Controls - Motion Control Tips

How an IDE reduces development time in PACs

May 10, 2018 by Danielle Collins Leave a Comment

Applications that require complex process or motion control also require elaborate and complicated programming — often across multiple components, functions, and parameters. But thanks to the integrated develop environment found in programmable automation controllers (PACs), the programming task for these complex applications is faster, less burdensome, and more reliable.

The Parker Automation Manager (PAM) software is an integrated development environment that allows users to program robotics applications in a user-friendly, graphical environment.
Image credit: Parker Hannifin Corporation

When ARC Advisory Group introduced the term “programmable automation controller,” they specified five characteristics that signify a PAC, including that it:

Employs a single development platform using common tagging and a single database for development tasks across a range of disciplines. The same software is used for all development; this IDE (integrated development environment) reduces development time.

Note that ARC’s definition specifically states that the purpose of the integrated development environment (IDE) in a PAC is to reduce development time. One of ways it does this is by managing all the tasks related to programming, including editing, compiling, and debugging. And because all programming is done in one software package — rather than requiring multiple software packages from different vendors — the IDE makes programming less tedious and easier to scale.

Also key to a PAC’s ability to simplify and reduce programming time are the two specific features of the IDE mentioned in ARC’s characteristics — common tagging and a single database. Common tagging means that each variable, or tag, the programmer defines (name and definition) can be used in every software application, whether it’s for control, human-machine interface, vision, or plant-wide ERP systems. And if a tag is changed at a later time, it’s easy to propagate the change throughout the system.

This common tagging is enabled by the use of a single database. In other words, the tag definitions are kept in one database that is available to all the applications in the IDE. This means that programmers don’t have to define and synchronize tags across different applications.

The integrated development environment that underpins PAC software simplifies programming for all the applications related to the control system.
Image credit: Opto 22

Integrated development environments aren’t exclusive to programmable automation controllers. While the idea of an IDE goes back to TurboPascal in the early 1980’s, Microsoft’s Visual Basic, launched in the early 1990’s, is commonly recognized among programmers as the first IDE. (Note that Wikipedia identifies Maestro I, from Softlab Munich, as the first IDE, but does not specify the characteristics that made it recognizable as such.)

Probably the most recognized benefit of IDEs during their initial development and adoption was their ability to write, modify, compile, and debug code within a single program, simplifying the iterative process of writing, testing, debugging, and re-testing that programmers were accustomed to.

Beckhoff Automation expands Ultra-Compact Industrial PC Series

May 3, 2018 by Miles Budimir Leave a Comment

In order to improve coverage for all tasks in the fields of automation, visualization and communication, the C60xx series of ultra-compact Beckhoff Industrial PCs has been expanded with the addition of the new C6017. This latest addition to the Beckhoff Industrial PC (IPC) portfolio combines compact design and installation flexibility with an increased variety of interfaces and an integrated UPS.

With miniaturized dimensions, the C6017 is almost identical in design to the popular C6015, currently the smallest ultra-compact IPC from Beckhoff. The success of the C6015 quickly created additional demand, especially from applications that have increased requirements for connectivity and data security in the event of potential power supply failures. The C6017 was developed precisely for these requirements: the existing C6015 configuration with DisplayPort connection, onboard dual Ethernet adapter with two 100/1000Base-T connections and USB 3.0 and USB 2.0 ports, is being extended on the C6017 by adding two RJ45 and two USB 2.0 interfaces. Moreover, an optional capacitive 1-second UPS is integrated, ensuring reliable storage of persistent data in the event of a power supply failure.

With dimensions of 82 x 82 x 66 mm, the size of the C6017 is similar to the C6015. Only the overall width is extended by a mere 24 mm. Equipped with an Intel Atom CPU with up to four processor cores, the passively cooled IPC also features a robust aluminum and die-cast zinc housing. This means the C6017 is ideal for automation, visualization and communication tasks up to the mid-performance range.

The new ultra-compact IPC series from Beckhoff meets today’s demanding requirements in machine building, such as increased modularization, reduced space requirements in control cabinets, higher processing power and competitive pricing. Designed precisely with these requirements in mind, the new device generation is well-suited for a broad range of applications, for instance in distributed topologies and advanced IoT or Industrie 4.0 applications.

For more information, visit www.beckhoffautomation.com.

What type of graphical user interface do PC-based controllers use?

April 27, 2018 by Miles Budimir Leave a Comment

Controllers that are PC-based are typically programmed via a Windows computer and used to communicate with, monitor, and control industrial machines and equipment. As the name implies, being PC-based means that the PC monitor is the main graphical user interface (GUI).

One advantage of PC-based controllers is their GUI. PC-based controllers are programmed via a PC that, using a monitor, is a better GUI than what a typical PLC or standalone controller offers. Usually these latter controllers have either an LCD display combined with a small keypad or maybe a touchscreen display, which can make viewing data as well as programming the controller difficult.

PC-based controllers, such as those pictured here from Beckhoff, come in a range of forms with different GUI options. For instance, controllers can be mounted inside control cabinets or embedded within machines, or are available as panel PCs with large monitors for easy access and programmability. (Image via Beckhoff)

Another advantage of PC-based controllers is that the PC platform is familiar and so there is less of a learning curve for commissioning and programming and setup. A big reason why it’s so familiar is the PC GUI which makes it much easier to program and work with the system than other types of controllers that may have GUIs that are not as intuitive or user friendly. PC-based controllers are also easily scalable for expanding and changing motion control requirements.

A common type of PC-based controller is the industrial PC. They run on processors like other PCs but are built with more rugged components designed to withstand the harsh conditions of industrial environments. These conditions can include shock and vibration, noise and dust, as well as exposure to harsh chemicals and extreme variations in temperature and humidity.

New controllers simplify machines, improve safety performance

April 23, 2018 by Paul Heney Leave a Comment

Engineers can simplify their machine safety systems and improve safety performance using new controllers from Rockwell Automation.

The Allen-Bradley GuardLogix 5580 and Compact GuardLogix 5380 controllers can be scaled from safety system levels SIL 2/PLd to SIL 3/PLe. This scalability can help engineers optimize a safety system design and potentially reduce its costs, while adhering to the latest machine safety regulations. The high-performance controllers also use increased processing power to achieve faster reaction times and shorter safe distances. This can help create smaller machines, save valuable floor space and increase operator efficiencies.

“Many engineers build safety systems to a higher safety level than an application requires,” said Dave Sullivan, product manager, safety systems, Rockwell Automation. “Such systems end up having more components than they need, leading to increased complexity and costing more than they should. Our new controllers allow engineers to right-size a safety system and its cost to meet appropriate safety levels, without excess.”

The new high-performing controllers can also help engineers consolidate the number of controllers they use in complex machines. Having a single high-performance controller for both standard and safety control can help improve productivity and reduce the system’s cost, complexity and cabinet size.

Other benefits of the new controllers include:

Greater Communications Capacity: Embedded gigabit Ethernet on the GuardLogix 5580 and Compact GuardLogix 5380 controllers provides greater communications capacity to support the growing number of smart devices. This can help engineers meet data-intensive smart-manufacturing goals without adding extra hardware. It also can help future proof machines for end users that may someday need to collect and share more data.

More Productive Machines: The controllers, when used with the Studio 5000 integrated development environment and Kinetix 5700 servo drive, support new safe-stop, safe-speed, safe-position and other safe-monitoring functions. These safety functions can create more flexibility in safety system operations, for example, slowing down a machine instead of stopping it when a worker approaches. This can improve machine productivity while still achieving a desired level of safety. These new functions are implemented using built-in safety instructions available in the Studio 5000 software.

Engineers can also use the safety functions to support applications like collaborative robots. If a human comes too close to the robot, the system can detect their presence and either slow down or stop the robot’s motion.

The GuardLogix 5580 and Compact GuardLogix 5380 controllers are TÜV certified for functional safety.

Rockwell Automation Inc.
www.rockwellautomation.com

When to use a programmable automation controller (PAC)

April 12, 2018 by Danielle Collins Leave a Comment

In a broad sense, a programmable automation controller (PAC) is an industrial controller that combines the functionality of a PLC with the processing capability of a PC. The term “Programmable Automation Controller” is generally accepted as having been coined by the ARC Advisory Group, which specified five characteristics that define a PAC:

Multi-domain functionality
A single, multi-discipline development platform
Flexible software tools that maximize process flow across machines or processes
An open, modular architecture
Compatibility with enterprise networks

PACs can operate in multiple domains simultaneously – such as motion control, process control, sequential control, logic, data management, and communication – using a single platform.
Image credit: Opto 22

But with no industry-standard definition of a PAC, the distinction between PACs and PLCs is blurry. Higher-end PLCs now incorporate some of the characteristics described above and are encroaching on what was once considered PAC territory. In fact, many PLCs now include standard programming languages, the ability to expand functionality through add-on modules, and connectivity to various bus systems.

However, PACs still differentiate themselves from PLCs by employing a more open architecture and modular design. They’re also more capable than PLCs at monitoring and controlling a large number of I/O, such as in a large processing plant or a complex automation system. They do this because data can be exchanged between devices and applications in different domains, such as motion and process control. And, a programmable automation controller can send and receive data to and from other PACs, creating a distributed control system of PACs. With large memory capacity, the ability to handle complex or high-speed analog I/O, and high-speed communication capabilities, PACs are well-suited for vision applications, including vision-guided motion.

PACs are often used in Cartesian, SCARA, and 6-axis robot applications, which require coordinated motion across multiple axes as well as integration with other motion and data systems.
Image credit: NEXCOM International Co., Ltd.

The ability of PACs to gather, store, and track large amounts of data means they can handle predictive maintenance and operations monitoring. Data is often stored and accesses through an Ethernet network or a USB storage device.

PACs use the IEC 61131-3 programming languages (ladder diagram, function block diagram, sequential function chart, instruction list, or structured text), and some include standard PC programming languages such as C/C++, so familiarity is retained and the learning curve for programming is low, regardless of prior experience or expertise.

Programming is done in an integrated development environment (IDE) that uses a single, tag-name database. This means that all the defined variables (tags) are kept in one database, which is used by all the software applications — such as HMIs, ERP systems, and vision applications. This greatly simplifies and reduces programming work and makes it easier to scale to larger systems.

In a nutshell, PACs are best suited for applications that require complex controls — in automation, this often means multi-axis, coordinated motion or circular interpolation — while PLCs work well for simple applications such as single-axis motion control.

AeroDef Booth #1053: Physik Instrumente (PI) motion simulation for image stabilization and rover-proven actuators

March 27, 2018 by Lisa Eitel Leave a Comment

PI (Physik Instrumente) is showing an application of its six-axis hexapod for motion simulation such as used to optimize stabilization systems on vessels, drones and even for cell phone cameras. PI hexapods come in a variety of sizes with bases ranging from 100 mm to 1m, different stiffness configurations, and supportive of loads from 2 kg to 1,000+ kg.

In addition to hexapods, PI will also show a variety of its world leading piezo ceramic actuators and transducers, such as the PICMA Multilayer actuators and the DuraAct flexible transducers.

Long-life temperature tolerant actuators: PI’s PICMA piezo actuators were tested by NASA/JPL for the Mars mission and passed 100 billion cycles of life testing without failures. They also work over a large temperature range and are vacuum compatible.

Piezoceramic flexibility and adaptability: A very versatile thin lightweight device, PI’s piezoelectric patch transducers reach a bending radius of 20 mm (0.8 in.) which allows it to be attached to moving structures where it gets deformed and generates charge transfers. Such adaptive technology and size allows bendable transducers to be used as both a sensor and an actuator in applications ranging from structural health monitoring to adaptive structures on aircraft.

PI has in-house engineered setups with over 4 decades of experience working with customers to provide products that meet application demands and can quickly modify existing product designs or provide a fully customized OEM part to fit the exact requirements of the application. For more information, visit www.pi-usa.us.

Motion Trends: Integration, software tools top controller trends

March 23, 2018 by Miles Budimir Leave a Comment

As machines become more complex, designers are looking for more integrated solutions to simplify overall machine design. So engineers are becoming more savvy about their automation choices, and are seeking solutions that offer better precision and performance all in one package.

And controls manufacturers have heard the message. For instance, Lenze just recently introduced a new safety controller, the c250–S. With the safety controller Lenze brings the whole safety solution into the machine. In combination with the Lenze controller family, the safety controller completes the total solution by adding required safety functions like the safe bus coupler and safe I/O.

The controller follows Lenze’s easy toolchain approach where the safety controller is part of the engineering toolchain for the whole Lenze system. The safety controller is integrated in the PLC Designer, the Lenze engineering tool for PLC programming, and requires no additional software. This makes it easy for machine builders to program the safety functions together with the whole machine application.

Other manufacturers are integrating components and functions while also shrinking their product footprints, another ongoing trend. AMK has developed MultiServo, four axes of motor control and an integrated motion control in the space (and cost) of two drives. With MultiServo, machine builders can make the control of servo axes even more multifunctional, precise, and cost-effective and up to 60 % more compact. The single module is only 130 mm wide, 320 mm high and 230 mm deep.

AMK’s MultiServo line combines four axes of servo motion control into the space of two drives, integrating industrial production and the latest communication technology for IoT/Industry 4.0.

The MultiServo module also has application in robots. Specifically, it is an IP20-based drive bank that has a robotic/motion controller integrated inside. It can control four servo axes configured to match the mechanical system being controlled. The compact design allows a cascade of robots to fit into a single small cabinet. The integrated controller means the robots can be standardized quickly regardless of the mechanical system, providing robust control from any supervising system.

As the AMK MultiServo example shows, robots and other automated vehicles are a growing area for controllers. These automated vehicles are at the front lines of full-automated operation, and many come in the form of mobile robots.

“Omron offers a variety of mobile robots – or Autonomous Intelligent Vehicles (AIV), that are able to carry different functions to help customers in manufacturing as well as warehousing and distribution,” says Greg Dieck, Motion Product Manager at Omron. “For example, in hospitality, they are used to deliver incidentals to guests’ rooms; in food and beverage packaging, they are used to carry raw material inputs to various lines for integration into the final product; and in manufacturing, they are often used to carry sub components to the production line for final assembly. We’ve even seen them used to deliver mail to different departments in large companies.”

Omron’s NJ5 controller features OPC UA compatibility, the industrial communication protocol that enables data exchange between machines and from machine to IT systems, especially useful for IoT or Industry 4.0 applications. It also offers data security through encryption and authentication.

Dieck adds that these AIVs are also used in many different facets of warehousing and distribution. The AIVs can be easily called from different locations to pick up and transport products to different locations within a warehouse.

Software developments also play a big role in controller developments. For instance, Omron has been adding software-based capabilities to its controllers that mean an array of applications can be serviced easily. Specifically, this affects the IIoT and the increasingly networked world of manufacturing.

“Omron launched IO-Link to help monitor and maintain the highest level of production integrity and accuracy,” adds Dieck. “Combined with Omron InduSoft, the company offers a predictive maintenance solution to prevent downtime or costly production stops before they occur.”

The LD robot from Omron is a self-mapping and self-navigating autonomous intelligent vehicle. The mobile robots are fully safety compliant and use an onboard laser and other sensors to detect obstacles in their path and, based on speed of travel, trigger an E-stop to prevent vehicle collision.

They’re also expanding into safe motion over EtherCAT, which will allow control and safety over one wire. Using the latest technologies, Omron offers advanced motion at a high safety level (SIL3), which helps designers with faster set-up time as well as better throughput, all while running in a safe mode.

Other software capabilities include the ability to use the company’s programming software to auto-tune and set-up servos. The software can also simulate the program performance and timing which allows users to calculate throughput on their machine while still in the designing stages and ensure that they are getting the best performance possible.

The company has also created their own sizing software, which lets them account for complex mechanical systems. Customers can export a file from the sizing software and use it to create hardware configurations in the company’s programming software.

Beckhoff touch panels with 10.1-in. widescreen displays

March 16, 2018 by Mike Santora Leave a Comment

Beckhoff Automation has announced the release of the CP6x00 Control Panels and Panel PCs with 10.1-in. widescreen displays. The expanded line of entry-level panels from Beckhoff, first launched with 7-in. displays, has been expanded by three new cabinet-mounted devices, each with a 10.1-in. widescreen display. PC-based control technology in the cost-sensitive, lower to middle performance range can now be scaled even more precisely in line with individual application requirements.

The new widescreen variants have a Thin Film Transistor (TFT) touch display with a resolution of 1024 x 600 WSVGA, which paves the way for comprehensive operator interface and visualization options. Added to this is superior display quality with 16.7 million available colors on the 10.1-inch diagonal screen. The latest additions to the entry-level class from Beckhoff include two fanless Panel PCs and a purely passive Control Panel. These devices permit the cost-effective implementation of control and visualization tasks for small and medium-sized machines, production systems and buildings.

The three new widescreen TFT touch Panel PCs from Beckhoff are:
˗ CP6600 Panel PC with 1 GHz ARM Cortex A8 CPU and 1 GB DDR3 RAM memory
˗ CP6700 Panel PC with Intel Atom processor (up to 1.91 GHz, four cores) and 2 GB DDR3L RAM (optionally extended up to 8 GB)
˗ CP6900 Control Panel with DVI/USB Extended technology for operation at a distance of up to 50 m from the Industrial PC or Embedded PC

Equipped with a robust metal housing consisting of an aluminum front bezel and a sheet steel rear cover, the panels offer higher quality and durability than the plastic panels typically offered in the low-cost, entry-level segment. In addition, the high-quality materials and a rounded front bezel lend a modern and appealing look to the panels, which can be used in the most diverse production and building environments at operating temperatures from 0 to 55 °C.

Beckhoff
www.beckhoff.com

IDEC introduces MicroSmart FC6A Plus PLC

March 13, 2018 by Mike Santora Leave a Comment

IDEC Corporation announces the release of its MicroSmart FC6A Plus, a PLC with up to 2,060 local I/O. With its expanded I/O capacity, the FC6A Plus can control and monitor the largest machines or entire small-scale manufacturing facilities, a capability seldom found in a micro PLC.

To ensure high-level performance with this expanded I/O count, basic instructions can be executed in 21 nanoseconds, and program memory is 800 kB (100K steps). These capabilities are combined with data memory, more than double the capacity of a typical micro PLC. These features allow the FC6A Plus to handle large programs with complex control requirements such as PID, flow totalization and recipes.

Two models are available, each with 24 Vdc input power. The 16 I/O model has 8 inputs, and 8 relay or transistor outputs. The 32 I/O model has 16 inputs, and 16 transistor outputs. Each model also includes an integral 0-10 Vdc analog input with 12-bit resolution. Each model can accommodate up to three plug-in discrete, analog, serial communication or Bluetooth cartridges. Each discrete cartridge has 4 discrete I/O points, either 4 inputs or 4 outputs. Each analog cartridge has 2 analog I/O points, either 2 inputs or 2 outputs.

Up to 63 I/O expansion modules can be added. This gives the FC6A Plus the capability to handle up to 2,060 I/O with a maximum of 511 analog I/O, much more than a typical micro PLC.

The FC6A Plus also includes an optional Bluetooth wireless communication adapter, giving users the power to monitor the PLC and download/upload programs from any PC or laptop with Bluetooth capability. This eliminates the need to stock, locate and connect a cable to the PLC for these tasks, and provides access to the PLC from a distance up to 10 meters. In addition, any device with Bluetooth capability, such as a bar code reader, can also be configured to communicate with the PLC.

FTP communication allows users to configure the FC6A Plus as a FTP Client or Server for transfer of programs and logged data between a server and the PLC, providing a convenient and effective way to remotely communicate with the PLC. Up to 16 users can be managed simultaneously, and access folders can also be managed. Files can be stored at the PLC or logged to the PLC’s SD memory card for transfer to an FTP server.

All models have two built-in RJ45 Ethernet ports. Optional Plug-in communication cartridges can be added to create two additional RS232C/RS485 ports. With the addition of serial communication modules, up to 33 RS232C/RS485 serial ports are supported

The PLC’s Ethernet port supports the Modbus TCP protocol, and the serial port supports the Modbus RTU protocol. Support for the BACnet communication protocol will be available in mid-2018 to provide communications with building automation components and systems. An SD memory port and a mini-B USB port can each be used for data logging, program storage/transfer, firmware updating or recipe storage.

An optional HMI module can be added to the CPU to provide operator interface via its display and control buttons. The HMI module can also accommodate an optional plug-in analog cartridge, and it has an integral Ethernet port. Using the operator interface functionality, any PLC parameter can be updated.

App Access
The FC6A Plus is one of world’s first micro PLCs with full-featured app access from any iOS or Android smartphone or tablet. These WindEDIT Lite apps can be downloaded for free on the Apple App Store or Google Play. Although browser-based access is also included, many users will prefer the one-touch access and superior speed of the app.

With the WindEDIT Lite app, users can upload and download user programs; monitor and control any parameters in the PLC; monitor and clear PLC error status; start and stop the PLC; send and retrieve program and logged files to a cloud database; and manage the SD memory card. Access control can be configured with different layers of user privilege and password. Connection from a PLC to the WindEDIT Lite app can established using Wi-Fi (internet) or Bluetooth.

IoT Ready
IoT capability is provided by default web pages or by custom web pages, each of which can be configured for remote monitoring and control. Web pages are created within standard IE, Firefox or Chrome web browsers using pre-built objects and symbol factories via simple drag-and-drop functionality. No HTML programming is required, a major advantage over competing products.

Web pages are stored in the PLC’s user web page 5 MB of memory space, or in the optional SD card’s 32 GB of memory space. Using this storage capacity, users can create professional web pages with high levels of graphical content without worrying about memory limitations.

These web pages allow the PLC to function as a web server when one of its two built-in Ethernet ports or the HMI Ethernet port is connected to the Internet. These web pages can be accessed via any web browser running on any Internet-connected device such as a remote PC, a tablet or a smartphone.

Connecting the Ethernet port on the PLC, or on the optional HMI module, to the Internet also provides email and text notification functionality, which can be used with third-party email servers such as Gmail and Yahoo.

Upward Compatibility
The FC6A Plus is programmed with IDEC’s WindLDR PC-based software, which includes no cost updates for the life of the product, and which can be used to program IDEC’s entire line of controllers in a simple and intuitive manner. Software programs from IDEC FT1A, FC4A, FC5A and FC6A PLCs can be automatically converted by the WindLDR programming software for execution on the FC6A Plus.

PLC programming languages include Ladder, Function Block Diagram and Script, the latter similar to the C programming language. The Script language can be used to create more complex programs, particularly those with multiple sub-programs and custom function blocks.

Industries particularly well suited to the FC6A Plus include oil & gas, chemical, solar, marine, packaging, food & beverage, material handling, utility vehicles, and OEM machinery and process skids. Within these industries, a wide variety of applications are a good fit-especially those requiring control of standalone machines, process skids, vehicles and small-scale systems. With its expanded I/O capabilities, the FC6A Plus is also capable of controlling entire small-scale manufacturing and other industrial facilities.

IDEC
www.IDEC.com/usa

Innovations in connectivity from cables and connectors for motion designs

March 5, 2018 by Lisa Eitel Leave a Comment

Easy connections to sensors, field devices, and other automation solutions are becoming the norm in motion control — that’s according to Brian O’Connor, director of product and market development at Aerotech. In fact, increasing affordability of electronics (and subsequent rise of IIoT) have spurred all branches of industrial automation to more networking. But even basic machine designs have benefitted from new cable and connector options that impart simplicity.

Our recent survey of connectivity experts yielded details on these and other cable and connector designs for power and networking components. This cable panel included Rich Buchicchio and Howard Lind of Cicoil Corp. and Eric Rice of Applied Motion Products; and Horst Messerer, data, network, and bus technology sales manager at HELUKABEL; and Mark Kojak, V.P. of product management and business development in the Americas at Harting Inc.

Read on for what they had to say — and be sure to visit motioncontroltips.com/category/networking-iot as well as wireandcabletips.com for additional insight from other sources on IIoT trends and where Ethernet-based networking protocols are overtaking traditional fieldbuses.

Image courtesy HELUKABEL

Buchicchio • Cicoil: Components with electronic functionality are clearly gathering and using more data than ever. We support this market segment with lightweight designs that exhibit reliability without signal degradation. More specifically, we’ve seen significant demand for data cable — including twisted shielded-pair data cables; Cat 5e, Cat 6A, and 50 & 75 W Coax cable; and HDMI, FireWire, Camera Link, and IDC ribbon cable.

Cicoil 0.025-in. IDC cable is suitable for tight spaces that need high signal density. Its ultra-flexible jacket is resistant to flames and harsh environments; single and double-row connections are suitable for mass termination — with up to 64 conductors. The cable also withstands temperatures to 260° C.

Messerer • HELUKABEL: We’re seeing a trend towards more use hybrid cables (those that combine power with control and data) for one-cable setups. More design engineers than ever are requesting these cables for use in drag-chain and torsion applications.

Related from sister site wireandcabletips.com: Single-cable solutions simplify servomotor design

Buchicchio • Cicoil: We stock and sell a wide variety of standard flat cable for motion control, data and video, and power-plus-signal applications … But engineering custom cable and assemblies is at the heart of our company. We manufacture sophisticated assemblies and cable harnesses for demanding applications — including those for military and aerospace, medical devices and diagnostics, and semiconductor-equipment manufacturers. We also offer value-added overmolding, box builds, plug-and-play designs, and other engineering design services … and custom assemblies are fully tested before delivery.

But others are taking a different tack to separate connections on relatively small motion components — to let engineers choose proprietary connectors only if they work for the application at hand.

Rice • Applied Motion Products: We now offer a daisy-chain board connector for NEMA-11-frame StepSERVO Integrated Motors that separates communication terminals into two standalone power and I/O connectors — making it easier to establish daisy-chain connections on RS-485 and Modbus RTU networks.

Some Applied Motion Products NEMA-11-frame StepSERVO integrated motors (left) separate terminals. In contrast, standard configurations integrate them.

In contrast, standard configurations of Applied Motion’s TSM11 (NEMA-11-frame) motors incorporate a single 12-pin header that provides a power supply, input, output, and RS-485 communication terminals in a small integrated space … without sacrificing input and output connectivity to other devices, controllers, or HMIs on the machine.

In traditional servo designs, the servo motor and controller connect by two cables — one for power to the motor and one for the transmission of sensor or encoder data. Now HELUKABEL TOPSERV single-cable solutions include conductor for the transmission of signals and power.

Of course, the materials from which cable and connectors are made continue to have significant impact on overall design.

Buchicchio • Cicoil: Our products are suited to an array of emerging applications. All of our flat cables feature flexibility and durability; the rugged outer jackets withstand environments that are hot, cold, indoors, outdoors, on land or sea or in the air … or even space. Our cable is also compatible with sensitive environments (that are cleanroom rated) and where designs require kink-free cable.

Related from sister site wireandcabletips.com: What are flat cables?

Messerer • HELUKABEL: We sell molded M12 connectors in D and X-coded versions (male and female) for use with Category 5 and 6A cables (which cover higher data transmission rates to 10 GBit/sec). But materials are important here; the metal casing of both the connector and socket makes the assembly robust and resistant to dirt and moisture — even to IP67.

Lind • Cicoil: Thinner-jacketed (more flexible) versions of our data cables maintain EMI/RFI protection … and we’ve recently developed round Cat5e cable, HDMI cable, and Micro IDC cable with a 0.25-in. pitch. These feature ultra-fine wire stranding and Flexx-Sil jacketing for unsurpassed flexibility, durability, and usability in extremely harsh environments.

Related from sister site wireandcabletips.com: Cat5e shielded industrial Ethernet patch cords

Messerer • HELUKABEL: PVC insulation in standard and hybrid cables is being reduced and replaced with PE or PP-based compounds. The latter compounds make cables low smoke and halogen-free (LSZH) … plus necessitate a smaller cable diameter (and lighter weight) because of reduced wall thickness. This in turn is due to the fact that PE and PP have higher insulation resistance than PVC compounds.

PVC is cheaper, but isn’t low smoke or halogen-free … and has limited insulation resistance (which is why cables with PVC jackets necessitate thicker walls to get adequate voltage-resistance levels).

Buchicchio • Cicoil: We’ve formulated a silicone rubber polymer called Flexx-Sil that works as a flat-cable outer jacketing … Plus we use ultra-fine wire stranding in conductors. The combination of this conductor wire and supple Flexx-Sil jacketing (made with our extrusion process) produces a cable unsurpassed in flexibility — one that weighs less and consumes less physical space than conventional round cable with comparable electrical and signal performance.

In addition, Flexx-Sil cable jacketing is translucent and waterproof; UV and chemical resistant; and can withstand temperature extremes (operating from -65° to +260° C and remaining flexible even at -100° C); has the natural flexibility of silicone rubber (which is more than twice as flexible as PVC and PTFE insulation); and exhibits high material stability and low outgassing (with zero halogen). The cable jacketing is also durable with a durometer rating of 65 (Shore A) or a durometer rating of 85 (Shore A) in a SuperTuff version.

When asked about cable and connector options to impart simplicity or turnkey operation, our sources cited modular and universal systems.

Messerer • HELUKABEL: Our UL/CSA-approved pre-assembled data cables for Industrial Ethernet systems can include molded M12 and RJ45 industrial connectors, so engineers can modularly assemble any possible combination of cables and connectors to design product built exactly for their needs. Plus with high-speed data cables (with transmission rates to 10 GBit/sec) the molded M12 and RJ45 connectors guarantee a faster and more reliable connection within control cabinets, machinery and in-the-field operations.

Kojak • HARTING: Connectivity components must be compact, so we’ve expanded the Han-Modular product line with Smart Han modules that allow connection of active components. Using the same footprint as other Han-Modular modules, these let engineers create custom connectors using off-the-shelf modules that join in any combination to integrate power, control signals, and data into a single connection. This connector series revolutionized the industry when released in 1994 and remains our fastest-growing product line.

Messerer • HELUKABEL: We offer one RJ45 connector that has bandwidth to 500 MHz and supports data rates up to 10 GBit/sec … so it’s suitable for demanding industrial applications. The connector comes in a linear or angled version so works in industrial areas with limited space.

Lind • Cicoil: EZ-Flexx Flat Cable features a new external profile and inner jacket that makes it just as easy to strip and terminate with connectors as conventional round cable — even allowing use of automated stripping equipment. This lets OEMs and other commercial users to capitalize on the advantages and benefits of flat cable attributes and performance, without the labor overhead experienced with other types of flat cable.

Rice • Applied Motion Products: Designing very small integrated motors — motors with a NEMA 11 frame size, for example — means fitting as much functionality as possible into a tiny footprint. Because many users of our NEMA-11 motors had space for a slightly larger connector arrangement, we configured a new three-connector arrangement as an optional add-on component to three lengths the TSM11. (These integrated motors include TSM11Q-1RM-H01, TSM11Q-2RM-H01, and TSM11Q-3RM-H01.) Owners of existing single-connector modules also can upgrade their TSM11 integrated motors in the field by purchasing the daisy-chain connector board separately.

Lapp Group USA ÖLFLEX SERVO 7TCE oil-resistant servo cable with TC-ER approval works on industrial machines and in cable trays — and eliminates the need for two cable or conduit types. A thermoplastic elastomer (TPE) jacket and cross-linked XLPE insulation can withstand temperatures to 105° C.

In some cases, sizing software simplifies the specification process.

Lind • Cicoil: Our online Flat Cable Configurator provides fast and easy custom cable design on desktop and mobile devices. Point and click to add any of a wide variety of conductors (including pre-configured modules) for many standardized functions — such as USB 3.0, Cat 6a, and Camera Link. A click-and-drag function lets users position their selected conductors anywhere they choose on the cable. Then engineering drawings, custom part numbers, and cost per foot are delivered immediately to the engineer’s email inbox.

More cable and connectivity offerings are designed with miniaturization or compactness in mind.

Buchicchio • Cicoil:

Micro IDC ribbon cable with 0.025-in. pitch is compact — and it’s more flexible (and can tolerate higher voltages) than standard designs … so is especially suitable for use in confined areas.

Machine monitoring is an option with igus intelligent robot cable that warns users of impending failure. If certain parameters are exceeded during dynamic cable operation, a warning is triggered, indicating that the cable must be replaced. The cable concept is based on igus’ Chainflex cables — stranded and shielded to maximize life with an array of jacket materials.