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CNC Motion Control

Smoother machine designs, better integration

Integration of motion control and robotics, along with high-powered processing capabilities enable smoother, more secure machine designs for packaging and other industries. See video from Pack Expo.

By Mark T. Hoske September 27, 2021
Courtesy: Lenze

Automation advances make it easier for machine designs to run more smoothly, integrate more easily into fast moving processes and lines and enable more flexibility, cybersecurity and information use in packaging and other industries. Pack Expo Las Vegas, Sept. 27-29, is helping demonstrate how automation enables packaging machines with faster and smoother movements, so machine designers can think again about capabilities offered to customers.

Levitating motion control, integrated servodrive, motors

Machine designers have the opportunity to rethink packaging machines with high-powered PC-based automation and flying motion controls with 6 degrees of freedom. XPlanar Flying Motion from Beckhoff Automation can be used for diverse processing, packaging and end-of-line applications, enabling non-linear and lot-size-1 production. It has automatic collision avoidance, path planning, anti-slosh, 360-degree rotation and performs instant changeovers via TwinCAT software and can reduce machine footprint up to 50% by eliminating outdated mechanical components. XPlanar tiles can be covered with stainless steel, plastic or glass surfaces in clean-room or washdown environments.

Floating motion: XPlanar Flying Motion from Beckhoff Automation can be used for diverse processing, packaging and end-of-line applications, enabling non-linear and lot-size-1 production. Courtesy: Beckhoff Automation

Floating motion: XPlanar Flying Motion from Beckhoff Automation can be used for diverse processing, packaging and end-of-line applications, enabling non-linear and lot-size-1 production. Courtesy: Beckhoff Automation

Also shown, the eXtended Transport System (XTS) has new track management capabilities that allow movers to transfer between tracks for added processes, inspection or storage.

AMP8000 distributed servo drives combine AM8000 servomotors with an integrated and efficient servo drive for mounting on packaging machines. Innovative power electronics with cold switch technology limit power losses to very low levels. Mounting space required for motors and drives is reduced to a minimum. The motor remains attachment-compatible and achieves almost the same performance as a comparable motor/servo drive combinations without integrated power electronics.

The Industrial PC series, which started with the C6015, has proven itself through its low space requirements, universal usability and flexible mounting. The C6017 offers additional interfaces and an integrated UPS. The C6030 and C6032 were developed for applications with maximum performance requirements. Apart from the well-known benefits, the PC features impressive computing power with up to 3.6 GHz per core with 4 cores.

www.beckhoff.com/packexpo

Automation portfolio for machine builders, end users

Lenze offers the packaging industry complete system solutions and automation portfolio for the machine builders and end users. Solutions include:

Lenze’s Smart Servo Axis solution – a smart, scalable drive. The combination of an i950 servo inverter, m850 synchronous motor, and g700 planetary gearbox – with One Cable Technology – is easy-to-handle and facilitates cost-effective and flexible production processes.

The i950 servo inverter has improved computing power, and the integrated EtherCAT-Port make it possible to control multiple axes synchronously at high speed, to complete complex tasks. The i950 fits many operational scenarios with three modes of operation. It can be programmed or serve as an actuating drive under a CiA402 motion control. The most common mode of operation being the use of integrated fast technology modules that allow simple parameter setting.

Optimize drives in 60 seconds with Lenze motion control autotuning software. Courtesy: Lenze

Optimize drives in 60 seconds with Lenze motion control autotuning software. Courtesy: Lenze

The m850 synchronous motor stands out because of the favorable ratio between the mass inertia of load and motor, resulting in very quiet running. Despite high mass inertia, it is dynamic enough to handle medium to high demands. The standard version is equipped with robust resolvers. When great precision is required, multi-turn sin/cos encoders can be used. The motor is available in three sizes, in power classes extending from 2.0 to 9.2 kW.

The g700 planetary gearbox is adapted for these motor characteristics and meets requirements of medium-performance applications with rigidity and high dynamics; 14 available versions include 1-stage, 2-stage or 3-stage planetary gearboxes in five sizes with transmission intervals of 3.0-8.0 to 6.0-512.0.

Using open motor feedback protocol Hiperface DSL, the i950 allows for the use of One Cable Technology. The use of hybrid cables allows for combined servo and rotary transducer cables. This minimizes connecting cables, cable variants, and connection costs.

X4 Remote Solution provides remote access and condition monitoring to integrate the machines of a smart factory, for supervisory control and data acquisition (SCADA), manufacturing execution systems (MES0 and enterprise resources planning (ERP) and cloud applications. This integrated and ready-to-use solution consists of cloud gateways and a cloud-based range of web services that can be set up and configured.

c500 Controllers – Growing machine requirements and new challenges in the field of digital services increase the demands on control units in automation systems. New controllers provide high computing power for complex control tasks and are maintenance-free and more resistant – with a battery-free design and extended ambient operating temperature up to 140°F (60°C).

i550 protec Frequency Inverter – If space in the control cabinet is limited, and dynamic speed and torque control is required, then Lenze NEMA 4X i550 protec is the ideal inverter solution for decentralized installation close to the motor. Available in 0.5 to 30 hp power range with Safe Torque Off (STO) option.

Lenze Smart Motor reduces the number of different drive versions needed by up to 70%. This motor works without contactor or starter, fixed speeds can be set at will, and there are many integrated functions for material handling applications. It also meets the strictest energy efficiency requirements, and can be operated using a smartphone. It’s an easy solution for any horizontal material handling applications.

www.Lenze.com

Video courtesy: Patrick Lynch, CFE Media and Technology

Machine design: Motors, motion control, cybersecurity

The increasing variety of individualized and personalized packaging requires plants to offer maximum flexibility, dynamic response, and reliability in the material and manufacturing flow. From series production down to a batch size of 1: Modular solutions from Siemens Digital Enterprise offerings combined with easy-to-integrate standard applications from Siemens for the packaging industry reduce the time to market and boost plant availability – with efficient engineering and less complexity.

Technology updates include a Siberprotect cybersecurity solution and Industrial Edge for the packaging industry.

Demand for filling and packaging lines is growing worldwide, particularly in emerging and developing countries. The trend toward individualized packaging requires dynamic, flexible plants with high throughput rates. As a specialist for the packaging industry, Siemens offers future-oriented modular solutions and complex motion control – even for series production in batch sizes of 1 with its Digital Enterprise portfolio.

Requirements for packaging manufacturers are undergoing a rapid transformation, and machine builders benefit from customized scalable solutions for applications, helped by local and global packaging expertise and reduced time to market with full support of international standards, along with ready-to-use configurable standard applications for packaging.

Siemens’ Simotics S-1FS2 servomotors, for food, beverage, sterile packaging, pharmaceutical and other process applications have stainless steel housings suited to high standards of hygiene and cleanliness; three sizes to 2kW (2.68 hp) power range and up to 14 Nm (10.32 ft-lbs.) torque. Courtesy: Siemens

Siemens’ Simotics S-1FS2 servomotors, for food, beverage, sterile packaging, pharmaceutical and other process applications have stainless steel housings suited to high standards of hygiene and cleanliness; three sizes to 2kW (2.68 hp) power range and up to 14 Nm (10.32 ft-lbs.) torque. Courtesy: Siemens

One engineering tool is used for automation and motion tasks providing seamless integration by means of standardized interfaces and performance optimization with line controller and monitoring systems.

Digital solutions along the production value chain, virtualization for a faster time to market – from the digital twin to the real machine, high-performance simulation tools for the packaging line, and increased transparency via global cloud-based solutions, such as MindSphere and local Simatic IT and line monitoring systems all help machine designers.

Also shown are Simotics S-1FS2 servomotors for food, beverage, sterile packaging, pharmaceutical and other process applications with stainless steel housings suited to high standards of hygiene and cleanliness; three sizes to 2kW (2.68 hp) power range and up to 14 Nm (10.32 ft-lbs.) torque.

With housings of 1.4404 (AISI 316/316L) stainless steel, EPDM seals and bearing grease with NSF H1 approval, the servomotors are resistant to corrosion and acidic chemicals found in the process industries. This high degree of protection is in accordance with IP66/67 standards on the entire motor, with IP69k (30-bar) protection provided on the motor housing.

High dynamics due to low inherent inertia plus high overload capacity for use in pick-and-place applications, plus precise movement of heavy loads, are added features. One cable connection is provided for easy installation and cleaning. The standard absolute encoder is 22-bit multi-turn.

They’re suitable for clean-in-place (CIP) processes and for use with all commercially available cleaning agents used with washdown motors.

https://usa.siemens.com/simotics-s1fs2

https://usa.siemens.com/packaging

Robotics, motion control, automation solutions

Yaskawa has many robots and other proven technologies that can help manufacturers solve workforce and production challenges. Simple-to-use tools and efficient programming methods with intelligent capability make it easier to configure and integrate an ideal robotic solution. Technologies include:

  • The industry’s first IP67-rated collaborative robot with an easy-to-clean surface and NSF H1 certified food-grade grease for use in sanitary environments
  • A precise, high-speed selective compliance articulated robot arm (SCARA) that enables fast and precise operation for small part processing
  • Easy-to-program, direct teach collaborative robot; a hands-on demo demonstrates easy robot programming
  • Feature-rich 2D vision functionality in a cost-effective and easy to integrate hardware and software
  • Fast pallet pattern generation enabling fast development and deployment of complex palletizing systems
  • High-speed picking for distribution automation combines motion planning artificial intelligence (AI) technology and intelligent 3D vision capability for optimized recognition.

www.motoman.com

www.yaskawa.com

Yaskawa's GA500 AC Microdrive is poised to take on today’s challenges of sustainability, flexibility and ease of use. It is designed to meet RoHS2, providing a sustainable and an environmentally friendly drive. A TUV safety rating meets stringent machine safety requirements and provides a long mission time for the life of equipment. The drive is rated up to 40 HP and can be applied to 240 VAC single-phase, 240 VAC three-phase, or 480 VAC three-phase incoming power. Courtesy: Yaskawa

Yaskawa’s GA500 AC Microdrive is poised to take on today’s challenges of sustainability, flexibility and ease of use. It is designed to meet RoHS2, providing a sustainable and an environmentally friendly drive. A TUV safety rating meets stringent machine safety requirements and provides a long mission time for the life of equipment. The drive is rated up to 40 HP and can be applied to 240 VAC single-phase, 240 VAC three-phase, or 480 VAC three-phase incoming power. Courtesy: Yaskawa

– Edited by Mark T. Hoske, content manager, Control Engineering, CFE Media, mhoske@cfemedia.com.

KEYWORDS: Machine design, packaging, motion control

See levitating motion control, integrated servodrive, motors

Review an automation portfolio for machine builders, end users

Explore easier machine design with motors, motion control, cybersecurity

Observe robotics, motion control, automation solutions.

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Mark T. Hoske
Author Bio: Mark Hoske has been Control Engineering editor/content manager since 1994 and in a leadership role since 1999, covering all major areas: control systems, networking and information systems, control equipment and energy, and system integration, everything that comprises or facilitates the control loop. He has been writing about technology since 1987, writing professionally since 1982, and has a Bachelor of Science in Journalism degree from UW-Madison.