Yaskawa and Micromech, a moving partnership

For the latest in technology of speed control and positioning products, Yaskawa are probably the best in the world
Yaskawa Wire Winder
Episode 6: Wire Winder

The previous wire winder machine had a number of issues to resolve, being very slow at only 40m/min and was experiencing wire breakage above 40m/min but needed to increase speed to at least 200m/min. The controls were not reliable and the tension was set ‘by feel’ rather than by set-point control also needing 2kg +/- 0.45kg to operate.

The manufacturer makes a variety of equipment to serve the semiconductor and solar industries was experiencing issues in the process to make a 0.140mm (0.0055″) abrasive-coated wire for use in cutting wafers. Their existing system relied on friction brake technology to set tension zones and control spool speeds therefore overall throughput was very slow at 40m/min and tension control was poor, resulting in product breakage. The old system was replaced with a 6 axis servo system to improve the processing speed and quality control. In spite of gearing, the Payout and Takeup spool axes could experience inertia mismatches of over 20:1. The industry leading Sigma-5 servopacks overcame the challenges without operator intervention using the 1.6 KHz response frequency, a 20-bit encoder resolution and advanced tuning-less control algorithms. Thus overall speeds of 500 m/min were comfortably reached. In addition a single 325 VDC supply was used to power the servopacks allowing for shared energy over the DC bus.

The performance achieved was a winding speed up to 500m/min (top speed), tension accuracy of +/- 0.1kg and the gained auxiliary function of geared traverse for spooling. The differentiating features of this solution were the pre-written solution toolbox for winding, Ethernet/IP interface, the Sigma-5 advanced ‘tuning-less’ operation and MECHATROLINK Digital Network. Importantly it was reliable and a simple system connecting 9 servo axes.

Yaskawa Wire Winder

The resulting benefits of this solution were the proven core code reduced commissioning time, reduced project risk, an improved performance which was a familiar connection to the PLC and HMI. The load/rotor inertia mismatches is up to 200:1 thus handling the product without re-tuning.

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’

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The Compax3 now has the New Force Control application template

Parker Hannifin has announced its latest application template T44 for the Compax3 family servo drive. Applications that require an external force sensor can now be easily solved using this template; additionally the force sensor is available as a selectable option for the ETH Electro thrust-cylinder. Furthermore many applications with other electric cylinders can be supported by the template in the same way.

Compax 3The entire T44 application template contains the following:

The template file T44 provides the input macro, which is used to configure the force control. (Inputs for force sensor, nominal data of sensor, operation modes push/pull) A suggested IEC program with the necessary functionality (positioning, activation of force control, speed supervision). The user can tailor this program exactly to customer needs
Detailed documentation for the IEC-program and template, as well as application examples.

The following Compax3 variants provide the template:

A46 for one 20mA-input with F10/F11 hardware
A47 for two 20mA-inputs with F12 hardware
A48 for two 20mA- inputs with F10/F11 hardware
A49 for one 20mA-input with F12 hardware
A37 for two 10V inputs with high input impedance.

Required firmware:

Standard force control: C3 2011R09-30 (Structure: force/current)
Advanced force control: C3 2010R09-11_ForceCtrl.fwp (Select either standard = force/current or advanced = force/speed/current; ( preferred)

Compax3 Servomanager:

>= R09_20.7

Template:

Compax3 Manager Template T44 V5
Compax3 Manager Template T44 V5
IEC: FORCE_SPEED_T44_5.PRO (as basis)

Using this template the following applications have been successfully solved:

The simulation of manual operating elements of a flight simulator (pitch elevator, side rudder, throttle control etc.)
Assembling and welding plastic tubes and ball cocks for pipelines
Riveting with a defined force profile (using electronic cam control)
Force sensor-testing equipment.

The template is available to download from the Compax3 ‘Knowledgebase’.

Micromech is the leading UK systems integrator and distributor for Parker Motion Products, for more information contact Stirling Morley on 01376 333333 or email stirling@micromech.co.uk

‘Affordable Automation’

Kollmorgen extend their range of servomotors with the introduction of the VLM series

The new VLM servomotors are available now covering the torque range of 0.5 to 4.5Nm and 16Nm peak with speeds of up to 6000 rpm. They offer two frame sizes VLM2 and VLM3 with three lengths each and many further useful options.

The Value-Line servomotors (VLM) offer good performance at an excellent price, the result is a high value, and limited feature set motor that delivers solid servo performance for a wide variety of applications. This brings exceptional value to machine builders who need good servomotor performance at the best possible price. By leveraging specially selected components and flying leads that help eliminate the need for intermediate cables, then utilising low cost feedback options, you get a servomotor product line providing a lower priced solution built around a focused set of options.

VLM servomotors are available in the most popular motor sizes with 12 standard windings, in both NEMA23 and NEMA34 (as well as metric sizes 60mm and 90mm) mounting standards, 1m and 3m lead lengths are available and with multiple shaft configurations for seamless integration into nearly any system. These servomotors can operate at 120/240 VAC or 160/320 VDC and deliver rated speeds up to 6000 RPM, while providing up to 16Nm peak torque and nearly 5Nm continuous torque. Additionally, multiple feedback devices: digital resolver SFD, resolver, Hall sensors or ComCoder with 2048 ppr and cable options: Molex, D-SUB (direct to AKD), cable with IP65 connectors and flying leads. This gives machine builders system configuration flexibility without adding significant cost. With IP40 protection, VLM servomotors are ROHS compliant, with CE, UL and cUL recognition pending.

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, research, defence 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 Alan Spinks on 01376 333333 or alan@micromech.co.uk

‘Micromech your Kollmorgen Silver Motion Partner’

Yaskawa and Micromech, a moving partnership

For the latest in technology of speed control and positioning products, Yaskawa are probably the best in the world

Yaskawa – Stove Knob TesterEpisode 5: Stove Knob Tester

The new production system for a stove knob tester required a mechanical setup with fixed position targets but also needed more speed, set point flexibility and a reduction in the excessive amount of scrapped products due to the open-loop stepper operation.

The end-user makes electrical ignition knobs for stove tops and tests the product at the end of the production line and also orients it for shipping. The system tests 12 units at a time by clamping the knobs and turning them 1.5 revolutions. While turning, the motor is looking out for an input signal indicating that a contact inside the knob was being made. When the signal is received the motor turns a preset distance, waits for a short period, and then goes to zero position waiting for the new test cycle to start. The machine zero position is established on ‘power up’ via the 20-bit absolute encoder built into the motor. The distributed servo network allows easy and reliable connection of 12 servo axes with room for expansion for up to 16 axes if necessary, all at no additional control cost.

The performance achieved by these changes is a throughput of 2000 parts per hour and an accuracy of ±2 degree per placement. The differentiating features of this solution are a 16 axis controller in a super compact package, target positions can be preset or over written by operator and absolute position feedback. The Modbus communication is to a RedLion HMI.

The resulting benefits of this solution are that the IEC 61131-3 programming environment allowed a faster implementation and commissioning time. The ‘no homing’ process on power up saves time and the machine now has a greater range and flexibility of product testing. This has achieved unbeatable price/performance combination which has saved money and justified the project.

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

Packaged 80VDC drive is compact, powerful and versatile

The stepper amplifiers WSE 04.80 V01 and WSE 08.80 V01 from Stogra are a micro-stepping bipolar chopper drive for 2-phases stepper motors, giving the maximum power integrated in the smallest housing

The compact metal housing fits into small switch cabinets available as DIN rail or panel mounted versions. Employing the latest FET-technology means extremely low power dissipation, therefore no forced cooling is necessary. All connections are easy by front side screw terminals and spring terminals for all lines and signals There is a wide range of voltage supply from 20 to 80VDC and the phase currents are adjustable from 0,5 to 8A/phase via a 16 stage rotary switch.

Stogra Power AmplifierThere are 16 different step angles between 200 and 12800 steps/rev selectable via DIP switches for optimal, smooth running of the motor. The step angle can be switched between two values via an external input even while the motor is running. The drives have electronic protection against short circuit (motor phases), over temperature (power amplifier) and under voltage. The ‘output ready’ signal is via a relay and input signals (pulse, direction, reset, boost, disable, change step angle) are optionally isolated by opto-couplers.

These packaged drives having 80VDC are highly suited to 23 frame motors to give a great performance. The optimal performance however for any stepper system is best achieved with STÖGRA series SM 56, SM 87, SM 88 and SM 107 motors. Selection of step resolution can be selected via the switches 3 to 6 then via a digital input the step resolution can be switched externally between two values. During motion, switching the step resolution is possible within the motor start-stop-frequency or at any frequency when changing the pulse frequency and step resolution simultaneously.

Micromech is Stogra’s UK distributor for stepper motors, drives and controls products. If you want to know more about these robust and reliable products then contact Alan Spinks on 01376 333333 or email sales@micromech.co.uk