Industrial Automation - Motion Control Tips

HMI simplifies setup of robot-assisted automation for one integrator

November 12, 2018 By Lisa Eitel Leave a Comment

Integrator Inovatech Automation recently decided they were spending too much time programming expensive HMI and PLC platforms, so contacted Pro-Face America for help.

The integrator needed an HMI capable of universal robot and I/O-Link integration, legal for Inovatech Automation branding, and easy to program.

“I was apprehensive at first because we have a lot of projects going … so timing is short,” said Inovatech director of operations Travis Buset. “More specifically, I had concerns about learning something on the fly — and feared the onboarding experience and programming were going double our time investment.”

Pro-Face America supplied its LT4000M HMI plus Control unit. This hardware reduces costs by eliminating the need for an external PLC. In addition, for Inovatech Automation the LT4000M halved engineering time for configuration; offered easy integration to a Universal robot and IO-Link network; and was delivered with a custom overlay for machine-branding purposes.

Inovatech uses Pro-Face America’s LT4000M HMI plus Control unit on its modular automation station.

Trimming the time for setup was the most important benefit, though.

“Another platform needed two different pieces of software. In contrast, Pro-Face uses one software with drag-and-drop functionality. What once took me 32 to 40 hours to program now takes eight hours on the Pro-Face.” In fact, Buset had one programmed in eight hours his first time trying.

“This a powerful unit and well worth its cost for the level of configuration it allows.” Inovatech estimates it’s now operating 75% more efficiently than before.

Finalists announced for Industrial Automation category in inaugural LEAP Awards

November 8, 2018 By Miles Budimir Leave a Comment

Eight finalists were announced on Friday November 2^nd for the inaugural LEAP Awards’ Industrial Automation Category. The competition was scored by a panel of independent technical/engineering-oriented judges. The four judges below were responsible for the Industrial Automation category:

Bonnie Baker
Consultant
ATW, LLC

Bonnie Baker is the author of six books, including A Baker’s Dozen: Real Analog Solutions for Digital Designers. Baker holds a Master’s of Science in Electrical Engineering from the University of Arizona and has authored more than 500 technical publications including magazine articles, app notes, seminar sessions, data sheets, and a few patents. She is also a frequent presenter at technical conferences and shows.

She has been involved with analog and digital systems for more than 30 years. Baker started as a manufacturing product engineer, supporting analog products at Burr-Brown. From there, she moved up to IC design, analog division strategic marketer, and then corporate applications engineering manager. In 1998, she joined Microchip Technology. This expanded her background to not only include analog applications, but microcontroller solutions as well.

Bradford L. Goldense
President
Goldense Group Inc.

Bradford L. Goldense is a subject matter expert in the management and processes of product development, innovation and performance measurement. He has authored or been cited in more than 300 articles and books and holds nearly 150 registered copyrights.

Brad was a faculty member of the Graduate Engineering School Executive Program at The Gordon Institute of Tufts University for 19 years. He is internationally recognized and has consulted with more than 200 of the Fortune 1000 in 500 manufacturing locations around the world. GGI has helped many companies to increase their stock price by improving R&D innovation and execution, and by improving communications of prowess to the marketplace and investor community.

He previously held positions at Texas Instruments, Price Waterhouse, Knight & Associates, Index Group, and a family engineering business before founding GGI. Brad has a BSCE from Brown University and an MBA from Cornell’s Johnson School. He holds four professional certifications: New Product Development Professional by the Product Development and Management Association, Certified Manufacturing Engineer by the Society of Manufacturing Engineers, Certified Computer Professional by the Institute for Certification of Computer Professionals and Certified in Production and Inventory Management by the American Production and Inventory Control Society.

Brad was a founding member of the Society of Concurrent Engineering and founder of the Society of Concurrent Product Development which he ran until 2006. He retired from the board in 2012. His non-profit corporation lives on, with appreciated support and funding from 3M.

Thomas E. Manley
Engineering Manager
Feedall Automation

Thomas Manley is Manager of Engineering at Feedall Automation, where he directs and designs the machine orders that come through the engineering department. He is also a part-time engineering instructor at Lakeland Community College and is the designer of 14 U.S. Patents for various companies that he has worked for.

Manley has worked with high-profile companies such as Harley-Davidson, American Axle, Meritor, Caterpillar, and Ford Motor Company, among others. He helps companies and engineers implement automation systems into their plant, while adhering to their desired budget and goals.

Karl H. Schultz
President
Schultz Associates

Karl Schultz is the President of Schultz Associates, specializing in manufacturing and technical management consulting in the electric motor industry. He is also considered an expert in implementing lean/world class business processes.

Schultz is an experienced hands-on manufacturing management consultant who has had both line and staff positions in the electric motor industry. He was the division Director of Manufacturing Engineering for Emerson Electric for 10 years, supporting four plants in the U.S. and Mexico. He was then the Business Director of Manufacturing Engineering at GE Motors for three years. Consulting has taken him worldwide in many various successful projects. He has more than 25 years in the electric motor industry.

Schultz holds a BSME in Machine Design from Western Michigan University. He was a member of the Electrical Manufacturing and Coil Winding Association, serving as the VP and a Board member. He is a senior member of the Society of Manufacturing Engineers and a past member of the Society of Automotive Engineers. He has received numerous awards such as Best Industry award (General Signal), Most Valuable Player award (BMI), performance awards (GE Corporate & Motors), and others. He is an adjunct instructor at the Oregon Institute of Technology – Wilsonville, teaching junior and senior level management courses such as Lean/6 Sigma and Organizational Behavior.

Below are descriptions of the eight finalists. The overall winner of the Industrial Automation category will be announced at an awards dinner on December 11th in Costa Mesa, Calif.

Cognex
DataMan 470

DataMan 470 series fixed-mount barcode readers solve complex, high-throughput manufacturing and logistics applications with ease. DataMan 470’s multi-core processing power, imaging technology, high-resolution sensor, advanced decoding algorithms, and simple setup delivers maximum coverage, speed, and ease-of-use.

Littelfuse
MP8000 Bluetooth Enabled Motor Protection Relay

The MP8000 Bluetooth Enabled Motor Protection Relay is a new category of product designed to enhance worker safety while allowing for faster, easier control and troubleshooting of machines. The first fully-programmable motor overload relay to offer integrated Bluetooth capabilities, the MP8000 relay enables maintenance personnel to communicate with the relay from up to 30 feet away using an app on an iPhone® or Android™ smartphone or tablet computer. A worker can set up the relay, view real-time data and troubleshoot fault codes while the panel door remains closed to prevent potential electrical shock and arc-flash hazards.

Bluetooth® communication provides several conveniences that improve productivity. Workers save time by leaving their PPE (personal protective equipment) in their locker. Motors are easier to troubleshoot when workers can stand nearby the motor, instead of next to the relay located at a distance up to 30 feet away. If the relay is located in an outdoor cabinet, workers can interact with it while remaining warm and dry in their vehicles during inclement weather.

Once a smartphone is securely paired with the relay, a worker can easily monitor system status in real time, set up the relay, adjust its settings, and review its fault history. Instead of turning knobs and scrolling through menus on a small display, workers can use a smartphone interface to interact with the relay. The app is intuitive and requires no training to use.

Omnify Software
Omnify Empower / 6 River’s Robot Chuck

Chuck is a warehouse robot built from the same technology and sensors as autonomous vehicles. Omnify Empower, a Product Lifecycle Management (PLM) Software, was instrumental in developing 6 River’s Robot Chuck. The Chuck Robot, using machine learning and artificial intelligence, leads associates through their work zones to help them minimize walking, stay on task and work more efficiently.

Chuck integrates with Warehouse Management Systems so it can be used in all put-away, picking, counting, replenishment and sorting tasks. Chuck keeps warehouse employees on task by guiding them through the facility through each step of the packaging process. It can glide around the room and also has a touchscreen to help workers locate items. Chuck uses sensors to help detect worker productivity. It’s also been designed to help with employee training.

6 River isn’t worried about eliminating humans and instead believes there is an opportunity to help industries that have a “massive labor shortage” for warehouse suppliers. There aren’t enough people to fill the jobs.

The 6 River System robots offer an intuitive design and guide workers to the correct locations and step them through the picking process at a granular level. The robots can clearly increase worker productivity and picking accuracy. 6 River Systems offering can increase units per hour per employee by 200 to 300 percent. Pricing runs at about $250,000 for 8 robots in the first year and maintenance costs of about $50,000 a year thereafter. 6 River Systems currently has 20 customer sites with a total of more than 200 robots in use. It is the company’s end of year goal to have 600 Chuck robots in use across 40 sites.

Omron Automation Americas
CIP Safety Controller

Omron’s new CIP Safety Controller (part of the NX controller series) is the world’s first to supply two popular safety networking protocols: CIP Safety, which is widely used among industrial robot manufacturers, and Safety over EtherCAT, a protocol that ensures a high-speed response.

CIP Safety is one of the most widely used safety networking protocols because it enables various nodes in the system – such as PLCs, I/O blocks, light curtains and interlock switches – to communicate with one another. Since it’s both network- and media-independent, it allows safety and standard control devices to reside on a single network. This eliminates the need for a purpose-built safety network and enables the sort of flexibility that manufacturers strive for in the face of more globalized, high-mix production needs.

The new controller will be a welcome solution for any manufacturers seeking to implement the CIP Safety protocol in order to have an alternative to the traditional purpose-built safety network. It is also designed to assist manufacturers in need of a thoroughly scalable safety system that provides direct node-to-node communication and those who are looking for a way to simplify their safety program design.

Parker Hannifin
Universal Pneumatic Valve Manifold

An industry leading product offering wide flow ranges and design versatility, the H Series ISO pneumatic valve family is intended to make the machine designer’s job easier.

An improved modular manifold provides the opportunity to mix ISO 5599 / 15407 02, 01, 1 and 2 valve sizes on one common manifold without expensive and bulky transition blocks. The ability to mix sizes allows for right sizing each valve to its specific flow and pressure requirement instead of sizing all valves to the largest requirement, thus reducing cost and space on the machine.

Designers may easily zone supply or pilot pressures, allowing for a mix of different pressures/vacuums on one valve manifold instead of requiring separate manifolds, reducing machine footprints.

Main and pilot supply/exhaust may be added anywhere in the valve manifold creating zone and pressure isolation for quick exhaust of a “safety zone”.

The subsequent cost savings are considerable: right-sizing a manifold with 10 valves can yield a 28% savings ($2,361 down to $1,704) or more depending on specific application.

The new H-Series valve family incorporates a P2H (Parker-to-H-Series) IO-Link network node allowing for an easy means of connecting the H-Series valve to a low-cost IO-Link network. The P2H IO-Link Node also features a convenient 7/8 power in and out connection for auxiliary power—a first for an IO-Link enabled valve device. Thanks to the P2H network node, machine builders can save up to 40% on total system and installation cost versus Ethernet wiring.

Protolabs
Farmbot – humanity’s first open-source CNC farming machine

FarmBot is humanity’s first open-source CNC farming machine. Using open-source technology, home gardeners can assemble the software and hardware to oversee and customize their own garden. FarmBot hardware employs linear guides in the X, Y, and Z direction to allow for tooling such as seed injector, watering nozzles, sensors, and weed removal tools to move with precision. Through the use of a phone or laptop application, it can accurately plant a variety of crops all in the same area at the same time. The game-like interface allows the grower to customize and build an entire growing season – with built-in regimens for taking care of each plant throughout its entire life by scheduling sequences to run when the plant reaches certain maturity.

At the core of the system is a single board computer, a programmable microcontroller, various motors, and rotary encoders. The aluminum frame combined with the electronics enables FarmBot to automate everything from planting seeds to watering plants on an individual basis.

Schneider Electric
EcoStruxure Augmented Operator Advisor

EcoStruxure Augmented Operator Advisor, an innovative augmented reality software that superimposes real-time data and virtual objects onto cabinets or machines, giving operators and technicians immediate access to relevant information.

The benefits of leveraging this state-of-the-art AR technology in the field or the plant include, but are not limited to:

Reduced downtime. Operators can open the electrical cabinet doors virtually with no need to shut down operations.
Speeding up operation and maintenance. Technicians can find information faster, with immediate access in the field to real-time data, user manuals, instructions, diagrams, etc.
Reduced human errors. Locates the right equipment and guides operators step-by-step to complete maintenance procedures.

EcoStruxure Augmented Operator Advisor’s interface gives direct access to information like labels, process variables, SQL database, machine documentation, electrical diagrams, web pages, instructions, notes, and instructional videos.

The plug-and-play architecture works on tablets (currently iOS®, and Android™ with Windows® versions in the works), and uses a Windows-based PC as the server platform. The server receives the data to share with the tablet from multiple sources, such as PLCs, SQL databases, and OPC UA servers for example. To ensure flexible integration into any user’s existing system, the software is compatible with servers and components from any vendor.

Serapid
Telescopic Jib

Telescopic jibs for intervention in confined environments are a powerful and economical solution for demanding jobs. SERAPID has recently designed a new telescopic jib for the nuclear market. It’s an actuator consisting of a specific rigid chain, which can be deployed over several meters without being supported, and thus ensure control operations or small mechanical work in confined environments such as tanks, containers or cells.

This new product is very compact, can be easily introduced by reduced access (manhole, coring, hatch, etc.) and is especially useful for dismantling work. With a simple and robust design, this telescopic arm will be a powerful and economical tool for everyday use.

It’s composed of stainless steel, titanium and plastic. Features include a maximum payload of 45 kg, a maximum extended length of 5 m, and speed of 30 mm/sec. The pitch of the chain is 60 mm and the deflexion at the end of the chain is 70 mm for 10 kg at 2 m or 500 mm for 10 kg at 5 m.

ACS Motion Control SPiiPlus library for MATLAB enhances application development

November 7, 2018 By Lisa Eitel Leave a Comment

ACS Motion Control has created a MATLAB library that enables users to develop sophisticated applications with advanced diagnostics capabilities directly with ACS control systems. The MATLAB library communicates with ACS’ motion controllers, allowing users to implement custom motion profiles, learning control algorithms, a custom FRF measurements, advanced monitoring systems, and much more.

The SPiiPlus Library for MATLAB allows users to experiment with algorithms to improve motion control performance for their application. It can provide design support at each stage of the development process, from modeling to deployment through automatic code generation.

“The SPiiPlus Library for MATLAB offers expanded flexibility and capability for motion control engineers. The library allows users to employ powerful MATLAB features to design, test and refine their motion control application. This enables a more robust and higher performance motion control system while reducing time to market,” said Jason Goerges, General Manager at ACS Motion Control.

The new library Supports MathWorks MATLAB R2011a (v.7.12) and later, as well as Microsoft Windows operating systems starting from Windows 7.

The SPiiPlus MMI is now officially MATLAB enabled and ACS is a member of the MathWorks Connections Program, defined as MathWorks Partner. For more information, visit acsmotioncontrol.com/spiiplusnt-inside or email sales@acsmotioncontrol.com.

A manufacturer of advanced multi-axis motion controllers, machine controllers and integrated control modules, ACS provides standard and custom products that combine power and precision to deliver flexible, economical, user-friendly motion and machine control solutions. Established in 1985, ACS’ headquarters are located in Israel and its North American headquarters resides in Bloomington, MN. ACS also has facilities in Germany, South Korea and China, and distributors worldwide that deliver dependable customer service and product support. ACS is an ISO9001 certified manufacturing facility, demonstrating its continuous commitment to providing customers with reliable devices that are thoroughly tested with the latest available techniques.

Chip-level connectivity and design sees synergies for motion and robotics

November 2, 2018 By Lisa Eitel Leave a Comment

In a recent interview with Brendan O’Dowd, general manager for industrial automation at Analog Devices, we got the chance to hear about new devices — even to the chip level — that allow better integration of robotics into motion designs and machines for automation.

Eitel • Design World: We cover motion control as it relates to motors, power transmission, and automation. What new developments in these areas do you consider most significant?

O’Dowd • Analog Devices: Our company has been around for 50 years. For some time, we’ve investigated the systems into which our parts go … to create better solutions for these designs. For example, sometimes engineers asked us to reduce power consumption. Usually there was something specific prompting the question — such as thermal dissipation being an issue. We learned that it’s not always the posed question needing addressing — but something related to it. So we began using technology and our silicon experience to solve problems in new ways.

On connected motion and servos and drives, several parts are involved in the sequencing. There’s the processor — the system brains — and the PWMs driving the signal … as well as the isolated gate drivers (IGBTs) … and the measurement of the currents returning — for a complete control-loop algorithm. We’ve worked to optimize many of these.

But from a system point of view, communications have become more critical — and deterministic Ethernet is increasingly a part of these communications. Even in factory control and process automation where 4-to-20 mA and fieldbuses have reigned for a long time, Industrial Ethernet is coming to the floor … in an array of standards.

Eitel • Design World: Our industry sees a lot of proprietary standards — all good for certain things — but not always able to work together.

O’Dowd • Analog Devices: They’ve been successful … but now as we need higher speeds, there’s migration towards unified standards — with the TSN collection of standards currently leading. In fact, nine or 10 different IEEE standards are part of that TSN bundle. They cover things such as ingress policing (for the prevention of traffic overload conditions on a network) and other network functions. We expect TSN standards to supersede most existing industrial Ethernet protocols.

Eitel • Design World: But it’s unlikely that those invested in existing industrial Ethernet networks will abandon what they use … and those networks’ unique benefits — especially for real-time functionality.

O’Dowd • Analog Devices: Yes — and with the growing tide of robots and especially cobots, real-time functionality is absolutely critical. So we’ve invested in multi-protocol solutions … because it’s okay if you’re Siemens, Rockwell, or Beckhoff with all your equipment the one standard you sponsored — but many smaller players must deal with these different standards. For them, it means unless they’re designing for an all-Siemens factory or an all-Beckhoff factory, they must support multiple standards.

Eitel • Design World: What kinds of products support all major protocols?

O’Dowd • Analog Devices: Some of our Ethernet switch ICs have built-in TSN features to support several IEEE TSN standards. We aim to offer compatible updates to next-generation TSN as those standards are finalized. As any latency-controlled Ethernet standard, TSN standards allow synchronization of the Media Access Control (MAC) physical interface on different boards at different parts of the system.

For a drive, motor, or robot, actual motion is controlled by PWM output. The time synchronization then has to make its way through the communications stack and through the motion-control stack and out to the PWM output — to drive the actual gate drivers to time the motor. So many view TSN from the Ethernet point of view — and focus on getting that synchronization down to the boards … a significant problem itself. But they leave the rest of the problem to individual designers.

That’s why we bring motor-control and motion-control signal-change domain expertise to our Ethernet work. We aim to deliver system solutions, and not just pieces of silicon.

The key point is when a semiconductor supplier can apply domain expertise to silicon design, it is possible to solve wider system-level problems.

Eitel • Design World: How does that relate to robots and the new wave of cobots in automation?

O’Dowd • Analog Devices: The latter are about sensing and understanding the environment … with many offerings today being very much in the analog domain. But using technologies borrowed from other fields — such as radar and LiDAR from automotive, for example— will come to expand the array of system-level domains in robotics. People often ask why we’re acting more as system suppliers and not acting as a traditional component supplier. Well, it’s because we’re working to be relevant at higher levels — by leveraging our domain-level expertise and newer expertise in robots, motor control, condition monitoring, and Ethernet.

Eitel • Design World: Just to be clear for engineers who don’t usually think of design work at the chip level — would you explain what you mean by domain in this context?

O’Dowd • Analog Devices: Sure. There are IC technology silos — for A-to-D converters, performance amplifiers, processors, and power supplies, for example. We also have experience silos for automotive, motor control, and process control. Some we developed internally from work with customers on applications. Some we’ve hired into the team — for example, in robotics and motor control design — to get views that are different from a silicon designer’s view.

The challenge is that silicon designers think in terms of what they know — transistors and fab processes and so forth — whereas motor-control designers think in terms of PWMs, and current feedback, and control loops. So having them work together for weeks, months, and years spurs richer conversations and solutions that wouldn’t have been created otherwise. That’s what constitutes domain-level design.

The fido5200 REM switch (one version of the fido5000 series) supports industrial Ethernet protocols such as EtherCAT.

Eitel • Design World: You’ve been gracious in not mentioning specific Analog Devices products for such flexible functionality. But may I ask what those are?

O’Dowd • Analog Devices: Our single piece of silicon — the fido5000 REM Switch IC — is configurable with a binary download we supply.

That means engineers can setup for an EtherCAT version of a field instrument … or a PROFINET version … or Ethernet IP version … and it’s the same hardware, just with a different binary download. With less designing and debugging, that in turn reduces time to market and models in inventory … and boosts assurance that what gets shipped to the end user will be the right version, as it’s just a software image.

In this way, the fido5000 REM Switch IC is a flexible part — with TSN protocols ready to go and pin-for-pin replacement compatibility.

Eitel • Design World: Many proprietary offerings provide real-time functionality. Does your new offering adhere to IEEE standards for that?

O’Dowd • Analog Devices: Our Deterministic Ethernet Technology Group (DET) director Jordan Woods also represents us on the standards bodies — so we can sell standards-ready silicon from day one. Even when standards aren’t finalized, we have customers evaluating our ICs’ functionalities to deliver on what’s coming.

Eitel • Design World: What in the motion and robotics markets are driving innovation?

O’Dowd • Analog Devices: Motor control and robotics are driving the need for higher bandwidth. Some in factory automation resist the idea of needing GbE — accepting 100 Mb as enough. But they’ll need higher bandwidth in the future. Even in residential homes, the number of Internet-connected things has risen dramatically. Factories are no different — and high-bandwidth items such as cameras and radar (for time-of-flight measurement and positioning, for example) are leading the charge. Such technologies are key to knowing where people are around a robot, for example. Having a work cell’s cameras execute auto recognition on workpieces … or artificial intelligence — these too demand big bandwidth.

What’s more, some design engineers are frustrated with accommodating lots of standards.

These two things are driving the trend towards standard TSN. So I predict the big players will continue to support legacy equipment with proprietary standards — even while next-generation standards are still being worked out. Rest assured we’ll be there to support the latest solutions.

Eitel • Design World: Do you offer software for configuring your chips?

O’Dowd • Analog Devices: We sell preconfigured chips — and supply the binary … already certified with the standards body — so the chips are ultimately pre-certified to EtherCAT or PROFINET or to the applicable standard. That minimizes work for the engineer. But higher-level software — that lets engineers configure networks — that’s not something we offer yet. At the moment these offerings are tied to more integrated designs.

Eitel • Design World: On the topic of more connectivity between motor-driven machine axes and robotics — what’s particularly innovative here?

O’Dowd • Analog Devices: We’ve supplied lots of I/O for PLC-based control … analog out and in … digital out and in. We see such controls moving to higher data rates as well — and I think TSN standards will become very prevalent here. But at Ethernet IP becomes standard in the factory everywhere — and not just in parts — it will replace some 4-to-20 mA and fieldbus connections. So while motor controls and drives will spur higher bandwidth, maybe not factory automation but certainly process control — including oil and gas and pharmaceutical industries — will increase use of lower bandwidth over longer distances.

Eitel • Design World: Another area of interest is network security.

O’Dowd • Analog Devices: Standard approaches to using PCs and IT infrastructure with firewalls and certificates doesn’t work well at the factory level. After all, firewalls between machines could quickly bring down production. So configuration and setup must be well engineered. Our security company subsidiary Sypris Solutions works on this for us.

Eitel • Design World: How does this relate to another connectivity-enabled function — that of condition-based machine health monitoring?

O’Dowd • Analog Devices: We’ve been doing MEMs vibration sensors for 25 or 30 years … with most airbags in the world controlled with our MEM sensors, for example … and first-generation Nintendo Wii consoles as well. With our motion and vibration-sensing expertise, now we’ve begun exploring ways to use MEM sensors in motor control … as a lot of information can be gained from monitoring motors over time to understand their states — as bearings wear or loads begin to have issues, for example. We’ve all heard stories of that one guy who can hear problems or lay his hands on a machine to detect issues — or skillfully use probes for measuring various characteristics.

In short, there is now a way to have this level of monitoring using technology rather than a highly skilled “machine whisperer” …

Allied Electronics & Automation breaks ground on new 220,000 square foot warehouse addition

October 16, 2018 By Miles Budimir Leave a Comment

Allied Electronics & Automation is expanding its warehouse to 520,000 square feet from its current 300,000-square-foot distribution center. The new addition will be built alongside the current warehouse in Fort Worth, Texas. When the addition opens in mid-2020, Allied will have the capacity to house more than 500,000 stocked products, up from 170,000 today.

“Allied is preparing for the future by developing our warehouse today,” said VP of Business Operations Scott Jayes. “We pushed our automation partner KNAPP to give us a state-of-the-art facility. Our expanded warehouse will include advanced technology that will cement our position as a true benchmark in the distribution industry.”

The new warehouse will make room for an additional 26 receiving stations and employ the latest automated order, storage, and retrieval shuttle system (OSR) for high-density storage. A GTP (Goods-to-Person) pick system, including robotics for repetitive tasks, and the addition of a matrix RFID pocket sortation and consolidation system, will enable pick-to-line process capabilities to enhance customer service. A new automated packing capability, designed to improve presentation while reducing packaging, material waste, and shipping costs, sits alongside an extended shipping sortation system.

Allied broke ground at an employee ceremony in early September and unveiled the new expansion plans to suppliers at the company’s recent EXPO 2018, its bi-annual trade show and sales meeting in Fort Worth. The facility is expected to be completed by July 2020.

For more information, visit www.alliedelec.com.

What is meant by the term General Motion Control?

October 11, 2018 By Danielle Collins Leave a Comment

There are numerous interpretations of what the motion control market entails in terms of products included and industries served, but there are some commonalities among the various definitions.

First, a motion control system includes at least three basic components — a motor, a drive, and a controller. Second, motion control systems are primarily used in discrete industries such as packaging and semiconductor manufacturing, as opposed to process industries such as chemical manufacturing and power generation.

No matter how it’s defined, the motion control market is huge, ranging anywhere from $9 billion to $12 billion, depending on which products and industries are included. With very large industries, the number of market players and drivers add significant uncertainty and complexity to everything from product planning to market analysis. One way to address this complexity is to divide the market into smaller segments, based on similar product groups or industry categories. Take, for example, the passenger vehicle market. Most passenger vehicle manufacturers and industry analysts recognize at least three subsegments of the market — cars, trucks, and sport-utility vehicles (and most break the market into even smaller segments).

Similarly, to address the size and complexity of the motion control market, manufacturers and analysts have divided the market into two subsegments: general motion control (GMC) and computer numerical control (CNC).

Most industry statistics show that general motion control (GMC) accounts for just over 50 percent of the overall motion control market, while computer numerical control (CNC) accounts for just under half.

The basic function of a general motion control system is to control the acceleration, speed, and/or position of a single motor or of multiple coordinated motors. From an OEM or end-user perspective, GMC systems provide general-purpose, coordinated motion. They are typically used in the industrial automation market, but exclude military, aerospace, and consumer products applications.

Semiconductor manufacturing is one of the key industries that general motion control systems serve, along with packaging, material handling, and a host of others.

In contrast, computer numerical control (CNC) systems provide multi-axis coordinated motion and are typically used for contoured moves that require interpolation. CNC systems are often designed to meet the specific requirements of the machine tool industry, although they can be used in other industries.

CNC systems are often tailored to the specific requirements of the machine tool industry.
Image credit: Gebr. Heller Maschinenfabrik GmbH

Note that GMC systems can also be used in machine tool applications, especially for processes such as loading/unloading parts and for coarse positioning moves not involved with actual material processing.

One thing that is not widely agreed upon among industry analysts and manufacturers is which components are included in a general motion control system. Case in point, ARC Advisory Group considers the components that make up a GMC system to be the motor, drive, controller, and any integrated feedback devices. Siemens, a leading manufacturer of motion control components and systems, includes two additional components in their definition: software that is developed specifically for the application (which, in some cases, would be included in the controller in ARC’s definition) and the mechanical system — belt, chain, ball screw, rack and pinion, etc. — that transmits work to the load.

Most experts agree that a GMC system consists of a motor, drive, controller, and feedback. Siemens’ definition of a GMC system also includes the application-specific software and the mechanical system.
Image credit: Siemens Industry, Inc.

It is recognized, however, that general motion control systems are most often based on servo motors and drives, although some manufacturers and analysts consider stepper-based systems to be part of the GMC market. (It could be argued that open-loop stepper systems — which are by far more common than closed-loop steppers — do not qualify as GMC systems since they don’t rely on a feedback device.) The most common definitions of general motion control also include both stand-alone drive amplifiers and motor-integrated drives, as well as stand-alone, PLC-based, and PC-based motion controllers.

Don’t confuse the term “general motion control,” as described here, with the term “generic motion control,” which is a software platform from B&R Automation.

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.

How to specify motion components for cleanroom environments: Part 2

September 5, 2018 By Danielle Collins Leave a Comment

In this two-part article, we cover the products, materials, and features that designers and engineers should specify when choosing motion components for cleanroom environments.

In part 1, we looked at how to reduce particle generation due to friction between moving components. In this second part, we’ll look at another source of contamination — outgassing — and how to minimize it.

Objective #2: Minimize outgassing

Silicon wafer processing is extremely sensitive to contamination, including both particulates and outgassing.
Image credit: WaferPro

In cleanroom applications that involve the manufacture of LEDs, optics, or glass, or the processing of silicon wafers, a second type of contamination can damage the process or the product: outgassing.

Outgassing is the desorption of vapors or gasses, either from within a material or from the surface of a material. ISO standard 14644-8 addresses outgassing in cleanroom environments and specifically refers to airborne molecular contamination (AMC) as:

The presence in the atmosphere of a cleanroom or controlled environment of molecular (chemical, non-particulate) substances in the gaseous or vapor state that may have a deleterious effect on the product, process, or equipment in the cleanroom or controlled environment.

These types of airborne molecular contaminants take the form of molecular vapor. They’re smaller than particles and easily pass through HEPA and ULPA filters, making them particularly difficult to control once released.

Minimize outgassing through material selection

The first criteria when choosing motion components for cleanroom environments where outgassing is a concern is to ensure the material has a smooth surface, which makes it more difficult for airborne molecular contaminants to adhere to the surface. Stainless steel and anodized aluminum are the preferred materials, although some epoxy paints are suitable for environments where low-outgassing is required.

Fortunately, numerous motion control components, such as linear guides, motors, and gearboxes, can be made of stainless steel. When possible, plastic end caps on linear guides and screws should also be replaced with stainless steel versions to further minimize the use of plastics. And standard steel fastening hardware, such as screws or pins, should be replaced with stainless steel versions.

Although epoxy paint is sometimes suitable for motor and gearbox housings, stainless steel versions are better options.
Image credit: Wittenstein

When the required material has a high outgassing tendency, other solutions exist. For example, epoxy paint is suitable in some cleanroom environments and can be applied to the housings of linear actuators, motors, and gearboxes. And when steel is required — to maintain hardness, durability or load-carrying capacity — nickel plating can reduce the tendency of steel to outgas. (Note: Some nickel-plating formulas include a PTFE, or Teflon^®, top coat. The use of Teflon is generally advised against, so be sure to choose a nickel plating formula that does not include Teflon.)

Good: Nickel-plated steel, epoxy coated aluminum
Better: Stainless steel or anodized aluminum; minimal use of plastics
Look for: Smooth surfaces (no textured paints)

Reduce outgassing from lubricants

A wide variety of cleanroom-rated lubricants are suitable for bearings, motors, gearboxes, and other motion components.
Image credit: NSK

When it comes to outgassing, lubricants are one of the major offenders, readily spewing molecules of water and oil vapor into the atmosphere. Unfortunately, in the majority of motion systems, the use of components that require lubrication simply can’t be avoided. When lubrication is required, ensure the lubricant is suitable for cleanroom environments. Cleanroom compatible formulas that minimize outgassing while protecting bearing surfaces from rust and friction are widely available.

Good: Cleanroom-rated lubricants
Look for: Opportunities to minimize the need for lubrication through component selection

Feature image credit: Lin Engineering, Inc.

How to specify motion components for cleanroom environments: Part 1

August 29, 2018 By Danielle Collins Leave a Comment

In this two-part article, we cover the products, materials, and features that designers and engineers should specify when choosing motion components for cleanroom environments. In part 1, we look at how to reduce particle generation due to friction between moving components.

Designers of automation systems are tasked with many competing demands, such as balancing cost and performance, fitting motion components and systems into existing machine or process layouts, and designing for ease of manufacturing and assembly — to name a few. But when the system is to be used in a cleanroom, an additional layer of complexity is added, requiring designers to choose products that won’t degrade or compromise the cleanroom environment.

The level of “cleanliness” of a cleanroom is determined by the number of particles, broken down into six size ranges, that are present in a specified volume of air. In the United States, Federal Standard 209E is often used for cleanroom ratings, although it was officially canceled in 2001. This standard specifies cleanroom levels from 1 (best) to 100,000 (worst) in multiples of 10.

The current, and more universally-accepted, standard is ISO 14644-1, which defines cleanrooms on a scale from 1 (best) to 9 (worst). Each of the ISO classifications has a corresponding FS 209E level, with the exceptions of ISO classes 1 and 2, which are higher (better) than the highest FS 209E classification, and ISO class 9, which is lower (worse) than the lowest FS 209E classification.

ISO standard 14664-1 rates cleanrooms on a scale from 1 (best) to 9 (worst). Federal Standard 209E uses a scale from 1 (best) to 100,000 (worst) based on the number of allowable particles greater than or equal to 0.5 micron.
Image credit: Mecart Inc.

Objective #1: Reduce friction

One of the two primary sources of contamination, or particles, that can degrade a cleanroom environment is friction from moving components. (The other source is people.)

Virtually every motion system involves some amount of friction between sliding or rolling surfaces — whether from linear bearings, rotary bearings, or meshing gears. And when there is friction, particles are generated. Therefore, when specifying motion components for cleanroom environments, reducing friction should be the foremost objective.

Linear guides and drives

To minimize friction from linear guides, choose rolling contact rather than sliding contact and, when possible, avoid systems with high preload. For example, a non-preloaded miniature rail guide that uses two rows of recirculating balls emits significantly fewer particles than a preloaded standard guide with four rows of recirculating balls. And because there’s little chance of the bearing experiencing contamination in a cleanroom environment, use linear guides with low-friction or non-contact type seals.

Air bearings are another, although less common, method for guiding and supporting loads. In cleanroom applications, however, air bearings are often the best choice for low particle generation, since they are completely non-contact devices.

When it comes to linear drives, belts and chains should be avoided in cleanroom applications, due to the significant contact and wear they experience. Similarly, the meshing of gears in rack and pinion systems cause high friction and wear, so these should also be avoided. This means that ball screws are typically the default choice for linear drives in cleanroom applications.

However, ball screws require lubrication, and the rotation of the screw can cause lubrication to “sling” or “splatter,” contaminating the cleanroom environment. Using low-friction or non-contact seals (see above) will help keep the lubrication inside the ball nut and protect the cleanroom.

Like air bearings for linear guidance, linear motors provide a completely non-contact option for driving the load. But in their traditional setup, linear motors operate with the forcer (primary part) moving. This means the cables must move as well, and as we’ll discuss below, cables are another source of particle generation. A better configuration for cleanroom applications is to keep the forcer (primary part) and its cables stationary and allow the magnet track (secondary part) to move.

The combination of air bearing guides and a linear motor drive in this ABL 2000 stage from Aerotech provides completely non-contact movement, ideal for cleanroom applications.

Good: Rolling contact (rather than sliding contact) guides and drives
Better: Air bearing guides and linear motors
Look for: Low-friction or non-contact seals; cleanroom lubrication

Cables and cable management

Another source of friction and, therefore, particle generation, is the cable management system, including the cables themselves. Traditional round cables can generate particles when they rub against each other or against parts of the cable track. The best way to reduce particulates from cables and cable management systems is to use components and system design practices that reduce the amount of cabling required — for example, using an integrated motor-drive system instead of separate motor and drive components.

Cable carriers used in cleanrooms should have low vibration, low-abrasion fastening, and smooth interior surfaces to prevent abrasion of cables.
Image credit: igus Inc.

For the power, feedback, and data cables that are necessary in a motion control system, manufacturers offer cable designs with special low-friction coatings to minimize particulates and reduce outgassing. Similarly, several cable track manufacturers offer systems that reduce wear between chain sections through the use of abrasion-resistant joints. And for shorter lengths, so-called “trackless cables” are self-supporting flat cables that don’t require a cable track or carrier.

Trackless cables are self-supporting and don’t require cable carriers.
Image credit: W.L. Gore & Associates, Inc.

Good: Round cables with anti-friction coatings; cable carriers with abrasion-resistant joints
Better: Self-supporting flat cables
Look for: Opportunities to reduce cabling

Rotating equipment: motors and gearboxes

When it comes to rotating equipment in motion applications, the bad news is, motors and gearboxes use rotary bearings, and gearboxes require meshing teeth — all of which are sources of friction and particle generation. The good news is that these components are enclosed, so particles are less likely to “escape” and contaminate the cleanroom environment. And there is a wide range of cleanroom-compatible lubricants that can be used in the high-speed, high-load conditions found in motors and gearboxes.

To improve cleanroom compatibility, it is also possible to add a slight vacuum to the motor or gearbox housing. The vacuum serves to extract and remove particulates so they don’t have an opportunity to contaminate the cleanroom. Note that vacuum purge is also a good option for enclosed actuators that have a static (non-moving) seal. Although the enclosed design tends to keep particles inside the actuator, adding vacuum purge helps to achieve higher levels (class 100, 10, or 1) of cleanroom compatibility.

Vacuum purge is an effective way to ensure particulates from closed systems, such as this linear actuator, don’t have a chance to escape and degrade the cleanroom environment.
Image credit: THK Co., Ltd.

Good: Fully enclosed housings
Better: Vacuum purge
Look for: Cleanroom grease options

In part 2 of this article, we’ll look at another source of contamination — outgassing — and how to minimize it.

WITTENSTEIN alpha CAD POINT smart catalog for gearbox configuration and selection

July 23, 2018 By Lisa Eitel Leave a Comment

CAD POINT by WITTENSTEIN alpha helps engineers and motion control specialists access product information, data sheets, and CAD data in just a few clicks. This online smart catalog features the entire product portfolio for WITTENSTEIN gearboxes and actuators in conjunction with a database of more than 16,000 motors.

CAD POINT makes it easy for users to compare products, then download data sheets, generate CADs and request pricing — all with a few clicks.

Users can search by product type or specific ordering code. Once they’ve found the product they are seeking, they can finish the selection process by requesting a non-binding quote.

CAD POINT supersedes the old Info & CAD Finder, getting the same results in half the time. Linking databases for gearboxes, motors, and actuators (with an enhanced user interface) makes it even easier to find CAD data, product information, data sheets, and quotes.

Users can begin with a known gearbox type or a preferred size and then compare it with different gearbox and drive configurations. Once selected, the characteristics are subsequently remembered throughout the configuration process … even after switching to a different size. This makes comparing several possible alternatives simple and fast.

To further expedite results, users can enter a specific product ordering code. CAD POINT automatically validates entered code to eliminate data entry errors and then generates the specific results.

CAD POINT is the latest enhancement in the robust portfolio of sizing tools from WITTENSTEIN. There are three distinct tools:

CAD POINT is for design engineers who already use drive solutions from WITTENSTEIN alpha, are familiar with the applications and benefits, and would like to compare configurations or retrieve CAD data just a few clicks.

SIZING ASSISTANT is designed for engineers searching for the quickest way to select the most suitable gearbox for their servo drives or kinematics based on a specific motor or a predefined application.

cymex 5 sizing software is used for more detailed sizing tasks such as:

• Main axes involving shaft and bearing calculations

• Simultaneous definition of any number of axes in one project

• Examination of electrically preloaded drives

• Optimization of design spaces.

Available as a free download with license registration, cymex 5 is the optimal multifunctional sizing tool. For more information, visit the CAD POINT website or www.wittenstein-us.com.

Located in Bartlett, Illinois, WITTENSTEIN Inc. produces servo gearboxes, actuators, linear systems and motion control systems that optimize machine performance and lower cost of ownership. WITTENSTEIN is worldwide for the quality of its products and its global network of engineering expertise, which combine to deliver competitive advantage for its OEMs, system integrators, distributors and end user customers.

With around 2600 employees worldwide and sales of €385 million in 2017/18, WITTENSTEIN SE is internationally known for for innovation, precision, and excellence in the field of mechatronic drive technology. The group comprises six pacesetting Business Units with separate subsidiaries for servo gearboxes, servo actuator systems, medical technology, miniature servo units, innovative gearing technology, rotary and linear actuator systems, nano technology and electronic and software components for drive technologies.