Meet the team – Dave Whitmell revisited

London Swim 2011

There is an ulterior motive to repeating my ‘meet the team’ which I will explain at the bottom of the page.

A lot has happened since 2003. Although my work position at Micromech has not changed I have achieved a certification in IPC/WHMA-A-620 as reported in the Micromech web news in June 2011 (click for details).

Peter and Robert who were then 12 and 8 when I did my last ‘meet the team’ have of course grown up. My eldest Peter has now graduated From Warwick University and is working as a Teacher in Cambridge. Robert is now doing his A levels in the 6th Form. In the summer he is helping out at the Olympics, and lucky me, I have managed to get a ticket for the events where he is working.

            Pete’s Graduation 2011           

Frances and I have now celebrated 26 years of married bliss. She is now a Teaching Assistant, which is something she has wanted to do, and she loves.

Things have changed as far as my swimming is concerned as I have stopped the Masters but I am working to get back to it by swimming at a local gym. When I gave up the Masters swimming, my waistline increased, the weight just pilled on. I am now ‘trying’ to address this little problem through the Slimming World.

With my water colour paintings, I have given a few away; to family and work colleagues, hopefully they have hung them in prime position in their homes.

Over the years I have lost both a good friend and my father in-law to cancer, and now my stepfather is recovering after having surgery to remove part of his liver. In addition to this, my father died of a heart attack 30 years ago at the age of only 49, I have therefore decided it is time to do some fund raising.

The event’s I have chosen are:

British Gas Great swim London on the 26th May
British Gas Great swim Manchester on 30th June
Annual Walk in Wales weekend of 16-17th June.

The annual walk has been taking place over the last ten years; it started when a group of dads at a local football club decided it would be a good idea to taken their sons on a weekend hill walking. Over the years we have climbed Snowdon, Ben Nevis and many other Mountains. Peter, one of the dads who organised the walks, passed away last year. It was appropriate that this years walk is dedicated to him. His sons will also be taking part.

The Charities I have chosen are:

The British Heart Foundation
Helen Rollason Cancer Charity

I guess by now you have easily figured out my ulterior motive for a ‘meet the team’ update. Clearly I am too late for my first event but if you would like to sponsor me for one of the events or perhaps both of them, please click on the links on the events to make your offer.

Many thanks

Dave Whitmell

The machine that machines the parts for precision machines often uses a direct drive or frameless motor

Manufacturing the gears or any other parts that go into a precision machine requires a machine that needs to operate at the very pinnacle of precision. If the parts produced are less than perfect then clearly any number of manufacturing businesses suffer the consequences.

Consisting of a rotor, stator and high-resolution feedback device, the DDR cartridge motor uses the machine’s bearings to support the rotor. An innovative compression coupling engages the rotor to the load and the frame of the direct drive mounts to the machine with a bolt circle and pilot diameter just like a conventional servomotor. This saves space and design time and simplifying the overall system.

The KBM is directly coupled to the machine’s load offering exceptional direct drive rotary benefits over traditional mechanical transmission systems. By eliminating the compliant components of the system, such as gearboxes, timing belts and pulleys, KBM motors increase machine throughput, reduce noise and reduce maintenance requirements to extend a machine’s useful life. These benefits are provided in a compact, yet high-performance, footprint, which allows OEMs to design smaller, more cost effective machines.

Direct Drive for the Perfect Cut Direct drive technology allows gear grinding tools, precision lathes and other machine tools to operate with the greatest possible precision and repeatability. By completely eliminating the need for transmission components, direct drive motion makes a machine simpler while reducing maintenance. And direct drive eliminates transmission backlash, chatter and compliance, so that every cut is exact, every time.
Maximum Performance with a Minimal Footprint Direct drive technology allows the motor to be located directly in the machine head, applying the required velocity and torque directly to the cutting tool. To meet the space and weight constraints of this approach these motors offer the widest torque range in the smallest possible package with the greatest installation flexibility. For this reason Kollmorgen developed the Cartridge DDR® technology to simplify things even more, enabling a simple five-minute installation process for mounting the motor and coupling directly to the load.

The Cartridge DDR™ direct drives and the KBM frameless motors consistently wins this business because it provides significant value to the customer due to greatly reduced parts count, resulting in improved simplicity and reliability. This also means reduced maintenance with the added advantage of increased accuracy for market leading registration.

Micromech is a leading UK motion expert in positioning and speed control supplying a wide range of motion control products plus associated equipment to medical, pharmaceutical, research, industry, printing, packaging, converting and manufacturing.

Micromech can supply goods either as components or complete packages and so is a significant force in the field of sophisticated multi-axis control and is a recognised specialist in servo and stepping motor applications. For more information about these exciting products contact Stirling Morley on 01376 333333 or stirling@micromech.co.uk

‘Micromech your Kollmorgen Silver Motion Partner’

SPYRAFLO ON TARGET WITH WEAPONS TRAINING SYSTEM

A leading supplier of integrated live fire and virtual weapons training systems for unmanned land and sea vehicles, aerial targets and electronic scoring devices turned to Spyraflo to help with their latest project. Given the mission-critical function of these systems for military security forces there is an overriding need for reliability, consistency and high-level system performance. To that end they have been designing Spyraflo bearings both into its individual stationary infantry target system and its stationary armoured target battle target systems. These are articulating mechanisms that achieve the long-term durability required, meeting and even exceeding their customers’ demands in respect of reliability.

Some 10 years ago this manufacturer selected Spyraflo’s flange-mounted, self-aligning bearings for one of its systems for the purposes of small arms training in the military. This was their most popular small arms training unit in the world, with over 30,000 units fielded to date.  After experiencing continued success with the Spyraflo bearings they felt confident enough to replace the bearings with another one of our important products, which was used for live fire training and qualification programmes.

The original bearings in the equipment were not sealed in any way and contamination in harsh and difficult environments led to poor bearing performance. The answer, it transpired,  was simple: a custom-designed 60mm diameter bearing from Spyraflo. After discussing the problem with Spyraflo engineers the solution was to use the self-aligning, fully sealed, flange mounted, Teflon Bronze bearing.

These leak-proof bearings are produced with corrosion-resistant aluminium housing and zinc plated steel components. The bearing also incorporates a ±5° self-aligning capability that provides the necessary shaft alignment when dealing with welded fabrications. This patented feature translated into ease of motion, while increasing the bearing’s durability and in addition enabling an extended product lifespan. A further benefit of the Spyraflo bearing is that there is no pre-assembly greasing and other preparation work is no longer required.

Micromech is the UK and Eire distributor for these intelligently designed bearings, if you would like more information about them or if desired, a sample, then contact Alan Spinks on 01376 333333 or email alan@micromech.co.uk

‘A revolution in bearing Solutions’

Direct Drive Motors on winder machines results in ‘less is more’

The Kollmorgen’s Cartridge Direct Drive Rotary™ (DDR) motors offers a rotary direct drive system solution that allows OEMs and end-users of winding machines to achieve significant competitive advantages. Consistently, the system enables 20% higher machine uptime and 30% more throughput than motor-gear solutions. At the same time, it features 40% fewer components and on average, generates a 20% lower service cost.

Significant improvements can also be achieved in acceleration and positioning accuracy, reliability, smooth running, servo drive properties, energy efficiency, and noise development. Over the entire life cycle, the Cartridge DDR motor can generate cost savings of up to 50%. They also offer further numerous advantages, not only compared to motor-gear solutions, but also in comparison with other rotary direct drives with no housing. Since they represent a standard solution, which is also extremely variable and flexibly adaptable, no individual components have to be modified to each other, then integrated in the development and production of the machine.

Consisting of a rotor, stator and high-resolution feedback device, the motor uses the machine’s bearings to support the rotor. An innovative compression coupling engages the rotor to the load and the frame of the direct drive mounts to the machine with a bolt circle and pilot diameter just like a conventional servomotor. This saves space and design times and simplifies the overall system.

Furthermore, no additional costs are incurred which are typical of other special solutions, given their significant time-consuming and labour-intensive assembly and more expensive test phase. At the same time, the risk of technical incalculability is also lowered.

Combining Cartridge DDR motor with Kollmorgen’s versatile AKD™ servo drive can improve the machine performance even further. The motor data stored in the AKD as well as sophisticated control algorithms permit greater precision, optimised energy usage and more productivity. Due to pre-configured motor data and feedback device data, the installation and commissioning is further facilitated and accelerated.

A sophisticated modular system enables the Cartridge DDR to be tailored precisely to customer requirements. Five frame sizes, 17 different lengths and 52 standard windings are available, while the nominal torque values range from 4 to 510Nm, reaching a peak torque of up to 1,090Nm, and speeds of up to 1,500RPM.

The Cartridge DDR motors combine the space-saving and performance advantages of a frameless motor with the ease of installation of a full-frame motor making them ideal for winding machines. Besides these machines, the Cartridge DDR motors are used in numerous other applications such as material punching and forming, printing, moulding and sealing.

Micromech is a leading UK motion expert in positioning and speed control supplying a wide range of motion control products plus associated equipment to industry, printing, packaging, converting and manufacturing. Micromech can supply goods either as components or complete packages and so is a significant force in the field of sophisticated multi-axis control and is a recognised specialist in servo and stepping motor applications. For more information about these exciting products contact Stirling Morley on 01376 333333 or stirling@micromech.co.uk

‘Micromech your Kollmorgen Silver Motion Partner’

The TMCM-1060 is an intelligent stepper motor controller/driver module using the new outstanding coolStep™ technology for sensorless load dependent current control

This is a single axis controller/driver 2.8A/48V, coolStep™, motor mountable (NEMA23/24) that allows for the first time an energy efficient operation of an open-loop stepper motor system. With the advanced stallGuard2™ feature the load of the motor can be detected with high resolution.

The module is designed to be mounted directly on a 57mm or 60mm flange QMot stepper motor. The module converts the motor into a compact mechatronic device with bus oriented or stand-alone control where the motor, switches, power and the multi purpose I/Os can be connected with small pluggable connectors.

The TMCM-1060 comes with the PC based software development environment TMCL-IDE for the Trinamic Motion Control Language (TMCL™). Using predefined TMCL™ high level commands like ‘move to position’ or ‘constant rotation’ a rapid and fast development of motion control applications is guaranteed. The TMCM-1060 can be controlled using a serial interface and communication traffic is kept very low since all time critical operations, e.g. ramp calculation are performed onboard. The TMCL™ programme can be stored in the on board EEPROM for stand-alone operation and the firmware of the module can be updated via the serial interface. Optional there is available CANopen firmware.
The main features of the module are: up to 256 times microstepping 51200 pos./rev (1,8° step motor), memory for 2048 TMCL™ commands and automatic ramp generation. There is on the fly alteration of motion parameters (e.g. position, velocity, acceleration), spreadCycle™ chopper for improved smoothness and high speed operation and microPlyer™ internal microstep multiplier (16 to 256 µSteps) for lower frequency on step input.
Micromech is the UK and Eire distributor for these amazing products and if you would like to find out more click here or contact Stirling Morley on 01376 333333 or email stirling@micromech.co.uk

‘Affordable Automation’

Micromech launches an ultra compact, robust 0.45Nm brushless servomotor

Now available from Micromech is the Parker Hannifin NX1, a robust brushless servomotor for applications including machine tools, palletising systems, X-Y tables, robots and a variety of special-purpose machinery.

This exciting development extends torque output down to 0.45Nm, bringing high-precision servo performance into several new areas. The NX1 series is now the smallest product in Parker’s existing range of brushless permanent magnet synchronous servomotors, which offer a choice of torque outputs from 0.45 to 64Nm, with power ratings from 0.2 to 13.7kW at operating at speeds of up to 7,500rpm.

These high performance servomotors feature an innovative ten pole, concentrated flux and rare earth magnet design of rotor, to provide outstanding motion quality and high torque density. Feedback is via a resolver, incorporated as standard, with the option to configure each NX1 servomotor to interface with Absolute, Endat or Hiperface encoders. Similarly, the new servomotor can be supplied with or without sensors, with both power and sensor connections being quick and simple, via compact rotary connectors that are auto-lockable.
The NX1 servomotor is sealed to meet either IP64 or IP65 standards, depending on requirements, as well as having CE and UL approvals. Cooling is not usually required although a forced ventilation option to IP44 is available for use in exceptionally demanding environments.

Micromech is the leading UK distributor for Parker electromechanical products and if you wish to find out more, then contact Alan Spinks on 01376 333333 or alan@micromech.co.uk

‘Affordable Automation’

Motion controller MP2310iec features modular expansion

Yaskawa’s universal standard motion controller MP2310iec, now available from Micromech, features three additional free slots for option modules. Used in conjunction with sophisticated multitasking functions this enables the module to control and monitor complex operations in a diverse automation environment.

For example, the motion controller can be equipped with communication modules for super-ordinate control units (Siemens) or for various bus systems. It can also be expanded using additional counter, I/O or positioning modules.

There are presently on offer nine different option modules. The motion controller programming is based on the international IEC61131-3 standard, so that all automation functions planned and programmed on this basis are interchangeable.

Pre-programmed software components from standard libraries help to shorten the time required for planning and putting (it) into operation. Together with its MotionWorks IEC design environment Yaskawa is providing a large number of PLCopen building blocks that ease efficient and standards-based planning and programming.

The MP2310iec is available in 4, 8, and 16 axes all comprising EtherNet/IP, Modbus/TCP and web server diagnostics. Users can select from up to three of 8 local I/O modules for the three open slots, and expanded I/O can be attained through EtherNet/IP, Modbus/TCP, and/or the Yaskawa MECHATROLINK-II network I/O modules from third parties.

Typical applications for this controller are random rotary placer, rotary table indexer, conveyor, winder, screw feeder, extrusion and precision grinder.

Micromech-Yaskawa is a website dedicated to the world-leading servo drive technology and linear products. Micromech is the UK distributor and systems integrator for Yaskawa motion products, for more information contact Stirling on 01376 333333 or stirling@micromech.co.uk

‘Affordable Automation’

News Flash: REPLACEMENT TRINAMIC PRODUCTS

Trinamic has announced the following products are to be discontinued:

EOL PRODUCT (to be discontinued)	TO BE REPLACED BY
PD-108-28 family	TMCM-1021 / PD-1021 family (to be launched)
PD-109-57 family	TMCM-1060 / PD-1060 family
TMCM-110-42 / PD-110-42 family	TMCM-1141 / PD-1141 family (to be launched)
TMCM-140-42 / PD-140-42 family	TMCM-1140 / PD-1140 family (to be launched)
TMCM-113-60 / PD-113-60 family	TMCM-1161 / PD-1161 family
TMCM-1060 / PD-1060 family	TMCM-1160 / PD-1160 family (to be launched)
TMCM-310/SG	TMCM-6110
TMCM-610/SG	TMCM-6110
TMCM-612/SG	TMCM-6110
(Please note that most EOL products can still be ordered subject to minimum quantities)

Micromech is the UK and Eire distributor for these amazing products and if you would like to discuss replacement parts or to find out more contact Stirling Morley on 01376 333333 or email stirling@micromech.co.uk

‘Affordable Automation’

Cartridge Direct Drive Motors speeds up flexographic print runs

The benefits of DDR™ technology means many customers are re-designing their entire machines around the Cartridge DDR™ motor. Flexographic printing is an ideal solution for customers who need a quick turnaround for medium to large print runs, up to about 50,000 metres of printed material. Compared to lithographic printing, advantages of flexo include faster start-up time, reduced waste and the ability to print a wide variety of inks on nearly any substrate, from thin, nonporous plastics to metal films, corrugated paperboard and more.

Consisting of a rotor, stator and high-resolution feedback device, the motor uses the machine’s bearings to support the rotor. An innovative compression coupling engages the rotor to the load and the frame of the direct drive mounts to the machine with a bolt circle and pilot diameter just like a conventional servomotor. This saves space and design time and simplifies the overall system.

Direct Drive for throughput and quality
The challenge for flexographic printing has always been to achieve quality and throughput comparable to lithography without making the process prohibitively expensive. Anilox rollers and plate cylinders must move in perfect synchronisation to ensure consistent results. For this reason printing machine OEMs are replacing bull gear and motor/gearbox driven systems with Kollmorgen direct drive technology which eliminates inaccuracies due to gear backlash, wear and compliance.

Better Motion Means a More Profitable Machine
Direct drive provides perfectly synchronised motion that’s 20 times more accurate than a geared servo system, so the press can run faster, with no loss of quality. Direct drive also minimises set-up time and eliminates the need to periodically re-tune the transmission to compensate for worn gears. Faster, higher quality printing with less downtime, maintenance and waste, this all adds up to a more profitable printing press.

Optimised solutions, end to end    
Flexo printing requires precise tension, motion control and synchronisation across the entire machine from the unwind to the rewind roller. The Kollmorgen, ‘whole system’ approach includes an integrated development environment for machine automation, motion control, I/O and HMI – speeding the time to market through graphical programming and real-time analysis. With the Kollmorgen unique co-engineering capabilities, the customer always has access to the motion solutions and expertise designers need to truly differentiate their machines from the competition. In addition, Kollmorgen is the only motor manufacturer who has the Cartridge format for a DDR™ motor. This is significant as many customers using alternative systems are replacing them with Cartridge DDR™ motor because they recognise the value this motor format brought to their machine.

Micromech is a leading UK motion expert in positioning and speed control supplying a wide range of motion control products plus associated equipment to industry, printing, packaging, converting and manufacturing. Micromech can supply goods either as components or complete packages and so is a significant force in the field of sophisticated multi-axis control and is a recognised specialist in servo and stepping motor applications. For more information about these exciting products contact Stirling Morley on 01376 333333 or stirling@micromech.co.uk

‘Micromech your Kollmorgen Silver Motion Partner’

Are your bearings causing you problems?

• Insecure mounting
• Need a minimum footprint
• Assembly difficulties
• Excessive Wear
• Misalignment
• You want minimal maintenance

We have the answer!

For children who are unable to pedal a conventional bicycle a company decided to develop a new cycle but to do this had to overcome some engineering problems. Unlike a traditional bicycle this innovative three-wheeled bike had to eliminate the difficult circular pedalling motion, replacing it with a more natural up and down stepping action.

The answer was to change this to be more like walking than cycling to give the forward motion. But of course a bike needs more than just special pedals, it also requires suitable handlebars, steering, and control. To tackle these issues the engineers realised they had to change their thinking and let the riders design the cycles. In addition the designers also involved physical therapists who suggested tilting the steering column back towards the rider so that children with spinabifida would be able to fit the cycle.

The first problem to deal with was the design of the steering column, which used a flange nylon bearing, located on a pin welded to the front axle. This caused major problems as it had no self-aligning feature and would just fracture when the steering column was tilted.

The engineers searched for suitable bearings and Spyraflo provided the answer. They requested samples of the oil-impregnated bronze self-clinching, self-aligning bearing that offers a ±5° self-alignment capability. The oil-impregnated bronze bearing was chosen for its rugged construction, as well as the self-lubricating feature as this would also keep the carbon steel alignment pin from corroding.

With the new bearing in place, the steering column could then be positioned where the rider needs the handlebars without inhibiting rotation of the column. Probably most children will not use the full 5° self-aligning feature but in tests it was used to its maximum and the steering column still worked flawlessly.

The engineers also had the added benefit in terms of cost saving and simplicity of assembly due to the patented self-clinching feature of the Spyraflo bearing. As the bearing is pressed into the bore, the tapered sides force material up into an undercut below the flange. The serration’s of the bearing act as multiple cutting edges that increase the flow of material into the undercut. When finished, the flange of the bearing is flush with the surface, and becomes an integral part of the assembly.

Micromech is the UK and Eire distributor of these clever bearings, if you would like more information about them, then contact Alan Spinks on 01376 333333 or alan@micromech.co.uk

‘A revolution in Bearings’