination is required, aside from the mentioned masters, the iPOS3602 MX can also be controlled through a PLC or a PC using one of the TML_LIB motion libraries.

Motion Control Tips

This delivers more efficient prototyping and bench testing to packaging, converting, medical, printing and other machine builders as well as enable smooth transition from a bus type to another.

“Where most servo drive hardware and firmware support just a single motion bus, a single AKD servo drive supports multiple motion buses that would otherwise require two different sets of hardware and firmware. With a simple parameter change and a power cycle, machine builders can quickly and easily change the AKD’s communication protocol between EtherCAT and CANopen giving them a clear competitive advantage in getting new and better machines to market, faster,” said Josh Inman, Product Manager at Kollmorgen for North America.

Without the need for a separate option cards, the AKD servo can also support various Ethernet motion buses from the base hardware as well as feedback devices.

It currently supports feedback devices such as BiSS, Endat, Analog Sine/Cos encoders, Smart Feedback Devices (SFD), HIPERFACE®, incremental encoders, and resolvers. Aside from CANopen and EtherCAT motion buses, the AKD also supports PROFINET, Modbus/TCP, EtherNet/IP and SynqNet®.

AKD servo drives cater great operational flexibility and quality at reduced costs, increasing overall footprint associated with integrating option card, as these capabilities are available within the base product’s dimensions.

The servo drives also feature 120/240 VAC or 480 VAC operation, power ranging three to 24 Arms continuous current and at peak, nine to 48 Arms.

Motion Control Tips

Offering extensive functionality with multiple I/O inputs, LVD can be operated in Velocity, Position or Current modes. The drive supports both DC and BLDC motors, and operates at a voltage ranging from 12 V to 48 V. Its selectable switching frequency allows the drive to support low inductance motors, effectively making it ideally suited for various applications, such as surveillance cameras, highly-sensitive medical applications and semiconductor wafer handling processes.

Its highly flexible tuning capabilities and space vector modulation current loop enables the LVD to deliver outstanding accuracy and performance. The drive also provides high sampling rates for the Position and Velocity loops, enabling increased accuracy and wider bandwidth.

Although the low-voltage drive measures just 117 x 83.5 x 21.5 mm, and weighs only 250 g, its compact scale does not mirror the power versatility that it can deliver. With switching frequency of up to 100 KHz and 12 Amps RMS peak current, LVD is one of the industry’s most potent low voltage drive, providing space efficiencies without sacrificing performance.

The Axis Manager of LVD, which is an easy to use drive commissioning software, features various control loops tuning, user friendly windows feedback and motor configuration, I/O setup window and comprehensive recording and monitoring features. It communicates with the drive through CANopen or RS232.

Motion Control Tips

A PC-based embedded vision board, the NI PCIe-1473R frame grabber seamlessly combines Camera link interface with field-programmable gate array (FPGA) to allow engineers to easily create high-performance inspection and imaging applications. It is ideally suited for advanced inspection and imaging applications demanding image preprocessing as well as high-speed control, such as high-speed sorting, medical imaging and web and surface inspection.

Aside from allowing engineers to drive brushless servo motors, the addition of the NI 9502 brushless servo drive C Series module for CompactRIO has also enabled engineers to power six new custom NI motor options from the reconfigurable CompactRIO system, addressing advanced motion control challenges. The NI 9502 features not only 4A continuous/8A peak current, but multiple commutation modes as well. It is complemented by NI’s six three phase brushless motors that are specifically developed for optimum performance and direct connectivity with the module.

“With its superior I/O and motion control capabilities, along with the flexibility and reliability of its onboard FPGA, the new NI CompactRIO system helped us to create a high-performance embedded monitoring and control system that matches our rigorous requirements,” commented Pascal Wattellier, Automation Products Coordinator at Serimax, an international full-service welding solutions company.

“The CompactRIO system was the only commercially available solution that we could use to integrate motion control, I/O measurements, and HMI functionality within one system.”

Motion Control Tips

Integrating a pneumatic drive motor and servo package, the PSD offers accurate flow control, consistent bead profiles and precise metered volumes. It features a lightweight positive displacement meter and pneumatic cylinder that are assembled in a compact metering module for robot, pedestal or floor mounting. A robot with a built-in PSD system delivers precise dispensing of fluids with outstanding response time for dispensing extruded beads.

The PSD has been specifically designed to provide maximum uptime and longer service life. Its components are easy to maintain and readily accessible. It is operated by automation integrated controls or by its own PSD Control Panel with dispensing software for a limited footprint, reduced system cost as well as a one-stop operator control of the whole robotic dispensing system.

The Pneumatic Servo Dispenser is ideally suited for dispensing application such as casting, adhesive bonding, molding, gasketing and sealing. It is also suitable for various designed dispense adhesives and sealants, which include mastics, 1-part epoxies, urethanes, abrasive materials and silicones. A complete PSD meter system comes with supply pumps and a dispense valve that is available in No-Drip, Tip-Seal and Snuf-Bak variants for precise start-stop of material flow for dispensing shots, beads or dots in streaming, extruding, high-speed stitching and spray applications.

Motion Control Tips

A servo driven gantry robot, this new machine is designed with three or four axes. It offers a compact footprint and can palletize crates, boxes, bags, buckets and other packed products from one or multiple lines. Its interpolated controls enable the heavy-duty linear axes to move like spiders with accuracy and speed. This allows the new machine to achieve a maximum speed of up to 10 cycles per minute.

It comes with an innovative fast gripper changing system that enables the machine to shift to clamping gripper from vacuum gripper. This makes the machine suitable for various sectors, including pharmaceuticals, cosmetics as well as food and drink. A stored pre-programmed pallet patterns allows the “Spider” to change over quickly and efficiently.

The status of the servo drives, machine, and the different peripheral equipment can be continuously monitored at its “operator display” panel. The software’s ease of use feature allows customers to integrate new palletizing patterns.

“The ‘Spider’ machine came to our attention through one of our European distributors – as the machine is particularly successful withinBelgiumandHolland,” said Alan Yates, MD and CEO of Endoline Machinery.

”It was the ‘Spiders’ ability to palletize different types of containers which was particularly appealing to us as this would work for all of our customers and is not dependant on the industry they are in. As a result we have established a joint venture with the Belgian company who manufacture the ‘Spider’ to produce it and launch it within theUK.”

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

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

Modularly engineered to cover both low-volume and high-volume applications, iPOS3602 (36 V, 2 A, 75 W) — which is the first member of this family — offers drive solution fitted on just 21 mm x 54 mm of PCB space as well as a complete motion control. It integrates all the basic motion control functionality, motor control functions as well as the PLC functionality on one compact plug-in module. Featuring CAN / CANopen interfaces and an optional EtherCAT interface, the iPOS drive controls any linear or rotary brushless, DC brush or step motor.

With the integrated EasyMotion Studio platform and motion controller, Technosoft’s iPOS3602 can execute complex motion programs at drive level. It can also operate as an intelligent CANopen and EtherCAT slave. In simple applications the new iPOS3602 can operate as a single-axis motion controller and drive while in a stand-alone mode and independently running the program within its non-volatile memory. In systems that need a host, the new iPOS drive functions as an intelligent slave executing motion sequences propelled by commands or input lines received though RS-232 or CAN bus.

The drive’s iPOS card features motion capabilities that include 3rd order PVT and 1st order PT interpolation, position or speed profiles (trapezoidal, S-curve), electronic gearing and camming, digital or analog external reference, matched with the cyclic synchronous position, torque and speed modes specific to EtherCAT.

The new drive can operate with a vast array of feedback devices. Sin/Cos and incremental encoders, linear or digital Halls are supported by default, while BiSS, SSI, EnDAT absolute encoders as well as resolver interfaces are offered through an additional extension.

Motion Control Tips

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

The new AMP-43540 and AMP-43640 4-axis drives are available as options for Galil’s DMC-40×0 Accelera and DMC-41×3 Econo motion controllers with Ethernet. Designed to minimize space, cost and wiring, the drives reside directly inside the controller enclosure. The packaging of the 4-axis drive inside the motion controller enclosure saves space compared to using external drives. The DMC-4040 4-axis controller and drive package dimensions are 8.1” x 7.3” x 1.7”. Two 4-axis drives can also be installed inside the DMC-4080 8-axis controller package which measures 11.5” x 7.3” x 1.7”.

The new AMP-43540 contains four 600W fully digital, transconductance amplifiers for driving brushless motors with sinusoidal commutation. Each amplifier drives motors operating at up to 8A continuous, 15A peak, 20-80 VDC. The gain settings of the amplifier are user-programmable at 0.4, 0.8 and 1.6A/Volt. Both the switching and sampling frequencies are 33 kHz. The amplifier offers protection for over-voltage, under-voltage, over-current, short-circuit and over temperature. A shunt regulator option is available. The U.S. list price of the AMP-43540 4-axis 600W drive is $1000 in single quantity and $600 in 100 quantities.

The new AMP-43640 contains four 20W linear, transconductance amplifiers for driving brushless motors with sinusoidal commutation. Each amplifier drives motors operating at up to 1A peak, 15-30 VDC with a gain setting of 0.1A/Volt. The U.S. list price of the AMP-43640 4-axis 20Watt drive is $600 in single quantity and $350 in 100 quantities.

The AMP-43540 and AMP-43640 don’t require hall sensors for brushless motor commutation. Galil provides commands for initialization of the motor using the encoder feedback.

The AMP-43540 and AMP-43640 are available for immediate delivery.

For more information, check out www.galilmc.com.

Motion Control Tips

The cross-lapper uses a light weight fiber web, which it accepted from the carding machine, to build a heavier web in layers. The cross-lapper then overlaps the layers through a group of reversing mobile carriages and conveyors that turn the material through 90°.

ABB’s machinery drives and servomotors are harnessed by Tatham’s TSX control system with various panel combinations, depending on the current cross-lapper configurations used.

Tatham’s system is connected to the main process control using Profibus, through which an ABB AC500 PLC delivers positioning data to the drives that gives control signals for the speed control of the servomotor.

“We chose ABB drives because of their versatility, power and competitive pricing,” said Tatham’s Senior Electrical Engineer Jim Kelly.

“Together with ABB, we developed control software based on their drives’ programmable function blocks, which meant we had a system that provided precise positioning … resulting in total control of the batt profile,” he added.

“Heaviness of the batt is a function of the speed it is laid down at, and using the ABB PLC, drives and servomotors allows us to vary this precisely, giving a much more accurate and controllable build up of the layers.”

Aside from ensuring fiber savings, the TSX control system is also energy efficient. Prior to installation of the ABB drives the cross-lapper utilized 60A peak, but after the installation the current has been significantly reduced to 15A.

Motion Control Tips

The SPiiPlus UDMnt is available in a 5A, 10A, or 20A peak current rating at up to 60Vdc bus voltage, and has dedicated encoder and limit inputs as well as general purpose I/O and robust fault protection. The drive performs real-time control of position, velocity and current at a 20kHz update rate for each axis.

The SPiiPlus EtherCAT family of products offer advanced, high-level machine control with a small footprint and low cost. The universal drive technology provides a flexible solution for all motor topologies, helping to reduce costs by letting users run multiple axes from one drive module.

For more information about the SPiiPlus UDMnt and other ACS EtherCAT network control components, visit the ACS Motion Control website at www.acsmotioncontrol.com.

Motion Control Tips

Borries latest markers feature an upgraded, high-speed stepper motor drive system that reduces cycle time in half-or more.

The drives were originally developed in response to the demands of the automotive industry for lower machine cycle times but faster production rates, as manifested by automotive stamping plants, where the stamping plants deliver 12 characters in three seconds at a speed of 5 mm.

Aside from the new systems, which are capable of increasing the throughput and reducing the cycle time, the company also provides retrofit packages for existing devices.

With the use of higher speed drives, the devices can be installed as retrofit kits either at the Borries factory or in the field. This gives users an affordable solution for optimizing marking speeds without the need of acquiring a new device.

Borries’ high-speed drives can be translated into several marking technologies: Stylus Marking, which utilizes fast-vibrating needle technology to produce minimal force on three-dimensional material; Scribe Marking, which is ideal in almost all deformable, three-dimensional configuration and delivers continuous-line mark that are easily-readable; Dot Matrix Marking, which is similar to Stylus Marking and Scribe Marking, but provides a visible dotted appearance; and DataMatrix Marking, which uses the same tool with the dot matrix and provides 2D codes (ECC 200 standard) that are camera-legible.

These high-speed drives are offered in the company’s programmable dot peen and scribe machines portfolio.

Motion Control Tips

Installed in all ACOPOSmulti drive units, the relay-free SafeMC safety circuit uses EN ISO 13849 certified digital encoders to monitor how the motor responds to the servo drive’s instructions. To avoid increasing response times, the electronics were fitted directly on the drive.

B&R’s servo drives provide external monitoring modules and eliminate the need for double wiring to offer optimum use of safety equipment. Together with the SafeMC, the ACOPOSmulti can be seamlessly installed in the existing system with the X20 Safe I/O and the SafeLOGIC safety controller. With this innovation, B&R became one of the first companies to offer a certified and intelligent drive safety function including a fully network-integrated safety system. The system not only improves the safety of the workplace, but also contributes to the machine’s efficiency, as well as increases its productivity.

The device’s programming functions are developed using SafeDESIGNER at B&R Automation Studio’s standard development environment. SafeMC components embedded with parameter chip including its autonomous configuration allow easy and fast configuration during service work.

Based on open network-based safety standard openSAFETY, the company’s synchronous servo motors and SafeMC with ACOPOSmulti provides a logical complement to integrated safety components portfolio for systems and machine manufacturing.

Motion Control Tips

MACCS-400

Based on Baldor Electric motion control products, the multi-axis system has three axes that use ACR’s Ethernet-compatible PowerLink servo drives.

ACR’s reasons behind the choice of this technology were the ease in applying real-time interpolated control over the machine’s five-axis servo and stepper driven motion, flexibility of Baldor’s motion control software and the simple building approach of the plug-together system provided by the Ethernet-based modules.

The new MACCS 400 machine delivers a fast and highly flexible way of selectively applying printed circuit board (PCB) mounted components with protective conformal coatings, and accommodate both batch and inline processing operations. With board components as high as 900 mm, it can coat PCBs as big as 500 x 480 mm.

MACCS 400 is a free-standing machine designed with small 1.4 m2 footprint. Capable of completely autonomous operation, it can be equipped with chain conveyors and be integrated with PCB production line. It is fully compliant with the SMEMA (surface mount equipment manufacturers association) electrical and mechanical interface standards.

The MACCS 400 can apply various conformal coatings, including HumiSeal and Parylene products, and provides a selection of cartridge or pressure vessel feed. Standard features include a remote teach pendant, an integral camera for manual alignment and built-in solvent and purge cups for flushing. The machine also has several optional facilities, such as fluid viscosity control, multiple spray heads, a laser pointer and a bar code reader.

Motion Control Tips

The multi-axis system is based on Baldor Electric motion control products, with three axes making use of the company’s Ethernet-compatible PowerLink servo drives. Key reasons behind the choice of this motion control technology were the flexibility of Baldor’s motion control software, the ease with which real-time interpolated control could be applied across the machine’s five-axis servo and stepper driven motion, and the simple plug-together system building approach offered by the Ethernet-based modules.

ACR’s new MACCS 400 machine provides a fast and flexible means of selectively applying protective conformal coatings to printed circuit board (PCB) mounted components, and can accommodate both inline and batch processing operations. Capable of coating PCBs as large as 500 x 480 mm – with on-board components as high as 90 mm – the programmable machine uses an advanced five-axis motion control system to combine high-speed throughput capabilities with precise spray-head positioning to an accuracy of 25 microns.

MACCS 400 is a self-contained, free-standing machine with a small footprint. It’s capable of completely autonomous operation, or can be equipped with chain conveyors and form part of an integrated PCB production line; the machine is fully compliant with the SMEMA (surface mount equipment manufacturers association) mechanical and electrical interface standards.

The X and Y-axes of the machine’s motion control system are based on a novel ‘H-belt’ actuator, driven by two Baldor BSM servomotors linked to Baldor MicroFlex e100 drives. The two motors are static – they occupy fixed positions at the bottom of the ‘H’ – and jointly act on a single belt. The advantage of this approach is that the motors do not contribute to the load inertia, and therefore permit fast and accurate movement – the machine can accommodate X-Y velocities as high as 800 mm/sec. The Z-axis controls the above-board height of the spray head, and is driven by a third BSM servomotor and MicroFlex e100 drive. All three drives are tightly synchronized to facilitate high speed Cartesian movement of the spray head, the angle and orientation of which are controlled by two rotary axes, driven by Baldor stepper motors.

All five electrical axes on the MACCS 400 are controlled by a Baldor NextMove e100 controller, using full interpolation to allow smooth high-speed tangential moves. Overall control of the machine is handled by ACR’s proprietary coating software, which runs under Windows XP on a built-in host PC, equipped with a large HMI (human-machine interface).

The MACCS 400 can apply a wide range of conformal coatings, including Parylene and many HumiSeal products, and offers a choice of cartridge or pressure vessel feed. Standard features include an integral camera for manual alignment, a remote teach pendant, and built-in purge and solvent cups for flushing. The machine also offers numerous optional facilities, such as multiple spray heads, fluid viscosity control, a bar code reader and a laser pointer.

www.baldor.com

www.advancedcoatingrobotics.com

Motion Control Tips

Specializing in automated food handling systems, the Cornish machine builder used controls and drives equipment from automation specialist Mitsubishi Electric (www.mitsubishielectric.com).

The machine deposits the correct amounts of Yorkshire pudding batter to the baking moulds for a frozen foods plant, and solves inconsistency problems by getting away from ordinary motors running for a set time.

WMH has developed a Mitsubishi servo-based system that increases throughput, while ironing out the inaccuracies of batter pumping.

The system consists of 10 axis J3 servo drive arrangement, with every servo connected through high speed SSC net from Mitsubishi Electric. Its nine axes are dedicated to the depositors, with each axis driving 32 pump chambers.

The servo drives are each programmed using a map of known volume to be dispensed, while the required number of pump rotation is calculated depending upon the needed product settings.

The system also has an anti-drip mechanism, which prevents excess product that causes cleaning issues in the production cycle. The servo drives cleverly suck excess batter back to the nozzle at the end of every cycle.

The 10^th axis then operates the depositor heads carriage, which coordinates with the conveyor speed, as detected by an encoder feedback. This helps reduce waste and increase throughput, according to the company.

Motion Control Tips

Manufactured by Ohio Tool Works Corporation (www.ohiotoolworks.com) and imported by Mollart-Cox (www.mollartcox.co.uk), the machine is an important investment for Premier and will be installed early next year.

The new OTW1000-5m to 2m horizontal honing machine, which features a full CNC for superior machining performance, will be the first of its kind in the United Kingdom. It is constructed from heavy, welded steel sections, providing the rigidity needed for precise bore sizing of components. The infinitely variable speed spindle drive motors and the 3.73kW servo drive reciprocation system offer quiet, trouble free and smooth operation under harsh conditions.

Stuart Grant, managing director of Premier, said: “We have ordered this new generation tube honing machine to fulfill a project for machining aerospace components. For the parts concerned its specification looked perfect on paper, and during performance trials we carried out it proved to be the ideal choice.”

Introduced last year, the model 1000 is offered in several standard stroke configurations between 2m and 6m with spindle drives up to 7.46kW. Honing diameters will range from 25.4mm to 559mm. Infinitely variable spindle speed motors of 1000rpm enable improved processing with both conventional metalbond and vitrified superabrasives.

“We have purchased the OTW1000-5-2m as a turnkey project,” said Mr. Grant. “As the components being machined required precise and consistent size control, we specified the optional Medium Size Control System which offers accurate and dependable size control to 12.5 micron, or better when metalbond abrasives are applied.”

Motion Control Tips

The Motorman hybrid connector’s key features include several pre-customized devices available for a variety of customer environments; easy-to-open enclosure: safe configuration thanks to the spacious side access to its interior; Cat 5e (ISO/IEC11801) communication in heavy environment; and usage of Tyco’s MCON interconnection system and stamped contacts, as well as compact size of a traditional hybrid construction and rectangular connector (power, communication, signal). All signals are also fitted in one interface, thus only one cable is needed. The device also offers space for, one protection earth contact, two 4-pin Ethernet sockets, five power sockets and five signal sockets.

Additional applications for the new Motorman hybrid connector include Drives (amplifiers), I/O connector on AC servo motors with PCB, I/O connector on decentral servo motors, and packaging, assembly, food producing or woodworking machine.

Motion Control Tips

“Manufacturers are challenged by tougher economic conditions. There is less capital available for new equipment purchases and users expect solutions that are easier to use and also yield greater uptime and return on investment,” said Oliver Haya, product manager of Rockwell. “When combining the new Kinetix 3 servo drive with Allen-Bradley MicroLogix controllers, machine-builders can deliver a cost-effective motion control solution for low-axis count applications, that is simple to use and maintain.”

The servo drive is configured with the Allen-Bradley UltraWare software. Configuration can be made easy by using the automatic motor recognition facilities in Allen-Bradley linear and rotary servo motors. More features include advanced auto-tuning, online vibration suppression, as well as rapid settling time, which cut start-ups by eliminating many steps during the commissioning process. The drive can also index up to 64 points through its digital inputs or via Modbus.

Connected Component Building Blocks technology from Rockwell are used to provide CAD drawings, bills of materials, sample code, operator interface screens and electrical layouts for the drive. Indexing operations for three axes are performed on the Modbus network using Rockwell MicroLogix 1400 controller, TL-Series motors, and Allen-Bradley PanelView component operator interface.

Motion Control Tips

The super miniature network-based servo drive has dimensions of just 55mmx46mmx15mm, and weighs a mere 55 grams.

The highly-efficient Gold Whistle has high bandwidth performance and supports a variety of feedback types such as Incremental Encoder, Resolver, Analog and Digital Hall, Potentiometer and Tachometer. The servo drive offers multiple communication options including EtherCAT, CANopen, Ethernet, USB and RS-232.

“Elmo Motion Control’s engineers have again succeeded in bringing innovative solutions to the marketplace. Ultimately, the most important user community for us are the application engineers who integrate Elmo’s motion control solutions into their applications. They are looking for flexible solutions that are lightweight, high power and support the latest EtherCAT communications technology,” said Haim Monhait, CEO of Elmo Motion Control.

“We launched the Gold Line technology about a year ago. This represented a real step forward and we are now in the process of launching a range of 10–12 new servo drives that are all based on this new technology. These are exciting times for Elmo, and based on the feedback we receive from our customers and the participants at international exhibitions, we know that our excitement is shared by application engineers all over the world,” he added.

Motion Control Tips

Aside from EtherCAT, the IDM680 embeds motion controller, PLC and drive functionality in a one compact unit. The servo drive can operate as a standard EtherCAT slave with a CANopen-over-EtherCAT (CoE) protocol, or can be programmed to perform complex motion programs at drive level, with the use of the built-in-motion controller, as well as the EasyMotion Studio platform, which generates all the TML instructions.

The IDM680 intelligent servo drive is ideal for the operation of brushless, linear or DC motors up to 640W continuous/1.3kW peak voltages. The addition of the EtherCAT compatibility to the IDM680 offers a strong combination of speed and several operating modes, which include third order PVT and first order PT interpolation, speed or position profiles (S-curve, trapezoidal), analogue or digital external reference, electronic gearing and camming, open/closed loop and microstepping (256 µsteps/step) for step motors.

The drive is equipped with several sensors: SSI, digital and linear Halls, BiSS, EnDAT, sine/cosine incremental resolver and encoders. PC/PLC motion libraries are also available for the quick industrial integration of the IDM680.

Motion Control Tips

The Accurax G5 features an external device monitoring output and two safety inputs, which can be connected to another drive even without additional safety relays. A total of eight drives can be linked to a single relay, significantly reducing wiring and hardware costs. The drives’ safety torque off function meets the PL-d in line with ISO13849, Cat 3 in line with EN954 and SIL2 in line with EN61508.

The drives have three types of control: EtherCAT, Analogue/Pulse, and MLII (Mechatrolink-II). They also support full-closed loop operation for specific applications where additional accuracy is required and include advanced tuning algorithms featuring a disturbance observer, an anti-vibration function and a torque feed-forward function to minimize following error.

Easy integration of these drives with, for instance, NS-series operator interface terminals and machine controllers, are guaranteed by their support into the automation architecture of Omron. It is based on Ethernet connectivity and readily configured with CX-Drive component of the CX-One software suite from Omron.

The Accurax G5 is complemented by motors with 10-pole construction to attain a 40-percent reduction in cogging. The drives, which have an IP67 ingress protection rating, feature an integrated 20-bit encoder. Omron’s drives in the Accurax G5 range are available for 230V single-phase operation with ratings from 50W to 1,5kW, and for 400V three-phase operation with ratings from 400W to 5kW.

Motion Control Tips

With the Model RG’s built-in modularity, several applications can now be used with its adaptability to NEMA frame and servo motors. The Model RG is the only model to offer true double enveloping worm gear technology, which is unrivalled in the market where positional accuracy and performance are demanded.

Model RG has center distances of 1.50in, 2.00in, 2.50in, 3.00in and 3.50in with NEMA frames or servo motor. It also provides an output torque of up to 8,540 lb-in, gear ratios from 5:1 to 60:1, backlash ranging from 6 arcminutes to 32 arcminutes and multiple output options, such as Solid, Hollow and Shrink Disc. In addition, both of its input and output shafts are doubled sealed.

Model RG features a flange mount that is placed on either side of reducer or mounting orientation flexibility from a single flange. It also offers double seal input and output to avoid leak issues regardless of a mounting position, zero backlash coupling to ensure proper fit of couplings and maximize overall stiffness, and double enveloping gearing with the highest capacity to improve reliability and minimize envelope. There is also a built-in lubrication (factory filled with synthetic oil & no breathers), as well as several output shaft options (metric or inch shafts as hollow or solid including shrink disc).

Motion Control Tips

The repair team works by first disassembling the customer’s servo motor and then testing each part for damage and functionality. A quotation will then be issued for the identified damaged parts. Upon receipt of a PO, the company’s technicians can repair most servo motor in a 6- to 8-day period, as well as offer rush turnaround services for emergency situations. The company’s fully integrated motor, machine and gear shop means that services is done in-house, which allows faster turnaround times. When the device is repaired, it will be immediately reassembled and tested to ensure that the servo repair conforms to Motor and Gear Quality standards.

The company’s specialty is Servo Motor Repair and it has a Servo Motor department with certified servo technicians who can assist customers for any servo repairs or servo motor sales. They can get the customers’ servo motors analyzed, repaired and returned without delays.

Ampion Industrial performs component level servo motor repair and mechanical repair services for any brands of industrial equipment including welders, robots, programmable controls, servo motors, servo drives, light curtains, video interfaces and much more.

Motion Control Tips

The ASDA-A2 series comprises a built-in E-Cam function, offering the best solution for rotary cutoff, flying shear and synchronized motion applications. The series also features CANopen interface and PR mode. The new position control PR mode is a significant and unique function that offers several control modes to improve system performance.

The new series also features CANopen high-speed network communication interface of 1M bps, which decreases the difficulties of creating programs in the controllers, as well as achieve multi-axis parallel control. The ASDA-A2’s auto notch filter, full closed-loop control, vibration suppression and gantry control functions help perform complex motions, which require smooth operation and high precision. The new series is designed with a 20bit level superior resolution encoder for precise positioning, as well as outstanding comparing and capturing functions for high-speed pulses, which offer the best support for step-less positioning.

“The need for better precision and position control by the machine makers is driving the motion business’s faster growth in India. This is coupled with the increasing demand for productivity enhancement across segments,” said Manish Walia, Director of Sales Industrial Automation Business Unit at Delta Group (India and SAARC region).

Motion Control Tips

The Panther can operate from a very high-voltage power source, even without a transformer, and using a direct-to-mains connection to a 750V DC or 400V DC power source.

The Extriq Panther measures 110mm x 75mm x 30mm and has the flexibility for PCB- or motor-mounting. It can also deliver up to 7kW of continuous qualitative power and is ideal for incorporating in several motion systems ­– multi-axis or single-axis – for high-performance motion control.

Extriq Panther has been designed for extended environmental conditions, allowing it to operate at extreme temperature, altitude and humidity, as well as endure mechanical shock and vibration. Just like any other Extriq Line products, the new device supports a wide range of demanding applications that require reliable and tough motion control, including specialized laboratory automation, unmanned vehicles, satellite communications, and oil refining, among others.

Extriq Panther operates with trapezoidal, sinusoidal and DC motors, combining programming flexibility, high power density, several motion control features and Canopen networking, which make it extremely effective for demanding applications. When using several Extriq Panthers in a multi-axis setting, Elmo’s Gold Lion Multi-Axis Controller can be utilized to control the servo drives network.

The Panther comes with two DC bus options (80V DC – 400V DC and 200V DC – 750V DC), along with a built-in smart supply to facilitate control of the back-up capabilities. The device also has the ability to operate with 24V DC auxiliary power supply intended for back-up features.

Motion Control Tips

The Ultra3000 family is available from 7.5A to 150A peak current in the 230V platform and 14A to 94A peak current in the 460V platform. Moreover, all power sizes are currently available with indexing. DeviceNet networking and SERCOS interface options.

The Ultra3000 offers simple integration into the Allen-Bradley machine control architectures and accepts step/direction, analog 0V to 10V and master follower command sources, along with DeviceNet connectivity and SERCOS interface across the Ultra3000 family. For multi-axis integrated motion (Kinetix), the SERCOS interface provides integration into the ControlLogix platform. The RSLogix 5000 is the only computer program required for both motion and sequential control. Optimized drive/motor combinations are now available for every application. The Ultra3000 can run several brushless servo motors, such as the Allen-Bradley LD-, Y-, H-, N-, W- and F-series and 1326AB motors with third-party and linear motors.

The Ultra3000 features 100V to 480V AC options, with single and three-phase input. It also has 7.5A to 150A peak current capability, as well as standard D-Shell connectors. It features flash memory firmware storage, seven segment LED, four selectable general purpose outputs and eight selectable general purpose inputs.

Motion Control Tips

The new AKM brushless servo motors provide superior dynamic performance, are available in four different frame sizes and feature high torque, density and speed ranges. The motors use low-inertia rotors and feature low-cog, low-harmonic distortion magnetic design. The motors also are perfectly matched with NI servo drives and provide plug-and-play configuration with integrated Smart Feedback Device (SFD) technology and simplified cabling.

The new AKD Servo Drives feature simplified setup and configuration through EtherCAT technology and integration with the LabVIEW project, a feature in LabVIEW software that engineers use to group together LabVIEW and third-party files, create build specifications for executables and deploy or download files to hardware targets. The new drives deliver cutting-edge technology and performance with torque loop updates in 0.67 μs, and velocity and position loops at 62.5 μs and 125 μs. The AKD Servo Drives provide a solution for a wide range of applications, from basic torque-and-velocity applications to indexing to multi-axis programmable motion, using graphical system design.

The new motors and drives provide seamless integration with LabVIEW graphical programming through the LabVIEW NI SoftMotion Module to deliver graphical development for custom motion control applications. With the module, engineers and scientists can use the LabVIEW project to configure motion axis settings, test configuration, tune motors and quickly develop a custom motion application. The new version of the NI SoftMotion Module features an updated interactive configuration and a high-level function block API for increased ease of use and makes the execution of motion applications on a Windows-based system possible. In addition, the new module easily connects to the new drives and motors as well as third-party drives and motors using NI C Series drive interface hardware.

Readers can visit www.ni.com/motion to learn more about the new servo drives and motors and NI motion control software.

National Instruments
www.ni.com

Motion Control Tips

The close relationship between the two companies spans over 30 years with thousands of successful, small and precision, brushed and brushless motor applications for Netherlands’ Premotec B.V., which is now one of the four Allied Motion’s Technology Units. The partnership aims to develop a similar success with Allied Motion Emoteq/COPI Technology Unit and will work across the company’s own products that include X-Drive digital servo amplifiers, housed and frameless torque motors up to 2000Nm, ultra-high resolution incremental encoders and Quantum NEMA frame servo motors.

“We are very excited about working with these new Allied Motion products. We have an excellent reputation with Premotec’s small and precision DC motor range and the Emoteq/COPI products offer similar flexibility with a strong standard range and the ability to custom engineer product – even for small quantities,” said Vic Sayer, managing director of Mclennan.

Highlights of Mclennan’s new products include Megaflux range (large separate and frameless rotor/stator servo motors) up to 790mm in diameter with almost five times the speed ratings of competitive units and two times the power density. The motors are characterized by a high-pole count that maximizes rotational smoothness and torque output. The motors’ housed versions, which come with bearing system, position feedback and commutation device, target direct-drive ultra-high precision motion control in demanding automation applications like robotics, where the large through aperture may be utilized to feed services such as optics, pneumatics or electrics.

Motion Control Tips

Compared with its brushed servo counterpart, the product’s modular design concept has a separately supplied SA1 serial port adapter to easily program the controller with the Red Drive computer-based graphical software. For cost-effective and faster OEM product development, a microprocessor chip is separately available to allow the full board version and its integral servo drive to be utilized in the pre-production and design phases with the IC version included in the final machine for full production. The option also gives machine users the flexibility to select and design-in I/O requirements and the optimum power components for the application.

The BLDC10A Brushless Red Drive can be easily programmed with the use of a “drag & drop” flowchart programming method that eliminates the complexity associated with other motion controllers available in the market. The Windows program permits scaling of gearbox and encoder resolution into meaningful units during setup along with I/O interfacing assignment. The setup stage also includes entering no-load speeds for automatic tuning and catalogue values for motor stall-torque. Homing, limits and reset inputs can also be set.

Motion Control Tips

Sensor data can be read quickly and securely using the new plug-in module for evaluating BiSS encoders.

These advantages make the BiSS encoder interface especially suitable for applications with high demands, for example when integrating fully digital hollow shaft encoders with large internal diameters or robust, absolute and linear measurement systems with high-speed movements.

ACOPOS is an intelligent servo drive that increases production volume, reduces production cycles and improves quality with greater precision. With ACOPOS, B&R offers bus-capable servo drives for machine manufacturing in the power range from 400 W to 64 kW. With Ethernet POWERLINK, it is even possible to operate up to 240 axes on one line using the same network.

B&R Industrial Automation, Inc.
www.br-automation.com

Motion Control Tips

The series is designed for uses where weight factors and limited space are important, including pen carriages in recorders and X-Y plotters or servo drives to stylus, counter drives and chart roll drives. The series is used in business machines, communication equipment, cameras and other electro-mechanical or electronic devices.

Made of non-magnetic black acetal, the drives are designed to operate in a wide range of temperatures from -40 degree Celsius to +121 degree Celsius. The series features a unit-link design, eliminating the need for a master link. Every unit-link measures 4.12mm wide and 2.08mm high. A length of 321 links snapped all together will equal one meter and a five-meter chain weighs only 0.031kg. Maximum operating loads of up to 0.9kg of tension, chain operating speeds of up to 5.1m/s and smaller eight-tooth sprockets are recommended.

Stocked in 14 sizes from eight to 48 teeth, the new A 6M 7M12 sprockets feature three bore sizes, which are stocked for press fitting the sprockets to 3mm, 4mm, and 6mm shafts. The sprockets have 24 teeth or more that are molded with a spoked configuration. Its diameters range from .371″ (9.4mm) to 1.939″ (49.3 mm) and pitch diameters from .318″ (8.1mm) to 1.865″ (47.4mm).

Motion Control Tips

The airframe manufacturing and assembly process incorporates use of both Wing Join and Major Join tools. The Wing Join tool is used to position the two major sections of the aircraft wing and hold them in place while they are permanently assembled to form one massive wing, which is ultimately assembled onto the aircraft. This tool is controlled by a number of jacks holding the wing in place; the wing sections must be positioned for a seamless fit, and then locked in place so that the mechanical join can be completed. The Major Join tool holds the four major pre-assembled aircraft sections together. The center section of the aircraft fuselage is placed atop of jacks, then positioned and leveled, followed by the aircraft nose, assembled wing and tail section. In order for these airframe components to be properly joined, use of high-precision and high-reliability servo systems and software is essential. Retrofits will improve airframe assembly operations by increasing reliability and will substantially reduce long term maintenance costs. This upgrade will also enhance the user interface which, in turn, will make the tools easier to use and more effective.

More than a dozen SMLC controllers and nearly sixty SD-Series servo drives will be used for communication, motion control and monitoring of each join tool. The systems are controlled through the use of operator interface consoles with touch screens for ease of use and remote pendants for flexibility. Available in 3-, 8- and 16-axis models, the SMLC family offers the benefits of both motion control and PLC functions within a single package. With high-performance computing capability and a true real-time operating system powered by Intel® 32-bit processors, the SMLC is able to provide cost-effective, robust computing power for even the most demanding multi-axis motion and I/O control applications.

ORMEC Systems Corp.
www.ormec.com

Motion Control Tips

The drives are versions of Baldor’s e100 single- and three-phase drives. Up to now, these drives have been compatible with the real-time Powerlink Ethernet standard, TCP/IP and Baldor’s Mint system building environment. With this release, Baldor upgrades the capability of the drives to additionally be configured for EtherNet/IP or Modbus TCP networks. These two communications protocols greatly extend the applications potential of the drives in PLC-controlled applications. The drives are easy to configure and use, through features such as wizard application software which removes the traditional complexity of drive set up.

The drives offer many hardware capabilities that PLC users can benefit from. The three-phase drives are energy efficient, offering a DC bus system that can share regenerated power with other axes. As well as their own local I/O and CANopen expansion, many drives also have option card slots, providing a high degree of configurability for specific applications including almost all fieldbuses. Other features include universal encoder feedback input, and programmable notch filters to eliminate mechanical resonance effects, as well as the ability to be used with servomotors, closed loop vector motors or in V/Hz motor speed control modes.

In addition to the new drive functionality, Baldor now supports all of the Ethernet networks on its NextMove e100 motion system and machine controller. This combines network control capability with control facilities for up to seven analog or stepper drives, and may be used standalone or in conjunction with PLC or PC hosts.

For more information, email sales.us@baldor.com or go to www.baldormotion.com.

Baldor Electric Company

www.baldor.com

Motion Control Tips

SimplIQ continues to be innovated and updated with its line of compact, high power-density digital servo drives. One of the important new features Trombone brings to the SimplIQ line of servo drives for industrial applications is the ability to operate from a high voltage power source without a transformer, using a “direct to mains” connection to a 400 Vdc or 750 Vdc power source.

The Trombone’s dimensions are 110 x 75 x 30 mm (4.3″ x 2.95″ x 1.2″). With its small footprint, the pin-based Trombone can be PCB-mounted or integrated within the motor.

Haim Monhait, CEO of Elmo Motion Control, says “The SimplIQ Trombone is for integration into any motion system, either single- or multi-axis, and results in a high performance motion control unit.”

There are two dc bus options: 80 – 400 Vdc and 200 – 750 Vdc, with a built-in smart supply for controlling the back-up capabilities. The Trombone can also operate with a 24 Vdc auxiliary power supply for the back-up features.

The Trombone operates with sinusoidal, trapezoidal and dc motors. When using a number of SimplIQ Trombones in a multi-axis application, Elmo’s multi-axis controller, the Gold Maestro, can be used to control the network of servo drives.

Motion Control Tips

The Economy version of the IndraDrive Cs comes with digital inputs and outputs and an analog input on board, integrated brake resistor, and an intelligent operation panel with programming module function. For users requiring more power or additional protocols, Rexroth also offers a Universal model of the IndraDrive Cs. The compact IndraDrive Cs Economy can be equipped with Safety-On-Board features such as Safe Torque Off and Safe Brake Control for certifiable drive-based machine safety, eliminating the need for separate safety components.

Available in models ranging from 50W up to 3.5kW, the IndraDrive Cs dimensions measure 50 x 215 x 196mm for one unit, and 70 x 268 x 196mm for the larger unit. Maximum current ranges from 3A up to 28A, with a high overload range.

The IndraDrive Cs platform includes Rexroth MSM and MSK series AC servo motors ranging from 50W up to 3.5kW continuous power with IP54 protection (MSM) or IP65 protection (MSK), multi-turn absolute encoder functionality, and optional holding brake.

The IndraDrive Cs Economy is part of the Rexroth advanced automation platform that supports the SERCOS III interface for connecting machines, controls, drives, I/O, safety, and HMI which helps to lower the controls cost and simplify integration for OEMs, systems integrators and end users. The drives are ideal for industries ranging from packaging, semiconductor and medical, to printing, converting, machine tool and metal forming – for small-size applications in a low-power range.

For more information on the IndraDrive Cs, visit www.boschrexroth-us.com/indradrive-cs.

www.boschrexroth-us.com

Motion Control Tips

The new 930K fluxxtorque servo drives feature a power range from 120 W to 440 W. These units are available for both low and extra-low voltage. These easy-to-clean and quick-to-install servo drives can operate precisely.

In its way of further development, the company has redesigned its synchronous servo motors, which resulted to having around 20 percent lower volume with the same power and increasing its efficiency.

In terms of functionality, these new series is ideal for a variety of options for controlling sensors and actuators through the integrated analog and digital I/Os. The 930K fluxxtorque servo drive is very communicative. In addition to the PROFIBUS and CAN fieldbus protocols, which were previously available, mechatronic units can also be integrated to Ethercat networks.

Feedback using multi-turn and single-turn absolute value encoders is also a new feature. Combined with a path program of up to 64 position points with the integrated positioning control, thereby makes the compact servo drive a small, precise positioning drive. Also, it can autonomously assume tasks in the machine network, with cost-effective control running the background. The “simplicity” resulting from this enables 930K fluxxtorque servo drive to be conveniently and quickly commissioned with the free of charge trilingual parameter setting software, which is supported by suitable system cables with Lenze’s fast connection technology (“SpeedTec”).

Motion Control Tips

The first range is a family of machine control inverters, which offer features such as: 200 percent starting torque at 0.5Hz; position control; drive sequence programming; one-parameter auto-tuning; control of induction and permanent magnet motors; and open-loop torque control.

The MX2 inverter drives are based on WJ200 series from Hitachi. They are available in 200 V single-phase versions from 0.2 to 2.2 kW, 200 V three-phase versions from 0.2 to 15 kW, and in 400 V three-phase versions from 0.4 to 15 kW. The current vector drives can be utilized in some applications to eliminate cost in servo drives or a flux vector.

The drives support logic programming with a flowchart tool, which can be utilized to create programs of up to 1,000 lines of code. Without extra hardware, they can be adjusted to follow a master speed signal. Also, they can be utilized for simple positioning without the need of external position controller.

Modbus RS-485 support is built in, while option cards are planned fieldbus networks such as EtherCat, Profibus and DeviceNet. A 24 V DC input is standard, and can be utilized to keep the drives running in the event of mains input failures.

The second range is a family of simpler drives for applications like pump control, fan and conveyor. The compact JX drives, based on X200 series from Hitachi, are available in three-phase versions up to 7.5 kW and single-phase versions with ratings up to 2.2 kW. The drives gave integral EMC filters as standard and they provide RS-485 Modbus connections without the need for extra hardware.

The front-mounted RS-485 Modbus communication ports make it simple to connect the drives into existing networks, especially when utilized with Omron’s programmable logic controllers (“PLCs”), which incorporate Modbus-RTU Easy Master functions.

Parameter settings for two different motors can be stored into the JX drives to allow the drives to be switched between the motors as required.

The third is a range of pulse control servo drives, which occupy 50 percent of space of its predecessors. The SmartStep 2 drives, based on Minas E family from Panasonic, are available in power ratings from 100–750 W and are ideal for point-to-point motion applications where economy and simplicity need to be combined with high performance.

The servo drives are made for easy integration with other automation components like Omron’s NQ operator terminals and CP1L PLCs.

Omron’s servo drives and inverters can be programmed with its CX-Drive software, which offers monitoring and parameter editing, alarm reporting and I/O status, and real-time data tracing, plus a simple auto-tuning procedure.

Motion Control Tips

The EtherNet/IP’s integrated motion within the Kinetix 6500 servo drive utilizes Common Industrial Protocol (“CIP”) Motion, an extension of CIP from the Open Device Vendors Association (“ODVA”). EtherNet/IP is the leading industrial Ethernet topology in the world, with more than 850 product lines in 250 companies and more than two million nodes sold.

Torque, speed and position loops can be adjusted within the Kinetix 6500 servo drive, giving an open, bandwidth solution for motion control. Adding the power of CIP Sync technology from ODVA (“IEEE-1588 compliant Precision Clock Synchronization”) and a variety of axes can be organized for synchronized motion control.

To leverage the tested performance of the Kinetix 6000 family, Kinetix 6500 drive also gives advance safety features, including safe maximum acceleration monitoring, safe direction monitoring, zero speed monitoring and safe stop. These amazing features will improve user safety and enhance machine efficiency by permitting access to guarded areas when a process or machine is still operating, to reduce downtime.

The Kinetix 6500 servo drives have an innovative modular structure to give an adaptable platform for machine enhancements, including increased power range. With interchangeable control modules, one axis can easily transit to another safety functionality or network, to help operators adapt new technologies or market trends, reducing upgrade costs by 50%.

The Kinetix 6500 servo drive is best suited for motion control applications where safety, efficiency and performance are crucial, such as printing and web, packaging, food processing, and other machine types that require position control.

Motion Control Tips

A typical linear motion control system has several basic components, including motors, actuators, controllers and drives. The drive type plays an important role in the overall system. Here’s a look at the most basic drive configurations, including the latest advancements in chopper drives.

The IDEA programmable actuator from Haydon Kerk is an example of cutting-edge intelligent chopper drive technology. IDEA consists of an advanced microstepping chopper drive with an intelligent programmable controller mounted to the rear section of a hybrid stepper motor linear actuator in one fully integrated package.

Defining the L/R Type Drive
An L/R type drive is a voltage source drive, where the L refers to electrical inductance and R stands for electrical resistance. Inductance is an electrical parameter relating mainly to inductors that are coils of wire wrapped around a core material that can be metallic, non-metallic, solid, liquid, or even air. Typical inductors are transformers, chokes, and motor coils (including the windings in stepper motors and stepper motor linear actuators). A related parameter called inductive reactance in an electrical circuit impedes the flow of current relative to the voltage frequency. It can be thought of as a “dynamic resistance,” increasing and impeding more of the current flow as the frequency increases. An analogy for inductance in the mechanical field would be the principle of inertia.

Resistance also impedes the flow of current in an electrical circuit but is a constant value and is not affected by the frequency value of the voltage or current. The stepper motor coil resistance remains essentially the same from standstill through maximum step frequency with only minor fluctuations due to temperature. A mechanical equivalent of electrical resistance would be the friction in a system.

Stepper motor manufacturers offer a variety of coil voltage ratings. With an L/R type of drive, you set the output voltage of the drive (measured at the motor leads) equal to the voltage rating of the stepper motor. The voltage level of the drive power supply will be set slightly higher due to voltage drops across the power transistors. The ratio of inductance to resistance (L/R) determines the current flow through the windings at a given step rate (or frequency) in steps per second. L/R = 1 time constant, which is equal to approximately 63% of the final steady-state current. At standstill, the maximum current flow into the windings is determined by the coil resistance alone. The impedance effect due to inductance is zero when the frequency is zero. This is the condition where the motor has maximum torque (holding torque) due to maximum ampere-turns, defined by:

T_H α N x I

Where:

T_H = the holding torque
N = the number of turns in the motor coil
I = the electrical current

As the step rate increases, the coil inductive reactance (X_L) also increases according to the formula:
X_L = 2πfL

Where:
X_L = the inductive reactance
f = the frequency (step rate)
L = the inductance of the motor coil

With a constant voltage source L/R type driver, the motor current decreases as the total impedance (X_L + R) increases.

Because torque, both static and dynamic, depends on ampere-turns, the output performance of the stepper motor or stepper motor linear actuator drops off as the speed increases. Another factor affecting motor performance is the back-EMF (electro-motive force) produced by the rotor rotating in a magnetic field. Motors also behave as generators. High step rates may produce peak back-EMF levels approaching or exceeding the L/R drive output voltage level. One method used to partially compensate for these effects is to improve the inductance to resistance (L/R) ratio by adding external series resistors and increasing the power supply voltage. Some common configurations are the L/2R and the L/4R drivers. Because the respective voltage sources would have to be doubled or quadrupled, the efficiency drops significantly and much more of the power is wasted as heat in the external resistors.

Categories of L/R Drives: Unipolar and Bipolar
Unipolar drives have simple output configurations and are used infrequently due to the relatively low torque output and low efficiency. A unipolar drive contributes to a torque reduction of approximately 30% as compared to a bipolar drive at the same electrical power. In a unipolar drive, only half the phase winding is energized at one time, whereas in a bipolar drive, the entire phase winding is energized.

A unipolar drive configuration. Notice that the motor phase winding is center-tapped, thus allowing current to flow through only half the phase winding at a time.

A bipolar drive configuration.

Bipolar drives have more complex output stages. Many of the new specialized integrated circuits have come down in cost, making bipolar drives more affordable. The output configuration is an “H-Bridge” which allows the reversal of the phase currents. Instead of the phase currents being switched on and off in just half of the windings like in a unipolar configuration, the currents flowing through the entire motor windings are reversed in bipolar drives. At equal electrical power into a given frame size stepper motor, the bipolar driver/motor configuration can produce greater static and dynamic torque than that of a unipolar driver/motor combination.

Chopper Drives
The term chopper refers to the method of rapidly switching a relatively high voltage to the windings on and off. This technique of switching the output voltage on and off controls the average current per phase.

There are several steps involved in selecting a chopper drive. First, choose a power supply that has a high output voltage relative to the voltage rating of the stepper motor to be driven. The high available voltage compensates for the increasing coil impedance due to rising inductive reactance as the motor speed increases. A power supply to motor coil voltage ratio of 8:1 or higher will provide the best performance at the higher motor speeds. Second, low-voltage steppers, with correspondingly lower inductance coils, are recommended. Linear type motor power supplies work well with these drives. Third, virtually all chopper-type drivers are a bipolar configuration, making use of the entire motor windings, which yields improved torque. Even unipolar stepper motors can be driven with these bipolar choppers as long as their rated coil voltage is not too high. Six-lead unipolar motors would be connected as a four-lead type by leaving the center-tap leads unconnected. With eight-lead steppers, you can connect the two coils of each phase in series (especially low-voltage coils) or in parallel. Because inductance changes as the square of the number of turns, putting two coils in series yields four times the inductance. Stepper motor performance improves at the higher speeds, as compared to an L/R type drive, due to the chopper drive’s method of monitoring and controlling motor current throughout the usable speed range.

To control the average current through the phase windings, this type of drive technology “chops” the high output voltage on and off. Most choppers use a fixed chopping frequency of approximately 20 kHz or higher. This helps keep system noise low, since the chopping frequency is above audible range. Based on this constant fixed chopping frequency, the average output current is controlled by varying the pulse width of these repetitive output pulses, a technique known as pulse width modulation (PWM).

The output current is monitored by comparing the voltage level across a small ohmic value series sense resistor with a set voltage that represents the rated motor current. During each cycle of the typical 20-kHz waveform, the voltage across the sense resistor begins to rise as the current increases through the motor winding. An electronic comparator continuously monitors this voltage level; when it equals the set reference voltage it turns off the output voltage until the start of the next 20-kHz cycle. The current in each motor winding builds and decays as the voltage source switches on and off during each cycle, yielding the proper average current per phase.

As the motor step rate, or speed, increases or decreases, so does the corresponding winding impedance and the chopper drive electronics help to compensate for this effect. At slow speeds (lower winding impedance) the on time of the voltage source is relatively short per cycle (small pulse width). At higher speeds (higher winding impedance) the on time is longer per cycle to allow the current to increase to the proper level (large pulse width); thus the term pulse width modulation.

Advances in Chopper Drives
Chopper drives are now selected for most new stepper motor linear actuator applications and there has been ongoing progress in this drive technology. For instance, the use of low on-resistance Field Effect Transistors (FETs) in the output power stage increases system efficiency and reduces power dissipation within the drive, which also reduces the required heatsink area and physical size of the drive package. Also, new power stage circuitry can provide the higher phase currents required from low-voltage, low-inductance motors, which can yield improved performance over a wider speed range. Enhanced phase current control increases motor performance such as automatically providing boosted current levels during acceleration and deceleration ramping, or shaping to reduce overall resonance of the system.

Other advances include multiple levels of microstepping (electronically splitting a full step into smaller increments) to increase motor resolution, reduce motor resonance, and lower the motor’s audible sound level during operation. Also, the integration of smart controllers, by use of on-board microprocessors, which allows for execution of real-time motion functions such as indexing with or without ramping, and creating complete interactive motion profile programs. These programs can be downloaded into non-volatile memory on the controller and then run independently and un-tethered from any host computer.

In the realm of I/O, interactive optically isolated inputs and outputs now allow the driver/controller to fully communicate with other devices and equipment in a motion control system. And smart controllers can accept encoder feedback, which can be used for motor positional verification or speed control.

Discuss this on the Engineering Exchange:

Haydon Kerk Motion Solutions
www.haydonkerk.com

::Design World::

Motion Control Tips

Providing 10-80Vdc operation while delivering 12A continuous/20A peak current, DZ Series can be configured to operate in torque, velocity, and position modes for brushed, voice coil, or brushless motors. Units deliver up to 1 kW continuous power when needed and can achieve up to 98% efficiency. Supporting CANopen and RS-232/485 up to approximately 1Mbaud, drives accept a variety of input commands including PVT, ±10V analog, encoder following, step and direction, and PWM and direction.

Designed to be completely compact, DZ’s take up little space, eliminate wiring hassle and still deliver unparalleled performance.

www.servo2go.com

Motion Control Tips

The Lexium 32 servo drives features rapid electrical and mechanical maintenance and installation are easily accomplished.

All of the Schneider Lexium 32 servo drives’ wiring connections are at the top or at the front, adding an on-board HMI, incorporating color-coded connectors, and using motors with rotatable, angled and straight connectors to accommodate any orientation.

It has three auto tuning wizards with level of expertise from beginner to advance to help users customize the system.

By incorporating support, the drives enhanced interoperability for a variety of standardized software and hardware motion interfaces such as EtherNet/IP, Profibus DP, DeviceNet and CANopen/CANmotion.

The device also features digital and analog feedback options, which include BiSS, SSI, Hall A/B/I, Hiperface, EnDat 2.1/2.2, and Resolver. It also has an optional memory card, which can help users clone or parameterize servo drives without a PC with the use of traditional commissioning software.

The Schneider Lexium 32 servo drive has a built-in Safe Torque Off (“STO”) function, per IEC/EN 61800-5-2, which prevents motor operation while maintaining AC input power. STO function provides faster restarts and minimize down time after incidents such as normal operator access intervention and emergency stops.

The Lexium 32 servo drives also offers an optional enhanced safety module (“eSM”) that provides additional safety interlock functions with IEC/EN 61800-5-2. This helps the user from having to clarify and engineer complex safety concepts requirements to meet international and federal regulations.

The Lexium 32 servo drives adapt to various machine needs and simplify selection by offering three servo drive models: the Lexium 32 Modular, Lexium 32 Advanced and Lexium 32 Compact. These are complemented by two motor families, the low-inertia Lexium BSH and the medium-inertia Lexium BMH. Each combination offers specific flexibility and benefits.

With nearly 550 Watts/L power density, the Lexium 32 servo drives are very compact and save the users’ control cabinet space which decreases costs and reduces the machine footprint. They also feature direct side-by-side cabinet mounting (“400% overload capacity”) and enhanced motor control features optimizing the life of the machine such as two notch filters, jerk limitation, vibration reduction and other functions.

Motion Control Tips

ISD860 can work in multi-axis, single-axis or stand alone configurations. Its motion programming, tuning and setup are simple with Technosoft Motion Language (“TML”) and EasyMotion Studio. Motion programming can be performed from a CAN master with ISD860, via PC/PLC, directly at drive level or using the motion library through a built-in motion controller. Its embedded TML has a high-level command protocol that can be used by the user through the on-board RS232/CAN serial interfaces. ISD860 CANopen version, supporting DSP-402 and DS-301 profiles, is also available. It can also be managed through analog inputs or programmable I/Os.

Multiple operations can be done with ISD860 using the TML language, such as changing motion modes and/or parameters, setting of various motion modes (PVT, profiles, PT, camming or electronic gearing, etc.), execution of program flow control or homing sequences. IDS860 can handle analog input signals and digital I/O, transfer data between axes and execute logic and arithmetic operations at the same time. The drive has the ability to control other axes through motion commands. In addition, ISD860 can synchronize all axes in a network or send commands to a group of axes.

Easy implementation and flexibility make the ISD860 servo drive an ideal solution to fulfill all higher-power motion axis control needs today through modern distributed intelligence architecture. It is perfect for cost-sensitive applications from medical automation to factory automation requiring enhanced compactness and high servo performance.

Technosoft
www.technosoftmotion.com

Motion Control Tips

“Many machine builders and end users are moving toward single network solutions,” said James Grosskreuz, Rockwell Automation’s product manager. “By leveraging EtherNet/IP technology, the world’s leading industrial Ethernet, the Kinetix 300 servo drive can eliminate the need for a dedicated motion network while maintaining high-speed connectivity with excellent reliability.”

The drive can support up to 32 indices and five indexing types. It is ideal for intermittent vertical and horizontal form/fill/seal machines, simple erectors, case packers and sleevers, as well as indexing tables.

By combining the Allen‑Bradley TL‑Series and Allen-Bradley MP-Series motors, and the CompactLogix L32 controller and Allen-Bradley CompactLogix L23 with the Kinetix 300 servo drive, Rockwell Automation delivers an alternative for machines that demand Rockwell Automation Integrated Architecture system’s power in a cost-effective low axis-count motion solution. The drive can also work with an Allen-Bradley MicroLogix processor to deliver a component machine-level solution in a cost-effective package.

Through a Kinetix 300 additional profile, the Kinetix 300 drive features smooth integration with Rockwell Software RSLogix 5000 software. The servo drive also provides drive-based web configuration tools. With this, machine operators no longer to maintain, load or learn dedicated motion software.

To increase productivity and help protect personnel, the Kinetix 300 is also equipped with safe torque-off capability. With this safe-off functionality, tasks like removal of jams, cleaning, machine setup, and other common maintenance work, which require power-down conditions before can now be achieved without removing power from the machine. The drive output can be disabled safely, allowing shorter machine downtime and faster machine restart. Additionally, components like input contactors are not required, helping reduce both overall system costs and panel space requirements, and simplifying machine design.

The Kinetix 300 offers a compact size and has the available power and voltage ranges to meet a wide range of global machine requirements such as alternative energy, applications in the packaging, and assembly industries and manufacturing.

Motion Control Tips

Variable frequency drives are reliable electronic devices that control three-phase electric motor speed. They are used in building automation, industrial, pumping, agriculture, irrigation, and water/wastewater applications to control the speed of fans and pumps in various systems. The payback period for installing drives is usually less than three years and can be less than one year.

Yaskawa
www.yaskawa.com

Motion Control Tips

The XD-Series allows programming of 32 individual motion profiles, which can be mapped to I/O points, 1 or 2 functions per point, initiated via Modbus/TCP, and chained or looped together. The adaptable I/O, with 14 inputs and 8 outputs, can be mapped to change from position, velocity or torque modes during program execution. Motion can be synchronized with supported machine I/O, allowing for start, stop or trigger speed changes, with inputs at any point in the chain, and user-defined units for axis position speed and acceleration. Using an HMI or optional Fieldbus communication, the XD-Series allows motion parameter adjustments, remote commanded motion and real-time indexer status read capabilities. Communication setup is via USB or Ethernet connections, with Modbus/TCP, Ethernet/IP, CANopen and Profibus-DP options. The XD-Series is available in 115, 230 and 460 VAC input power, with 3 to 60 amp continuous current ratings.

The XD-Series also features a built-in Motor Wizard, which simplifies non-standard motor integration and lets users quickly commission unproven motors. Once the program and motor data are loaded onto the indexer, configuration data is stored both in the indexer and on a removable memory card, simplifying software transfer, duplication requirements, and hardware replacement needs. Software includes extensive support for monitoring and optimizing an application, allowing the application program to be quickly honed to perfection. ORMEC’s software tools can reduce conventional setup efforts, from what typically was days, to a matter of minutes, with the supplied pre-defined “load and go” application templates.

Typical applications for the XD-Series include intelligent conveyor control, pick and place, labeling, flying shear, rotary knives, scanning, high-speed printing, part storage and retrieval, and many others. Also, built-in features of the XD-Series allow it to support otherwise difficult application requirements, such as tension control, dual loop feedback, registration, gearing and others.

ORMEC is offering Free Applications Development Assistance on any XD-Series Indexer purchased before April 2010. Visit http://www.ormec.com/indexerpromo.aspx, and enter code XD011310PR to register.

For more information on the XD-Series, contact ORMEC toll-free at 1-800-656-7632, 585-385-3520 (global), email at sales@ormec.com, or visit www.ormec.com.

www.ormec.com

Motion Control Tips