StandAlone Controllers - Motion Control Tips

New Omron NX-Series safety network controller supports two industrial safety networks

September 11, 2018 By Miles Budimir Leave a Comment

Omron Automation Americas recently developed a new safety controller featuring both CIP Safety and Safety over EtherCAT. The CIP Safety networking protocol has gained popularity among industrial robot manufacturers thanks to its ability to enhance flexibility and facilitate advancements in the industrial internet of things (IIoT). This protocol is now supported by a new version of the NX-series safety controller from Omron Automation Americas.

This addition means that the new controller is the world’s first to support two industrial safety networks – CIP Safety and Safety over EtherCAT (FSoE), a protocol favored for its high-speed response. The controller is optimized to support applications in industries like automotive manufacturing and food factories where a wide variety of products are produced and production lines are frequently modified.

As the largest safety networking protocol, CIP Safety enables communication between nodes such as PLCs, I/O blocks, light curtains and interlock switches. Unique among safety network protocols, it was developed to be network- and media-independent as a fundamental part of its design philosophy. It enhances flexibility by allowing safety and standard control devices to reside on a single network, thereby eliminating the need for purpose-built safety networks.

Flexibility is extremely important as production becomes more globalized and high-mix production becomes the norm. The main challenge of flexible manufacturing is its high level of complexity. The new version of NX safety network controller helps manufacturers introduce flexibility into their production lines while keeping design effort and maintenance time to a minimum. It enables quick and easy safety program design and improves the efficiency of safety management and maintenance.

The new controller is also scalable from large automotive production lines to small parts production lines. With both CIP Safety and Safety over EtherCAT, Omron’s latest solution addresses 40% of the global market’s requirements for safety networking.

In addition to the new hardware, enhancements have been made to the programming and configuration software. Sysmac Studio now offers functions such as automatic programming, safety data logging, online functional test and third-party CIP Safety device connectivity that include industrial robots.

For more information, visit www.omron247.com.

Compact positioning controllers from maxon communicate via EtherCAT

August 28, 2018 By Miles Budimir Leave a Comment

The EPOS4 Compact positioning controllers from maxon can now be incorporated into EtherCAT networks, thereby creating new opportunities for a large range of applications. The new EtherCAT models comply with the CoE standard (CAN application layer over EtherCAT) and can be easily integrated into existing EtherCAT networks.

The new, intelligent motion controllers with real-time communication offer a simple, plug-and-play solution for controlling brushed DC and brushless EC motors (BLDC) with peak currents of up to 30 A. With their modular design, they’re particularly suited to applications with single or multi-axis systems in small devices and machines, as well as robotics.

There are also an extensive range of accessories to make the connection and integration process as easy as possible. Besides the intuitive “EPOS Studio” software, Windows DLL and Linux Shared Objects Libraries are also freely available for incorporating the controllers into a variety of master systems.

The versatile EtherCAT controllers are available immediately in two power versions: 50-V/8-A and 50-V/15-A. Other variants in the Compact series (EPOS4 Compact 24/1.5 EtherCAT & EPOS4 Compact 50/5 EtherCAT) will follow by the end of 2018.

More information about EPOS controllers, visit epos.maxonmotor.com.

Elmo Motion Control at IMTS: Making smart machines smarter

July 10, 2018 By Lisa Eitel Leave a Comment

At IMTS 2018, Elmo Motion Control will showcase its new Double Gold Twitter ultra-small servo drive and its Platinum Maestro motion controller, which controls up to 256 axes. These motion products suit the most demanding applications in the era of Industry 4.0.

The new Double Gold Twitter is among the smallest STO-certified (IEC 61800-5-2, SIL-3) servo drives on the market. It delivers to 10,000 W and weighs only 1.2 oz — with continuous currents of 160 A (80 V) and 140 A (100 V).

Platinum Maestro motion controller

This miniature drive can mounts on moving loads, on motors, or inside motors to help engineers save space, improve machine performance, reduce cabling, and eliminate electrical cabinets, all while delivering unprecedented power.

Visit Elmo Motion Control at IMTS 2018 (IAMD) in Chicago at Booth #134142 to see these and other innovative motion solutions and capabilities for efficient and cost-effective smart machines.

Also — learn how smart drives and controls can help improve machine performance while enabling manufactures to achieve more for less at an Elmo Motion Control presentation.

The Paradox of Smart Manufacturing — which won the 2018 first prize SPS Roberto Maietti Award (recognizing thought-leading abstracts) will be presented in a session — Challenges of automation: Efficiency and flexibility. Join Elmo product & sales enablement manager Tomer Goldenberg for this live presentation on Tuesday, September 11, 2018 at 3:15 pm (W196-A).

Also be sure to visit www.elmomc.com.

maxon motor’s EPOS programmable smart drive-controller simplifies positioning setup

July 9, 2018 By Lisa Eitel Leave a Comment

EPOS is a modular, digital positioning controller by maxon motor. It is suitable for controlling permanent magnet-activated motors with encoders in a range of 1 to 1,050 W continuous output power. The wide range of operating modes (as well as various command interfaces) make it versatile for use in many different drive systems in the fields of automation technology and mechatronics.

With the EPOS4 Compact 50/8 EtherCAT and EPOS4 Compact 50/15 EtherCAT, maxon launches the first compact devices compatible with the fast industrial Ethernet connection EtherCAT.

Click to enlarge.

The fully integrated, plug-and-play positioning controller in a compact design is perfectly suited for use in networks with cycle times up to 1 msec.

Powerhouse with excellent position-control characteristics

The functionality, operation, software, and accessories of the new controllers are derived directly from existing products in the EPOS4 range.

The devices are suitable for use with both brushed DC and brushless EC motors (BLDC) and come with comprehensive feedback options such as Hall sensors, as well as incremental and SSI absolute encoders. State-of-the art concepts such as FOC, feed forward, and observer control allow optimal control in a wide variety of applications.

Comprehensive motion-control scope and operation

The existing digital and analog inputs and outputs are freely configurable and ideally matched to the numerous functions and operating modes of CiA-402 positioning controllers. Products are set up using the EPOS Studio graphical user interface (Version 3.4 and higher) for Windows PCs. In addition to the intuitive commissioning software, Windows DLL and Linux Shared Objects libraries are freely available to make integration into a wide variety of master systems as easy as possible.

Additional information on the EPOS Positioning Controller can be found at this deep link on the maxon motor site on the EPOS.

High-performance sensorless control from maxon motor

July 5, 2018 By Lisa Eitel Leave a Comment

Now, a new control option from maxon motor has compact wiring and slim design. Called the HPSC, this sensorless speed and torque control allows field-oriented control (FOC) of brushless motors. Such control is without sensors from full stop to full speed under load.

This HPSC uses a sophisticated signal-injection algorithm which precisely determines the rotor position for a smooth startup each and every time. The motor control’s key benefits include:

• Low noise and no vibrations

• Maximum power efficiency

• Robust and reliable

This system contains an HPSC module 24/5 … and the dimension and power range can be adapted if required. The firmware of the module may be customized for every drive system.

The HPSC is a custom-made solution that’s suitable for surgical systems, fluid-delivery systems, rehabilitation, and prosthetics. Contact maxon for more information at info@maxonmotorusa.com.

New compact EPOS programmable smart drive/controller from maxon with EtherCAT

June 27, 2018 By Miles Budimir Leave a Comment

With the EPOS4 Compact 50/8 EtherCAT and EPOS4 Compact 50/15 EtherCAT, maxon launches the first compact devices compatible with the fast industrial Ethernet connection EtherCAT. The fully integrated, plug-and-play positioning controller in a compact design is perfectly suited for use in networks with cycle times up to 1 msec.

EPOS is a modular, digital positioning controller from maxon motor suitable for controlling permanent magnet-activated motors with encoders in a range of 1 to 1050 W continuous output power. The wide range of operating modes, as well as various command interfaces, make it versatile for use in many different drive systems in the fields of automation technology and mechatronics.

The functionality, operation, software, and accessories of the new controllers are derived directly from existing products in the EPOS4 range. The devices are suitable for use with both brushed DC and brushless EC motors (BLDC) and come with comprehensive feedback options such as Hall sensors, as well as incremental and SSI absolute encoders. State-of-the art concepts such as FOC, feed forward, and observer control allow optimal control in a wide variety of applications.

For more information on the EPOS Positioning Controller, visit https://www.maxonmotor.com/maxon/view/content/epos-detailsite.

www.maxonmotor.com

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.

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

New autoclavable BLDC motor controller from Portescap

March 5, 2018 By Lisa Eitel Leave a Comment

Portescap now sells an autoclavable Brushless DC motor controller — the CNT1530 — for driving large bone orthopedic handpiece motors. The controller leverages Portescap’s market leading autoclavable design capability and surgical application expertise to provide a reliable, customizable setup to the orthopedic market. This new controller will help improve surgical hand tool’s performance and reliability, and take application to market sooner.

The CNT1530 controller uses on-board hall effect sensors; the magnetic actuation of speed and direction provided by this design delivers exceptional reliability due to a lack of mechanical components. In addition, the electronic components are encapsulated in a silicone potting material within an aluminum housing, which provides protection of the circuit board from the harsh environments of sterilization washers and autoclaves. The controller is compatible with a range of input voltages allowing for use with multiple battery types. A small form factor enables designers to house the controller within a tool’s pistol grip to create exceptionally ergonomic designs.

The new BLDC controller is compatible with Portescap’s Large Bone Orthopedic motors. Customization is available for partners needing tailored setups.

Portescap offers the broadest miniature and specialty motor products in the industry, encompassing coreless brush DC, brushless DC, stepper can stack, gearheads, digital linear actuators, and disc magnet technologies. Portescap products have been serving diverse motion control needs in wide spectrum of medical and industrial applications – medical, life science, instrumentation, automation, aerospace and commercial applications, for more than 70 years.

Unboxing video: Nippon Pulse Motion Checker controllers for two-phase stepper motors

January 22, 2018 By Lisa Eitel Leave a Comment

In a recent video, my colleague Miles Budimir and I got the chance to program and play with an MCH-5 motion checker controller from Nippon Pulse America. These come in versions for both unipolar and bipolar stepper motors, and we got a sample of one for bipolar. The controllers provide pulse-direction output signals — so the MCH-5 can also work as a standalone controller for any external stepper motor-driver board.

They’re available with input ports for external signals — including end limit and home-origin switches and external starts and stops. Plus they include nonvolatile memory that can save up to six different motion profiles. In fact, Nippon Pulse shipped the MCH-5 to us with this 25-gram PFCU-20 tin-can stepper motor. These motors are also called can-stack, claw-tooth, or claw-pole motors … which we cover in more depth here and here.

Click to enlarge.

We connected the four wires for little stepper motor to the MCH-5 through the gang of terminals labeled motor. Then we programmed the controller’s standard mode as well as six routines by following a simple flowchart from Nippon Pulse. Users can use the MCH-5 to set the number of program repetitions, motor-shaft output direction, moving pulses for positioning, optional sensor input, low and high speeds, and acceleration and deceleration times between low and high speed. Other functions are a zero-return operation and jog and homing settings via the controller’s ORG switch.

Just for the sake of illustration and where it made sense, I arbitrarily filled all the user-selectable values for Pr1 with 9s for the leading digits; and Pr2 with 8s; and Pr3 with 7s; and Pr6, 5, and 4 with 6s for leading digits.

We also set the controller to drive the motor with full stepping (and not half stepping, which is another option). The controller has non-volatile memory and stores program settings even when unplugged.

Click to enlarge.

A key takeaway point on this little controller is that is has robust capabilities, especially for its compact size — and this little unit requires no connection to a CPU. The MCH-5 can also be programmed for burn-in testing to run stepper motors for extended periods (for detection of design problems before end products ship) … or the motor controller can be used to go back and forth indefinitely on product testing. For more information on tin-can stepper motors in general or the MCH-5 controller, visit the page detailing the MCH-5 at nipponpulse.com.