Lisa Eitel - Motion Control Tips

maxon precision motors awarded top LEAP prize in Motion Control for Exoskeleton Joint Actuator

December 14, 2018 By Lisa Eitel Leave a Comment

At the recent LEAP Awards dinner gala in Costa Mesa, Calif., maxon precision motors was awarded the trophy for top design in Motion Control — for its Exoskeleton Joint Actuator.

The judges commented: “Excellent product in a ground breaking application. maxon has taken a leadership role by packaging products specifically for the exoskeleton market … By providing an integrated assembly, customers will be able to focus on application specific elements without the burden of reinventing joint actuation.”

The global Exoskeleton market is growing in both market share and technological developments at a rapid rate each year. maxon motor worked with several global customers to design and develop brushless DC motor solutions for use in robotic limbs. The Exoskeleton joint actuator is for use in hip and knee exoskeletons. A complete joint actuation unit includes a pancake brushless DC motor (EC90 flat) with inertia optimized rotor, an internal high-resolution 4096 MILE Encoder, a planetary gearhead with absolute encoder and an EPOS4 position controller with CAN and RS232 interface.

Fitting the 17-bit SSI absolute encoder directly at the joint rotation to a degree will negate the effect of gearhead backlash … giving designers increased positioning accuracy. The unit will deliver 54 Nm of continuous torque and 120 Nm on a 20% duty cycle. The system can be operated on supplies between 10 and 50 Vdc and the actuation speed is up to 22 rpm. The wide variety of different operating modes provides high flexibility in testing and optimizing of the entire exoskeleton system.

CleanMove Standard conveyors now come with inner drive option

December 7, 2018 By Lisa Eitel Leave a Comment

Now, belt and plastic modular-belt varieties of CleanMove Standard conveyors from mk North America are available with an inner drive. Conveyors with these drives can deliver speeds to 250 fpm and are suitable for horizontal, incline, and Z-shaped conveying applications.

Conveyor inner-drive features

The conveyor inner drive takes the form of an energy-efficient permanent-magnet drum motor. Because the motor is oil-free, it’s safe for inclusion on conveyors that transport food. The inner drive option makes for more compact conveyor designs than those based externally mounted motors. In addition, conveyors that include this drive technology are easier to clean due to the integrated motor format. All of these benefits ultimately lower per-conveyor operating costs.

For more information, visit mk North America at www.mkcleanmove.com.

Note that CleanMove stainless-steel conveyors excel in the pharmaceutical and food industries — with three platforms offering cleanability, performance, reliability:

CleanMove Standard conveyors for handling packaged food or pharmaceuticals in relatively dry environments

CleanMove Plus conveyors for processing bakery goods, snacks, and fruits and vegetables

CleanMove Ultra conveyors for caustic settings subject to high-pressure washdown — whether clean in place (CIP) or Clean Out of Place (COP). CleanMove Ultra conveyors are employed in facilities that process raw meats, poultry, fish, and dairy products.

Video on torque limiters: Examples of how to customize for industrial applications

December 6, 2018 By Lisa Eitel Leave a Comment

In a recent video with Lee Teschler, we go over three torque limiters from Mach III — a Kentucky-based manufacturer of stock and custom brakes, clutches, and torque limiters. The manufacturer can usually deliver custom designs within two days of obtaining application requirements. Mach III also meets or beats purchase-order ship dates 98% of the time. Catalog products ship in 2 to 5 weeks and custom in 3 to 6.

Recall that friction torque limiters transmit a set torque from the motor end of an axis to the driven-load end — and protect both from overload. Should torque exceed a set value, the torque limiter slips.

So let’s check out our first sample — a T2A2R-STL mechanical torque limiter … on which a sprocket, pulley, or sheave can mount. This is a spring-engaged design having low-coefficient friction discs. Minimum torque is 20 lb-in. and maximum torque (with 27% spring compression) is 200 lb-in. This one-pound torque limiter works on axes with speeds to 1,750 rpm.

Of course, torque limiters can integrate into motion systems in a few ways. We just considered one that accepts input via a sprocket-and-chain or pulley-and-belt assembly. Now let’s consider one for shaft-to-shaft mounting.

The V2R2R-STL is a mechanical torque limiter with adapter sleeve. The latter necessitates simple but precision installation with a torque wrench and other tools … But these torque limiters usually ship with the specified torque value to within about 10%.

Our third and final sample here is a V2G2R-STL shaft-to-shaft mechanical torque limiter. It’s complete with rigid coupling. This is a spring-engaged unit capable of torque maximums of 20 to 200 lb-in. depending on the setting.

One caveat: All these torque limiters are for momentary events and will continue slipping until the jam or other overload source is cleared. That means designs employing these components must include some way to detect torque overloads.

For more information, visit machiii.com and motioncontroltips.com.

New ICs for step-motor control from Performance Motion Devices

December 6, 2018 By Lisa Eitel Leave a Comment

Performance Motion Devices now sells new Juno Step Motor Control Integrated Circuits (ICs) in a 56-pin VQFN package. The new Juno Step Motor Control IC is the latest addition to the Juno Velocity and Torque Control IC family … the industry’s first family of compact ICs with full four-quadrant motion control; direct input accepted from quadrature encoders; profile generation; and advanced current control.

Juno ICs are for designs with limited space that need to control noise, vibration, and power consumption. Juno ICs are also easy to deploy with embedded motion commands and onboard intelligence.

Performance Medical Devices recently released the Juno Velocity and Torque Control IC series — the industry’s first family of compact ICs with full four-quadrant motion control, direct input quadrature encoder, profile generation, and advanced current control.

The Juno Step Motor Control IC 56-pin VQFN package has the highest PWM frequencies offered by Performance Motion Devices and the smallest IC parts — measuring 7.2 x 7.2 mm. Juno Step Motor Control ICs are available both with encoder input and without.

The Juno Step Motor Control IC also comes with numerous safety features … including stall detection, over- and under-voltage sense, overcurrent detection, over-temperature, and i²t current foldback. Coupled with compact MOSFETs, the Juno Step Motor Control IC can replace older step motor amplifiers and dramatically reduce the size and heat output.

“Juno Step Motor Control ICs offer embedded motion and use a proprietary current control technique that results in ultra-smooth, quiet, and efficient motion of the step motor,” said Chuck Lewin, CEO of Performance Motion Devices.

“By driving step motors more quietly and rapidly, existing step motor-based systems can get a performance boost and avoid an expensive transition to a brushless dc motor. In short, this IC lets step-motor users upgrade the controls but keep the motor … and get a big jump in machine performance.”

The Juno IC family is suitable for a wide range of applications including precision liquid pumping, packaging and lab automation, pick and place machines, flow rate control, XYZ tables, and many other robotic, scientific, and industrial applications. For more information, visit www.pmdcorp.com/JunoIC.

Performance Motion Devices supplies high-performance integrated circuit, board, and drive-based motion control solutions to OEMs and contract manufactures around the globe. Its technology controls more than five million motors worldwide, providing motion solutions to some of the world’s largest manufacturers. If speed, efficiency, and reliability are top of mind, Performance Motion Devices has proven motion control technologies that can decrease development time.

Video: Spring or air-engaged friction brakes from Mach III (a Design World overview)

December 5, 2018 By Lisa Eitel Leave a Comment

In a recent video with Lee Teschler, we got the chance to handle two brakes from Mach III. Watch the video:

Our first sample — a D2F3R-STH spring-engaged brake — is one of more than a dozen standard variations … with many more customizable options.

This modular brake design has subcomponents grouped into kits — for drive-hub elements, drive-disc elements, piston elements, cylinder elements, and a final kit that includes two O-rings, 24 coil springs, and three friction discs. It’s recommended that end users keep these common wear items on hand for very critical applications where downtime must be minimized.

Torque is to 91 lb-in. and maximum speed is to 1,750 rpm. As with most all brakes, the manufacturer recommends a service factor of 1.5 to 2 when calculating required torque. Brakes shouldn’t be used at maximum rated torque for continuous duty.

So that was a spring-engaged brake … the other sample we show in the video is an air-engaged brake — the Mach III B2F2R-STH. Dynamic torque for this flange-mounted brake at 80 psi input is 100 lb-in.

Of course, torque capacity is only one factor to consider when selecting a brake. Mach III recommends that design engineers contact the engineering department for application review and assistance.

The pneumatic supply must include a flexible airline and correct fitting for the brake inlet’s NPT size — and fixing with a thread-sealing compound. Air supply should be both filtered and regulated. For more information, visit machiii.com.

Click to enlarge.

POSITAL adds to its range of kit encoders

December 5, 2018 By Lisa Eitel Leave a Comment

POSITAL is expanding its line of kit encoder solutions for motion control applications to satisfy a wider range of needs faced by machine builders, system integrators, and motor manufacturers.

Kit encoders are component-level products, designed to be built into motors or other types of equipment where real-time measurement of rotary position (angular displacement) or rotational speed is required. Compared to POSITAL’s widely used IXARC series of self-contained encoders, kit encoders typically lack sealed housings, ball bearings or separate shafts. Instead, they are intended to fit inside the host machine’s casing, with rotating components connected directly to the machine’s shaft. This results in rugged, compact installations with direct measurement of rotational position and speed.

The POSITAL kit encoder family now includes:

Multi-turn battery-free magnetic kit encoders: These provide absolute position feedback in a compact, rugged, low-maintenance package. Multi-turn models feature a rotation counter that is self-powered, eliminating the need for backup batteries. This makes these units highly reliable and virtually maintenance-free. Variants for stepper motors that feature the same mounting footprint as popular incremental encoders are available, providing motor builders with a convenient upgrade path to absolute position control. POSITAL’s magnetic kit encoders support non-proprietary communications interfaces, including SSI, BiSS C and BiSS Line.

Through hollow kit encoders are designed for installations where there are benefits to having the measurement element fit around a machine’s shaft or axle. With their slim design (only 18 mm thick) and generous central opening (30 or 50 mm) these are an excellent solution for many motor installations and compact robot joints. These devices are based on a capacitive measurement technology that combines accuracy with tolerance to shock and vibration, dust and moisture, and magnetic fields. Here again, battery-free multi-turn models are available.

Compact incremental optical kit encoders are optimized for speed control of small drives, low power motors and stepper motors. These devices are simple, robust and easy to install, with a mounting footprint that is compatible with optical kit encoders from other manufacturers. They are available with a wide range of resolutions.

Magnetic Kit encoders are currently available. For more information, visit www.posital.com.

The new CC-Link IE TSN — for time-sensitive networking for open industrial Ethernet

December 5, 2018 By Lisa Eitel Leave a Comment

The CC-Link Partner Association (based in Nagoya Japan), the organization promoting the Ethernet-based integrated network CC-Link IE, has announced the completion of the specification for CC-Link IE Time Sensitive Networking (TSN) – a next generation network based on the current CC-Link IE. CC-Link IE TSN was developed to meet future market demands and has added Time Sensitive Networking (TSN) technology, which are additional standards related to IEEE Ethernet, to integrate Operational Technology (OT) and IT while strengthening performance and functionality.

CC-Link IE TSN combines industry leading gigabit bandwidth with TSN to deliver open networking solutions for smart factory construction.

Plus with the diversification of development methods, it has enabled flexible implementation for various types of equipment and also achieved mixed usage of information communications by using Internet Protocol (IP) and control communication technology. It is expected that these will improve efficiency and reduce time for the construction of smart factories using the IIoT. More details of the CC-Link IE TSN specification will be published on the CLPA Members Site.

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The CC-Link IE specification was released in 2007 as the first 1-Gbps Ethernet-based open industrial network and has expanded its function and scope of application to motion and safety control after starting from general input-output control. Its features reach a mixture of high-speed and large-capacity control communication (cyclic data) that combines with non-control communication (transient data). The two can coexist thanks to the 1Gbps bandwidth. Furthermore, it is easy to diagnose the cause of network errors. Since it is simple to build not only the system that controls and monitors a production site but also the system that collects and analyzes information on the production site, it is expected to bring benefits to a range of different industries.

But as IIoT systems have progressed to the practical stage in recent years, market demands for utilizing a wide range of devices implementing general purpose Ethernet communication have increased. Moreover, requests for high function motion control equipment and protocol implementation for various types of equipment have increased.

So to meet these demands, CC-Link IE TSN was developed — a network that significantly improves the performance and functions of the current CC-Link IE. Plus it’s increased openness through use of TSN technology.

CC-Link IE TSN includes:

• Flexible IIoT system construction for faster time to market and reduced downtime

• TSN Ethernet communication technology as a time-sharing method; collection of information from end devices by IP communication while securing real-time control communication

• Easier network diagnosis by using general-purpose Ethernet diagnostic tools compliant with SNMP

• Time synchronization of compatible devices, for simpler investigation into problem root causes; supports both 1 Gbps and 100 Mbps

• Top communication performance for best-in-class motion control operation cycle times … of better than 31.25 µsec

• Segregation of high and low performance device communication, for optimized performance on all network stations … and the system as a whole

• Diverse development methods; hardware (ASIC and other device based) and software (protocol stack) development methods

What’s in development for CC-Link IE TSN-compatible products

The detailed specification of CC-Link IE TSN will be released to CLPA partner companies through the website. Those partners who were involved in formulating specifications are considering product development and compatible products are expected to be released from 2019.

Endorsements for CC-Link IE TSN

The CLPA partner companies that have considered development for CC-Link IE TSN compatible product as of November 2018 are listed below. Following are endorsement comments from the Board of Directors and partner companies.

“Recently, industrial networks that control various manufacturing equipment, robots and sensors are expanding rapidly with the demands for visualization of manufacturing processes and production improvement efficiency. We welcome the release of CC-Link IE TSN to achieve more evolution with the integration of IT and control. We will promote provision and development of network connectors and cable assembly products that realize high transmission reliability and robustness, and will support “CC-Link IE TSN” promotion activities globally.” — Akiyoshi Funayama | Senior Manager, Interconnect Sales and Marketing Dept. Electrical Interconnect Solution Division • 3M Japan Limited

“We, Advantech Japan Co., Ltd, believe that CC-Link IE TSN will be the key product to ensure the construction of a flexible IIoT system, which is the basis of the new Ethernet technology and we would like to actively contribute to it.” — Takaaki Furusawa | Director, Industrial-IoT Group iFactory Sector • ADVANTECH Japan Co. Ltd.

“Analog Devices has a rich history of providing industrial communication solutions – from the early days of 4 to 20mA and serial fieldbuses to today’s Ethernet-enabled protocols for the factory of the future. Through this evolution, CC-Link has played a vital role solving customers’ most complex automation challenges. ADI strongly supports CC-Link with a robust portfolio of products that includes a roadmap of Ethernet solutions for CC-Link.” — Brendan O’Dowd | Automation Energy Group, Industrial Automation, General Manager • Analog Devices, Inc.

“Balluff, as a CLPA board member, has supported CC-Link and CC-Link IE for many years. the slogan “Innovating Automation” expresses that we are a specialist in sensor and automation application, offering also solutions beyond the sensor core business. As a leading company in conveying IO-Link Data from intelligent sensors to the control, Balluff is a partner for digitalization and the IIoT strategy of the customers. The CC-Link IE IO-block family gives high-speed data access in nearly any application. Balluff is looking forward to continuing the excellent relationship with the CLPA and will expand the portfolio with new solutions and products.” — Jürgen Gutekunst | Senior V.P. of Mobility • Balluff GmbH

“Hirschmann Automation and Control GmbH is a pioneer in TSN. We’ve helped develop the technology since the early start in the IEEE 802 standardization years ago, and we are excited to see its adoption into the CC-Link IE TSN networks. By using TSN technology, CC-Link IE takes the next step to supporting the applications of the IIoT and the smart factory of today and tomorrow. Hirschmann Industrial Ethernet Switches provide extremely high synchronization quality and high-precision transmission functions and we are looking forward to enable CC-Link IE TSN networks with the TSN portfolio.” — Oliver Kleineberg | Global CTO Core Networking • Hirschmann Automation and Control GmbH (a Belden brand)

“Cisco supports digital transformation that brings creative disruption to business. CC LINK IE TSN serves as a robust platform that helps manufacturing customers digitalizing their systems … by integrating OT and IT at factories and promoting data trading, which will lead to creating business value.” — Kazuhiro Suzuki | Chairman • Cisco Systems G.K.

“CC-Link IE TSN, which enables high-speed I / O communication and information data transmission at the same time, will provide a lot of value to customers. We welcome this release and will contribute to the promotion of CC-Link IE TSN through product development and sales.” — Hiroyuki Mizuno | General Manager, Network Engineering Department, Components Business Division • CKD Corp.

“CC-Link IE TSN is a breakthrough in interoperability and performance in network technology. Cognex vision sensors help automate the manufacturing process and communicate critical Industry 4.0 data. The flexibility of this network architecture will make it easier to collect this data by a variety of existing data management, diagnostic, and monitoring systems. In addition, the high speed, high precision synchronization feature enables advanced vision – motion solutions leading to improved productivity. Cognex sees CC-Link IE TSN as a significant advancement in network technology that will help create smarter factories.” — Justin Testa | V.P. of In-Sight Business Unit • Cognex Corp.

“CC-Link IE TSN is a major innovation that evolves machine tools and robots. We expect that with the integration of motion control and the combination of TSN technology support with Contec’s IPC and IIoT solutions, it would bring new value creation to customers.” — Katsutoshi Fujiki | President and CEO • CONTEC Co. Ltd.

“We have had a close partnership with the CLPA since we started to develop the first CPV valve terminal with the CC-Link fieldbus in 2001. During the development of these and following products like CC-Link for CPX and CTEU, we’ve received excellent support from the CLPA Testing Center and also from CLPA who helped us to establish the network in Asia between the subsidiary there and the colleagues in Japan, Korea, China. We’re pleased that based on increased demand for the next generation gigabit-capable fieldbuses we’ve started a CC-Link IE Field project. We know we can also count on good cooperation and support in this project.” — Lale Hübner | Product Management IO Terminals • Festo AG & Co. KG

“I am very pleased about the completion of the CC-Link IE TSN specification. As IIoT is becoming common in manufacturing industry, this network based on TSN technology will play a key role in accelerating use of IIoT. Fortinet continues to support efforts conducted by CC-Link Association and contribute to industrial security.” — Kubota Norio | Country Manager & VP Sales for Japan • Fortinet Japan K.K.

“Hilscher is one of the key technology suppliers for industrial communication solutions. We have been supporting the CC-Link technology portfolio over the years, following up with the innovative standards CC-Link IE and CC-Link IE Field Basic. Therefore, it is a must for us to stay on track with this success story for CC-Link IE TSN within the Product portfolio. With this new technology we see the enablement of devices for IIoT, with Sensor to Cloud Communication.” — Sebastian Hilscher | Division Manager, Development • Hilscher Gesellschaft für Systemautomation mbH

“HMS Industrial Networks, world leading provider of connectivity solutions to the automation industry, is taking the next step to provide industrial grade communication from factory floors all the way to Enterprise and IT levels worldwide. With the announcement of CLPA’s latest network at SPS/IPC/Drives 2018, we are excited to continue the journey together … which began with the collaboration on reliable Anybus products enabling communication for CC-Link and CC-Link IE Field. This collaboration between HMS Industrial Networks and CLPA has been a great success and will continue to be so.” — Christian Bergdahl | Product Marketing Manager • HMS Industrial Networks AB

“We are pleased to see that the market-leading software development toolchain IAR Embedded WorkbenchⓇ for Arm has been selected as a reference tool for enabling CC-Link IE TSN because of verified sample protocol stacks from various companies. We believe that this joint activity will help to expand the industrial network market as well as boost the use of the powerful toolchain.” — Kiyofumi Uemura | APAC Director & Japan Representative Director • IAR Systems

“As the trend of IIoT expands globally, we welcome the release of CC-Link IE TSN, which will be expected to spread globally with the collaboration with other industrial networks. We will contribute to the expansion of CC-Link IE TSN through compatible product development and sales of network equipment, code reader and switching devices.” — Hiroki Matsumoto | General Manager, Automation Solutions, Products & Markets Strategy Division, Sales & Marketing Headquarters • IDEC Corp.

“MESCO is a partner for innovative software and hardware development in the field of process and factory automation with unique knowledge in industrial communication, functional safety and explosion protection. CC-Link IE TSN fulfills high performance requirements for industrial communication. CC-Link IE Safety enables the technology for safety critical implementations. A MESCO CC-Link Software Development Kit makes the technology available and facilitates development. The kit includes CC-Link IE TSN Stack, CC-Link Safety IE Stack, evaluation board for safe and non-safe applications. Additionally, MESCO provides coaching and service for customized hardware and software development with use of CC-Link IE TSN SDK.” — Peter Bernhardt | Head of Sales & Marketing • MESCO Engineering GmbH

“We have been supporting CC-Link and CC-Link IE for many years, as well as developing and selling a variety of FA products and proposing FA Integrated Solutions e-F@ctory. We will adopt TSN technology … which will become the mainstream of future industrial networks as soon as possible … and will lead to the expansion of CC-Link IE TSN. We will contribute to the development of the FA industry by providing solutions using CC-Link IE TSN.” — Takayuki Tsuzuki | General Manager, FA Systems Div. • Mitsubishi Electric Corp.

“CC-Link IE TSN realizes high-speed computing, motion control and visualization that integrates IT and OT to accelerate the construction of the IIoT. We will also contribute to the popularization of CC-Link IE TSN through product development and collaborations such as network I/O, safety system and edge computing related products.” — Riky Comini | Director, Industrial Automation, Transportation and Industrial Solutions • Molex Inc.

“We believe that expansion of CC-Link IE TSN will more strengthen cooperation of existing IT and FA, and bring new business opportunities to both industries. We will not only enhance interoperability and security of IT and FA systems, but also promote technological development enabling wireless CC-Link IE TSN.” — Yoshimitsu Okayama, Digital Platform Division, Senior Manager • NEC Corp.

“We are focusing the attention on CC-Link IE TSN as one of the core networks of the future. We will consider development of stepping motors/actuators that will lead to CC-Link IE TSN as the control for networks that contribute to the construction of IIoT systems.” — Ryuta Sugimoto | Chief Product Planning Department Sales Headquarter • ORIENTAL MOTOR CO. LTD.

“As the trend towards implementing the IIoT is accelerating, network compatibility is strongly needed for control devices. We will develop CC-Link IE TSN compatible products for sensing and safety products and contribute to IIoT for FA industries.” — Jun Kasugai | General Manager Product Planning Department Sensing Division • Panasonic Industrial Devices — SUNX Co. Ltd.

“Industrial networks are one of the most important technologies in the digitalized Factory Automation industry. CC-Link IE TSN is a leading-edge technology that integrates control and system networks, and Renesas sees this technology as a key driver for the evolution of the industry. Renesas has been providing products supporting the CC-Link Family and we plan to continue to expand the line up to support the next- generation standards.” — Yuji Mori | Director, Industrial System Solution Department, Industrial Automation Business Div. of the Industrial Solution Business Unit • Renesas Electronics Corp.

“As a CLPA board member, we plan to manufacture CC-Link IE TSN compatible products that will offer real-time extensions supported by world standard technology. Pro-Face HMIs are planned to be part of an extensive line up of compatible products.” — Minoru Yoshida | Strategy & BD Director • Schneider Electric Japan Holdings Ltd.

“SecurityMatters has over 15 years of experience ensuring mission-critical industrial cyber-resilience. We have a proven track record of protecting industrial environments from undetected threats, process flaws and maintenance issues. In this context, CC-Link IE and CC-Link have always been vital components. The secure, open, and complete specifications have allowed the most advanced network analysis. This enables better cyber protection and preventative maintenance of complex industrial automation networks. CC-Link IE TSN will provide a strong foundation for Smart Factory applications and Industry 4.0. On this solid foundation, we will work together to develop even better protection capabilities.” — Damiano Bolzoni | Chief Executive Officer • SecurityMatters B.V.

“SMC welcomes CC-Link IE TSN. We will contribute to disseminate CC-Link IE TSN by product development and sale of it in the market. We cultivate advanced technology trusted by customers, and strive to develop products that meet customer needs.” — Fumio Morikawa | General Manager, Product development division • SMC Corp.

“As global trend of smart manufacturing using IIoT is accelerating, we expect CC-Link IE TSN from Japan will bring customer productivity and profitability to a new level. ZUKEN ELMIC has been actively developing products ranging from protocol stacks to software packages, based on networking, video streaming technology, and CC-Link as well. We will continue active marketing and development efforts on CC-Link IE TSN.” — Takashi Fujii | General Manager, Development Division • ZUKEN ELMIC INC.

“With the CC-Link IE TSN support for the STM32 family, developers of CC-Link IE devices have access to the industry’s most popular variety of Arm Cortex -M core microcontroller to accelerate Industrial IoT development with optimized cost and higher flexibility.” — Paolo Oteri | Director, Microcontroller & Digital ICs • STMicroelectronics K.K.

The CC-Link Partner Association (CLPA) is an Intl. organization with over 3,400 member companies worldwide. The partners’ common objective is promotion and technical development of the family of CC-Link open network technologies, helping their joint customers reach their integrated manufacturing aspirations. The CLPA organization is the driving force behind developing new standards in industrial communication while also supporting the device development activities of its members as well as certification of those devices. For more information, visit am.cc-link.org.

Video: Five air-engaged clutches from Mach III (a Design World overview)

December 4, 2018 By Lisa Eitel Leave a Comment

In a recent video with Lee Teschler, we investigated five air-engaged clutches from Mach III. The company designs and manufactures an array of air and spring-applied friction brakes and clutches — as well as mechanical torque limiters and combination clutch-brakes for industrial applications to 5,000 ft-lb. Watch the video:

First we detail a C2H2R-STH air-engaged shaft-to-shaft flexible-coupling clutch. These friction clutches (as with all the other samples we detail in this video) engage with air pressure and then are spring released upon air exhaustion.

In this way, they connect and disconnect fully supported shaft pairs. An elastomeric element compensates for up to 3° of angular misalignment and up to 0.040 in. of parallel offset between shafts.

In contrast, a sprocket or pulley mounts on the pilot of the C2A2R-STH air-engaged clutch. This is a through-shaft-bored variation in a miniature-clutch line for torque requirements of less than 200 lb-in.

The C2D2R-STH air-engaged clutch we examine in the video is designed for end-of-shaft mounting … and for cycling and connect-disconnect applications.

It fixes to the shaft with setscrews or a customer-supplied key and includes a rotary air seal. Unlike the other clutches we consider in this video, this one does not need an anti-rotation arm to prevent rotation of the air housing.

Next check out this M2G2R-STH air-engaged shaft-to-shaft rigid clutch coupling. It has a two-piece coupling body — with both the clutch mechanism and coupling half bored to accommodate differing shaft sizes.

Last but not least, we have an M2R2R-STH air-engaged clutch mechanism with adapter. Torque capacity is to 190 lb-in. As with the other clutches here, torque is linear in response to input air pressure. It’s also available with friction linings having a low or high coefficient for the same price. Linings with a low coefficient of friction are for designs needing a bit of slip or a narrow torque range.

These are just a tiny sample of what the manufacturer offers — in more than 2,000 standard models — though most of what Mach III supplies are slightly custom to very custom designs. In that regard, the manufacturer is somewhat ahead of a growing trend we see in industry. For more information, visit machiii.com.

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Access your own smart data —with Lenze and IoT specialist ei3

December 4, 2018 By Lisa Eitel Leave a Comment

Lenze (manufacturer of drives, motion control, and automation technologies) in partnership with IoT specialist ei3 (based in New York) now helps customers reach the promised value of IoT and advanced analytics. Return on investment (ROI) is possible using quantifiable metrics, available in dashboard or report form, within the first few months of deployment. At both PACK EXPO 2018 and Hannover Messe USA, booth visitors learned more about this solution which is suitable for services such as remote diagnostics and predictive maintenance, while maintaining high levels of security. Lenze is able to demonstrate that Industry 4.0 is no longer an abstract concept, but indeed a reality. The cloud offers an infinite amount of storage space and computing power, but it first needs the right concepts and applications before it can become a genuine added value. Machine data from the control, the drives and the sensors can now be transferred securely to the cloud with minimal effort.

“Companies can monitor their machines’ performance in real time to increase asset utilization, improve production quality, reduce service costs, and save energy,” according to Daniel Repp, automation product manager at Lenze Americas. “This leads to operational savings and increased profit margins, without compromising machine and data safety.”

For customers of automation specialist, Lenze there’s now an easy way for OEMs to collect all the data that is available inside the Lenze controllers. They can then evaluate this data and make it available to their own customers, either as an up-to-date dashboard or in the form of reports providing performance figures. This data can be used to determine how to optimize systems and processes. In addition, the solution is suitable for services such as remote diagnosis and maintenance, and it can also be used to provide predictive services.

The data from a machine is first transferred via OPC-UA (Unified Architecture) to a security appliance within the production network. From then on, all the communication takes place in encrypted form at a high level of security in ei3’s own data centers. It is a private cloud offering big-data services with easy accessibility – preconfigured and available to OEMs. To start collecting data, machine builders will specify the target data points in the needed application – no prior knowledge of IT or big data necessary. It is also easy for the OEM to carry out remote diagnosis and remote maintenance once the product is up and running.

Data security takes top priority in ei3’s own regional data centers. There are three of these: one of each in the USA, Europe and Asia. A fourth one is currently being created in Germany so that the customers’ local data never leaves the country. The data specialist from New York employs strong encryption systems for the data transfer – comparable with the kind of encryption that is used by banks.

Data sent to the cloud can be analyzed for different applications. The simplest case would be when a warning is generated because a specific critical value has been exceeded, such as the ambient temperature (condition monitoring), or because it might be exceeded in the near future (predictive maintenance). This enables the maintenance department to plan the maintenance window in advance, combining different upcoming tasks into one maintenance job and thus reducing the system downtimes, which has a positive effect on OEE and ROI.

Industry 4.0 doesn’t only mean better machine control and the optimization of processes for the user, but the OEM also benefits from the additional information. He can optimize service on the basis of the machine data. The analysis of the usage data shows what the machines’ real operating conditions look like, since they often diverge considerably from what the customer previously reported. Accordingly, the machines can be precisely adapted to the actual operating conditions, and weaknesses that emerge can be eliminated. The machine manufacturer can also strengthen customer ties significantly with custom-made solutions and individual service offers.

Lenze offers all of the necessary modules to create smart machines – from the automation and drive technology, to the necessary development tools and software tools, and now the cloud connection. For more information, visit www.Lenze.com.

PowerPlus stepper motors from Moons’ Industries — high-torque replacements for NEMA 23, 24, and 34 motors

December 4, 2018 By Lisa Eitel Leave a Comment

To upgrade machine performance or address stalling problems, manufacturers often resize motors with greater torque to reach greater accelerations for proper operations. Retrofitting a stepper motor, however, is time-consuming and expensive as it requires machining new mounting brackets and increasing the drive size and power supplies. PowerPlus Hybrid Stepper Motors from MOONS’ Industries eliminate the hassles of resizing motors by providing 25% to 40% more torque across the entire speed range of a motor. With the same physical dimensions as standard NEMA 23, 24 and 34 stepper motors, PowerPlus Hybrid Stepper Motors often drop into place to minimize upgrade costs while improving performance.

The increased torque of the PowerPlus technology is the result of higher motor efficiency. In a conventional stepper motor, some of the torque-producing flux that links the rotor to the stator is formed outside the stator teeth. The stray flux wastes power and adds little to motor torque.

A higher magnetic flux density within the motor increases the performance of the PowerPlus Stepper Motor, enabling it to generate up to 40% more torque than conventional motors. Magnets placed between the stator teeth redirect and refocus most of the stray magnetic flux into the stator teeth to produce additional torque with the same input power.

Retrofitting existing motors with PowerPlus technology offers a quick path to producing new machines with improved performance.

Because the motor size, drive, and mechanical parts remain the same, PowerPlus Hybrid Stepper Motors:

Reduce engineering costs
Expedite new product introductions with an easier production phase
Reduce spare parts inventory
Provide a quick solution to stalling machines due to unexpected field conditions such as low temperature, dirt, wear of mechanical parts or lack of maintenance

Application for PowerPlus stepper motors

In a typical application upgrading stepper motor performance with PowerPlus technology, a manufacturer of CNC cutting systems wants to produce a high-performance version of its current machine to increase cutting speeds by 75% to 100% and improve move speed.

Machine specs of current machine

Machine specs of high-performance machine

· Rapid move speed: 300 rpm

· Cutting speed: 150 rpm

· Power supply output: 24 Vdc @ 5 A

· Stepper drive output: 1.5 A

· Motor holding toque: 210 oz-in.

· Rapid move speed: 600 rpm

· Cutting speed: 300 rpm

· Power supply output: 24 Vdc @ 5 A

· Stepper drive output: 1.5 A

· Motor holding toque: 330 oz-in.

Engineering this new product, the CNC manufacturer wants to minimize engineering time while limiting parts inventory. A PowerPlus Stepper Motor provides twice the additional power over the existing motor needed for the new CNC machine without redesigning new parts or changing drives, power supply or the control program. In fact, by using PowerPlus motors, the machine builder can possibly use a smaller size motor and drive system to reach the same performance in a smaller and more cost-effective package.

For more information on the PowerPlus motors, visit moonsindustries.com/c/powerplus-hybrid-stepper-motors-a020102 or email chuck.leonard@moonsindustries.com.

MOONS’ Industries is a manufacturer of key components for motion control, intelligent LED lighting control, and industrial equipment management. MOONS’ cooperates with leading companies to provide creative solutions and high quality products focused on efficiency and performance. For more information, visit moonsindustries.com.