XMC for Xact motion control - XMC controllers utilize the EtherCAT high-performance protocol which is specifically designed for real-time communication and deterministic data exchange, making it ideal for precise motion control applications.
XMC for EtherCAT Xpansion -XMC controllers feature full EtherCAT Master capabilities, meaning they can communicate with and/or control any EtherCAT device including EtherCAT I/O, encoders, AC drives, etc.
The LS Electric XMC motion controller has numerous tate-of-the-art features built into its compact brick-style design. These controllers are optimized for advanced motion control, are available in 8- or 16-axis models, and offer a variety of high-tech capabilities for a price that can’t be beat! Research, price, buy at: www.automationdirect.com/motion-control
XMC for Xtensive automation -Not only can XMC controllers handle numerous EtherCAT devices, they also support G-code, M-code, and programming specific to robot control including Delta3, Delta3R, Linear Delta, and more.
XMC for blazing fast Xecution -The XMC controllers offer extremely fast processing capabilities, with a scan time of 6.25 ns for basic commands, 5ns for motion commands, and 30ns for arithmetic commands. EtherCAT-based high-speed communication cycle times are 0.5/1/2/4ms.
XMC for Xtreme value - The XMC controller provides both highly advanced motion control with EtherCAT communication and built-in PLC functionality for a price well below the competition. By using the powerful XMC controller for your next motion control application, you could save thousands on hardware costs alone, not to mention the FREE software and support!
Our Certifications
ISO 9001 + AS9100
ITAR Compliant-DDTC Registered
DFARS Compliant
RoHS & R.E.A.C.H. Compliant
NIST SP 800-171 Compliant
Precision Gears and Superior Mechanical Components
Turning Ideas into Reality since 1950
Engineering development, design, and manufacturing expertise combined with mechanical and electromechanical component options.
Streamline Your Supply Chain
We deliver parts and subassemblies complete, eliminating your need for additional sourcing, time, and cost.
Customized Solutions
Custom Gears & Mechanical Components
Custom Gearheads & Gearboxes
Complex Gear Assemblies
Mechanical Assembly
Electromechanical Assembly Bearings
Bevel Gears
TRENDS INCLUDE THE PRACTICAL AND EXOTIC
A protein taken from squid suction cups serves as a light-activated device that absorbs and releases chemical fuel to move.
This year Design World is taking a different tack for its coverage of Trends
We begin the year covering a representative collection of stories (as found in this issue) that typify larger shifts we’re seeing in the industry. We’ll follow with in-depth pieces in coming months highlighting the input of industry leaders and what trends they’re observing.
One new trend is the accelerated adoption of biomimicry for practical real-world applications. These include certain specialty actuators, drones (battery powered and tethered), and grippers as well as other end effectors. For the latter, biologically inspired flying robots and other designs from Festo over the years (some now commercialized) come to mind. To some extent, even humanoid robotics draw inspiration from the natural world.
Bleeding-edge biomimicry designs tend toward the tiny and exotic. Consider new micro-actuators that are inspired by the movement of water-gliding insects — tiny robots controlled by light. These robots could soon be applied in environmental remediation and biomedical applications.
“The swimming robots … respond to external cues such as light or
magnetic fields,” said University of Waterloo SMART-Lab director Hamed Shahsavan.
The research team was inspired by the movement strategy of Gerridae insects, commonly known as water striders, which release chemicals through their bodies to allow them to glide on water. They also manipulate the water’s surface with their legs to control the direction of their motion.
Tiny robots made to mimic the insects feature liquid crystal elastomers, materials that change shape in response to light, and protein-based chemical motors inspired by squid biology. When exposed to ultraviolet ( UV ) or visible light, flexible legs on the robots bend upward or downward, altering surface tension with the water and mirroring how water striders steer to move forward, turn or pivot.
“We’re laying the foundation for a new generation of microrobots,” added Shahsavan. “With more development, these smart could autonomously navigate environments.”
It’s always the combination of seemingly fanciful research like this along with incremental industry-driven innovations that continually advance machine designs and engineering. •
Rotary Actuators with Integrated Servo Drive Simplify.
The IDT Series is a family of compact actuators with an integrated servo drive with CANopen® communication. They deliver high torque with exceptional accuracy and repeatability, and feature Harmonic Drive® precision strain wave gears combined with a brushless servomotor. Some models are available with a brake and two magnetic absolute encoders with the second providing output position sensing. This revolutionary product line eliminates the need for an external drive and greatly simplifies cabling, yet delivers high-positional accuracy and torsional stiffness with a compact form factor. For
• Actuator with Integrated Servo Drive utilizing CANopen®
• 24 or 48 VDC nominal supply voltage
• A single cable with only 4 conductors is needed: CANH, CANL, +VDC, 0VDC
• Zero Backlash Harmonic Drive® Gearing
• Panel Mount Connectors or Pigtail Cables Available with Radial and Axial Options
• Control Modes include: Torque, Velocity, and Position Control, CSP, CSV, CST
YOUR CUSTOM SOLUTIONS ARE
STANDARD PRODUCTS
Advanced Products for Robotics and Automation
CGI Motion standard products are designed with customization in mind. Our team of experts will work with you on selecting the optimal base product and craft a unique solution to help di erentiate your product or application. So when you think customization, think standard CGI assemblies.
Connect with us today to explore what CGI Motion can do for you.
AUTOMATED MARKETS LEADING THE CHARGE
Consider one cutting-edge advancement for industrial automation: Festo SupraMotion technology uses superconductors to contactlessly suspend and move objects. The system leverages the way in which superconductors (when cooled below a transition temperature) can hold the field of a permanent magnet. This keeps the magnet and superconductor at a defined distance from each other — even through walls, in liquids, or in a vacuum.
The result is stable levitation sans the need for active control. The technology could soon see use in cleanrooms and other exacting settings involving laboratory automation, medical-device manufacture, and food processing.
Over the last year, Design World has tracked several persistent and emerging trends that build on the last decade’s innovations. With some notable exceptions, many of the core technologies employed in motion systems and automation are familiar. Yet, propelled by the radically increased capabilities of electronics and software, these core technologies have catapulted the design-engineering space into new application arenas. Just one example is the Festo SupraMotion technology mentioned above.
The trends towards increased digitization and interconnectivity continue, as do efforts towards digitaltransformation ( DX ) initiatives based on cloud-based analytics.
Image: Festo
For motion systems and automation, such programs offer real-world uses for realtime monitoring, adaptive predictive maintenance, and self-optimizing controls. Visit designworldonline.com/trends for some perspective on past years’ steady march to the current state of the industry.
At the recent MD&M ATX West tradeshow in Anaheim, Calif., many discussions covered the introduction of ever-tinier components. These include precision planetary gearing with gears ∅2 mm and smaller, NEMA-stepper actuators (to NEMA 6), dc micromotors (especially slotless motors to below ∅11 mm), dime-sized power supplies and drives leveraging new proprietary forms of heat shedding, and linear bearings to 2 mm wide. Manufacturing such technology necessitates the use of precision modeling and machining, micromolding, and additive-manufacturing
processes capable of producing minuscule parts with top accuracy.
Medical-device manufacturing continues to drive demand for these kinds of tiny motion components to complement disposable equipment, implantables, and high-precision components as for fluid metering and heart-valve control. In addition, all need cleanroom manufacturing demanding it own unique lineup of motion systems.
However, smaller components and cleanroom manufacturing aren’t only for medical devices. The semiconductor and aerospace industries make heavy use of many of the same technologies.
When designs are especially small, they’re usually one-of-a-kind. Here, manufacturers often eschew off-the-shelf products for custom assemblies. So, it’s no wonder motor, gearing, and other motioncomponent suppliers are continually
increasing emphasis on early involvement in customer projects needing tailored solutions. This trend began years ago and the approach has come to dominate in industries solving unusual design challenges.
Acquisitions and the consolidation of motion-component companies have been around since time immemorial, and is no trend at all. That said, the past year saw many more businesses merge to offer comprehensive motion-solution portfolios. Many brands specializing in power transmission, precision motion control, and mechanical components are now in the Nidec, Regal Rexnord, Timken, ABB, and Designatronics families.
This industry consolidation means in many cases, design engineers can (at least in theory) source components and subsystems from technology-agnostic suppliers. For example, OEMs in the
With a comprehensive line up of encoder solutions, Renishaw brings the expertise needed to address your manufacturing challenges. Whether your application calls for optical, magnetic or laser technology, our encoders achieve the highest levels of accuracy, durability and reliability.
Powerfully positioned for innovative motion control.
robotics space can now get strain-wave gearing, planetary gearing, and cycloidal gearing from single sources that in many cases offer motor integration as well. This is helpful where a given six-axis robotic design employs all three gearing types.
As covered many times in the past by Design World, engineering teams are often short-staffed (in some cases assuming motion system design work outside a core area of expertise) so all global suppliers are touting and promoting their customization and system-integration services. Some also underscore the importance of digital accessibility of product data and specifications in the form of CAD files (including those generated on the fly from online configurators) and freely available online product information.
In a related trend, there continues to be a global labor shortage specific to skilled workers for manufacturing and qualified machine operators. Especially in the U.S., the labor market is facing
challenges due to an aging population and (some would argue) insufficient support of national trades-related apprenticeship and internship programs.
All this has driven new investment in training programs as well as the adoption of automated solutions — especially for machine tending and assembly tasks. Though geopolitical developments could change overall business trends, many companies in automation have recently expanded operations or plan for expansion of physical facilities as well as reach into international markets.
More specifically, the Southeast U.S. continues to see onshoring and other investment in new automotive and EV manufacturing, while the Midwest is seeing expansion of advanced manufacturing of motion components and robotics as well as traditional and EV automotive manufacture.
Meanwhile, the West Coast and Northeast continue to leverage existing networks to drive software, consumer
electronics, robotic, and biotech and medical-device development and manufacture.
Thanks in large part to the CHIPS Act, the Southwest (led by TSMC, Texas Instruments, and Samsung) has benefited from expanded semiconductor manufacture with new chip-fabrication facilities. One caveat here: As reported by Design World Editor-in-Chief Rachael Pasini, the Semiconductor Industry Association predicts that while 114,800 new jobs will be created in the U.S. semiconductor industry by 2030, more than half of those jobs to go unfilled. Visit designworldonline.com and search Chips Act for more information.
Since the COVID-19 pandemic, the U.S. has also seen a surge in the use of laboratory automation. The latter is helping meet high-throughput testing demands, minimize the effect of human error on workflows, and speed the pace of life-sciences and pharmaceutical research. Employed here are precision motion systems (including compact Cartesian motion designs), robotic arms, and software leveraging AI.
With all the buzz surrounding these markets, let us not forget how the packaging industry around the globe also continues to drive technology trends.
By most estimates, U.S. packaging is a $240B industry — a large piece of the $3T manufacturing as well as the $2.3T logistics and services industries.
In fact, packaging machinery has become increasingly adaptive with modularity, controllability (via DX connectivity), and the safety, efficiency, and global networking standards. Today’s packaging equipment also leverages motion and mechanical mainstays with control software and electronics enabling accuracies, speeds, and other performance characteristics impossible just a decade ago.
While the comparable size of the packaging industry could recede with the renaissance of U.S. semiconductor manufacturing, it will continue to drive innovation to meet high throughput, sustainability, and flexibility objectives. •
You won’t have any doubts about the gearmotor in your next machine design after consulting with the experts at Bodine Electric Company. From diagnosing the symptoms of your application to prescribing the best treatment, our engineering team will be on call during the entire procedure. With 120 years of experience, and over 1,500 stock products to choose from, Bodine’s second opinion may very well become your final answer.
Check out our case study to see how Bodine’s second opinion for a quiet gearmotor resulted in a stress-free atmosphere for mammography patients.
Recent warehouse-efficiency improvements benefit manufacturers, distributors, and buyers.
BY KELSIE MCMILLIN SENIOR TECHNOLOGY SPECIALIST, I o T DIGIKEY
Supply chains have significantly transformed in the last decade with the advent of the Internet of Things (IoT) and digital-transformation (DX) initiatives. Beyond tracking a package or product, the ability to monitor specific details has become key to today’s warehouses and distribution centers.
More specifically, connected devices and sensors enable realtime monitoring of production processes, facilitating predictive maintenance and improving overall efficiency. In fact, the proliferation of the IoT in supply-chain operations has spurred development of some of the most innovative sensor technologies on the market. Image: DigiKey
SENSORS FOR VISIBILITY
An effective supply chain starts with optimized warehouses. Here, sensors are key to improving visibility, efficiency, and successful management of materials as they move through production, storage, and distribution. Using IoT sensor data allows manufacturers to make well-informed decisions, whether in the warehouse or remotely monitoring the system.
Though the type of connectivity may vary depending on the range needed and the location of the sensor, many facilities use Ethernet in combination with WiFi, Bluetooth low energy (BLE), and cellular communications. Sensors can ensure that environmental factors (including temperature or humidity) are stable to provide realtime tracking data or even monitor predictive maintenance needed on warehouse machinery. Further, positioning sensors such as accelerometers and gyroscope sensors can track a product’s position and orientation.
Tapping into IoT sensors allows data to be stored, analyzed, and interpreted. This can identify areas for improvement or solutions for issues that may arise. Asset trackers and sensors are becoming less expensive, so they are more widespread in manufacturing and warehousing facilities. With the increasing number of sensors available, data management becomes more important.
SENSORS FOR TRACEABILITY
IoT sensors are also key to inventory management and traceability. These include sensors connected to barcodes that automatically log items in and out to ensure reliable stock levels. Barcode scanners with image sensors also provide valuable realtime visibility throughout a product’s journey through the supply chain.
In the past, cameras only took pictures. Now though, they are used to track objects, monitor quality control, and ensure accurate orders. With the addition of IoT to warehouses, sensors and the corresponding data can go to the cloud and stored in case of future detection of defects or recalls.
Advanced traceability solutions are essential for a welldeveloped supply chain and optimized warehouse functionality. Traceability scanners minimize manual checks and add efficiency by viewing multiple items simultaneously, aiding in quality control, packaging and accuracy for current and future orders.
ROBOTICS LEVERAGE THE LATEST SENSING TECHNOLOGIES
Sensors are also core to the functions of advanced robotic systems to perform various tasks along the supply chain with greater precision and complexity than ever before. Collaborative robots (cobots), autonomous mobile robots (AMRs), and automated guided vehicles (AGVs) all see increased adoption as they optimize supply-chain efficiencies. AMRs can also work around tight spaces where toxic chemicals and heavy machinery pose a danger to humans.
Using sensors, machine vision, and artificial intelligence,
With enhanced scanners and camera options from suppliers such as Omron Automation, design engineers can improve their warehouse capabilities for full operational transparency and traceability. SenSWIR
Image: DigiKey
The DigiKey Supply Chain Transformed series at digikey.com details (among other technologies) the sensors necessary for many different applications in warehouse and supply-chain optimization
new format Longer lasting new rormat Belts, HEHT Split Spools_Layout 1 12/5/2
Longer Lasting Belts & Pulleys
Round, Flat, Vee and Poly-V belts and pulleys
Imaging and sensing solutions from onsemi provide valuable realtime visibility throughout a product’s journey through the supply chain.
We use 100% virgin urethane (no regrind waste) Makes stronger, longer lasting belts
« Ultra-Drive belts on standard rollers move 350+ lb boxes
« Super Strong Joints are virtually unbreakable.
« Low cost, highly efficient, elastic flat belts.
« High Tension Belts move heavier loads
« HEHT black belts double capacity
Split Line-shaft Spools
l High precision Reasonable price l Easy to install. Zero downtime.
800-770-2358 614-777-0295
614-777-9448 www durabelt com Better than Lifetime Warranty
AMRs can navigate surroundings accurately and are completely independent of human control. AGVs excel at material handling in warehouses and distribution facilities. They move on preprogrammed paths through software programming and using sensors such as LiDAR. AGVs are designed to handle basic tasks such as moving pallets or removing trash.
Cobots do menial and dangerous tasks alongside human counterparts freed to work on more complicated jobs. Cobot sensor arrays to detect the presence of people or obstacles. For example, laser scanners on cobots prompt speed reductions in predetermined zones to ensure worker safety.
With DX programs in place, all information related to these actions can go to the cloud for analysis anywhere. This ensures continuous operational improvement for full-capacity performance.
ENHANCED CONNECTIVITY
The latest communication technologies also complement sensors for fully optimized warehouse processes. Besides Ethernet, these include 5G, new forms of WiFi, and BLE for more effective data transmissions.
In fact, ever-smaller communication-component sizes are enabling connectivity in more spaces than ever before. Enhancing connectivity across warehouses assists in efficient data collection — automatically bringing it to one place for a cohesive view of what is happening and when. The future of the supply chain depends on realtime data collection, predictive analysis and end-to-end visibility, all of which rely on a strong connective platform across the supply chain.
Image: Onsemi
Ball & Crossed Roller Linear Slides
Del-Tron’s
Ball & Crossed Roller Linear Slides
• Accuracy ranging from 0.0005”/” to 0.0000040”/” of travel.
• Low friction straight-line design reduces the coefficient of friction to 0.003.
• Factory preload adjustment prevents side-play and backlash.
• Lightweight aluminum carriage and base with high load capacity.
• Inch or Metric built-in holes simplify installation and component mounting.
• Available with ball slide or crossed roller slide technology, varying precision grades and corrosion resistant materials.
• Solid Models Available for all Del-Tron Models.
FASTER MANUFACTURING WITH HIGH-SPEED AUTOMATION
MILES BUDIMIR SENIOR EDITOR
Quick and reliable data networks are a key driver of high-speed automation across numerous industries and applications.
PI’s F-141 photonics alignment system provides high throughput with motion in 4 and 6 degrees of freedom for industrial test and assembly of photonic integrated circuits (PIC).
Evolving motion control capabilities have contributed to the increased prevalence of high-speed automation, with gains in precision and adaptability. One of the keys to high-speed automation have been data networks such as EtherCAT, which have improved synchronization and scalability. EtherCAT is suitable for applications that require high speed and low latency, such as real-time multiple-axis motion control.
High-speed automation is central to many applications, including fiber alignment and optical component alignment in photonic systems, as well as assembly in silicon photonics.
One example is a new photonics alignment system from PI (Physik Instrumente). The company’s F-141 photonics alignment system provides high throughput with motion in 4 and 6 degrees of freedom for industrial test and assembly of photonic integrated circuits (PIC). This ultra-compact precision alignment system fits inside a space of approximately 5 x 7 x 4 in. (W x L x H) while providing 40 mm of XYZ travel and 12
Image: PI
degrees of rotation around the optical axis, suitable for array alignment. Direct-drive motors provide high acceleration, speed, and resolution, with long working life, while crossed-roller bearings and flexure guides ensure precision guidance.
The system is controlled by an advanced multi-axis EtherCAT-based control system with rapid signal analysis for onboard machine learning. Sophisticated scan and alignment routines are embedded in the controller, offering improved performance and simple integration compared to software-based alignment algorithms running on the host computer. PI proprietary alignment algorithms boost performance with the short firstlight detection and signal optimization times, said to be up to two orders of magnitude faster than conventional methods. The system can manage all tasks in the field of photonics and fiber-
optic alignment including simultaneous alignment in several degrees of freedom. The use of ultra-low noise electronics, PWM amplifiers, and onboard integrated 24-bit analog inputs for the highbandwidth optical power meter enable repeatable and stable optical signal coupling in a variety of environments.
TACKLING EV MOTOR MANUFACTURING
The next generation of automation, sometimes also known as Industry 4.0, calls for even more faster system performance, as well as increased precision and flexibility. And manufacturers are answering the call with a wide range of offerings and services to bring this about. In the area of motor manufacturing, one company has developed a scalable assembly system that
SMOOTH OPERATORS ROTARY MOTION COMPONENTS
meets the challenges many manufacturers are facing, including finding ways to increase production speed and efficiency while remaining adaptable.
Comau, a company delivering sustainable advanced automation solutions, has developed an innovative rotor assembly system that addresses the complex demands of new energy vehicle (NEV) production. Leveraging its automation expertise, Comau delivers flexible, scalable systems that enable manufacturers to adapt to changing industry needs while maintaining operational excellence and a competitive edge.
The rapid market evolution of NEVs is revolutionizing electric drive systems, propelling motor assemblies toward new levels of integration, higher voltage capabilities, and enhanced power outputs. As the driver of energy conversion, the electric motor plays a pivotal role
Available in Standard, Heavy Load, and Lightweight Configurations. Offering High Precision, Efficiency, Torsional Rigidity, and Low Starting Torque.
And Compact Design. Easy to Install and Maintenance. Varieties of Bearing Types and Sizes for Solution.
engineers are available to assist in finding the ideal solution to your application. Contact us for details.
in determining a vehicle’s efficiency, reliability, and overall performance.
At the heart of every motor are the stator and rotor, two critical components that define the motor’s overall performance. Because the rotor is an intricate assembly of windings, magnet steel sheets, bearings, cores, and end caps, its production necessitates cutting-edge design methodologies and manufacturing techniques to ensure highspeed operation, extended durability, and optimal vehicle performance.
The shift to advanced NEV motor technologies has significantly heightened the demands of rotor manufacturing, requiring increased precision, flexibility, and adaptability to varied product specifications. This evolution presents a series of challenges, including component alignment, strict quality requirements, and the necessity for efficient, scalable production processes. Traditional methods often fall short in addressing these complexities, calling for new, innovative solutions.
Comau’s automated rotor assembly systems are specifically engineered to tackle these challenges head-on. With modular workstation designs and adaptable configurations, its systems deliver high precision and efficiency while enabling seamless transitions between diverse product variants. This lets NEV manufacturers excel in the dynamic and competitive marketplace by leveraging
long-term scalability and operational agility. Comau’s rotor assembly lines incorporate advanced automation technologies to achieve efficient, highperformance production while setting new standards for flexibility and compatibility. The integration of 3D vision technology, which is seamlessly incorporated into rotor core and shaft loading stations, ensures precise detection. It also facilitates the smooth adaptation to varying product specifications, enhancing overall production accuracy.
To reduce downtime and maximize productivity, the optimized design incorporates lean manufacturing principles through space-efficient layouts and maintenance-friendly features, reducing downtime and maximizing productivity. In fact, the system has been proven to achieve a First Time Through (FFT) rate exceeding 99%, with standard cycle times reduced to under 90 sec.
When the Geely Group needed to ramp-up production of its high-quality electric drive components, Comau was tasked with developing and deploying a new e-drive assembly line that would guarantee high-speed, end-to-end production of the electric motor, gearbox and inverter at its Geely Vremt plant. Comau provided Geely with a process solution using multiple robots to install the motor rotors. The automated line also features 3D vision positioning and guidance, automatic high-speed magnet installation, automatic injection of rotor cores and the automatic dualposition dynamic balance correction, magnetization – all of which contributes
to ensuring higher quality and better throughput in less time.
The innovative electrification solutions are further strengthened by decades of expertise and successful delivery of turnkey rotor production lines. For example, the automated magnet insertion solution integrates vision systems and pressure monitoring to prevent misalignment or missing magnets. Real-time depth detection ensures precise positioning during the insertion process, meeting stringent quality standards. Additionally, a multi-gripper design supports simultaneous pick-and-place operations, reducing the cycle time per magnet to under 3 sec while maintaining extremely high accuracy.
Furthermore, to accommodate diverse product requirements, Comau provides multiple rotor fixation methods, including adhesive dispensing, plastic injection, and potting. Its customdesigned dispensing nozzles ensure precise adhesive application, even in narrow magnet slots. This approach guarantees uniform sidewall coverage while preventing overflow, enhancing rotor durability and performance under highspeed operating conditions.
The production lines also feature automatic balancing technologies, using high-precision components for weight addition and removal calibration. This ensures seamless adaptability across various products while maintaining equipment accuracy. Another benefit of the solution is its full compliance with stringent NVH (Noise, Vibration, and Harshness) standards, which can contribute to improved bearing longevity.
Lastly, the core shaft assembly process integrates advanced methods, combining liquid nitrogen cooling with rotor core heating to minimize assembly resistance. A pressure feedback system ensures consistent quality and dependable performance for every unit produced. These methods exemplify Comau’s commitment to integrating cutting-edge technologies that enhance both product quality and operational efficiency. •
COMAU | WWW.COMAU.COM PI | WWW.PI-USA.US
The layout of the automated rotor assembly system at the Geely Vremt plant.
Image: Geely Vremt
DRIVES BOOST MANUFACTURINGAUTOMATION EFFICIENCY
Nidec Drives has led motor-control innovation for decades from its UK headquarters in Newtown, Mid Wales. Recently, the company updated its own manufacturing operations from Industry 3.0 operations dominated by manual tasks to Industry 5.0. For example, raw materials were once manually transported by operators from a warehouse to a module assembly plant via forklift trucks and across three separate levels. This process was timeconsuming and resource intensive.
“We conducted value-stream mapping, and by taking an overview of production, preparation, and process formulated the plan for a conveyor and lift system to move raw materials around the factory — where and when they needed to be,” said Nidec Drives warehouse and distribution manager Jamie Evans.
Shigenobu Nagamori’s Nidec Way is a business-management principle employed at Nidec to promote lean-management strategies such as just in time (JIT) inventory management and kaizen (continuous improvement). Intralogistics engineering experts Invar was chosen as a partner to update the Nidec operations because of the company’s dedication to the similar core values of innovation and efficiency. Invar proposed a solution that was fully tailored to Nidec Drives’ needs and values for maximally efficient warehouse logistics.
Core to the design are pieces of production equipment, conveyors, and component store cranes that are (when possible) run off Nidec’s own Control Techniques variable speed drives.
A tote transportation system uses about 300 meters of Interroll powered tote conveyor complemented by three Nerak lifts across three buildings. Two conveyor tiers transport goods in and out of the main assembly area. Operators use screens at the infeed stations to select totes’ destinations.
In short, a tote license plate number (LPN) is scanned, and the operator places the carton onto the powered conveyor ± selecting the tote’s destination via an HMI. The tote is then transported to the first lift and directed to the operator station. Once the operator has completed their tasks, the directing and transport process repeated. Plus, in the store area of the facility, a lift
Nidec components impart the conveyors and lifts with efficiency and advanced functions.
allows for infeed or outfeed from both sides depending on where the materials need to go next.
On-demand operation and halting between tote loads minimizes unnecessary energy consumption and could yield a return on investment (ROI) in less than a year.
Integral to the system’s efficient stopstarting are three Control Techniques Unidrives and eleven Digitax HD M750
drives. Unidrives for the system lifts impart control stability and bandwidth for all industrial motor types, with the M702 variant featuring onboard Ethernet and dual STO inputs.
Option modules fitted to the Unidrive include an SI-I/O interface module and an SI-Universal encoder module for positional accuracy. The latter checks if the encoder’s value matches that of a second encoder measuring position with
a laser; if the values align, a PLC lets the drive to run. Otherwise, brakes are applied.
Nidec engineers also utilized a PTi210 Easy Motion Controller to avoid the need for software development. The module was simply plugged into the drive and connected via PowerTools Studio software — thus enabling quick creation of simple and repeatable routines repeatedly executed by the conveyors’ Unidrives.
Images: Nidec
(The PTi210 is compatible with both Unidrive and Digitax HD M750 drives.) For implementing advanced control over a single axis (as with a conveyor) the PTi210 and Power Tools software make for a costeffective option. Users of all skill levels can configure, program, select functions, and set parameters — expediating the configuration, management, and long-term conveyor maintenance.
Finally, the KI-Keypad was installed to display current draw, RPM, and faults as well as let users adjust drive parameters.
Control Techniques Digitax HD M750 servodrives complement the Unidrive range by providing maximum servo performance in a compact package. Digitax HD M750 is optimized for high-dynamic applications, offering flexibility in both standalone and modular configurations. This drive delivers full servo control, plus open-loop permanent magnet motor and induction motor control, across four functionality levels: EtherCAT, MCI machine control, Ethernet, and the flexible Base servodrive.
The Digitax HD M750 drives chosen in this project control drum motors 1) along the powered roller conveyors and 2) on conveyor inclines and declines. The drives’ benefits are compact size and high power density, dual STO, and PROFINET connectivity.
As a full machine control solution, the Unidrive works in harmony with
The installation of the new conveyor and lift system was completed in just four months.
Images: Nidec
It’s Time to Replace Your Motion Platform
Is your system outdated or not meeting expectations?
Consider a motion platform with a reputation for success.
Mitsubishi Electric’s servo motor and amplifier portfolio is respected for its precision, performance, and compatibility while offering various functions and capabilities to accommodate unique application requirements.
Read our latest success story.
Discover how an OEM grew output 300% by switching to a standardized motion control platform.
three Leroy-Somer IMfinity three-phase induction motors — one on each lift of the conveyor. Provided by Nidec ACIM, IMfinity motors reach premium efficiency up to IE4; maximizing energy savings, enhancing performance, and optimizing the productivity of the lifts. The robust design of the IMfinity range of Leroy-Somer motors ensures guaranteed performance and reduced cost of maintenance. To work seamlessly with the Unidrive, the IMfinity motors have winding protection as standard … thermal reserve for maintaining the rated torque over an extended speed range … and adaption of the metal support plate to reduce EMI.
“The conveyor is just the latest in ongoing efforts; we’re always exploring the next steps we can take to improve efficiency and quality, and we look forward to more growth,” added Evans.
“At Invar, we meticulously maintain every element of the solution through bespoke maintenance, communication, and strong connections,” said Invar project manager Sham Jama.
Looking ahead, Nidec Drives may soon implement autonomous mobile robots (AMRs) at the UK manufacturing site as well. By independently navigating their environment and picking, sorting, and transporting components) AMRs enhance employee safety and let teams focus on more complex tasks. In addition,
Nidec Drives will collaborate with Nidec Automation (producing motors, controls, integrated drives, and AMR batterymanagement systems) to explore how
FOR POSITION FEED BACK ENCODERS
Implemented in April 2024, the automated equipment now lets the team retrieve parts without physically moving and accessing bulk materials. So, production bottlenecks have been eliminated, and individual efficiencies have markedly increased.
these robots can boost the manufacturing site’s performance. •
NIDEC DRIVES
WWW.CONTROLTECHNIQUES.COM
Position, angle and speed measurement
Contactless, no wear and maintenance-free
High positioning accuracy and mounting tolerances
Images: Nidec
AD INDEX
EDITORIAL
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com
Executive Editor Lisa Eitel leitel@wtwhmedia.com
Managing Editor Mike Santora msantora@wtwhmedia.com
Senior Editor Miles Budimir mbudimir@wtwhmedia.com
VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com
Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com
Digital Design Manager Samantha Goodrich sgoodrich@wtwhmedia.com
Webinar Manager Matt Boblett mboblett@wtwhmedia.com
DESIGN
DESIGN
MOTORS TAILORED TO ROLLER TABLES
One trend in industry is toward use-specific technologies. In steelmaking, rolling mills produce sheet metal by sending material though and over a series of motorpowered compressing and transport rollers. This rolling-mill environment subjects drives to dire challenges. As plates and billets travel along roller tables, the motors driving the rollers experience high torque loads. Drivesystem reliability is concurrently threatened by high temperatures, humidity, and dust potentially infiltrating the motors.
Now, new low-voltage IEC squirrelcage motors for roller tables are helping to optimize these rolling systems in steel mills and other heavy industries with a fully sealed construction to withstand the conditions of a rolling-mill environment. In fact, a strong housing and other ruggedized features help the motors withstand extreme temperatures, vibrations, heavy loads, and falling debris. IP55 enclosures are standard, with up to IP66 available as an option, ensuring that moisture and dust can’t enter. The stator frame can be pressurized with air to prevent any ingress of water or dust. A non-ventilated design with vertical cooling ribs ensures no dust can collect on the surface and cause internal heating.
TOP:
The totally enclosed construction of ABB’s M3RP induction motors renders them immune to the ingress of moisture and dust.
BOTTOM: The ABB motors are totally enclosed frame-cooled motors (with no external cooling fan) in accordance with IEC 60034-6 IC 410. The stator frames have crosswise vertical cooling ribs, allowing optimum heat flow away from the motor surface.
The motors are low-speed units intended for direct connection to rollers and designed for use with frequency converters. End users can select motor pole number and frequency (and can even specify drive-motor packages) to avoid the need for gearboxes. That in turn trims maintenance costs and boosts efficiency. Other options include temperature sensors, encoders, and brakes.
Easy-to-use online tools allow quick motor and drive selection. In fact, a given roller table can use several of these motors under one or more drives’ stepless speed control. •
