Miles Budimir - Motion Control Tips

Servo motor offers increased torque, speed and efficiency in compact footprint

May 16, 2019 By Miles Budimir Leave a Comment

Kollmorgen’s AKM2G synchronous servo motors are the next generation of its AKM motor product family, and provide increased capabilities for demanding applications. The higher torque density of the AKM2G allows OEMs to substantially increase machine performance without increasing motor size. Greater flexibility and wider speed range enables machines to run faster, move heavier loads, and increase throughput. The AKM2G is also highly efficient, offering lower energy consumption and costs compared to competitive motors.

Key benefits include:

Smaller footprint – With average continuous torque increases of 30 %, AKM2G significantly reduces the space dedicated to motors and mechanical components without sacrificing performance. Newly available space allows for additional production capacity, and smaller machines can allow operators to run multiple machines at one time.

Increased torque – The higher torque density of the AKM2G allows machines to do more and increases throughput. With six sizes and performance levels between 0.3 and 10 kW, the AKM2G helps existing machines produce new variants such as larger-size product.

Wider speed range – With rated speeds up to 8,000 rpm, the AKM2G allows existing machines to run faster, change-over quicker and produce more when production demands surge.

Greater flexibility – The AKM2G supports a wider array of feedback, brake, thermal sensor, and shaft seal options, allowing OEMs maximum flexibility in machine design and compatibility with current machine configurations. Now available for low voltage and dc applications from 24 to 96 V providing optimum high-performance solutions for portable and mobile applications including operation from battery systems.

Higher efficiency – The AKM2G builds on the AKM’s industry-leading efficiency, bringing models to as much as 98 % efficient. OEMs can meet energy efficiency parameters that are becoming requirements in multiple markets.

For more information visit www.kollmorgen.com.

What are some common PAC chassis, module, controller, and I/O options?

May 15, 2019 By Miles Budimir Leave a Comment

ControlLogix PACs from Rockwell Automation feature tight integration between the programming software, controller, and I/O modules which helps reduce development time and cost.

In the field of programmable controllers, there are a number of different types of product offerings, depending on the application requirements. Traditional programmable logic controllers (PLCs) have been the industry standard for decades. They are well known and understood in terms of operation and programming and there are many PLC manufacturers to choose from.

As control demands became more complex, programmable automation controllers (PACs) came onto the scene to handle these more demanding cases requiring more complex control and coordination, involving many more axes and I/O than a typical PLC could handle. According to an industry standard definition, PACs operate on a single platform and handle multiple tasks including logic, motion, drives, and process control.

PACs stand between PLCs and PC-based controllers, combining the best elements of both. PACs are characterized by multiple processors, more memory and communication options, and more functionality beyond just the logic-based operations of traditional PLCs. They also can be programmed using ladder logic familiar to PLC programmers and other higher-level languages consistent with IEC 61131-3 standards.

Because PACs are similar to PLCs both in function and form, many of the options ordinarily available for PLCs are the same for PACs. So for instance, common component options include the controller, chassis, modules, and I/O.

Analog I/O modules from AutomationDirect are available in current, voltage, and temperature models with LCD displays. They can handle many standard analog I/O signal types including 0-20 mA, 4-20 mA and 0-10 Vdc.

Controller – the controller contains the central processing unit (CPU), memory, and the main networking and communication ports such as Ethernet and USB.

Chassis – the physical enclosure housing all the PAC components such as the controller/CPU unit, power supply, and modules and I/O. Options include rack-based systems (mountable to backplanes inside equipment racks via DIN rails) or mounted directly to machines.

Module – modules exist for all manner of applications and uses, designed to perform some specific function. So for instance, there are modules designed specifically to accept either analog or digital signal inputs and designed for specific uses. Examples include relay modules, counter modules, serial modules, servo or stepper controller modules, timer modules, and data acquisition modules, among others, including I/O modules (see below).

I/O – Just as with PLCs, I/O type can include voltage or current analog, digital, or mixed analog/digital. Common physical variable inputs to I/O modules can be pressure, force, or temperature data from thermocouples, among others.

ADVANCED Motion Controls debuts family of compact FlexPro digital servo drives

May 14, 2019 By Miles Budimir Leave a Comment

The FE060-25-EM is the first servo drive of the new FlexPro digital drive family from ADVANCED Motion Controls (AMC). Designed with compact form and power density in mind, the micro-sized FE060-25-EM can outperform larger-sized digital servo drives and still be integrated into tight spaces.

At just 1.5 x 1 x 0.6 in. (38 x 25 x 16 mm) in size, the footprint of the drive is approximately the same as two standard postage stamps. In other words, four of these drives can fit on a standard business card. Even with its small size, the FE060-25-EM can supply brushed, brushless, stepper, and linear servo motors with up to 25 A continuous current and 50 A peak current.

AMC_Image_FE060-25-EM features include:

10 to 55 Vdc supply voltage
Highest power density servo drive from ADVANCED Motion Controls to date
EtherCAT Communication
Incremental encoder and BISS C-mode feedback
Torque, velocity, and position operating modes
Configuration and full loop tuning
IMPACT architecture

IMPACT (Integrated Motion Platform And Control Technology) is the architecture that makes AMC’s FlexPro drives possible. The stacking of circuit boards with creative selection and placement of high-power components allows for much higher power density than previously produced servo drives.

A developer version is available for proof-of-concept and testing purposes – part number FD060-25-EM. It comes with an FE060-25-EM soldered to a larger board equipped with various connectors for simplified interfacing.

The small size of the FE060-25-EM makes it perfect for cobots (collaborative robots), AGVs, portable devices, lab and warehouse automation, military equipment, and any other integrated design.

For more information, visit www.a-m-c.com.

Compact step motors with high torque for space-limited applications

May 10, 2019 By Miles Budimir Leave a Comment

Applied Motion Products offers compact step motors in NEMA sizes 8, 11 and 14 for applications with limited space including medical devices, 3D printers, analytical and medical instruments, robotics and others.

These lightweight and low-cost motors offer high torque up to 22 oz-in. at low speed. Even while sized smaller, the compact step motors operate with high step accuracy and resolution as well as low vibration and noise – important factors in machinery lines and medical equipment. The compact step motor line includes:

NEMA size 8 in two lengths (1.24 in. and 1.85 in.) and holding torque up to 4.53 oz-in.
NEMA size 11 in two lengths (1.22 in. and 2.05 in.) and holding torque up to 14.16 oz-in.
NEMA size 14 in two lengths (1.02 in. and 1.57 in.) and holding torques up to 25.53 oz-in.

These hybrid-type small motors offer the highest torque density in their frame size. With a 1.8˚ step angle and being RoHS compliant, units are available in both single and double-shaft versions. To address customers requirements for specific connectors and couplings, Applied Motion Products provides its compact motors with customized cable and connector assemblies and a variety of options including flats, thru-holes, custom lengths, and more.

Applied Motion Products also offers a full complement of stepper drives that optimize the torque and speed performance of its compact step motors while providing smoother and quieter operation. For basic step and direction control applications, operators can set up the miniature STR3 stepper drive with just a screwdriver. A new STF stepper drive family offers on-board programming and network communications. All software tools for these drives are free and easy-to-use. Q Programming provides the option to store motion profiles on STF drives and execute profiles in stand-alone mode or via a digital I/O.

For more information visit www.applied-motion.com.

Haydon Kerk Pittman adds 42-mm motor to IDEA Motor series

May 9, 2019 By Miles Budimir Leave a Comment

Haydon Kerk Pittman, a business unit of AMETEK Advanced Motion Solutions, announces the latest addition to its line of brushless dc motors: the EC042B IDEA Motor Series. The new motor is 42-mm in diameter and integrates a high-torque, precision brushless servo motor with an IDEA Drive in a single compact unit. The IDEA Motor enables distributed control without the use of a costly PLC or external motion controller.

The EC042B IDEA Motor is offered in three motor lengths with continuous torque up to 0.15 Nm with integrated inputs, outputs, encoder, and RS-485 communication. The GUI (Graphic User Interface) integrates a trapezoidal and S-curve trajectory generator with a movement profile plotter. The IDEA Motor can store and execute multiple programs with I/O driven nested, prioritized, and vectored interrupts as well as polled I/O for autonomous real-time control. Users familiar with the current IDEA Drive GUI will recognize the layout and appreciate the expanded features of the GUI.

Haydon Kerk Pittman standard PLG42S and PLG52 gearboxes are available as factory options. Torque ratings for PLG42S are as high as 14 Nm while the PLG52 torque rating achieves up to 24 Nm. The wide range of reduction ratios and torque capabilities enable optimized performance of the EC042B IDEA Motor for highly specialized or unique motion applications. These applications include lab automation, medical devices, communications equipment, semiconductor processing equipment, aerospace systems and many other applications where precision motion and compact packaging are critical.

For more information visit www.haydonkerkpittman.com.

ADS Uptime for wireless encoder service check-up from Leine Linde

May 7, 2019 By Miles Budimir Leave a Comment

Leine Linde’s next generation of condition monitoring system for encoders is ADS Uptime. The Advanced Diagnostic System (ADS) retains the core features of its previous generation (ADS Online), and also introduces new features such as a wireless service check-up through Bluetooth and single cable support for diagnostic and control loop feedback information.

As with its previous generation, Leine Linde ADS Uptime continues to offer system monitoring features on parameters such as vibration and temperature. It also offers the ability to set various alarms and warnings, as well as record and access information over the encoder’s lifetime.

The new features of ADS Uptime such as wireless encoder service check-up, through Bluetooth connectivity, facilitate simplified maintenance routines in production lines and allow quick access to important factors affecting the encoder. Users can now perform service checkups on the go via the ADS Uptime app on their mobile device or tablet. With this type of effective maintenance check-up, maintenance technicians can detect unusual trends or recognize warning signs in an early stage and start practicing proactive maintenance. This greatly minimizes or eliminates unplanned downtimes.

ADS Uptime also allows users to store recorded information and access information over the encoder’s lifetime. Detailed data and parameters on things like scanning quality, time in motion, temperature, frequency and vibration are available for quick and easy access. The vibration parameter specifically has been enhanced to allow measurement in both the radial and axial directions providing further comprehensive analysis. Values are stored in the encoder and easily accessible in a variety of ways.

For more information, visit www.leinelinde.com.

Dunkermotoren BG series motors now compatible with Siemens SIMATIC MICRO-DRIVE servo drive system

May 7, 2019 By Miles Budimir Leave a Comment

As part of a product partnership with Siemens, Dunkermotoren BG series motors are now also available in specific versions compatible with the new Siemens SIMATIC MICRO-DRIVE servo drive system. The series BG 45, BG 65(S), BG 75 and BG 95 are 24 to 48 V brushless dc motors with power ranges from 20 to 1,000 W.

The simple integration of the SIMATIC MICRO-DRIVE servo drive system into the SIMATIC world significantly shortens engineering time. The integration into Siemens automation technology is possible via the TIA portal and simplifies commissioning and service. Communication is via PROFINET IRT with PROFIsafe and PROFIdrive profiles. The new Safety Integrated Function SLT (Safely Limited Torque) ensures a limited torque by monitoring the motor current during operation.

Smart components in the motor, together with a patented data transmission system, set the controller to a preset state after it is connected to the motor. It eliminates cumbersome drive tuning and parameterization of the controller control loops.

A modular system allows the motors to be individually adapted and matching planetary and right-angle gears and brakes complete the comprehensive portfolio.

For more information, visit www.dunkermotoren.com.

EtherCat compatible piezo motion controller for nano-scale automation and precision positioning

May 2, 2019 By Miles Budimir Leave a Comment

PI (Physik Instrumente) now offers a new EtherCat compatible version of its E-727 digital piezo controller family. The piezo controller can be easily integrated into complex automation environment systems and operated as an “intelligent driver” for two- or three-axis piezo-based nanopositioning systems. PI also offers ACS based EtherCat motion controllers for long travel precision positioning stages such as used in laser machining and gantry systems for 3D printing.

Piezo controllers with digital servos provide advantages over traditional analog piezo controllers, such as higher bandwidth, linearity, and easy optimization of the servo parameters by software. The E-727 also provides two notch filters that help suppress mechanical resonances in high-speed operation of piezo-mechanisms yielding higher bandwidth. A sensor sampling frequency of 100 kHz and servo update rate of 20 kHz boost performance while minimizing noise. Intelligent servo algorithms minimize the settling times and allow repeatability into the subnanometer range.

Other advanced features of the digital piezo controller include 4th-order polynomial linearization for the piezo mechanics and control electronics, an integrated data recorder, an ID chip for fast and quick exchange of the system components, as well as subordinate, programmable drift compensation. There’s also an option of dynamic digital linearization. This DDL function lowers phase shift and trajectory errors to an indiscernible level in the case of dynamic-periodic applications. This is important for scanning applications that have to identify a particular position and reach it again accurately.

Like all PI motion controllers, the E-727 comes with extensive software support such as LabVIEW drivers and dynamic libraries for Windows and Linux. The E-727 can also be operated via TCP/IP or USB even without an EtherCAT master and commanded with PI GCS codes. Additional interfaces are SPI for fast serial transmission of position values to/from an SPI master, 4 digital I/O (each) and 4 optional high-resolution analog I/O (20 bits) for external sensors, target values or external amplifiers.

For more information, visit www.pi-usa.us/enc.

New brushless motor with integral drive from Allied Motion

May 2, 2019 By Miles Budimir Leave a Comment

Allied Motion Technologies’ new EnduraMax 75i Series is a 75-mm diameter brushless dc motor with an all-digital integrated drive. The EnduraMax 75i is capable of controlling torque, speed, and position in a wide range of commercial and industrial applications including: AGV vehicle traction or steering, medical patient-handling equipment, rotary/linear actuators, pumps, mobile HVAC blowers, and material handling systems. Compared to brush dc motors, the cost-effective EnduraMax 75i features quieter operation and longer life without the need for brush maintenance, making it suitable for equipment modernizations and new designs.

The EnduraMax 75i offers three standard stack lengths with continuous rated power up to 370 W, continuous rated torque up to 1.3 Nm (190 oz-in.), and rated speed of up to 5,150 rpm. The 12, 24, or 48 Vdc winding voltage choices make the EM75i suitable for battery-powered applications. Command inputs may be: ±10 Vdc, 4 – 20 mA, or via an optional CANopen or Modbus port. Customized winding designs and voltages, shaft, and mounting options are available to meet custom application requirements.

Options include:

Integration with Allied Motion gearboxes
Stainless steel shaft
9- or 10-mm diameter shaft
Pre-made connectorized cables
Integral holding brake
Sealed ball bearings
IP67 protection level

For more information, visit www.alliedmotion.com.

Beckhoff Automation offers OPC UA integration in TwinCAT Scope software

April 30, 2019 By Miles Budimir Leave a Comment

Beckhoff Automation announces greater integration of OPC UA communication technology into TwinCAT Scope software. In the context of Industry 4.0 and big data applications, machine data acquisition via OPC UA and analytics tools are becoming increasingly important. The information must be presented in clearly and efficiently, and the machine control system also has to cover a wide range of other smart components. TwinCAT Scope software provides optimum support for integrated data acquisition across heterogeneous system environments. A standardized OPC UA communication channel enables this charting tool to analyze data from diverse sources such as TwinCAT controllers and third-party components.

TwinCAT 3 Scope consists of Scope View for the graphical display of signal curves and Scope Server for the actual data logging. The Scope Server can be installed on a target device for autonomous logging (without the View component if desired) or on the corresponding engineering system together with Scope View for remote logging. The latter solution offers the advantage that no additional software has to be installed on the target device. As a result, no updates to TwinCAT controllers are required, and devices without TwinCAT software do not require modification to display their data graphically in Scope View.

For logging measured signals, the Scope Server now not only features a TwinCAT-specific ADS channel, but it also offers support for another standardized communication channel in the form of an OPC UA client. The widespread use of OPC UA in automation technology enables TwinCAT Scope to acquire and display measured data in a vendor-independent way. OPC UA achieves this reliably and securely, especially if certificates are used.

The TwinCAT Target Browser, which is used to manage connected data sources in TwinCAT Engineering, has also been expanded with OPC UA support. It enables browsing in the namespaces of connected OPC UA servers. This feature can be used to select the desired variables for logging by the Scope Server with configuration options for certificate-protected access.

A TwinCAT 3 Engineering installation always includes a Scope View tool and a local Scope Server. Both software components are included free of charge in the basic version, which enables testing of the OPC UA communication. With a rich set of features including multi-core support, triggers, chart synchronization and numerous zoom functions, the tried and tested charting tool is now perfectly suited for an even larger group of users and even more diverse application scenarios with these newest communication enhancements.

For more information, visit www.beckhoffautomation.com.