Saturday, October 28, 2006
IR thermometer gives on the spot readings
A novel handheld, infra-red temperature measurement device enables engineers to measure the surface temperature of objects down to 13mm. The unit benefits from a slimline, ergonomic design and the appearance, size and weight of the device is comparable to that of a standard TV remote control, so can easily fit into the user's pocket. Micro-Epsilon's Optris MiniSight and MiniSightPlus portable measuring devices are ideal for maintenance technicians, plant engineers, test engineers, service and field engineers, who need to quickly but accurately measure the temperature of critical components, systems or equipment.
The device is capable of measuring temperatures from -32 to +530C.
Operation is straightforward.
The user simply spots an object to be measured, presses the trigger and the infra-red thermometer displays the temperature instantly.
Applications range from measuring the temperature of motors, drives, bearings, valves, heating and ventilation equipment, through to electrical connectors, fuses, electric motors, electrical wiring and control cabinets.
The device is also well suited to automotive tasks, including engine and catalytic convertor temperature checks, the scanning of ignition systems, tyre checks, the analysis of cooling system restrictions and for air conditioning system diagnosis.
The optical resolution of the Optris MiniSight is 20:1, therefore users can measure smaller targets (down to 13mm) that are further away.
This is achieved by a worldwide patented laser sighting with narrow beam aiming.
Most competing products on the market only use an 8:1 ratio.
And, because the MiniSight has a 300ms response time, engineers can sweep the device around a room looking for hot spots.
Most competing products have a slower response time of around 0.5s.
System accuracy is +/-1% from 0 to +530C and +/-1C from 0 to -32C.
The display and user interface enable engineers to set maximum and minimum limits and audible alarms.
The device is low cost (from GBP 60 to GBP 90) and more compact than other products on the market.
The unit weighs just 150g and has dimensions of 190 x 38 x 45mm.
Battery life is between 20 and 40 hours, depending on whether the backlight is used.
On the MiniSightPlus unit, offset and hold functions enable the user to make intelligent measurements.
The device is capable of measuring temperatures from -32 to +530C.
Operation is straightforward.
The user simply spots an object to be measured, presses the trigger and the infra-red thermometer displays the temperature instantly.
Applications range from measuring the temperature of motors, drives, bearings, valves, heating and ventilation equipment, through to electrical connectors, fuses, electric motors, electrical wiring and control cabinets.
The device is also well suited to automotive tasks, including engine and catalytic convertor temperature checks, the scanning of ignition systems, tyre checks, the analysis of cooling system restrictions and for air conditioning system diagnosis.
The optical resolution of the Optris MiniSight is 20:1, therefore users can measure smaller targets (down to 13mm) that are further away.
This is achieved by a worldwide patented laser sighting with narrow beam aiming.
Most competing products on the market only use an 8:1 ratio.
And, because the MiniSight has a 300ms response time, engineers can sweep the device around a room looking for hot spots.
Most competing products have a slower response time of around 0.5s.
System accuracy is +/-1% from 0 to +530C and +/-1C from 0 to -32C.
The display and user interface enable engineers to set maximum and minimum limits and audible alarms.
The device is low cost (from GBP 60 to GBP 90) and more compact than other products on the market.
The unit weighs just 150g and has dimensions of 190 x 38 x 45mm.
Battery life is between 20 and 40 hours, depending on whether the backlight is used.
On the MiniSightPlus unit, offset and hold functions enable the user to make intelligent measurements.
Relays provide robust motor protection
ABB has expanded its range of electrical relays with the addition of a new multifunction protection device for medium and large standard MV asynchronous motors. Designed primarily for motor applications ranging from 500kW to 2MW, the REM610 motor protection relay features a range of integrated functions for protection against motor damage. Part of ABB's new R600 relay series, which also includes the REF610 feeder protection relay, the REM610 handles fault conditions during motor startup, normal operation, idling and cooling down at standstill, for example, in pump, fan, mill or crusher applications.
The REM610 is suitable for use in both circuit-breaker and contactor controlled drives.
With single-, two- and three-stage overcurrent and earth fault protection functions, as well as thermal overload protection, it is also ideal for feeder cable and power transformer applications.
The REM610 comes with a built-in disturbance recorder that records instantaneous values or RMS values of measured signals via four analogue channels and up to eight user-selectable digital channels.
With its nonvolatile memory, the REM610 records fault data and reports it, even after auxiliary power failure.
This, combined with a long mean time between failure (MTBF), enables the REM610 to offer high availability.
Three fixed and eight programmable LEDs enable fast fault indication and location.
A new interface on the REM610, featuring pushbuttons and an LCD, makes it easy for users to select and view data in seven languages, ranging from details of recorded faults through to current and temperature measurements and historical data.
A user-friendly graphical configuration tool also allows users to set up application-specific configurations.
Users can program the relay by using the pushbuttons on the front of the unit, via serial communication with a computer connected to the communication port, or remotely through a control or monitoring system connected through the unit's serial communication bus.
The REM610 features a range of communication options, including SPA-bus slave, Modbus and IEC60870-5-103.
It can also communicate wirelessly with a laptop computer if required.
The REM610's compact size and small mounting depth makes it ideal for retrofits and confined space installations.
Its withdrawable 'plug and play' cassette design, makes it simple to fit and remove, helping to greatly reduce the amount of downtime required for installation, testing and maintenance.
Based on two separate units, this design automatically closes off the current transformer when the unit is removed, enabling work to be carried out safely without shutting off the supply.
The REM610 is suitable for use in both circuit-breaker and contactor controlled drives.
With single-, two- and three-stage overcurrent and earth fault protection functions, as well as thermal overload protection, it is also ideal for feeder cable and power transformer applications.
The REM610 comes with a built-in disturbance recorder that records instantaneous values or RMS values of measured signals via four analogue channels and up to eight user-selectable digital channels.
With its nonvolatile memory, the REM610 records fault data and reports it, even after auxiliary power failure.
This, combined with a long mean time between failure (MTBF), enables the REM610 to offer high availability.
Three fixed and eight programmable LEDs enable fast fault indication and location.
A new interface on the REM610, featuring pushbuttons and an LCD, makes it easy for users to select and view data in seven languages, ranging from details of recorded faults through to current and temperature measurements and historical data.
A user-friendly graphical configuration tool also allows users to set up application-specific configurations.
Users can program the relay by using the pushbuttons on the front of the unit, via serial communication with a computer connected to the communication port, or remotely through a control or monitoring system connected through the unit's serial communication bus.
The REM610 features a range of communication options, including SPA-bus slave, Modbus and IEC60870-5-103.
It can also communicate wirelessly with a laptop computer if required.
The REM610's compact size and small mounting depth makes it ideal for retrofits and confined space installations.
Its withdrawable 'plug and play' cassette design, makes it simple to fit and remove, helping to greatly reduce the amount of downtime required for installation, testing and maintenance.
Based on two separate units, this design automatically closes off the current transformer when the unit is removed, enabling work to be carried out safely without shutting off the supply.
Motor protection relay boasts extra features
ABB is expanding its range of electrical relays with the addition of a new multifunction protection device for medium and large standard MV asynchronous motors. Designed primarily for motor applications ranging from 500kW to 2MW, the REM610 motor protection relay features a range of integrated functions for protection against motor damage. Part of ABB's new R600 relay series, which also includes the REF610 feeder protection relay, the REM610 handles fault conditions during motor start-up, normal operation, idling and cooling down at standstill - for example, in pump, fan, mill or crusher applications.
The REM610 is suitable for use in both circuit-breaker and contactor controlled drives.
With single, two and three-stage overcurrent and earth fault protection functions, as well as thermal overload protection, it is also suitable for feeder cable and power transformer applications.
The REM610 comes with a built-in disturbance recorder that records instantaneous values or RMS values of measured signals via four analogue channels and up to eight user-selectable digital channels.
With its non-volatile memory, the REM610 records fault data and reports it, even after auxiliary power failure.
This, combined with a long mean time between failure (MTBF), enables the REM610 to offer high availability.
Three fixed and eight programmable LEDs enable fast fault indication and location.
A new interface on the REM610, featuring push buttons and an LCD display makes it easy for users to select and view data in seven languages, ranging from details of recorded faults through to current and temperature measurements and historical data.
A user-friendly graphical configuration tool also allows users to set up application-specific configurations.
Users can program the relay by using the pushbuttons on the front of the unit, via serial communication with a computer connected to the communication port, or remotely through a control or monitoring system connected through the unit's serial communication bus.
The REM610 features a range of communication options, including SPA-bus slave, Modbus and IEC 60870-5-103.
It can also communicate wirelessly with a laptop computer if required.
The REM610's compact size and small mounting depth makes it suitable for retrofits and installation in confined spaces.
Its withdrawable 'plug and play' cassette design makes it simple to fit and remove, greatly helping to reduce the amount of downtime required for installation, testing and maintenance.
Based on two separate units, this design automatically closes off the current transformer when the unit is removed, enabling work to be carried out safely without shutting off the supply.
The REM610 is suitable for use in both circuit-breaker and contactor controlled drives.
With single, two and three-stage overcurrent and earth fault protection functions, as well as thermal overload protection, it is also suitable for feeder cable and power transformer applications.
The REM610 comes with a built-in disturbance recorder that records instantaneous values or RMS values of measured signals via four analogue channels and up to eight user-selectable digital channels.
With its non-volatile memory, the REM610 records fault data and reports it, even after auxiliary power failure.
This, combined with a long mean time between failure (MTBF), enables the REM610 to offer high availability.
Three fixed and eight programmable LEDs enable fast fault indication and location.
A new interface on the REM610, featuring push buttons and an LCD display makes it easy for users to select and view data in seven languages, ranging from details of recorded faults through to current and temperature measurements and historical data.
A user-friendly graphical configuration tool also allows users to set up application-specific configurations.
Users can program the relay by using the pushbuttons on the front of the unit, via serial communication with a computer connected to the communication port, or remotely through a control or monitoring system connected through the unit's serial communication bus.
The REM610 features a range of communication options, including SPA-bus slave, Modbus and IEC 60870-5-103.
It can also communicate wirelessly with a laptop computer if required.
The REM610's compact size and small mounting depth makes it suitable for retrofits and installation in confined spaces.
Its withdrawable 'plug and play' cassette design makes it simple to fit and remove, greatly helping to reduce the amount of downtime required for installation, testing and maintenance.
Based on two separate units, this design automatically closes off the current transformer when the unit is removed, enabling work to be carried out safely without shutting off the supply.
Thursday, October 26, 2006
Inverters promise plug-and-play installation
Designed with simplicity in mind for machine builders and end users, the Bonfiglioli Vectron range of IP65 inverters is ideal for applications that require easy uncomplicated installation where cost savings are a high priority. They are particularly suited to applications with wash down areas without the need for cabinets. Bonfiglioli have seen an increase in demand for simple modular machines that require variable speed drives without over sophistication and its attendant high cost.
This would include for example conveyors in converting/packaging, labelling and the food processing sectors and applications such as roller shutter doors and safety barriers.
The existing IP65 inverter range has been extended to offer greater flexibility for a wider scope of applications with additions in sizes from 2.2 to 7.5kW.
Competitively priced and with full IP65 protection all these units are available from stock as 'plug and play' items that Bonfiglioli says you can 'fit and forget'.
They eliminate the need for control panels and internal wiring and are supplied complete with isolator, forward/off/reverse switch, potentiometer and keypad, digital display and EMC filter.
All units are of a durable construction in a modern compact design and are available as a single unit or with geared motors.
This would include for example conveyors in converting/packaging, labelling and the food processing sectors and applications such as roller shutter doors and safety barriers.
The existing IP65 inverter range has been extended to offer greater flexibility for a wider scope of applications with additions in sizes from 2.2 to 7.5kW.
Competitively priced and with full IP65 protection all these units are available from stock as 'plug and play' items that Bonfiglioli says you can 'fit and forget'.
They eliminate the need for control panels and internal wiring and are supplied complete with isolator, forward/off/reverse switch, potentiometer and keypad, digital display and EMC filter.
All units are of a durable construction in a modern compact design and are available as a single unit or with geared motors.
Interbus motor switch with expanded bottom housing
Interbus motor switch with expanded bottom housing sections In order to simplify the on-site assembly and installation of motor switches and to allow for the integration of additional functions, the Phoenix Contact product family of interbus motor switches has now been enlarged by two new housing versions. The new housings are equipped with a switch-disconnector and directly integrated fuses. The disconnector allows the load voltage to be easily switched on and off on the spot.
It can be secured with up to three locks against accidental switch-on for service work.
The supply voltage can be applied in the motor switch's connecting space using, for example 3 x 10mm2 cable, which is then directly passed on.
Universal terminals are used for this purpose that enable an easy distribution of power, without the need for any additional terminal boxes, saving space, time and costs at the same time.
Our new housing version is available both in mild and stainless steel.
It can be secured with up to three locks against accidental switch-on for service work.
The supply voltage can be applied in the motor switch's connecting space using, for example 3 x 10mm2 cable, which is then directly passed on.
Universal terminals are used for this purpose that enable an easy distribution of power, without the need for any additional terminal boxes, saving space, time and costs at the same time.
Our new housing version is available both in mild and stainless steel.
Motor switches have fibre optic connection
Motor switches have fibre optic connection Interbus-Drive-Shuttle motor switches from Phoenix Contact are now also equipped with a fiber optic connector that is especially suited to applications in electromagnetic interference environments. Data transfer via polymer or HCS fiber lends two particular advantages: Transmission is immune to electromagnetic interferences and the full electrical isolation prevents potential difference problems. F-SMA plug connectors are used to connect the fiber optic cable.
These can be assembled using a special fiber cutter without subsequently polishing the polymer fiber.
The fiber optic cable feeds into the protection category IP 54 housing through special hook-in type screw connectors with integrated kink protection.
These also enable pre-assembly of these cables.
Inside the housing, the fiber optic cables feed through a radius-optimized guide plate, so protecting them.
Rapid device replacement for servicing and a wide range of diagnostics functions ensure high system availability.
A permanent diagnostics feature monitors the optical transmission quality and controls the light output.
It also supplies information to the controller, which can recognize creeping deterioration in an individual fiber optic cable in the early stages, before transmission problems occur.
The CMD software enables visualization of this diagnostics information.
The software additionally offers the option of creating an extensive inspection log on the quality of all installed fiber optic cables at any time.
This eliminates time-consuming calibration of the entire installation.
These can be assembled using a special fiber cutter without subsequently polishing the polymer fiber.
The fiber optic cable feeds into the protection category IP 54 housing through special hook-in type screw connectors with integrated kink protection.
These also enable pre-assembly of these cables.
Inside the housing, the fiber optic cables feed through a radius-optimized guide plate, so protecting them.
Rapid device replacement for servicing and a wide range of diagnostics functions ensure high system availability.
A permanent diagnostics feature monitors the optical transmission quality and controls the light output.
It also supplies information to the controller, which can recognize creeping deterioration in an individual fiber optic cable in the early stages, before transmission problems occur.
The CMD software enables visualization of this diagnostics information.
The software additionally offers the option of creating an extensive inspection log on the quality of all installed fiber optic cables at any time.
This eliminates time-consuming calibration of the entire installation.
Wednesday, October 25, 2006
Digital motor relays for protection and control
A comprehensive range of digital protection relays to protect motors from abnormal conditions in the power supply, faults in the cable and problems in the motor itself is now available from Softstart UK. Manufactured by Solcon Industries, the range includes models to cover all requirements from monitoring abnormal temperature conditions alone to providing full protection from all possible faults with the addition of advanced control capabilities for all types of starting methods. Affording the highest levels of motor protection, the MPS 3000 and MPR 2000 are ideal for high voltage motors, large low voltage motors and applications where full protection and advanced warning is crucial.
Both digital motor protection relays monitor three phase currents, ground currents, voltages and up to ten temperature inputs, with the MPS 3000 offering multiple levels for each protection function.
For both models, each protection function can be designated as an alarm fail-safe, a trip (or trip fail-safe), an auto reset, a panel reset or a remote reset.
Within the 3000 and 2000 ranges are models that offer advanced motor control functions in addition to motor protection.
These cover all types of starting methods, including soft starters and variable frequency drives.
For example, the MPS 3000/C provides 16 discrete inputs to enable full control of motor start, stop, rotation direction change, etc Where such high levels of functionality are not required, the MPR 6/3 DGF is a new generation of microprocessor based relay designed to protect three phase induction motors.
With its full array of motor protection functions, the addition of direction ground fault function and three thermal sensor inputs, the MPR 6/3 DGF provides a comprehensive protection package.
In the same family as the MPR 6/3 DGF, the TPR 6 provides comprehensive protection from abnormal thermal conditions.
Monitoring up to 14 temperature inputs, the TPR 6 accurately creates a thermal model to protect the motor from faults such as abnormal heat in the windings or bearings.
Each protection function can be designated as alarm only, trip only, combined alarm and trip, disabled, enabling auto reset, or a programmable output.
Serving the UK and Republic of Ireland as the exclusive agent for Solcon, Softstart UK is dedicated to the supply of solutions to the starting, protection and control of AC motors, offering a vast wealth of experience in the planning, development and application of all motor starting solutions.
Both digital motor protection relays monitor three phase currents, ground currents, voltages and up to ten temperature inputs, with the MPS 3000 offering multiple levels for each protection function.
For both models, each protection function can be designated as an alarm fail-safe, a trip (or trip fail-safe), an auto reset, a panel reset or a remote reset.
Within the 3000 and 2000 ranges are models that offer advanced motor control functions in addition to motor protection.
These cover all types of starting methods, including soft starters and variable frequency drives.
For example, the MPS 3000/C provides 16 discrete inputs to enable full control of motor start, stop, rotation direction change, etc Where such high levels of functionality are not required, the MPR 6/3 DGF is a new generation of microprocessor based relay designed to protect three phase induction motors.
With its full array of motor protection functions, the addition of direction ground fault function and three thermal sensor inputs, the MPR 6/3 DGF provides a comprehensive protection package.
In the same family as the MPR 6/3 DGF, the TPR 6 provides comprehensive protection from abnormal thermal conditions.
Monitoring up to 14 temperature inputs, the TPR 6 accurately creates a thermal model to protect the motor from faults such as abnormal heat in the windings or bearings.
Each protection function can be designated as alarm only, trip only, combined alarm and trip, disabled, enabling auto reset, or a programmable output.
Serving the UK and Republic of Ireland as the exclusive agent for Solcon, Softstart UK is dedicated to the supply of solutions to the starting, protection and control of AC motors, offering a vast wealth of experience in the planning, development and application of all motor starting solutions.
Robust test rig speeds servomotor repairs
Reliability and robustness were the key requirements when Wyko Industrial Services set about building a load test and torque calibration rig for its servomotor repair business at Aintree near Liverpool. The company based its design on a noncontact torque sensor that could effectively be isolated from damaging shock loads. The test rig enables Wyko to provide full test and performance certification with every repaired servomotor.
The argument for conducting the routine maintenance and overhaul of servo systems can be clearly demonstrated by one of the UK's major car plants, where servo equipment on the production line is removed, checked, refurbished and returned to service by Wyko every five years, and as a result there have been zero failures to date.
Companies such as this also require comprehensive documentation to support any work that is done on plant equipment, something the new rig is designed to provide.
The proven success of the service has led to increased demand and this is another of the main reasons why a replacement test rig was required; a higher capacity, improved reporting and greater accuracy were all necessities.
Typically routine servicing is based on four or five-year cycles and can be planned for, whereas a large amount of servo equipment installed during the 1990s is starting to require attention.
The increasing number of breakdown situations with which Wyko is dealing illustrates this.
Breakdowns have to be acted on immediately due to the obvious downtime implications, and put added pressure on both the repair team and the equipment.
The test rig therefore has to be correspondingly robust.
'We knew the rig would be in virtually constant use, so wanted to design out breakdowns as far as possible', said Vic Harris Wyko's Director for Electronic Developments.
'Unexpected stoppages would be disruptive to us, but potentially disastrous to our customers who often run 24 hours a day and therefore need to manage their spares and repairs with military precision'.
Wyko's clients include BAE, transmission giant Ford Getrag and several of the food processing majors, alongside many smaller companies.
Basically the rig runs the test motors against a 22kW DC spindle motor controlled by a Sprint Electric four quadrant DC drive which is switchable between speed and torque modes to give both back driving and load testing capabilities.
Back driving the servomotor is very important because it lets Wyko capture the setup data for each servomotor before it is dismantled, which in turn makes recalibration quick and simple.
Harris says he selected a Torqsense noncontact sensor, made by Sensor Technology, because it was the most advanced solution he could find and its noncontact characteristic isolates it from shock loads.
'The torque sensor is rated at 20Nm and can take 400% overload, so it can cope with just about anything it is ever likely to experience on our rig'.
'To be extra safe we have mounted it using Fenner Jaw coupling on both shafts, with the rubber inserts selected to take the sting out of any unforeseen shock loads'.
Torqsense monitors the shaft under test using a radio transmission head, which both supplies power to and picks up signals from two tiny piezo ceramic combs attached to the shaft.
Rotational torque in the shaft contracts or stretches the combs, altering their radio emission signals in proportion to the torque experienced.
'Sensor Technology also supplied us with a software suite, Torqview II, which interprets the sensor's output signal in real time and presents it in ease-to-understand graphic form'.
'It also logs and analyses the data, so we can print out a pass certificate for each tested motor'.
Thanks to the new test rig, Wyko's servo repair capacity has increased, and repaired servomotors now carry the same guarantee as the majority of new products (up to 12 months).
The rig also provides data on units as they arrive for service, allowing performance data to be compared and helping to identify potential problems before any work is carried out.
Wyko also supplies a full range of new automation equipment, ensuring a replacement is always at hand in the event that a motor should prove uneconomic to repair.
The argument for conducting the routine maintenance and overhaul of servo systems can be clearly demonstrated by one of the UK's major car plants, where servo equipment on the production line is removed, checked, refurbished and returned to service by Wyko every five years, and as a result there have been zero failures to date.
Companies such as this also require comprehensive documentation to support any work that is done on plant equipment, something the new rig is designed to provide.
The proven success of the service has led to increased demand and this is another of the main reasons why a replacement test rig was required; a higher capacity, improved reporting and greater accuracy were all necessities.
Typically routine servicing is based on four or five-year cycles and can be planned for, whereas a large amount of servo equipment installed during the 1990s is starting to require attention.
The increasing number of breakdown situations with which Wyko is dealing illustrates this.
Breakdowns have to be acted on immediately due to the obvious downtime implications, and put added pressure on both the repair team and the equipment.
The test rig therefore has to be correspondingly robust.
'We knew the rig would be in virtually constant use, so wanted to design out breakdowns as far as possible', said Vic Harris Wyko's Director for Electronic Developments.
'Unexpected stoppages would be disruptive to us, but potentially disastrous to our customers who often run 24 hours a day and therefore need to manage their spares and repairs with military precision'.
Wyko's clients include BAE, transmission giant Ford Getrag and several of the food processing majors, alongside many smaller companies.
Basically the rig runs the test motors against a 22kW DC spindle motor controlled by a Sprint Electric four quadrant DC drive which is switchable between speed and torque modes to give both back driving and load testing capabilities.
Back driving the servomotor is very important because it lets Wyko capture the setup data for each servomotor before it is dismantled, which in turn makes recalibration quick and simple.
Harris says he selected a Torqsense noncontact sensor, made by Sensor Technology, because it was the most advanced solution he could find and its noncontact characteristic isolates it from shock loads.
'The torque sensor is rated at 20Nm and can take 400% overload, so it can cope with just about anything it is ever likely to experience on our rig'.
'To be extra safe we have mounted it using Fenner Jaw coupling on both shafts, with the rubber inserts selected to take the sting out of any unforeseen shock loads'.
Torqsense monitors the shaft under test using a radio transmission head, which both supplies power to and picks up signals from two tiny piezo ceramic combs attached to the shaft.
Rotational torque in the shaft contracts or stretches the combs, altering their radio emission signals in proportion to the torque experienced.
'Sensor Technology also supplied us with a software suite, Torqview II, which interprets the sensor's output signal in real time and presents it in ease-to-understand graphic form'.
'It also logs and analyses the data, so we can print out a pass certificate for each tested motor'.
Thanks to the new test rig, Wyko's servo repair capacity has increased, and repaired servomotors now carry the same guarantee as the majority of new products (up to 12 months).
The rig also provides data on units as they arrive for service, allowing performance data to be compared and helping to identify potential problems before any work is carried out.
Wyko also supplies a full range of new automation equipment, ensuring a replacement is always at hand in the event that a motor should prove uneconomic to repair.
SmartMotor now with multi-axis contouring
Animatics has now added multi-axis contouring capability to its line of SmartMotors. The SmartMotor is a single component that combines the technologies of servo motor, controller, amplifier, encoder and PLC. This totally integrated servo motion control system delivers higher reliability, smaller foot print and radically simplified field service.
With this new contouring capability, an RS-485 network of SmartMotors can perform motion profiles as complex as multi-axis splines or as simple as circular and linear interpolation.
CAD and G-Code host interfaces can turn a laptop computer and three SmartMotors into a complete 3-Axis CNC control system on the back of the machine, without a NEMA cabinet.
Such machines are typically expensive to service and render the owner helpless in the face of down time whereas a SmartMotor based machine consists simply of motors and a PC.
The contouring function employs PC resident drivers.
These drivers are used by Animatics host interfaces and are available to OEMs for custom applications.
The interfaces are compatible with Visual Basic as well as many other tools.
Applications that benefit from this technology range from CNC milling and turning to laser cutting and water jet cutting to glue laying or engraving.
It is appropriate for any application where circular interpolation and G-Code compatibility are needed, but also where the machine builder wants a simpler, less expensive solution that is easier to support.
All that is needed is a PC with an RS-232 port.
Animatics supplies an RS-232 to RS-485 converter, resident to the mating connector to link the chain of SmartMotors.
Because bulky PC expansion cards are not used, a simple laptop will complete a system.
Contouring capability is standard in all SmartMotors and comes at no additional cost.
Host level programs to support the capability range from free to $985.
With this new contouring capability, an RS-485 network of SmartMotors can perform motion profiles as complex as multi-axis splines or as simple as circular and linear interpolation.
CAD and G-Code host interfaces can turn a laptop computer and three SmartMotors into a complete 3-Axis CNC control system on the back of the machine, without a NEMA cabinet.
Such machines are typically expensive to service and render the owner helpless in the face of down time whereas a SmartMotor based machine consists simply of motors and a PC.
The contouring function employs PC resident drivers.
These drivers are used by Animatics host interfaces and are available to OEMs for custom applications.
The interfaces are compatible with Visual Basic as well as many other tools.
Applications that benefit from this technology range from CNC milling and turning to laser cutting and water jet cutting to glue laying or engraving.
It is appropriate for any application where circular interpolation and G-Code compatibility are needed, but also where the machine builder wants a simpler, less expensive solution that is easier to support.
All that is needed is a PC with an RS-232 port.
Animatics supplies an RS-232 to RS-485 converter, resident to the mating connector to link the chain of SmartMotors.
Because bulky PC expansion cards are not used, a simple laptop will complete a system.
Contouring capability is standard in all SmartMotors and comes at no additional cost.
Host level programs to support the capability range from free to $985.
Tuesday, October 24, 2006
Failsafe industrial drive links to Profisafe
A new frequency converter from Siemens Automation and Drives is the latest addition to the Simatic ET 200S family of failsafe control systems, offering safe standstill monitoring and speed control.
The new ET 200S FC converter delivers stepless speed control of asynchronous motors, handles drive tasks ranging from simple frequency control through to stringent vector control and includes functionalities such as Safety Integrated (including Profisafe compatibility) and hot swapping. With its line-commutated regenerative feedback, the converter can be operated extremely efficiently.
The ET 200S FC is fully integrated into the Simatic ET 200S system and offers all the system advantages: lower wiring costs, self-assembling communications and energy bus, and rapid replacement of modules during operation (hot swapping).
This compact device has a modular construction and comprises a closed-loop control section and a power section that can be selected with rated outputs ranging from 0.75 to 4kW.
The new converter has a series of integrated protection mechanisms that increase the safety of equipment where there is a risk of personal injury.
Safety functions such as 'safe stop' prevent unintentional starting of the drive and 'safe braking ramp' (SBR) monitors standstill (to EN 60204 Category 0).
In addition, the 'safe reduced speed' (SG) function prevents a speed limit from being exceeded and can be implemented very cost-effectively without the need for motor encoders.
The ET 200S FC can be used for applications requiring safety related control systems conforming to EN 954-1 Category 3 and IEC 61508 SIL 2.
The power sections of the converter do not need chopper modules or brake resistors; when in generating mode, power is fed back into the supply system line-commutated.
Furthermore, the converter is operated without line-commutating reactors; this creates space in the control cabinet and reduces the power losses of the overall system.
As well as being suitable for simple drive and positioning tasks, the converter also supports torque control for conveyor system applications in the automobile, food, drink and tobacco industries, winding and unwinding drives as well as lifting gear.
Using a motor encoder, applications range as far as closed-loop control for high-precision speed and torque control.
The new ET 200S FC converter delivers stepless speed control of asynchronous motors, handles drive tasks ranging from simple frequency control through to stringent vector control and includes functionalities such as Safety Integrated (including Profisafe compatibility) and hot swapping. With its line-commutated regenerative feedback, the converter can be operated extremely efficiently.
The ET 200S FC is fully integrated into the Simatic ET 200S system and offers all the system advantages: lower wiring costs, self-assembling communications and energy bus, and rapid replacement of modules during operation (hot swapping).
This compact device has a modular construction and comprises a closed-loop control section and a power section that can be selected with rated outputs ranging from 0.75 to 4kW.
The new converter has a series of integrated protection mechanisms that increase the safety of equipment where there is a risk of personal injury.
Safety functions such as 'safe stop' prevent unintentional starting of the drive and 'safe braking ramp' (SBR) monitors standstill (to EN 60204 Category 0).
In addition, the 'safe reduced speed' (SG) function prevents a speed limit from being exceeded and can be implemented very cost-effectively without the need for motor encoders.
The ET 200S FC can be used for applications requiring safety related control systems conforming to EN 954-1 Category 3 and IEC 61508 SIL 2.
The power sections of the converter do not need chopper modules or brake resistors; when in generating mode, power is fed back into the supply system line-commutated.
Furthermore, the converter is operated without line-commutating reactors; this creates space in the control cabinet and reduces the power losses of the overall system.
As well as being suitable for simple drive and positioning tasks, the converter also supports torque control for conveyor system applications in the automobile, food, drink and tobacco industries, winding and unwinding drives as well as lifting gear.
Using a motor encoder, applications range as far as closed-loop control for high-precision speed and torque control.
High torque delivered without damaging shafts
Heavy duty stepper motor for high torque applications in industrial machinery avoids damage to shafts or flanges in high torque industrial applications, such as packaging or machine tools.
Astrosyn has introduced a new heavy duty stepper motor intended for high torque applications in industrial machinery. The unit overcomes the growing problem of damage being caused to shafts or flanges in arduous industrial motion control applications arising from the increased power made possible by the latest high torque, rare earth, hybrid stepper motors. 'In packaging machinery for example,' explained Simon Hunt, Astrosyn's technical sales director, 'it is not uncommon for conventional hybrid stepper designs to suffer from this type of damage when excessive loads are placed on the motor.' The ruggedised model L706-1 is a 3A, 1 Ohm, eight lead hybrid stepper with a step angle of 1.8 degrees.
The motor housing incorporates an ultra-robust 15mm thick Nema flange and the heavy duty motor shaft has a 9.5mm diameter.
Its rare earth magnet design generates an exceptional bipolar holding torque of 165Ncm despite its size 23 frame size.
As well as for packaging machinery, the new motor is ideal for high load applications in the machine tool industry.
Astrosyn has introduced a new heavy duty stepper motor intended for high torque applications in industrial machinery. The unit overcomes the growing problem of damage being caused to shafts or flanges in arduous industrial motion control applications arising from the increased power made possible by the latest high torque, rare earth, hybrid stepper motors. 'In packaging machinery for example,' explained Simon Hunt, Astrosyn's technical sales director, 'it is not uncommon for conventional hybrid stepper designs to suffer from this type of damage when excessive loads are placed on the motor.' The ruggedised model L706-1 is a 3A, 1 Ohm, eight lead hybrid stepper with a step angle of 1.8 degrees.
The motor housing incorporates an ultra-robust 15mm thick Nema flange and the heavy duty motor shaft has a 9.5mm diameter.
Its rare earth magnet design generates an exceptional bipolar holding torque of 165Ncm despite its size 23 frame size.
As well as for packaging machinery, the new motor is ideal for high load applications in the machine tool industry.
Integrated motion/control offer advantages
Motion and machine control systems offer advantages for automated packaging and processing machine applications, providing fully integrated, single sourced systems.
Within the packaging and processing industry, many manufacturers use motion controls, PLC, HMI, and vision systems from different vendors; Aerotech specialise in providing such integrated solutions from a single source with an extensive range of feature-rich motion and machine controls, high performance servo and stepper drives and brushless linear and rotary servomotors with the advantage of lower system and integration costs, faster time to market and lower life-cycle costs. Aerotech's A3200 Automation Platform is a software only, 32-axis distributed motion control system that runs on standard Windows based PCs and combines tightly synchronised motion with a selection of 'soft' machine control modules for HMI, vision and PLC. Using the non-proprietary IEEE-1394 Firewire protocol, the controller provides a fully deterministic, high-speed, distributed control architecture in combination with Aerotech's Ndrive servo amplifiers which independently process position and velocity motion updates at 20kHz servo loop closure rates, with power ratings up to 100A peak current.
Multi-axis packaging machine operations such as fast registration or 'virtual line-shaft' based synchronisation are easily undertaken with all motion commands accessed in C, C++, Visual Basic or in AeroBASIC - a rapid prototyping development language based on RS-274 G-code.
Alternatively, the optional Ncontrol SDK software development kit may be used to program the unit with Windows based ActiveX components, C++, VB and .NET class libraries that help to reduce programming time and effort.
Machine control modules are available for HMI (Nview) and PLC (Nlogic) with the industry standard IEC61131 language.
A vision control module (Nvision VCM) supporting standard and non-standard cameras greatly simplifies quality control or part identification requirements.
As well as the integrated 10 base T Ethernet port on Aerotech's Ndrives, a devicenet compatible module is available for interfacing third party analogue and digital I/O or other machine control components.
Within the packaging and processing industry, many manufacturers use motion controls, PLC, HMI, and vision systems from different vendors; Aerotech specialise in providing such integrated solutions from a single source with an extensive range of feature-rich motion and machine controls, high performance servo and stepper drives and brushless linear and rotary servomotors with the advantage of lower system and integration costs, faster time to market and lower life-cycle costs. Aerotech's A3200 Automation Platform is a software only, 32-axis distributed motion control system that runs on standard Windows based PCs and combines tightly synchronised motion with a selection of 'soft' machine control modules for HMI, vision and PLC. Using the non-proprietary IEEE-1394 Firewire protocol, the controller provides a fully deterministic, high-speed, distributed control architecture in combination with Aerotech's Ndrive servo amplifiers which independently process position and velocity motion updates at 20kHz servo loop closure rates, with power ratings up to 100A peak current.
Multi-axis packaging machine operations such as fast registration or 'virtual line-shaft' based synchronisation are easily undertaken with all motion commands accessed in C, C++, Visual Basic or in AeroBASIC - a rapid prototyping development language based on RS-274 G-code.
Alternatively, the optional Ncontrol SDK software development kit may be used to program the unit with Windows based ActiveX components, C++, VB and .NET class libraries that help to reduce programming time and effort.
Machine control modules are available for HMI (Nview) and PLC (Nlogic) with the industry standard IEC61131 language.
A vision control module (Nvision VCM) supporting standard and non-standard cameras greatly simplifies quality control or part identification requirements.
As well as the integrated 10 base T Ethernet port on Aerotech's Ndrives, a devicenet compatible module is available for interfacing third party analogue and digital I/O or other machine control components.
Monday, October 23, 2006
Linear drive simplifies gantry building
Modular linear drive unit with integrated position sensing can simplify the building of gantry and xyz handling systems
A type of modular linear drive unit from Copley Controls with integrated position sensing can simplify the building of gantry and xyz handling systems. Using IP67 rated industrial linear motor technology, linear stages can be bolted together in minutes to produce a rugged multi-axis configuration. The Servotube-based linear stage consists of an off-the-shelf unit with two parts, the forcer (the coils) and the thrust rod (permanent magnets).
Because direct drive actuation is used, a gearhead, servomotor and ballscrew do not have to be aligned and integrated, saving engineering time.
Backlash between a screw and nut and gearhead teeth are avoided using tubular direct drive technology, resulting in a repeatability of 12um.
Eliminating the mechanical drive train also improves speed to 10m/s, which is more comparable to belt drives, but delivers a more dynamic response reliably and with higher accuracy.
External position encoders require precise alignment, extra wiring and mounting area, occupying valuable machine space.
By using an in-built position sensor, mechanical integration is simplified; this also allows the IP67 rated system to be used in a dirty environment such as a bottling plant or food slicing machinery.
Saving space is another benefit of tubular direct drive technology.
Machine builders may find that they have to compromise on their design to accommodate a servomotor.
For example, an xy system of 1m square could require an additional 20mm for the servomotor and gearhead.
Whether affecting the external footprint or the internal operating space of the machine, eliminating this overhead is an advantage.
Large air gaps between the forcer and the thrust rod further simplify machine integration.
Alternatively, load-bearing x and y axes can be built from pre-assembled Servotube modules that typically use a single rail linear slide for support.
The rugged aluminium extrusion has Din standard T slots so that a load can be mounted directly onto the forcer.
Similarly, a z axis actuator can be bolted perpendicularly onto a z axis for instant configuration.
The Servotube requires no lubrication and a typical configuration is non-contact so it will not wear like gearheads and ballscrews.
The only maintenance that may be required is the lubrication of any external bearings added to improve radial load handling.
In addition to traditional moving forcer configurations, it is also made in a moving rod configuration called the Servotube actuator.
Often preferred for a z axis, the moving rod actuator uses a long life polymer bearing that requires no lubrication.
Servotube systems can be operated using standard sinusoidal drives, including their own range of drives such as the Xenus drive, which is matched to Servotube operation and provides plug-and-play multi-axis operation using Canopen.
A type of modular linear drive unit from Copley Controls with integrated position sensing can simplify the building of gantry and xyz handling systems. Using IP67 rated industrial linear motor technology, linear stages can be bolted together in minutes to produce a rugged multi-axis configuration. The Servotube-based linear stage consists of an off-the-shelf unit with two parts, the forcer (the coils) and the thrust rod (permanent magnets).
Because direct drive actuation is used, a gearhead, servomotor and ballscrew do not have to be aligned and integrated, saving engineering time.
Backlash between a screw and nut and gearhead teeth are avoided using tubular direct drive technology, resulting in a repeatability of 12um.
Eliminating the mechanical drive train also improves speed to 10m/s, which is more comparable to belt drives, but delivers a more dynamic response reliably and with higher accuracy.
External position encoders require precise alignment, extra wiring and mounting area, occupying valuable machine space.
By using an in-built position sensor, mechanical integration is simplified; this also allows the IP67 rated system to be used in a dirty environment such as a bottling plant or food slicing machinery.
Saving space is another benefit of tubular direct drive technology.
Machine builders may find that they have to compromise on their design to accommodate a servomotor.
For example, an xy system of 1m square could require an additional 20mm for the servomotor and gearhead.
Whether affecting the external footprint or the internal operating space of the machine, eliminating this overhead is an advantage.
Large air gaps between the forcer and the thrust rod further simplify machine integration.
Alternatively, load-bearing x and y axes can be built from pre-assembled Servotube modules that typically use a single rail linear slide for support.
The rugged aluminium extrusion has Din standard T slots so that a load can be mounted directly onto the forcer.
Similarly, a z axis actuator can be bolted perpendicularly onto a z axis for instant configuration.
The Servotube requires no lubrication and a typical configuration is non-contact so it will not wear like gearheads and ballscrews.
The only maintenance that may be required is the lubrication of any external bearings added to improve radial load handling.
In addition to traditional moving forcer configurations, it is also made in a moving rod configuration called the Servotube actuator.
Often preferred for a z axis, the moving rod actuator uses a long life polymer bearing that requires no lubrication.
Servotube systems can be operated using standard sinusoidal drives, including their own range of drives such as the Xenus drive, which is matched to Servotube operation and provides plug-and-play multi-axis operation using Canopen.
CNC automatic uses three tools simultaneously
High-speed CNC automatic lathe - with a linear axis drive, Y-axis and 36 driven tools - can apply three cutting tools simultaneously on bar components up to 65mm.
The Sprint 65 linear offers numerous advantages for the bar machining of workpiece diameters up to 65mm., as well as for chuck workpiece diameters up to 175mm. The machines are designed with impressive linear drives in the X3-axis, a Y-axis in the standard version, a 55 deg slanted bed and three dynamic 12x turrets. In the manufacturing process, the simultaneous utilisation of up to three tools leads to the highest available productivity for non-stop operation, both for complex or simple turning workpieces.
The new Sprint 65 linear now completes the Sprint linear Series for the highly efficient machining of workpieces in the diameter range up to 65mm.
With the standard-equipped 3 turrets and the Y-axis, this new machine can perform simultaneous machining with three independent tools.
This leads to shortest cycle times during machining.
In addition, the 36 driven tools on the Y and C-axes allow the machining of complex workpieces.
In short: the new automatic lathe Sprint 65 linear is the perfect alternative in the machining of short turning workpieces for small and medium lot sizes.
Especially the utilization of pioneering linear drive technology in the X3-axis contributes greatly to this achievement.
The machines of this series not only offer high dynamics with acceleration up to 1G and fast rapid traverse speed up to 40m/min, but their direct measuring systems also lead to maximum precision.
An additional productivity increase is achieved by the integrated spindle motors on main and counter spindle, each with rotational speeds of 5,000 rev/min.
After finishing, the workpieces are transported out of the work area through the counter spindle, which again reduces idle times and leads to even shorter job times.
The bar feed itself does not impact productivity, because this step in the process occurs parallel to the ejection of the workpieces.
As an option, the new Sprint 65 linear can also be equipped with an integrated gantry system, both for bar and chuck machine.
Drives and CNCs are delivered as packages, from either Fanuc or (as an option, new at the EMO) from Siemens.
The innovative control technology of the servo motors and the digitally controlled drives ensure control processes with the highest possible speed, precision and data transfer rate.
The CNC itself is located in the DMG SlimLinePanel with 15in TFT-screen, which can be swiveled, allowing the operator to always move it into the best position.
In addition, easy-to-use functionality for automatic programming helps the operator perform his task.
Finally, the integrated software for tool-wear control and automatic access to spare tools, ensures the highest degree of operational safety in three-shift operation, even in the sector of hard-to-machine materials and large series.
Innovations - Sprint 65 linear: * Up to three driven tools in operation simultaneously.
* Linear drive in X3 for maximum precision on both spindles.
* Three tool revolvers, each with 12 driven tools.
* Y-axis in the standard version for use on main and counter spindle.
* Two cooled spindle motors for high availability.
* Hydraulic quill fitting for main and counter-spindle.
* Standard-equipped with conveyor belt handling system for finished workpieces.
* tool wear control and sister tool system for increased productivity in three-shift operations (optional).
* Automation with integrated gantry-system both for the bar and for the chuck machine (option).
The Sprint 65 linear offers numerous advantages for the bar machining of workpiece diameters up to 65mm., as well as for chuck workpiece diameters up to 175mm. The machines are designed with impressive linear drives in the X3-axis, a Y-axis in the standard version, a 55 deg slanted bed and three dynamic 12x turrets. In the manufacturing process, the simultaneous utilisation of up to three tools leads to the highest available productivity for non-stop operation, both for complex or simple turning workpieces.
The new Sprint 65 linear now completes the Sprint linear Series for the highly efficient machining of workpieces in the diameter range up to 65mm.
With the standard-equipped 3 turrets and the Y-axis, this new machine can perform simultaneous machining with three independent tools.
This leads to shortest cycle times during machining.
In addition, the 36 driven tools on the Y and C-axes allow the machining of complex workpieces.
In short: the new automatic lathe Sprint 65 linear is the perfect alternative in the machining of short turning workpieces for small and medium lot sizes.
Especially the utilization of pioneering linear drive technology in the X3-axis contributes greatly to this achievement.
The machines of this series not only offer high dynamics with acceleration up to 1G and fast rapid traverse speed up to 40m/min, but their direct measuring systems also lead to maximum precision.
An additional productivity increase is achieved by the integrated spindle motors on main and counter spindle, each with rotational speeds of 5,000 rev/min.
After finishing, the workpieces are transported out of the work area through the counter spindle, which again reduces idle times and leads to even shorter job times.
The bar feed itself does not impact productivity, because this step in the process occurs parallel to the ejection of the workpieces.
As an option, the new Sprint 65 linear can also be equipped with an integrated gantry system, both for bar and chuck machine.
Drives and CNCs are delivered as packages, from either Fanuc or (as an option, new at the EMO) from Siemens.
The innovative control technology of the servo motors and the digitally controlled drives ensure control processes with the highest possible speed, precision and data transfer rate.
The CNC itself is located in the DMG SlimLinePanel with 15in TFT-screen, which can be swiveled, allowing the operator to always move it into the best position.
In addition, easy-to-use functionality for automatic programming helps the operator perform his task.
Finally, the integrated software for tool-wear control and automatic access to spare tools, ensures the highest degree of operational safety in three-shift operation, even in the sector of hard-to-machine materials and large series.
Innovations - Sprint 65 linear: * Up to three driven tools in operation simultaneously.
* Linear drive in X3 for maximum precision on both spindles.
* Three tool revolvers, each with 12 driven tools.
* Y-axis in the standard version for use on main and counter spindle.
* Two cooled spindle motors for high availability.
* Hydraulic quill fitting for main and counter-spindle.
* Standard-equipped with conveyor belt handling system for finished workpieces.
* tool wear control and sister tool system for increased productivity in three-shift operations (optional).
* Automation with integrated gantry-system both for the bar and for the chuck machine (option).
IC integrates Hall element and motor control
The new A1441 from Allegro MicroSystems Europe is a full-bridge motor driver integrated circuit designed to drive single-phase, low-voltage bipolar brushless DC motors. Commutation of the motor is achieved by the use of a single Hall-effect sensing element which detects the position of an alternating pole ring magnet. The Allegro advanced IC semiconductor process allows the integration of the Hall element on the same IC as the motor control circuitry, providing a single-chip solution for high reliability.
The A1441 is optimised for use with the vibration motors - including the thinner coin-type motor designs - that are typically used in portable electronic devices such as mobile phones, pagers, and hand-held video game controllers.
It is also suited to use in gaming machines, where brushless motors are increasingly being used for higher reliability, as well as for driving low-end fan motors that do not require currents above 150 mA.
All necessary circuitry is integrated and no external devices are required - although a bypass capacitor is recommended to lower switching transients and therefore reduced radiated emissions.
The switch-points of the device are chopper-stabilised for precision over a range of operating temperatures and voltages, providing highly accurate and repeatable commutation.
The device will operate at voltages down to 2.0 V, and the full H-bridge output provides higher torque at start-up.
An active braking function and 'sleep' mode can be enabled by an external signal.
The active braking function allows for a quick stop in order to improve stop/start cycles in applications such as gaming machines.
The micro-power sleep mode reduces current consumption to near zero current for battery management in portable applications.
The device is available in a low-profile 2 x 2 x 0.5 mm MLP package with 100% tin plating (EL package).
The A1441 is optimised for use with the vibration motors - including the thinner coin-type motor designs - that are typically used in portable electronic devices such as mobile phones, pagers, and hand-held video game controllers.
It is also suited to use in gaming machines, where brushless motors are increasingly being used for higher reliability, as well as for driving low-end fan motors that do not require currents above 150 mA.
All necessary circuitry is integrated and no external devices are required - although a bypass capacitor is recommended to lower switching transients and therefore reduced radiated emissions.
The switch-points of the device are chopper-stabilised for precision over a range of operating temperatures and voltages, providing highly accurate and repeatable commutation.
The device will operate at voltages down to 2.0 V, and the full H-bridge output provides higher torque at start-up.
An active braking function and 'sleep' mode can be enabled by an external signal.
The active braking function allows for a quick stop in order to improve stop/start cycles in applications such as gaming machines.
The micro-power sleep mode reduces current consumption to near zero current for battery management in portable applications.
The device is available in a low-profile 2 x 2 x 0.5 mm MLP package with 100% tin plating (EL package).
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