Trio Motion unveils two new motion controllers

Trio Motion (www.triomotion.com) has introduced two new motion and machine controllers that economically and flexibly provide new levels of multi-tasking stepper or servo control for high performance automation.

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.

Single-Axis Controller with 800W Sine Drive from Galil

Rocklin, Cal. – Galil Motion Control introduces the DMC-300xx Pocket Motion Controller Series, a single-axis Ethernet motion controller. It combines a high performance motion controller and a 800W sine drive in a low cost, compact 3.9-in. x 5.0-in. x 1.5-in. package. The DMC-300xx is also available as a controller-only model that can be connected to a stepper or servo motor amplifier of any power range. Using a 32-bit RISC processor and improved power technology, the DMC-300xx provides higher speed, better power efficiency and smaller size than their prior generation controllers. The DMC-300xx is designed for single-axis motor control applications where compact size, low cost and remote location are important. 

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

Servo2Go Adds New DMC-1417 Econo PCI BUS Motion Controller from Galil

Greenville, Del. – Servo2Go.com has added Galil Motion Control’s new PCI BUS Econo Motion Controller, the DMC-1417, to its broad range of PCI-based motion controllers. 

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

Siemens expands its Simotion D motion controllers portfolio

Siemens Industry, Inc. (www.sea.siemens.com) has expanded its range of upper performance Simotion D motion controllers with the addition of the latest Simotion D445-2 DP/PN and D455-2 DP/PN versions.

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 controller

Motion controllers are the brains of any motion control system. In feedback-based systems, they take an input command from the user, compare it with a feedback signal from the motor, and take corrective action to bring the output (or actual position) and input (or desired position) in line with one another, ideally with little or no error.

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.

New Simotion D Motion Controllers from Siemens

Atlanta, Ga. – Siemens Industry, Inc. has announced an extension of the upper performance range of its popular Simotion D motion controllers. The new generation of Simotion D445-2 multi-axis controllers has new features such as onboard Profinet interfaces, high-speed I/O, and with three times the performance, a single controller can support up to 128 axes of motion. 

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.

Delta Tau Introduces Next Generation Motion Controller

Delta Tau Data Systems has taken the leap into a more innovative and useful general-purpose control format for OEMs and end users alike. Their Power PMAC Motion and Machine Controller features a full-featured real-time operating system. Due to the latest embedded hardware available, the unit is said to provide the highest level of peripheral integration on the market, while maintaining the lower power consumption needed for most applications. 

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.

Single-Axis Motion Controller with Onboard Brushless/Brush Servo Drive

Greenville, Del. – Servo2Go.com has just added Galil Motion Control’s New Econo Series Motion Controller with Ethernet & Onboard Servo Drive, the CDS-3310, to its broad range of high-performance cost-effective Ethernet-based motion controllers.

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

ATEX-Rated High-Temperature Hazardous Location Positioner from Exlar

Chanhassen, Minn. – Exlar’s EXP-24 Positioner conforms to both ATEX (Directive 94/9/EC) and CSA regulations for explosion-proof applications, and can be used to control most of the company’s three-phase linear and rotary actuators, including the EL100 linear and ER115 rotary actuators.

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.

www.exlar.com

WMH perfects Yorkshire pudding recipe with motion controller

Western Mechanical Handling (WMH) (www.wmh-uk-ltd.com) is pleased to announce the development of a machine that produces perfect Yorkshire puddings every time.

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.

Yaskawa Launches New Single Axis Motion Controller

The Drives & Motion Division of Yaskawa America announces the release of the MP2600iec motion controller. The controller provides motion control of 1 or 1.5 axis along with machine control. Yaskawa is one of the first in the industry to provide full IEC61131-3 functionality in a 1/1.5 axis controller. The controller extends the MP product family, which now includes three controllers covering the range from 1 to 16 axes.

The MP2600iec machine controller supports all five IEC61131-3 programming languages: Ladder Diagram, Function Block, Structured Text, Sequential Function Chart and Instruction List. The Function Block language provides execution of MotionWorks® PLCopen function blocks. These pre-programmed blocks provide all of the standard functionality required for most motion control applications, eliminating the need for custom programming.

For many machine control applications, the MP2600iec machine controller can provide complete control and monitoring, eliminating the need for a separate PLC or other low-level controller. The MP2600iec motion controller provides machine control and monitoring via 15 discrete inputs, 11 discrete outputs, one analog input and one analog output. All of these inputs and outputs can be controlled via execution of any of the five IEC61131-3 programming languages.

Interface to automation, monitoring and control systems external to the machine are provided by the discrete and analog I/O, or via the EtherNet/IP and Modbus/TCP digital networks. An optional OPC server allows for the transfer of real time data over Ethernet from the machine process to the factory network. The MP2600iec motion controller also includes full Web server capability, allowing access to the controller from any standard web browser.

The entire family of MP controllers including the MP2600iec controller is programmed with Yaskawa’s MotionWorks® IEC software, either MotionWorks® IEC Express or MotionWorks IEC Pro. MotionWorks® IEC Express allows programming in Ladder Diagram, Structured Text, and Function Block and is well suited for less complex machines that require only one task. MotionWorks® IEC Pro has all the features of Express, but also offers 16 prioritized tasks. It also gives users easier control of machine states via Sequential Function Chart, and it includes Instruction List programming.

Both MotionWorks® IEC Express and Pro encourage the programmer to take advantage of the best of several programming languages within one development package. Ladder Logic is perfect for representing digital sensory data. Structured Text is a great solution for mathematical algorithms and assignments, and Function Block is best suited for motion control. These languages seamlessly and predictably cooperate with one another. Variables and outputs from a program structure can be referenced by other programs, providing the ultimate automation development environment.

The MP2600iec motion controller combines execution of all five IEC61131-3 programming languages, pre-programmed PLCopen function blocks and support for the most widely used digital communications networks into one compact and low-priced 1/1.5 axis controller. For many machines, the MP2600iec motion controller can provide complete control and monitoring, eliminating the need for a separate PLC or other low-level controller.

Yaskawa
www.yaskawa.com

Galil unveils Ethernet motion controller

Galil Motion Control (www.galilmc.com) is proud to announce the release of the latest product in its Econo series – the DMC-41×3. Compared to previous Econo controllers, the new product features several enhancements, which include a USB 2.0 port, Ethernet 10/100Base-T, analog inputs, larger program memory, higher speed performance and optically isolated I/O.

The DMC-41×3 can operate as a stand-alone or can interface to a PC with USB or Ethernet 10/100Base-T. The controller comes in one through eight axis formats, with each axis being user-configurable for servo or stepper motor operation. The product can also be connected with Galil’s multi-axis (500W per axis) servo drives, 60V, 3A microstepping drives, or external drives of any power range.

Among the standard I/O of the new product includes 32 I/O for the five to eight axis models and 16 optically isolated inputs and outputs for the one to four axis models. Aside from optically isolated forward and reverse limits and home input for every axis, eight analog inputs are also provided.

Other features of the controller include I/O processing for synchronizing motion with external events, multitasking for simultaneously running up one to eight programs, memory for user programs and PID compensation with velocity and acceleration feedforward. A selection of modes of motion is also available, which include position tracking, point-to-point positioning, circular and linear interpolation, jogging, electronic gearing, contouring, PVT and ECAM.

The controller and drive package measures 8.1” x 7.25” x 1.5” for the one to four axis model and 11.5” x 7.25” x 1.5” for the five to eight-axis model. The DMC-41×3 accepts power from a single 20-60V DC source and is available packed in a metal enclosure or as a card-level product.

Delta’s Curve Tool Makes Complex Motion Profiles Easier

Delta Computer Systems, Inc. announces the Curve Tool feature that delivers graphical ease-of-use to the custom motion and camming profiles. The Curve Tool is now available in Delta’s RMC70 single- and dual-axis and RMC150 multi-axis motion controllers. For more information, download the RMCTools software and also view a video at http://deltamotion.com/curvetoolvideo.

The Curve Tool’s graphical environment for creating and editing curves–also called cams or splines– makes it easy to view the RMC’s many curve features. With options such as linear or cubic interpolation, velocity and acceleration limits, endpoint behavior and more, the RMC curves satisfy a wide range of applications.

Delta Computer Systems
www.deltamotion.com

Cito introduces new PC/104 Motion Controller Boards for embedded systems

Cito Systems, Inc. (www.citosystems.com) is proud to announce the new PC/104-bus multi-axis motion controllers, best suited for embedded system applications. These high performance feature-rich controllers harness the ability of the advanced high-speed DSP chip and incorporate surface mount and ASIC technologies. The Millennium controllers, featuring an advanced PID filter, are available in configurations of one, two or four axes for brushless or brush, brushless or mixed brush, as well as microstepper or stepper motors.

The DSP unit offers electronic gearing motion, velocity contouring, trapezoidal and S-curve profile modes for several motor outputs. 64kByte Dual-Port RAM permits ultra-fast data exchange and makes the capture of on-the-fly motion data for system performance analysis and tuning of servo filter gains possible. The motion trajectory segments can be mixed into the continuous motion path. The ultra-fast synchronization signal permits multiple boards to achieve coordinated motion.

The controller boards interface with external components through a 100-pin high density connector. The connector provides PWM motor outputs or +/-10 V differential analog and reads single-ended and absolute encoder or differential incremental signals. It also supplies opto-isolated dedicated input signals for home/fault functions and limit switches. They can run in +5V, +12V, +24V or +48V level supplies. Eight uncommitted discrete output lines can be operated at TTL level or up to 50V. These are high-current opto-isolated signals capable of sourcing or sinking maximum 350mA at 50V and can be used as servo drive relays or amp enable, solenoids, LEDs or amps. The TTL level signals can expand to 128 discrete outputs. Moreover, the board has eight analog input channels and eight discrete input lines working in range of 0 to +5V.

The cards are well supported by MotionStation(TM), an Integrated Motion Environment (IME), which consists of GUI applications, drivers and software libraries for all Linux and Windows operating systems. It also permits development of any motion control application.

Cito Systems introduces Web Server with embedded multi-axis motion controller

Cito Systems (www.citosystems.com) unveiled its latest advanced server made to control brushless and brush DC servo motors as well as microstepping and stepper motors actuating any mechanism, AMCS [pronounced as “a-maks”] (“Advanced Motion Control Server”). This advance server has much more compared with typical stand-alone motion controller with network connectivity.

The new AMCS is a Web Server with embedded multi-axis motion controller at a very compact enclosure. It gives remarkable capabilities in network communication such as Internet and at the same time it works independently through its own system software. The server is accessed either through client applications or a HTML graphical interface. Devices incorporating the controller can be monitored and controlled from any place around the world through the worldwide computer network. AMCS is best suited for many automation applications, including industrial, textile, packaging, medical, scientific, semiconductor, machine tools and robotic.

AMCS can work in Client-Server network architecture with a possibility of creating local sub-networks, if there are a bigger number of control devices. In that case, the controllers can work in a hierarchical Server-Agent configuration. Unlike the agent, the server has the system software with additional features and monitors a group of agents. The agent and the server are both capable of directly controlling motor drives.

The motion controller has the power of both ASIC and DSP chips to implement the motion control algorithms. It has an advanced PID filter with acceleration feedforward and velocity, 32-bit position error and bias offset.

The controller is commonly programmed by used languages. Therefore, it does not require an advance level of knowledge in programming. With embedded interpreters, it is possible to write control programs in C language, HPGL standards and G-code and a language used in controllers from the Galil company. The writing control programs permit programming of advanced motion trajectories realized by a variety of kinematical configurations.

ABB introduces new generation of process controller and indicator instruments

ABB (www.abb.com), a world leader in power and automation technologies, is proud to announce its new generation of process controller and indicator instrumentation, ControlMaster. The latest line-up includes four new models which are highly powerful and intuitive and is very east to operate. Its comprehensive portfolio of capabilities makes it ideal for a wide spectrum of industries. ControlMaster’s flexible I/O capabilities simplify model selection. Each ControlMaster model can be scaled suiting basic to advanced application requirements by adding plug-and-play function keys.

The new ControlMaster elevates process control and monitoring to a higher level.

The full-color thin-film-transistor (“TFT”) liquid crystal display of ControlMaster provides unsurpassed ease of use and it shows process information. Operator prompts and menus display in full text. ControlMaster’s formats include historical trending and dual-loop displays.

A sampling of the functionality in the controller includes totalization, dead-time compensation, delay timers, problem-solving diagnostics, cascade, ratio control and feedforward, predictive, adaptive and dual-loop control.

The latest units offer flexible communications: Modbus, Profibus and Ethernet protocols. Enclosures provide NEMA4X and IP66 environmental protection.

Two-Axis Motion Control Modules from AMCI

Terryville, Conn. - Advanced Micro Controls Inc. (AMCI) announces the 3100 Series two-axis motion control modules for the 1762 MicroLogix PLC. These two-axis controllers plug directly into MicroLogix PLCs and are available in two versions: 3102 (X-Y motion control) and 3102i (X-Y motion control + interpolation).

AMCI’s 3100 series modules provide encoder feedback in addition to a wide range of motion commands, satisfying simple to sophisticated application requirements. Both the 3102 and 3102i are 100% compatible with MicroLogix 1100, 1200, and 1400, and are easy to program using Allen-Bradley’s RSLogix 500 software.

AMCI’s 3100 series motion modules are easy to program with no extra software required, and offer a wide range of motion commands including registration, jogging/changing speed on the fly, and blend moves. Linear and circular interpolation are exclusive to the 3102i module, enabling more sophisticated motion control. Both modules provide encoder feedback, providing closed-loop positioning.

The 3102 module can control servo and/or stepper drives with step/direction input.  Motion commands include jog, home, and point-to-point control. Common applications for this motion controller include assembly lines, conveyor control, in-process gauging, and valve control, among others.

Developed to simplify more complex applications, the 3102i module includes linear and circular interpolation commands. These additional features make this module stand out with the ability to reach specific target positions and output contoured motion profiles.  Popular applications for this more advanced controller include high-speed assembly, water jet cutting, storage and sorting, laser trimming, needle inspection systems, and more.
www.amci.com

Controls Guide Automatic Writing

The motions required for engraving text onto products from jewelry to cell phones offer unique challenges in motion control. Artesà, in Barcelona, Spain, has developed a machine capable of mimicking the craftsmanship of hand engraving. The company’s machine uses a Galil DMC-2143 4-axis motion controller to guide the precise movements.

“The Artesà machine reproduces a high quality ‘hand like’ engraving. With the help of the Galil motion controller it can reproduce engravings identically,” said Leondardo Di Benedetto, the Artesà machine developer. “The hand engraving work of an artisan consists of a downward and upward movement with the chisel each time a cut is made in the surface of the object being engraved. The engraved line has a curvilinear or open polygonal trajectory in the vertical plane achieved with non-rotating cutting tools, which give the brightness and beauty characteristic of these
engravings.”

A Galil DMC-2143 4-axis motion controller enables
a machine to minic the precise movements of hand engraving.

The machine consists of a table with a bed frame that firmly holds the material to be engraved. Just above the table is the spindle-mounted, engraving tool head that includes a laser pointer and three carbide inserts with 35°, 90° and 135° corner cutting edges. A DMC-2143 four-axis Ethernet motion controller controls the complex and precise X, Y and Z movements of the tool head with carbide inserts. An SDM-20240 step drive controls the four stepper motors.

In addition to the three degrees of freedom, the DMC-2143 also controls the critical PT (line depth) and SV (vector tracing) axes. The PT axis gradually moves the cutting tool downward on a vertical plane so it can cut into the material to a desired depth doing the descending part of the curve, and then upward to the material surface cutting the ascending part of the curve. The SV axis manages the 360º motion of the cutting tool, ensuring the cutting edge always faces in the pre-programmed direction to effectively trace the vector being engraved and do so with a positioning accuracy of 0.1 mm/300 mm (0.004 in./12 in.) that is repeatable to 0.02 mm (0.0008 in.), under no-load conditions.

Galil Motion Control, Inc.
www.galilmc.com

Artesa
www.artesa-nc.com

Fully Integrated MC4U Machine Control Solution from ACS Motion Control

Eden Prarie, MN – ACS Motion Control has developed a fully integrated machine control solution that provides superior performance while reducing the footprint and cost when compared to many network-based multi-axis solutions. Optimized for machine automation, the MC4U includes the motion controller, drives, power supplies and high speed PLC in 9-, 11- and 19-in. units.

The MC4U can directly drive up to eight highly coordinated axes with network extension capability of 64 additional network nodes for a total of up to 72 axes. The integrated universal amplifiers can directly drive any stepper (in open-loop or as closed-loop servo with sinusoidal commutation), DC brushless, DC brush, or AC induction motor (as closed-loop servo with sinusoidal commutation) from 100W to 5kW with standard digital quadrature or Analog Sin/Cos encoder. The MC4U’s integrated architecture uses dedicated servo processors on the controller board to provide real-time servo control of each axis including position, velocity, current servo loops, and sinusoidal commutation.

The dedicated motion programming language (ACSPL+) that runs on the MC4U controller provides a simple environment for users to program motion. Some of the standard motions available include 3rd order vector point-to-point moves (one to eight axis), two- and three-dimensional geometric shapes, electronic multi-axis camming, non-Cartesian kinematic structures (hexapod, delta robots, SCARA robots), complex eight-dimensional paths and splines, multi-axis master/slave and much more.

In addition, the standard software package features a full motion controller simulator that allows users to develop application code and a host front end, all from the PC, without hardware. The MC4U also supports the five standard IEC-61131-3 languages running on a high speed virtual PLC, allowing
programmers who are familiar with this environment to easily develop PLC programs. Full transparency between the PLC and ACSPL+ environments provide users with the opportunity to utilize the strengths of both languages to develop an entire machine control application quickly and efficiently.

Applications involving demanding requirements for multi-axis motion coordination and servo control, as well as high speed PLC functionality can benefit from the integrated MC4U architecture. Applications include large-format gantry inspection systems (flat panel display, solar, Inkjet, Web handling), small to large scale imaging machines (nuclear, magnetic, interferometric, and ultrasonic), semiconductor and PCB assembly (printed circuit boards, wire-bonding, wire-EDM, pick and place robots), biomedical laboratory stations (DNA handling/sequencing, surface patterning, molecular printing) and general industrial automation (load-cell testers, food packaging, document sorters, etc.)

Typically available with a lead time of two to four weeks, please contact ACS for pricing information. A free motion simulator can be downloaded at www.acsmotioncontrol.com.

For more information about the MC4U fully integrated machine control solution, contact ACS at 763-559-7669,  or visit www.acsmotioncontrol.com.

Stepper Motor Controller ICs for Bipolar and Unipolar Motors

Melville, NY – LSI Computer Systems, Inc. (LSI/CSI) announces the availability of three new high performance stepper motor controller ICs, designated the LS8297, LS8297CT and LS8397. These devices offer half-step and full-step sequences in both normal drive and wave drive modes. In addition, the LS8297CT and the LS8397 offer correction for the torque-ripple. A power saving holding-torque mode is also available in LS8397 for maintaining the drivers at a reduced power level when the motor is not turning. Four phase outputs and two inhibit outputs are provided for driving external H-bridge drivers, allowing for the selection of a standard driver or an application specific custom driver. An external reference voltage, in conjunction with the winding current sense voltages, regulates the PWM duty cycles of the driver outputs. One of two decay modes, fast-decay and slow-decay, can be selected to suit the characteristics of the motor winding.

LS8297 and LS8297CT features include inputs for step, forward/reverse, reset and output blanking control, supply current < 400µA, and supply voltage of 4.5 to 7V. The LS8397 includes a mode for reduced power holding torque.

LS8297 and LS8297CT devices are available in 20-pin DIP, SOIC and TSSOP packages and the LS8397 is available in 24-pin DIP, SOIC and TSSOP packages.

Complete data sheets for these devices can be found by visiting www.lsicsi.com. For more information, including price quotes and technical assistance, please contact sales@lsicsi.com.

Multi-axis Machine Control

Eden Prarie, MN – ACS Motion Control has developed a low-cost, small-footprint approach to complete machine control. Designated the SPiiPlus LF-CM, the machine controller provides multi-axis integrated control and up to 64 additional nodes (axes or I/O) via CANOpen network extension in a fraction of the footprint size of similar products. The controller includes a full PLC, programmable in any of the standard five IEC61131-3 languages with an update rate of 1ms. The SPiiPlus LF-CM is ideal for cost-sensitive multi-axis systems where space is at a premium including biomedical, wafer handling and inspection laboratories, factory automation machinery and servo control applications.

The SPiiPlus LF-CM amplifiers use a bus voltage of 60V DC and have a maximum output voltage of 53V. With a continuous output current of 4A per axis, the controller provides uncompromised accurate machine control. The controller has a fully automatic drive protection and controls 1 and 3 phase motors and 2-phase/stepper motors with encoders.

The machine controller features interface capabilities with many of ACS SPiiPlus’ accessories including HSSI I/O modules, HSSI external drive modules and HSSI absolute encoder modules. Design-in of the SPiiPlus LF-CM is simple with the use of ACS’ terminal breakout kits and DIN-rail mounting kits. The controller comes with a free complete software package and is available for download from the ACS website at www.acsmotioncontrol.com.

For more information about ACS Motion Control, call 800-545-2980.

www.acsmotioncontrol.com

Nanopositioning and Piezo Technology Catalog and Reference Guide

PI’s (Physik Instrumente) 2009 hardcover catalog “Piezo Nano Positioning Inspirations 2009″ covers nanopositioning and piezo technology. The 530-page publication is a comprehensive reference book on the fundamentals of nanopositioning, piezo systems and micropositioning technology. The catalog contains over 200 product families, 30% of which are new, with more than 1,000 drawings, graphs, images and technical diagrams.

Products and technologies covered include:

• Parallel-kinematics nanopositioning / scanning stages
• High-speed ultrasonic linear motors for automation
• Ceramic-encapsulated piezo actuators
• PiezoWalk® piezo worm type linear motors for Bio/Nanotechnology
• 6-Axis Hexapod micromotion robots
• High-load, low-speed mirror alignment systems for astronomical telescopes
• Motorized precision actuators and stages for semiconductor applications
• Digital & Analog nanopositioning motion controllers & piezo drivers
• Servo & stepper motor controllers
• Photonics alignment systems, photometers

In addition to product descriptions and selection guides, extensive tutorials on piezo technology, the fundamentals of nanopositioning, micropositioning and nanometrology are included to aid users in selecting the system that best meets their needs.

A PDF catalog version can also be downloaded from PI’s website at http://www.pi.ws/2009cat

For more information or to download individual catalog sections, visit:

http://www.physikinstrumente.com/en/news/fullnews.php?newsid=149

Mercury Motion Controller

In one single physical device, the Mercury motion controller includes the control and power amplifier needed to run brushed DC and brushless PMSM motors. The controller can be operated from RS232 or CAN with Node-ID hardware.

Its extended voltage operation range allows it to be used in industry or robotics, and its reduced size (83x64mm) and the absence of any external heat sink allow the controller to be integrated into critical-size applications.

Thanks to the MCLib software, the device parameters can be easily configured and monitored, using simple functions written in C/C++.

www.ingenia-cat.com

Single-Axis Motion Controller for Linear Servo Amplifiers

Torrance, CA — Varedan Technologies has introduced the VMC-3000 series single-axis motion controller module for their LA series linear servo amplifiers. The controller is a DSP based plug-in card that can be configured in a variety of modes including position mode, torque mode and a high-precision frequency locked velocity mode for systems requiring ultra-low jitter performance.

The controller accepts quadrature encoder feedback from a motor mounted encoder and provides sinusoidal commutation of the linear servo amplifier stage. The controller can accept industry standard +/-10vdc input for simple torque control, or can be configured as a complete single-axis positioning or velocity control system.

A built-in operating system allows the user to program the motion parameters over a high-speed serial interface. The rich set of internal commands allows customization and tuning of the PID parameters to the application. Acceleration and deceleration ramps are built into the software and include both linear and S-curve profiles. The controller can be configured to generate position or velocity commands internally, or follow an external pulse train for slaving or electronic gearing applications. Using stored position or velocity profiles, speeds up to 30,000 rpm can be achieved with the proper motor/amplifier combination. On-board optically isolated I/O allows the module to interface to a wide variety of sensors and switches within the range of 5-24vdc.

www.varedan.com

Plug-in Motion/Machine Control Module

Fort Smith, AR — Baldor Electric Company (NYSE: BEZ) has launched a new plug-in motion/machine control module for its Ethernet-compatible Powerlink drives. The new controller module allows machine builders to eliminate the need for a separate external network controller, along with all of the cabling and panel space that would normally be required. As switching to real-time and deterministic Ethernet-compatible motion control is already proving extremely popular for machinery builders, the additional cost savings offered by this new approach make adoption of the technology almost irresistible.

Baldor’s new plug-in controller for Powerlink drives.

The new Mint Machine Module plugs into a hardware expansion slot in any of Baldor’s MotiFlex range of Powerlink-compatible three-phase AC motor drives. Two variations of the card are offered: a dual-axis version that will control the host Powerlink drive plus another external drive via a conventional analog interface, or a high-speed version that will also act as a Powerlink network controller to manage a complete multi-axis control system. Both options are compatible with Baldor’s powerful Mint motion language, with its rich development support.

The multi-axis control made possible by the new Mint Machine Module is a unique offering in the real-time Ethernet market. The design approach adds a number of further savings to the already-established cabling reduction and system building and benefits of Ethernet-compatible Powerlink networks. The hardware bill of materials can be reduced as the module can eliminate the need for a separate standalone system controller. It also eliminates the cabling, power supply, and panel space that would otherwise be required.

Baldor’s economic control card plugs into a Powerlink drive to create multi-axis control systems.

Plugging a controller into the drive itself still provides machine builders with complete flexibility of control system architecture, as the drive can be used as a standalone intelligent automation solution, or as a distributed element of a larger Powerlink network, or a complete multi-axis motion control system that operates autonomously.

The basic dual-axis version of the card will convert a MotiFlex drive into a very economic ‘intelligent drive’. This provides a complete standalone motion control solution with the possibility of local I/O and HMI: all drives include a complement of digital and analog I/O and this may be expanded easily via further card slots or the drive’s CANopen fieldbus interface. As many industrial automation projects also require some simple material handling functions as well, such as a material feed axis or a conveyor, the card offers a traditional analog interface that is ideal for controlling a low-cost frequency inverter drive.

If the motion control requirements are more sophisticated, the multi-axis version of the card will also act as a Powerlink network controller, powerful enough to control five axes of interpolated motion: the host drive itself, three other Powerlink-connected drives, plus another drive via the analog interface. As each drive includes a complement of I/O, plus a CANopen fieldbus expansion port, systems for highly complex automation requirements are easily configured.

Two further expansion card slots on MotiFlex drives also allow a system to be configured with any of a comprehensive range of fieldbus interfaces including Profibus DP, DeviceNet, Ethernet IP, Modbus TCP, and CC-Link – to act as a gateway to PLCs (etc), plus further I/O including encoder or resolver interfaces for dual loop feedback. The encoder option can, alternatively, be employed as a line shaft encoder for electronic geared motion applications.

Baldor’s Powerlink hardware comes with a versatile machine control development environment called Mint. Mint provides a high level control language that is similar in style to BASIC, but with advanced structured programming features, multitasking support, and a very large library of high-level ‘keywords’ that provide ready-to-use software for common motion control (and machine control) functions. Using Mint, and its development toolsuite, which is provided without charge, complex process automation requirements can often be programmed within hours. The Mint language can be used to create a standalone system. Alternatively, developers have the option of developing motion control programs on a host PC and transferring movement and I/O commands to the motion subsystem. Windows support is provided using the object-oriented ActiveX protocol.

The Mint Machine Module plugs into any of Baldor’s MotiFlex range of Powerlink-compatible, three-phase AC motor drives. There are currently eight choices of MotiFlex drive with power outputs from 1.5 to 33.5A. MotiFlex drives can operate independently, or as part of a shared DC bus system. When operating in a shared DC bus system, power regenerated back into any drive during the deceleration phase of an axis may be utilized by the other axes, saving energy costs. As each drive has a local capacitor bank, an external braking resistor is often not required – because the total capacitance of the system may be sufficient to store the energy without reaching the over-voltage limit.

Unlike traditional shared DC bus systems, MotiFlex drive systems do not always require a separate power supply unit. Instead, the AC-DC converter stage in each drive is capable of supplying power not only to itself, but also to a drive or combination of drives of the same total rating. For many multi-axis applications, this will often mean that the highest-rated drive will be able to power the rest of the system. For many multi-axis systems, this approach almost invariably results in the need for fewer electrical components, and simpler system building, as only one set of contactors, fuses or MCBs, terminal blocks, and one EMC filter is needed for the whole system.

If the multi-axis version of the plug-in card is chosen, Baldor’s three-phase drives can be used to control a motion system with single-phase and three-phase Powerlink servo drives, as well as an external frequency inverter axis.

www.baldor.com

Advanced Motion Controls Boost Wafer Handling Efficiency

BlueShift Technologies recently debuted its QuickLink™ vacuum wafer-handling system. It is configured with linear, linkable architecture that provides OEMs a competitive edge over conventional radial systems. The system offers a common vacuum platform for a variety of tools and process applications.

One of the greatest challenges in developing this wafer handling systems was testing and implementing a motion control system that could meet demanding requirements for expandability, resolution, stiffness, and reliability at a competitive price. The company opted for the Danaher Motion XMP series motion controllers. “We discovered that we could add up to 32 axes of motion simply by plugging them in. The XMP motion controller bolsters quality and helps us remain competitive. It meets our demanding repeatability and speed requirements with ease,” says Chris Kiley, BlueShift vice-president of engineering.

Wafer handling
Conventional cluster tools are arranged in a radial pattern with processing stations and load locks for inserting and removing wafers located around their circumference. As wafers have grown larger and semiconductor processing operations become more complex, the size of these cluster tools has continued to grow.

QuickLink versus cluster tools.

Today, the transfer chamber at the heart of the cluster tool can easily be 10 ft long by six ft wide, even before adding process chambers where the wafers are turned into valuable integrated circuits. Designed to maintain high levels of vacuum, transfer chambers are machined from large, expensive pieces of aluminum.

The QuickLink linkable vacuum wafer handler delivers significant technical benefits over current cluster tool offerings. It offers better particle performance, reduced organic and metal contamination, better process isolation, and automatic software configuration.

BlueShift’s linear geometry allows wafers to pass along a line of process modules. The linear transfer chambers are much smaller than radial chambers which reduce raw materials and machining costs, and makes the new approach between 30% and 40% less expensive. The linkable design permits processing modules to be added as needed in a compact configuration, resulting in footprint reductions up to 40% compared to radial footprints and allowing the fabricator to optimize throughput by balancing the flow while eliminating bottleneck processing chambers. The use of building blocks makes it easy to configure wafer handling systems for high capacity and long process time, high throughput and short process time or increased vacuum isolation and contamination control.

Kiley adds, “When we were designing QuickLink, it was apparent that off-the-shelf components had improved to the point where they could handle this application. With current manufacturing practices, their reliability is higher and cost is lower than custom components. We started with motion control cards and amplifiers based on the Firewire A standard. Firewire A is fast but susceptible to noise and it could not run more than one robot axis at a time. Each of our robots has three axes; alpha and beta rotational axes, and A/Z axis for vertical motion. Our
design specifies that one card will control an entire wafer handling system which might easily utilize six robots.”

BlueShift called in Target Electronic Supply, Inc., a system integrator involved in motion control applications. BlueShift needed to add axes as needed to support the QuickLink modular architecture. The Danaher XMP series motion controllers provide up to 32 axes and support servo update rates up to 16 kHz, which helps provide high levels of speed and accuracy. The XMP delivers a synchronous real-time connection between the motion controller, servo drives, I/O modules, and custom nodes.

BlueShift offers a world-class 3D remote diagnostic monitoring interface.

“Target got us up and running with the XMP motion controller quickly,” says Kiley. “The controller worked well out of the box and can scale well beyond our requirements in this application. Our systems can be expanded simply by snapping the robot transfer links together and connecting the cables to link the new robot to the controller. We have had no problems with the capabilities and robustness of the Danaher Motion control components. They can easily meet our requirements to position the wafers within about 100 microns.”

BlueShift is also using Kollmorgen S200 servo amplifiers from Danaher Motion. The company’s robot drives have only 10 components and are designed for 24 million mean cycles between failures. The modular design makes it possible to service the system in place rather then replacing entire robots in the case of a failure.

Danaher Motion
www.danahermotion.com

Mitsubishi Electric Introduces Motion Controllers for the iQ Automation(TM) Platform

VERNON HILLS, Ill.–Mitsubishi Electric Automation, Inc. introduced its Q172D and Q173D motion controllers for its leading-edge iQ Automation™ platform at PACK EXPO International 2008. These new controllers are engineered for simple to complex motion control applications including packaging, material handling, printing, semiconductor fabrication, solar panel movement, automotive manufacturing and all non-metal cutting applications.

Source: Mitsubishi Electric Automation, Inc.

“The Mitsubishi Electric iQ Automation platform combines all aspects of control — PLC, motion, CNC, HMI, robotic, communications and more — in a compact rack-based configuration,” said Sunny Ainapure, Mitsubishi Electric Automation servo and motion product manager. “The iQ Automation platform addresses the needs of OEMs and system integrators for flexibility, ease of use, enhanced control, reusable design, safety and faster time to market.”

The Q172D is an 8-axis motion controller and the Q173D is a 32-axis motion controller expandable up to 96 axes. These controllers offer high-performance positioning, speed, synchronous phase and torque control. The units provide on-the-fly mode switching and registration through electronic cam and gearing. Q172D and Q173D are ideal for such packaging applications as feed-to-length, roll feeding, bag making, press feed, flying cut-off, random in-feed, form-fill-seal, linear slide, linear motors and indexing conveyors and rotary tables.

The Q172D and Q173D motion controllers connect to Mitsubishi Electric Automation’s MR-J3B servo over SSCNET III, Mitsubishi Electric’s proprietary serial servo control network, which has an installation base of more than 1.5 million axes – one of the largest motion networks in the world. The MR-J3 servo offers OEMs compact design, side-by-side mounting for reduced panel space and the ability to operate rotary and linear motors, and fully closed loop systems. Quick release connectors reduce wiring and setup time. Amplifiers are plug-and-play and all operating parameters are instantly downloaded at power up. Servo axis tuning is quick and easy as is in-plant replacement of servo drives.

The iQ Automation platform’s high-speed, high-accuracy machine control is achieved through the simultaneous processing of sequence programs and motion programs by multiple CPUs and through a high-speed communication bus. The motion control’s CPU cycle time is 0.44 msec, two times faster than previous models. Most of the sequential functional chart motion commands are executed four times faster than previous models. With the new iQ Series programmable controller system bus, the high volume of data exchange — 32K words between multiple CPUs —is about four times faster than previous models.

Programming tools allow users to program in real or virtual mode. The Mitsubishi Electric Mechanical Support Language represents complex motion and mechanical relationships in a graphical manner. This means users can program complex motion on screen using a mouse. The virtual environment allows simple and complex motion programs using a series of mechanical icons to visually represent gear ratios, transmissions, line-shafts, cam profiles and more. The result is that a significant amount of traditional mechanical control can be replaced by servo control, so machine size and cost is reduced and programming is simplified.

Sequential function chart programming is straightforward and easy to learn, allowing for quick programming, as well as visual identification or diagnosis of motion and sequential event processing. This block-by-block format is further simplified with clear distinctions of motion, arithmetic and sequence commands. Detailed descriptions and notation capabilities allow for an easy-to-follow program and cam profiles can be created using advanced software tools or using predefined standard profiles. Additionally, free-form cam profiles can be created using spline interpolation. Once the profiles are created, these motion controllers have the capability to store multiple profiles and change those profiles on the fly. This eliminates the typical downtime associated with mechanical cams.

In terms of programming software, MT Developer, MR-Configurator, GX-Developer 2, GT Works 2 and GT Designer may be used with the new motion controllers. This allows programming motion profiles by using a sequential function chart format, which is the same as the company’s Q170M stand-alone motion controller and the MR-MQ100 single axis/1.5 axis motion controller. This standard programming environment ensures faster set up and ease of programming. The new Q172D/Q173D is CE, UL, and cUL approved as well as RoHS compliant.