Some of the leading drive manufacturers tell us what trends they’re seeing in the industries they serve and what is new and coming down the road.

What new design trends are you seeing in areas such as robotics, battery powered designs, automated vehicles, and safety in motion control designs?

Tom Jensen
SVP/General Manager
AMK Automation

AMK has worked on two aspects of mobile applications; higher power density servo motor modules and remote connectivity for control of devices. Power density is important because mobile applications commonly run on batteries, so we have to make the most of a small power source. AMK has for years made low voltage (24/48 Vdc) servo motors and has introduced a better magnet design and high-density motor windings to get even more power from the same input energy. Because these are servos, we add value to the needed motion controller, offering web-based GUI (reachable through WiFi or Bluetooth), making the diagnostic and control of mobile vehicles and peripherals secure and safe from wireless devices.

For logistics centers, AMK has developed a turnkey conveyor cell control “MAKeCC” that can be quickly deployed across an entire facility. The core of the technology is the AMK iX decentralized amplifier/IO module that is used 1-for-1 on the physical conveyor modules that comprise a manufacturing/conveyor cell. The iX daisy-chained conveyors can be dynamically discovered and parameterized by an AMK iSA controller to work in conjunction with dozens of other conveyor modules, and other like conveyor cells. This structure provides product flow control, OEE for all plant equipment and expandability, and eliminates the need for integration of nonstandard / non-control-based equipment.

ABM Drives

ABM’s continuous developments of integrated steer feedback sensor systems in traction units for AGV applications combine mechanical and electrical reliability with closed-loop steer feedback to meet any upcoming regulations.

Electric on-road applications, all-terrain vehicles, utility vehicles, agricultural vehicles, and mobile construction vehicles require a well-thought-out low-voltage and high-current drive technology for the best performance. In addition to optimum gearmotor technology and good aerodynamics in order to travel long distances, energy-efficient motor components are required. Battery-powered vehicles require lightweight construction for all components. The dynamic response and quiet operation of the drive unit system must be designed to ensure the optimal driving comfort. Rough environmental conditions and a long operating life require robust and reliable solutions.

The industry-wide proven asynchronous motor was further developed by ABM Drives for use in mobile traction drive units to considerably increase the energy efficiency of the motor. It’s a very economical alternative to the often specified permanently excited synchronous motor.

In warehouses, drive units must be installed in confined spaces. Our modular component system offers a decentralized controller design, which reduces the engineering and installation costs considerably. SINOCHRON motors from ABM Drives operate reliably under harsh environmental conditions such as cold storage warehouses and do not require a mechanical speed sensor, with decentralized controllers, it’s a simple and robust design.

Daniel Repp
Lenze

One of Lenze’s focus industries is consumer packaged goods. Consumers want and expect highly customized products, and companies that can corner the market expect to turn a neat profit. Whether it’s individualized sports shoes, a personalized soda bottle, or the latest luxury car with custom features, unique products require an exceptionally responsive production floor with control technology that can quickly and easily adapt to changing requirements.

In a manufacturing environment like this, the machine builder needs to be focused on minimizing engineering requirements and expediting machine development by breaking down complex sequences into functional machine modules —and then seamlessly linking mechanics, electronics and software.

Don Nasca
Business Development Manager for IEV products
Delta Products Corporation

In the material handling industry it’s important that all electric vehicles be readily available and fully functional twenty-four hours a day, seven days a week. However, the uptime of an electric vehicle depends largely on the proper sizing of its battery, and the rate at which it can be safely charged with minimal human intervention for handling or maintenance.

Most industrial electric vehicles have been charged using low-efficiency chargers that can waste more than 50 percent of the power consumed from the AC line. Recently, vehicle makers have begun to increase their use of lithium-ion batteries, as the benefits for high uptime far outweigh those of lead acid. This change in battery technology within the marketplace has created an opportunity for Delta to leverage its industry-leading expertise in datacenter and telecom power electronics to bring to market battery charging systems that offer higher efficiency and higher power density than any other systems within the industrial marketplace.

Bill Faber
Director, IABG Product Marketing & Business Development
Industrial Automation Business Group
Delta Products

Regarding networked manufacturing, integration of connectivity for information and control is key to merging machine automation within factory automation environments. It brings the real-time control world in touch with production lines and enterprise systems, and defines the basis for smart manufacturing.

The AH10EMC is an example of the latest control CPU module for the AH500 series that includes two Ethernet-based network platforms built-in to accomplish this integration – EtherNet/IP for critical information sharing, and EtherCAT for real-time control. The AH10EMC includes PLC and Motion Control in one to further enhance programming and setup efficiencies in the design and development stage.

In terms of IIoT, all the above points tie into corporate IIoT initiatives to fulfill smart manufacturing. Technology enables this on the factory floor when they are IIoT ready. Simply connecting to the web or cloud is not always enough, the devices need to be smarter to provide key information; not just data. For example, in a VFD, it’s possible to collect data on current, voltage, or I/O status – but if the VFD has local computing capability to determine kWh, then energy usage can be directly interpreted. This is similar to how an edge-controller or data concentrator would collect or calculate data and translate it into key information that is easily consumed at the enterprise or cloud level.

Once the enabling technologies are in place, it is then just a matter of transporting the data and information to a place that is available and securely accessible. The DX-2300 Series Cloud Router from Delta allows for connectivity to the cloud and has strength in availability and security. With more than 15 cloud servers worldwide, Delta ensures that data is more robustly available and quicker to access than one server that might be a long distance away. Delta’s DIACloud has multiple patent designs for authentication, authorization, and data encryption to ensure that the device side of security mitigation is covered. DIACloud is also able to address many security concerns for its users, including insecure communication, authentication issues, weak cryptography and privacy issues.

Delta’s new MS300 and MH300 series High Performance Compact drive comes with an enhanced feature to run up to 1,500 Hz and 2,000 Hz respectively. These drives provide a highly competitive power electronics technology that makes high speed spindle control a possibility in an incredibly small form factor. The MH300/MS300 Series boats the smallest form factor in the industry for 480 VAac input models, and are equivalent or smaller for 240 Vac input models.

The built-in PLC sequences local operations to make it an easier drop-in solution, and reduces the need for reprogramming the existing main controller. This allows the VFD to single-handedly handle motor bearing warm-up and pneumatic control of air which might be used to keep the motor bearings cool in high speed operation.  Additionally, the drive comes with a new feature to enhance braking capability, defined as Energy Control Mode, which allows for shorter motor braking time by dynamically adjusting the motor speed and current.  In one installation, it reduced the braking time from 21 seconds to 7.8 seconds and eliminated a bulky braking resistor.

Tell us about any sizing software you have and how such tools are changing how design engineering is done.

Tom Jensen
SVP/General Manager
AMK Automation

AMK has gone way out of its way to not make proprietary sizing software. We instead work with customers to promote the use of COTS tools (like Servo Soft) to promote the understanding of electromechanical systems. It’s a trend we are hearing from customers; proprietary sizing software sizes the user into a vendor’s solution, and out of the freedom of choice.  

Daniel Repp
Lenze

Lenze has a complete engineering tool chain in place that is consistent throughout the entire machine life cycle, offering a common view on the machine to everyone involved. We can distinguish typical applications in which people with different professional backgrounds and various vocational trainings have to master their tasks within different stages of the machine life cycle.

Throughout our tool chain, we continuously accompany the customer from one phase of the machine life cycle to the next one, precisely tailored to the application and to the user’s needs.

After the machine basics are defined and available Lenze offers the DSD. DSD (Drive Solution Designer) is a program for dimensioning drives and configuring Lenze drive components to a drive system. It’s developed to help the customer find the best possible solution for their application. This includes not only the optimal drive, motor and gearing selection, but also takes into account getting the best energy savings. In order to draft and safeguard a machine concept, user-oriented drive sizing is of great importance. The DSD helps to create, optimize, and document drive solutions. Furthermore the energy efficiency for the application can be taken into consideration and can be made transparent.

How do you see IIoT influencing your products and what you supply to industry? In what ways is your company helping end users increase use of application data?

Tom Jensen
SVP/General Manager
AMK

Since the IIoT has really existed for years before being identified, we have focused on the communication passed by our products over the existing infrastructure. By making our products communicate from the “things phonebook”, they can communicate more quickly and use more features of the internet regardless of medium. By example, the AMK MultiServo uses cloud technology to retrieve kinematic models for use in the unit based on the input of the engineer configuring the unit. The communication can be Bluetooth or Ethernet connection – the controller knows where to go and how to talk.

Daniel Repp
Lenze

One of the most important drivers of IIoT is the customization of products in every facet of our lives. Only highly-flexible, intelligent and connected machines are able to manufacture customized products with the highest degree of productivity, quality and resource efficiency in large-series production. The factory of the future will only have temporary production lines and will continuously reconfigure itself – ideally fully automatically.

But IIoT also significantly increases technical complexity in mechanical engineering. OEMs are undergoing the most fundamental change since the introduction of digital control – we are entering an era of unprecedented machine intelligence.

What are some newer products your company sells with features to impart simplicity or turnkey operation?

Tom Jensen
SVP/General Manager
AMK

Our AMK MultiServo uses canned kinematic profiles to allow the quick control of standard machines. More and more we are finding that we can add value to our product by making solutions based on application needs. The first developed by AMK Automation in the U.S. is “MAKeCC”. Among the goals of this turnkey solution was to make the focus of integration for a warehouse full of conveyors an exercise in configuration, not integration. This idea makes the installation quick, provides excellent OEE on all machine modules in the space, and most of all provides plant personnel with the ownership needed for years of productivity.

Bill Faber
Director, IABG Product Marketing & Business Development
Industrial Automation Business Group
Delta Products

In response to the industry’s move to lithium batteries, Delta has focused on three key charging product segments and brings a variety of unique benefits to each that simplify operation and increase efficiency for end users.

Delta’s modular charging stations for forklift applications offer standard, opportunity and fast changing capabilities all in one charging cabinet. They are modular in design, fully programmable, and capable of charging any battery chemistry.

Delta’s on-board chargers, which are mounted inside the vehicle, require less space, and provide more power at higher temperatures. These systems also include IP65 protection, CANbus and RS232 communication, and easy-to-use applications that allow operators to upload charge profiles and download charging history.

Delta is addressing the emerging wireless charging segment with its 1kW, 24V/40A wireless charging system. Comprised of a base-pad that is connected to a wall-box and a low-weight on-board unit that is integrated into the vehicle, this solution eliminates the need for connectors or cables that frequently disconnect or fray, providing convenient, automatic charging without manual intervention.

What are some pre-engineered motion components (or even complete systems) that your company has begun to offer and why?

Daniel Repp
Lenze

The most significant factor for our customers these days is optimized engineering. This is not only because of the increasing complexity of machines, but also an ever-growing lack of technically skilled employees. Time-to-market is also becoming more and more important.

The key to making complex technology manageable and engineering processes more simple, leading to the implementation of IIoT, is consistent modularization of machine concepts and standardization of varying functional units. This will standardize and reuse the functional units needed on a regular basis, creating room for the most important factors – namely the elements specific to a certain project.

We offer our customer the Lenze FAST application software toolbox, where typical machine functions are pre-defined and are available as technology modules.

What kinds of customization have you done on your products to satisfy specific customer and application requirements? What design problems are you eliminating with this customization?

Tom Jensen
SVP/General Manager
AMK

We work hard at AMK to keep customers in our full-featured, high performance standard product categories. This is why we can offer a product catalog on an 8.5” x 11” piece of paper. Of course, we’ll do customs for customers that we have long-term relationships with, but we feel that we’ve developed our product line with enough flexibility for design options that customers won’t have to go outside of it.

Bill Faber
Director, IABG Product Marketing & Business Development
Industrial Automation Business Group
Delta Products

In order to meet the diverse needs of the industry and Delta’s wide customer base, its wireless charging systems can be applied to a wide range of industrial vehicles, from forklifts to Automated Guided Vehicles (AGVs), covering applications from 1kW to 30kW. Furthermore, they can be designed for any power level to accommodate varying utility infrastructure at each installation site. Delta’s wireless solutions eliminate the need for expensive cables and connectors, saving significant time that was once spent by operators who needed to manually charge their equipment.