Software - Motion Control Tips

Applied Motion Products debuts programming tools for Python language

March 19, 2019 By Miles Budimir Leave a Comment

Applied Motion Products now offers a set of free tools for programmers using Python, the popular computer programming language, to use with its stepper and servo motors to quickly and efficiently integrate motor control into their applications. These new tools, including an application note and sample code, guide Python programmers in sending high-level motion commands, using Applied Motion’s Serial Command Language (SCL), to one or more axes of stepper and/or servo motors. Step-by-step instructions and examples explain how to:

Establish communications between a Python application and the motion control axes
Send commands to one or more axes
Handle replies from the axes including acknowledgments and data requests

Simple and intuitive, the SCL commands are text-based, making them easy to read and understand. Programmers can stream SCL commands to one or more motor axes at a time, creating straightforward sequences of motion profiles on multiple axes. SCL provides commands for motion control including homing, absolute, relative and jog move types as well as input/output control, drive status, alarm status, and much more. SCL commands can be sent over Ethernet TCP or UDP, RS-485, and RS-232 connections.

Based on the popularity of the Python language, the new tools from Applied Motion Products can help users worldwide to incorporate step motors and servo motors into their projects using a simple, yet powerful command set specifically designed for motion control.

To download Applied Motion Python programming tools for its stepper and servo motors, visit https://www.applied-motion.com/news/2019/03/new-application-note-python-programmers.

For information on the company’s motors, visit https://www.applied-motion.com/products.

Application example: Motion components on a typical form-fill-seal machine

November 12, 2018 By Lisa Eitel Leave a Comment

Form-fill-seal machines are used to package edible powders, dry food, and liquids into bags and pouches. It’s a common machine design that comes in versions for both continuous and intermittent operation. No matter the design, top design objectives for form-fill-seal machines are high throughput with minimal downtime and the ability to reconfigure the machine to satisfy changing production requirements.

Mitsubishi Electric Automation Inc. offers an array of solutions in its Pak/iQ suite to improve the builds of such packaging equipment with reliable machine performance and communication of system analytics for IIoT functionality.

Consider the build shown in the illustration.

Bulk food product enter from the top as servo-driven axes pull bag material off roll stock (spools). The funnel hood shapes the plastic sheet into a cylinder. Then a thermal heat sealer melts together bag edges; bags are filled from above as the web travels downward. Vertical film index drives time this function to match the machine’s operation cycles. From there, the bags get their final cutting and sealing — and then go onward to conveyors that carry them away.

On this machine, a PLC (in the form of an iQ-F compact controller) provides necessary functions while helping OEMs keep cost down. Programming of the PLC is through simple parameter setting: iQ-Monozukuri Packaging software gives engineers sample programs, sample GOT HMI screens, and auto-generated function blocks — including those for rotary-cutter, camming, long-dwell, flying-shear, box-motion, and mark-detection tasks.

To command and drive the motion tasks, the machine build uses an FX5 Simple Motion controller, MR-JE Series servo amplifiers, and (on the conveyor) an FR-E700 Series VFD. Two of the MR-JE Series servos are for web-index control; one is for the sealer axis. The three servo-driven motor axes are networked through fiber-optic-based SSCNETIII/H. Servo-network refresh rates to 0.222 msec allow accurate control.

Capabilities of Mitsubishi-outfitted form-fill-seal machines include auto-generated function blocks for camming as well as advanced synchronization that’s easy to configure … for fully synchronous multi-axis performance. The hardware also allows for direct control of the VFD from the HMI.

Coordination of motion automation with robotics — with unifying software and hardware

October 5, 2018 By Lisa Eitel Leave a Comment

Automated installations feature more robots than ever. But unless it’s a custom or Cartesian setup, robot controls are traditionally segregated from those for automated motion axes. So connectivity between robot and system controller or PLC is via a network — usually based on Ethernet. Then a control system coordinates the machine functions of nearby conveyors or other workcell systems with those of the robot controller.

B&R has expanded its portfolio of modular mapp software components … so now, mapp RoboX and mapp Teach make it faster and easier than ever to get robotic systems configured and ready for operation. mapp RoboX controls any kinematic system with up to 15 axes. Developers get design freedom … yet the robot is simple to parameterize, with visualization and diagnostics already onboard. This saves time in development and during operation. For the next step there’s mapp Teach, which provides intuitive teach-in functionality to define and manage the robot’s movement sequences and quickly get it going. mapp technology consists of individually encapsulated blocks that streamline development of new applications. The components provide basic functionality with graphic configurability — cutting development times by an average of 67% … and all mapp components are connected via mapp links. Each mapp component retrieves the data it needs from other components using a client-server model.

Synchronization can be limited, and integration requires use of separate motion and robot programming — with the latter (if not code generated by teach modes and pendants) in proprietary software.

In contrast, some newer functionalities are helping engineers more tightly coordinate robot operations with motion systems — especially for common applications. These also simplify integration. Epson Robots T3 SCARAs integrate controllers in their bases that (in some versions) run conveyor-tracking software for simple setup of assembly and other automation. DENSO Robotics, Mitsubishi Electric, and Universal Robots also offer conveyor-tracking functions that leverage either sensor networks or machine vision.

Such synchronization is tight enough to allow for execution of pick-and-place, sorting, and other motion-to-robot automation tasks.

Integration of motion and robots (including SCARAs and parallel robots such as delta robots and hexapods) is also possible through unified or unifying software and hardware. That includes robot programming for converting to and from coordinate reference frames more commonly used by motion design engineers. Case in point: Galil motion controllers with an onboard Coordinate Transformation function execute code to control robots without the latencies of other options. Design engineers work with an application engineer to define reverse and forward transformations; then equations are written into the controller’s firmware for quick execution. Beckhoff TwinCAT Kinematic Transformation software also allows programming and reading robot moves in Cartesian coordinates.

Stay tuned to therobotreport.com for more on this topic and other open solutions.

Some controllers for automated installations can command coordinated motion axes while concurrently controlling a robot set to run off a remote host. Lenze Americas modules for controller-based automation incorporate delta robots essentially as motion axes. These unifying controllers and a single programming environment maximize cross-functionality between motion axes and robot.

In a similar way, an Adept Robot Control Library allows control of SCARA, parallel (hexapod) and articulated robots by Omron NJ/NX controls or NY-series Industrial PCs with common instructions and programming.

Consider still another example: Mitsubishi Electric Pak/iQ offerings for the packaging industry include integrated robotics and servo and PLC programming with one piece of software. Onboard analytics help operators avoid unplanned shutdowns; machine learning and continuous-tuning algorithms optimize servo performance. A typical setup might include a robot controlled via a MELSEC iQ Platform … with a Q series PLC and integrated robot controller on the same rack. Then communication between robot controller and PLC CPU is across that rack for top speed and throughput — and simplified robot-cell setup. Networking connects other components such as inverter drives and dedicated safety controllers.

Integrating robotics with other machinery allows top overall equipment effectiveness (OEE) by going beyond simple handoffs. The trend is towards complementary control, motion, robotics, and data management. Image courtesy Mitsubishi Electric

New functions in B&R SafeDESIGNER 3.1 include expanded numeric ranges for functions

October 5, 2018 By Lisa Eitel Leave a Comment

The latest version of B&R’s SafeDESIGNER tool now makes it possible to process and compare safe INT and DINT signals in addition to linking them mathematically using basic arithmetic operations. Safety-oriented function blocks are also available for converting INT and DINT values in either direction. This expansion now rounds off the full range of numeric functions for the Automation Studio 4 development and configuration tool.

Safety applications increasingly need numeric functions to manage values for pressure, temperature and speed. Since its introduction in 2008, SafeDESIGNER has provided support for safe INT data types and associated arithmetic operations and comparison functions. This range of functions has been continuously expanded ever since.

Monitoring synchronous operation with B&R software

Users of Smart Safe Reaction technology from B&R can now process safety-related speed and position values and use them to initiate safe machine states. These functions are suitable for cases where requirements go above and beyond the possibilities provided by prepackaged SafeMOTION functions. Possible scenarios include integrating additional safe rotary encoders in a safety application or monitoring several power transmission systems for synchronism. In process control applications, SafeDESIGNER has become a widely used tool perfectly suited for the safe processing of pressure, temperature and flow signals.

B&R is a privately owned company with headquarters in Austria and offices all around the world. As a global leader in industrial automation, B&R combines state-of-the-art technology with advanced engineering to provide customers in virtually every industry with complete solutions for machine and process automation, motion control, HMI and integrated safety technology. With industrial fieldbus communication standards like POWERLINK and openSAFETY as well as the powerful Automation Studio software development environment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations. For more information, visit www.br-automation.com.

New Add On Instructions for Allen Bradley software from Applied Motion Products

September 27, 2018 By Miles Budimir Leave a Comment

Applied Motion Products has released new Add On Instructions (AOI) for Rockwell Automation’s RSLogix 5000 software to better control industrial devices and motion control components over EtherNet/IP networks. The new Add On Instructions increase the capabilities of Applied Motion Products’ drives and integrated motors within the RSLogix 5000 environment, supporting a faster and easier integration into PLC projects.

Most of the new AOIs use implicit messaging, known as I/O messaging or polling, that simplify sending commands to the drive while making data received from the drive more PLC-friendly. The AOIs also reduce communications overhead to lighten the work required to integrate Applied Motion Products motors and drives into new and existing PLC programs.

Applied Motion offers twenty new AOIs that feature a range of commands and functionality including absolute, relative, jog, and homing moves; motor enable/disable; reading the drive and alarm status; and much more. The company specifically designed these free AOIs for motor and drive users to take advantage of its latest EtherNet/IP firmware.

Applied Motion Products offers a range of integrated motors and drives compatible with popular Rockwell PLCs such as ControlLogix and CompactLogix. Many of these products also feature dual-port Ethernet connections for easy integration into a variety of network topologies. Products include:

StepSERVO™ Integrated Motors: SSM, TSM and TXM series
Stepper Drives: ST5, ST10 and STAC5 series
Integrated Stepper Motors: STM and SWM series
SV200 Servo Drives

For a full list of integrated motors and drives that incorporate EtherNet/IP network communications, the widely used industrial protocol for manufacturing automation applications, refer to the website at www.applied-motion.com/products/series/ethernetip-products.

www.applied-motion.com

Festo Industry 4.0-Enabled technology and engineering productivity tools — and electric and pneumatic automation systems — at IMTS 2018

September 11, 2018 By Lisa Eitel Leave a Comment

At IMTS this year, Festo is showing the Motion Terminal, a modular Industry 4.0 device – a single unit capable of replacing 50 different components through the download of various combinations of cloud-based apps. The Festo IMTS Booth is 134357 — in the East Building Level 3.

The Motion Terminal seamlessly integrates computational algorithms and physical components. This new cyber-physical system enables the Industry 4.0 advantages of small lot size manufacturing, adaptability to shorter product life cycles, scalability, resiliency, energy conservation, cloud-based predictive analytics, and more.

At IMTS, Festo also features the latest version of the Handling Guide Online and the new Festo Motion Control Package. These engineering productivity tools slash the costs of Cartesian robot engineering, assembly, and programming as well as shorten time to market for new machines.

Festo showcases the company’s expanded offering of electric automation devices, including the new low-cost linear axes ELGC and mini slide EGSC. These new electric actuators offer an optimal ratio between installation space and working space. Additional IMTS highlights from Festo include:

A portfolio of IO-Link solutions
A host of mechanical grippers
Electric and pneumatic safety systems that lower overall risk of equipment damage and worker injury
A flexible loading system for end-of-line packaging and other applications
The new CPX-E compact, low-cost controller for handling systems.

Festo demonstrates how the company’s global Stars of Automation program lowers downtime and reduces overhead through guaranteed 24-hour shipment of core Festo products. For more information, visit www.festo.us.

Updated Motion Analyzer software from Rockwell cuts system design time

June 7, 2018 By Miles Budimir Leave a Comment

An updated version of the Allen-Bradley Motion Analyzer software tool from Rockwell Automation offers simplified workflows and improves design efficiency. The enhanced software offers an optimized user experience with intuitive navigation and in-workflow product selection. This can help engineers more easily and efficiently develop complete motion control systems for their machines.

Using the Motion Analyzer software, engineers can determine a system’s specifications, evaluate multiple products to find the best fit, finalize the design and create a bill of materials. The tool can also help reduce motion-system design time from a multi-day process to a few hours.

“Sizing a motion system can be time consuming,” said Brett McNalley, product manager, motion solutions, Rockwell Automation. “In the latest release of the Motion Analyzer software, we have simplified workflows to improve user experience. And we have added additional features that make the process of designing a motion system as efficient as possible.”

Key improvements include faster axis definition and sizing, redesigned solution search and configure components features, additional application template profile support, and the ability to import from a legacy motion profile with support of more advanced motion segments.

For more information, visit www.rockwellautomation.com.

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.

Connectivity and IoT expand control design functionality (a Motion Trends report)

March 5, 2018 By Lisa Eitel Leave a Comment

A recent survey of industry experts had many underscore that connectivity in manufacturing is nothing new … bu there are significant new developments in IIoT.

MEET THE CONNECTIVITY and IoT EXPERTS …

O’Connor of Aerotech

O’Connor • Aerotech: Connectivity in manufacturing is not a new idea — it’s been around for decades — but what is new in IIoT is the volume and type of equipment (and devices) on the market that now offer connectivity. For an extreme example, there are now smart toilet-paper roll holders that let one know (from a mobile device) that one needs to change the roll. Products like this didn’t exist a decade ago.

The proliferation of low-cost sensors and communication devices gives engineers (and hobbyists) easily accessible devices to integrate into their products.

Kawaller • ISL Products: IIoT provides opportunities for new devices that may or may not require electromechanical functions to complete a task (and provide data to a client or system) … of course, motors we design and supply work in systems that support IIoT.

Messerer of HELUKABEL

Messerer • HELUKABEL: Electronic components are clearly gathering and using more data than ever … and cables are passive components on machinery that support all this active equipment (such as electronic sensors or Ethernet cables with protocols to sense component failures). Here, if the system reaches a critical sum of failures, spare-part orders from a purchasing system might automatically execute to avoid downtime.

Leveraging the connectivity of consumer phones and tablets (and user familiarity with them) is a common refrain.

O’Connor • Aerotech: IIoT is a hot area. In our everyday lives, we expect devices to connect and just work. We carry those habits to our jobs. Manufacturing plants and the teams that run them expect systems to connect and work together. That means motion systems are becoming smarter as well as more connected … which is why we currently have designs in the field as well as designs in development that simplify connectivity and improve intelligence of automation and motion-control systems.

Rojas of WEINTEK

Rojas • WEINTEK USA: We believe HMIs should access all machine information — and communicate with different brands of controllers or I/O systems; gather valuable information; and send that data to cloud storage for real-time analysis. We think the HMI will come to be the IIoT gateway for all machines … and that HMIs will be the “spokesman” of every machine — to help machines “talk” with controller networks and the Internet.

cMT Viewer is free remote-control (and viewer) software for Weintek cMT series HMIs. With careful engineering, users can get real-time information even on an unstable WiFi network. The software runs natively on mobile devices, so machine operators can use off-the-shelf phones and tablets (including iOS and Android products) to control up to 50 cMT machines.

But it’s not just HMIs that incorporate connectivity features for support of IoT — though they certainly continue to lead in this arena.

Kawaller of ISL Products Intl. Ltd.

When asked about increasingly networked manufacturing, some cited motor products and servo drives that integrate with control systems for IoT functions as well.

Kawaller • ISL Products: Electromechanical devices with networking capabilities are emerging rapidly where functions are performed, and data is captured for analysis — yielding everything from buying trends to demographic information to restocking alerts and other relevant marketing data.

Zumbusch • Eaton Hydraulics: IoT has changed the landscape tremendously, particularly over the last few years. This has allowed products with onboard intelligence (such as our AxisPro valves) to interpret upstream fluid signatures and communicate critical information … including machine performance and prognostics for maintenance of large and complex systems.

As IIoT continues to expand, we’ve seen a steady increase in needing to address both hydraulic as well as electric machines’ performance … such as variable speed electric drives coupled with variable displacement pumps to provide faster response times while still reducing energy use.

Ocampo • Bosch Rexroth: One example of motion-component IoT functionality is the drive-based software called Productivity Agent, which supports predictive maintenance and local data processing in real time while boosting machine availability and overall equipment effectiveness (OEE).

Feketa • LinMot USA: On the topic of IoT, servo drives with connectivity allow access to (and recording of) drive vitals … and that’s helpful because more OEMs and design engineers now want data collected by servo drives to include specific data points — especially those important to operations. Plus engineers want real-time communication of this data to PLCs — where they can access and interpret the data. Real-time data flow allows faster decision making and is especially important for predictive maintenance. On a related note, we also see servo drives including more safety features — including safe-torque-off and safe speed settings. Safety is a core concentration, and we predict industry will soon see far more products that integrate safety.

Zumbusch of Eaton Hydraulics

Zumbusch • Eaton Hydraulics: One of the most powerful outcomes of IoT has been the increase in component intelligence. These devices now offer myriad customized features for specific applications through the use of software. As machines identify new needs, over-the-air programing can update the software and add new system features that end users may decide to adopt. IoT functions even address motion-control issues such as oscillation and stability problems on the fly (even as machines are modified and systems change).

Others also stress the usefulness of software tools to boost productivity and (in some cases) even get automation information to enterprise-level functions.

Rojas • WEINTEK USA: EasyBuilder Pro (programming software for our HMIs) offers native client support of the OPC Unified Architecture (OPC UA) machine-to-machine communications protocol. That helps users save time because it makes browsing PLC data structures easy. Native MQTT and AWS IoT support also reduces the time needed to setup secure telemetry servers and environments. An encrypted connection to the user’s own AWS IoT service allows gathering of machine information.

Some motion-component manufacturers cite in-house experience with their own software for implementation of IIoT as valuable in understanding OEM engineers’ own IIoT projects and challenges.

Ocampo • Bosch Rexroth: More than 250 Bosch plants worldwide have implemented IIoT lines or projects. One Bethlehem, Pa. plant completed implementation of a smart multiproduct line (MPL) for hydraulic valves in 2017 with numerous Rexroth IIoT technologies. The MPL can output more than 30,000 product variants — switching on the fly from one valve type to another. One online tool supporting communications for IoT setup is Improvidus software, which lets engineers analyze OEE data before implementing IIoT in their factories. Improvidus is a Rexroth IIoT (I4.0) online consulting tool for OEE analysis. The partially free tool gives design engineers access to I4.0 experts with a subscription.

In fact, the term “smart” is often shorthand for IIoT functions — as in the name for Weintek’s cMT-G01 smart communication gateway explained below — or in reference to connectors.

Kojak of HARTING

Kojak • HARTING: Han connectors are the first to integrate “smart” functionalities … and are compatible with the Han-Modular series, so are a safe choice for IIoT applications. Currently, there are three smart Han modules: One is a Current Surge Protection Module (to protect sensitive electronics from over-current conditions) and another is an ID Module (which stores information that might be serial identification or a BOM of all modules in a connector). Where the latter is installed in an inaccessible place, it can be interrogated via a CAN interface to feed information out.

In short, we design products that enable IIoT connectivity … and soon, we’ll be releasing modules and setups with even more functionality — including power measurement and analog-to-digital conversion.

Gateways are core to many basic IoT functions — including the management of cross-platform communications and access to HMIs (and PLCs) from remote locations.

Rojas • WEINTEK USA: EasyAccess 2.0 (our remote assistance and control software) helps engineers save time and money … as when a machine triggers an alarm, the software sends a push notification to mobile devices. A pass-through function even lets users control or program PLCs via an HMI or IIoT gateway … and setup the system to get detailed permission control through a Domain-User architecture.

Ocampo • Bosch Rexroth: IIoT is inspiring new product development — as our IoT Gateway to connect legacy machine infrastructure to IoT-based systems, for example. This IoT Gateway connects PLC and sensor hardware with cloud and data-processing systems for simple implementation of local dashboards, data processing, and data streaming to Cloud services (such as Bosch Cloud, Microsoft Azure, or Oracle). Product functions and tools are based on an open and distributed control architecture.

In addition, a Data Analytics Server supports data analysis and monitoring for new and existing machines. Real-time data can be saved, evaluated, and visualized close to the machine. Plus users can quickly setup predictive maintenance and other IIoT (I4.0) uses based on machine learning.

On the topic of increasingly networked manufacturing, some primarily view higher connectivity as a way of improving the overall lifecycle of machines.

Rojas • WEINTEK USA: IoT is more about industry and helping operational technology (OT) adopt technologies from IT. After all, aggregation and statistical tools can support OT tasks … and data sent and collected can inform ideas for next-generation machines. Such data can also help day-to-day machine use — to maximize workflow and machine efficiency, and optimize user experience.

NEXT PAGE for IoT in motion machinery →

MEET THE CONNECTIVITY and IoT EXPERTS

Horst Messerer — Data, network, and bus technology sales manager at HELUKABEL

Steve Zumbusch — Director of technology development at Eaton’s Hydraulics business

Brian O’Connor — Director of product and market development at Aerotech

Ken Kawaller — President of ISL Products Intl. Ltd.

Mark Kojak — V.P. of product management and business development in the Americas at Harting Inc.

Steven Feketa — Regional sales engineer for LinMot USA Inc.

Oscar Rojas — Senior software engineer at WEINTEK USA

Joaquin Ocampo — Product manager of motors and drives at Bosch Rexroth

Illustrations ⚙ of IoT in motion machinery →

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Galil Motion Control intros the Galil Design Kit (GDK)

February 6, 2018 By Miles Budimir Leave a Comment

Galil Motion Control Inc. has released the Galil Design Kit, the company’s newest software environment, providing easy communication with Galil’s motion controllers and PLCs. Galil recently introduced the new scope and tuner to GDK’s growing list of tools and capabilities. All tools are customizable by editing the XLM, located in the “more options” menu at the top right corner of the software.

“The scope and tuner tools of GDK now provide customers with the functionality to easily troubleshoot and tune a system,” said Amber Ehardt, applications and marketing engineer with Galil Motion Control.

“GDK’s wide range of tools increases the motion control system’s performance and decreases integration time and effort.”

GDK currently includes these six tools:

Scope: emulates a traditional digital oscilloscope.
Tuner: assists in optimizing a system’s performance.
Terminal: sends commands and receives responses from the controller.
Editor: writes, saves and executes application programs.
Viewer: enables real-time viewing of the controller’s I/O status, motor position and more.
Setup: reads, edits, saves and restores all controller memory.

GDK’s communications library, gclib, now uses a communications server by default. This software layer works as a multiplexer to the hardware and allows multiple applications to communicate with the same controller. Data that was once only available to one application is now distributed to all subscribing clients. The benefit is that an application can leverage all communication features of a Galil controller while an attached debugger, for example GDK, can also have full-featured access.

For more information, visit www.galilmc.com.