Success Story from Kollmorgen – The precise geometry of 3D cutting

KBM motors as a byword for accuracy in laser cutting

Kollmorgen Success Story 3D Cutting

Pipes for industrial and residential flue ducts are made using machines by KOLLMORGEN Direct Drive motors.

The production of automation systems for sheet metal forming for sectors such as air conditioning, flue ducts and the automotive industry is the core business of TTEngineering. Located in Lomazzo near Como in a modern building of more than 2,000 m2, the company has also gained expertise in the cosmetics, medical, packaging and assembly sectors. More than 1,500 systems running in factories all over the world and exports accounting for well over 90% of total turnover are sources of pride for the company whose service department is able to respond precisely, quickly and punctually, even remotely.

To meet the ever more pressing needs of the market in terms of delivery time and performance, TTEngineering has concentrated on a design that can satisfy performance requirements in terms of acceleration, precision, productivity and flexibility. During a meeting in Parma during the SPS trade fair, the Como-based company set out its requirements to KOLLMORGEN. The motion control specialists proposed direct drive technology as the optimal solution for doing away with the complex mechanical transmission that involves drive belts and gear motors. In doing so, TTEngineering embraced the concept of a direct drive motor.

“We see two big advantages with Kollmorgen: it is a global brand that offers design consultancy and after-sales services of a high standard,” explained Massimiliano Crespi, who was Head of Engineering & Production at the time of this particular project and is now Managing Director at TTEngineering “The approach of the Kollmorgen staff during the design phase was outstanding.” The final tests provided the anticipated responses and allowed us to launch the TOP600 onto the market little more than a year later.

TOP600 machine for pipes for flue ducts

Success Story from Kollmorgen - 3D CuttingThe TOP600 is a machine for the 3D cutting of pipes intended for use as flue ducts for all sectors, from industrial to residential, produced with a range of materials.

The TOP600 is a Siemens CNC 5 interpolated axis laser cutting cell suitable for machining pipes with a maximum length of 1,500 mm, with a diameter of between 3” and 30” and thicknesses of 0.4 to 2 mm, made from steel, iron, or copper. The patented pipe clamping system has been created with a CNC self-centering spindle. This machine is aimed at companies operating in the HVAC and chimney pipes sectors. Depending on the combination of materials, thickness, and laser power, it is possible to cut at variable speeds of up to 20 m/min.

It is a modular machine which can be used by one operator who manually loads/unloads the pieces or in “fully automatic” mode, integrated into an automated line where a robot loads/unloads the pieces.

At the same time as updating the direct drive equipment with a torque motor on the rotation spindle, new software has been developed that allows for cutting with beveling.

TTE has its own cad cam platform and sophisticated cutting management software with predictive mathematics to compensate for out of roundness errors: the machine provides perfect cuts even for pieces that are slightly out of gage.

There are two versions available, the TOP600 Plasma and the TOP600 Laser, depending on the cutting technology used. The two machines are identical in terms of their configuration. The only changes are to the source used and, therefore, the type of cutting head used.

KBM Frameless Motors, modern direct drive technology

As an alternative to the technology that has been used in the past, namely precision gear motors and belt drives, KOLLMORGEN recommended a KBM™ series direct drive motor to TTEngineering that can offer greater flexibility and a range of different speeds so the machine can be adaptable and produce pipes with differing diameters.

The design of the machine also benefits, becoming flexible and compact, ensuring stable performance over time, remaining constant even with a high number of cycles (no downgrade).

Success Story from Kollmorgen - 3D CuttingThe KBM™ Series has been developed to be integrated directly into the machine, using its own bearings to support the rotor; it provides a high level of performance whilst allowing for a smaller size. There is a wide range of standard motors (14 sizes with varying lengths); different configurations and options are available depending on the requirement, and changes to the shared design can be made quickly and cost-effectively. “The performance offered by the Kollmorgen KBM™ series motor is so high that they even prompted us to redesign part of the frame and the cutting automation,” explained Mr. Crespi. “The use of the motor also enabled TTEngineering to patent an automated pipe clamping system.”

Properties

  • Fully encapsulated stator windings
  • PTC thermistor overload protection
  • Rare-earth neodymium iron boron magnets
  • Fail-safe bands over rotor magnets
  • RoHS compliant
  • UL and CE certification
  • Optimizations include rotor hub dimensions, rotor length, diameter, mounting features, windings, insulation, connection type, and much more
  • Optional latching digital Hall effect sensors are pre-aligned and factory-installed

Benefits

  • Direct load connection eliminates the need to maintain gearboxes, belts or pulleys
  • The absence of backlash and displacement provides a more responsive system
  • The removal of coupling devices reduces overall machine size
  • Embedded motor enables a compact machine design, helps protect intellectual property
  • Huge selection of standard motors and extensive customization options

Conclusion

The profitable collaboration with Kollmorgen continues with a new objective: TTEngineering is working on a product which will replace mechanical cutting with a high-tech laser and Kollmorgen linear motors will again be of great assistance in this case.

Success Story from Kollmorgen - 3D Cutting

Authors:
Ilario Manzi, Key Account Manager, KOLLMORGEN Italia
Angelo Trombetta, Direct Drive & Mechanical Transmission, KOLLMORGEN Italia
Elisabetta Redaelli, Marketing Communication, KOLLMORGEN Italia

 

Disclaimer
The use of this news article and images came with permission from Kollmorgen.

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How Using Electric Linear Actuators Can Save You Money

Article Posted by Parker’s Electromechanical Team on Monday, July 1, 2019 on the Parker Motion & Control Technology Blog
Parker BlogIt’s well documented that creating compressed air for use by pneumatic cylinders is not a particularly cost-effective process, largely as a result of generator and system inefficiencies. With accounts departments leaning hard on engineers to deliver lower operating costs, increasing numbers are turning to the latest electric actuator solutions.
Why so?

Well, the design features of electric linear actuators mean they are able to deliver enhanced performance levels while also achieving lower total energy consumption. In fact, based on trials, savings of €3,200 can be anticipated for a typical single-actuator application over a two-year period.

Two steps become one

Parker BlogIn pneumatic systems, two steps are necessary to produce compressed air: electricity first produces air, before air pressure is converted into linear movement using a pneumatic cylinder. Similarly, two stages are required in a traditional electric solution, namely converting motor rotation to the movement of the electric actuator.
Electric linear motor actuators Parker ETT Series Machine Design

However, this double step can be reduced, with subsequent energy savings, by using a linear motor rod-style actuator solution such as a Parker ETT series unit, which is able to directly generate linear motion through the principle of electro-magnetism.

Another favourable attribute of an electric linear motor actuator compared versus a pneumatic actuator solution is the precise positioning achievable along its entire stroke. On-board feedback via an integrated analogue linear position sensor allows positioning precision to within 0.05mm.

Advantages of electric actuators: significant savings potential

The technical advantages of the latest electric linear motor actuators are clear, but what about the cost comparison we hear you ask?

Well, consider electric actuators applications and performance. A typical application involving the transfer of a 15kg load at 30 cycles per minute, for example. Here, a pneumatic cylinder solution would work with a pressure of approximately 2 bar, while the Parker ETT linear motor actuator solution consumes just 30W of electricity every cycle. Sure, the initial start-up cost for the electric actuator solution is higher than its pneumatic counterpart, but the cumulative energy cost savings mean your initial investment would be recouped well within one year.

Parker Blog

Moreover, just 24 months after start-up, savings will have increased to around €3,200. This savings is for just one actuator—if you multiply the number of actuators found on a typical production line it’s easy to see the vast savings possible.

Learn more

Download our electric tubular motor catalog to learn more about how your plant can save money on its factory automation.

Parker Blog

Article contributed by Alessandro Porro, product manager, Motors, Electromechanical Division Europe, Parker Hannifin Corporation.

 

 

 


Disclaimer
Licensing for these images came with permission from the Parker Hannifin Media Manager collection.
Article reposted with Parker Hannifin’s permission.

 

Kollmorgen has awarded Micromech ‘Best European Distributor 2019’.

We are proud to announce that Micromech has once again been awarded the Best European Distributor.

In addition we are pleased to have achieved the necessary sales and requirements to remain the UK’s only Kollmorgen Gold Partner and Certified Partner for the third consecutive year.

This enables us to continue to supply Kollmorgen’s excellent product range and provide our first class service and support.

Kollmorgen’s product range includes Servo Drives, Servo Motors, Stepper Drives and Stepper Motors, Motion Controllers, Linear Motors and Linear Actuators.

With their innovative approach and vast knowledge in motion control design and development, Kollmorgen is one of the few companies in the world that designs and manufactures such a wide range of complimentary products.

Kollmorgen products are supplied to a wide variety of industries including Aerospace and Defence, Printing, Packaging, Food and Beverage, Medical, Pharmaceutical Manufacturing and many more.

We are extremely proud to receive these awards and remain dedicated to the Kollmorgen brand.

Visit Kollmorgen’s supplier page to view the full Kollmorgen range or for assistance specifying Kollmorgen products for your application, contact Micromech on 01376 333333 or Email sales@micromech.co.uk

Disclaimer
The use of these images came with permission from Kollmorgen.

RTA EtherCAT FLEX-DRIVE now available from Micromech

Micromech would like to announce the latest series of EtherCAT stepping motor drives from RTA.

RTA - Flex DriveFeatures

  • The Flex-Drive allows connection with any stepper motor up to Nema 24 (60mm) with or without encoder feedback, supporting PP, CSP, CSV and Homing mode of operation
  • All models are equipped with one configurable fast capture input, suitable for Touch Probe, proximity or free use.
  • Easy Setup: no need to program software; all settings are made through EtherCAT network.
  • Separated power supply for logic circuit and motor power.

 

RTA Flex-Drive: Perfectly fitting Trio Flexslice architecture

 

RTA - Flex Drive– The series is designed to fit into the FLEXSLICE system, the modular EtherCAT architecture by Trio Motion Technology

– The direct connection with FLEX-6-NANO or FLEX EtherCAT COUPLER creates a powerful multiaxis modular system, composed by a Motion Controller, stepping motor drives, digital and analogues I/O, all sharing the same internal EBUS and logic power supply.

 MODEL VOLTAGE  CURRENT   SENSOR FEEDBACK
 MSE-408  24-48 VDC  4 Amps  Encoder
 MSB-204  24-48 VD  2.5 Amps  Open Loop

Success Story from Kollmorgen – Bricks that can put in an appearance

Motion Control by KOLLMORGEN makes fast and precise cuts from the column of clay

Kollmorgen - Success Story

Neat as a pin, each brick on the pallet is identical to the next. Deviations at the building site are accepted only within tight tolerances. Standardized measurements are already in demand simply because bricklayers these days rarely lay the vertically perforated bricks with mortar but glue them together with thin-bed mortar as piece work. Balancing gaps – error reports. And then every deviation from the norm also costs time – which is why manufacturers such as the Swiss brick manufacturer Landquart AG is continuously improving its established production process. To cut off the endless column of clay into individual bricks, the company has now integrated a servomotor driven module.

It is iron compounds which give clay bricks their typically orange-brown color. The precise color that the building materials ultimately take on depends just as much on the minerals contained within the clay as the firing temperature and the prevailing atmosphere in the oven. There are a number of adjustment screws which the manufacturers of so-called coarse-ceramic products can turn so that the construction industry can deliver perfect bricks. In so doing, it is important to observe that a good brick – with all its claims to automation – still takes time. The most important components of brick are loam, clays and marl.

Cut clean from the endless column

The brick manufacturer Landquart from the place of the same name in the canton of Graubünden extracts the clay from its own clay pit. “Before it is shaped, the ingredients need to be well mixed and, with a view to a homogeneous distribution of moisture, temporarily stored for days. Only then can the paste go into the extruder which compacts the mineral mixture and presses it through its mouthpiece. This creates an endless brick with a fixed length and width. The height is achieved from the speed at which the cutter from the Swiss company Freymatic AG works,” explains Daniel Bärtsch, Plant Manager at the Landquart AG brickworks.

Success StoryCharacteristic for the cut is the combination of the continuous feed of the clay column from the extruder and the discontinuous cutting. To do this, it takes the basic drive arrangement of the flying saw – in essence designed like a thin steel wire which runs from top to bottom through the soft clay columns like a harp string in time with the band speed. The cutter by Freymatic is at the same time cyclically positioned by a Thomson linear axis and synchronized with the band speed. To drive the linear unit with its interior ball screw, TBM Automation AG opts for synchronous servo motors in the AKM series by KOLLMORGEN. TBM and Freymatic have fostered a trusting collaboration for many years in matters of drive technology, motion control and automation. “We need to understand the processes, know how our customers think and then learn about the intricacies from our growing experience,” says Silverster Tribus, Managing Director at TBM. The Swiss engineering specialists from Widnau have on their part been cooperating closely with KOLLMORGEN as a certified partner.

Drive simulation from the workstation

In the past, the vast majority of functions needed to be constantly re-programmed – and a huge amount of code needed to be written for this. “These days, we pull our prepared blocks into a motion project – and that’s it.” In conjunction with graphic programming, the on-site engineers can see considerably better “what impact each of the changing parameters has”. The basis for this unerring and efficient way of working is created by the Kollmorgen Automation Suite – above all in the design of the pipe network contained within.

Pipe Network clearly and precisely replicates the machine architecture including the dependencies between the axes of an application in a very short space of time. The otherwise very complex programming in Pipe Network is replaced by a graphic description with drag-and-drop function. Starting from a virtual master, all functions and relationships between components as well as all movements and settings can be defined with graphic description blocks. If the system is available, the Kollmorgen Automation Suite also offers the opportunity for virtual simulation. Movement profiles, axis conditions or synchronizations can be optimized in real time without the need to connect a single device.

“This is a real advantage because we can test the axes in the office and initiate start up with a prepared, fault-free application,” stresses Danijel Todorovic-Grabher, Senior project manager at TBM Automation. If adjustments need to be made on site, there is a KOLLMORGEN touch panel at the ready right by the system in the brickworks. “We can simply leaf through the drives and don’t need an additional laptop on site.”

Additional overload capacity protects against process fluctuations

The user-dependent access for this in the first step is carried out on the freely programmable controls in the IEC 61131-3 languages. It is part of the functional scope of the KOLLMORGEN Motion Controller PCMM. The compact device takes on the sequential control and the motion control of the connected AKD servo drives with the AKM synchronous servo motors. Motion Control has designed TBM in such a sophisticated way that the machine actually removes the bricks from the column with the beautifully soft motion task profiles. At the Landquart brickworks, the unit is placed directly between the formed part of the extruder and the discharge conveyor. The high overload capacity of the AKM motors up to five times the nominal current ensures that, during operation, the sudden occurrence of speed fluctuations does not lead to a fault in the cutting process. Changed requirements in power are not a rarity in the brick industry; they actually happen on a regular basis. After all, it’s a natural product with a fluctuating consistency that is processed into bricks fully automatically.

Against this background, it is also common practice to regularly optimize the settings of the cutting unit. The water in the clay alone or the detailed changing composition of minerals changes the mechanical shaping of the brick which is still highly sensitive after extrusion. The motion control for taking the cut raw bricks away for drying is configured in a similarly challenging way. Days later, it then goes into the oven for several hours.

For the flow of materials, Freymatic also opts for servo axes by Kollmorgen which are coordinated alongside the multi-axis arrangements of the PCMM. From the viewpoint of motion control, this process is characterized by exactly managed acceleration and braking profiles which transport off and therefore separate the bricks during production. Integrated into the automation is the pallet loader which pushes metal profiles from a magazine under the bricks for their further transportation.

This is what good clay needs

A view into the clay industry shows how existing systems have allowed themselves to become efficiently modernized when machine engineers, system integrators and drive manufacturers work closely together.

“We present data about what quantity needs to be shifted and what times and accuracy are required,” says Marco Breitenmoser, head of construction at Freymatic. “TBM then uses this as a basis to make proposals.” Good clay has for many years relied on the cooperation between Freymatic and TBM discussing jobs together and then also finding the best solution together. “Our expertise lies predominantly in the machine concept and TBM’s is in the drive technology and automation,” says Marco Breitenmoser in summary.

Author:
Martin Zimmermann, Key Account Manager, KOLLMORGEN Switzerland

 

Disclaimer
The use of this news article and images came with permission from Kollmorgen.

Available from Micromech – Premo, Wittenstein’s new powerful actuator platform

Absolute precision meets perfect movement: premo combines precision with motion  – as efficiently as never before

Wittenstein - PremoThe central idea behind the first fully scalable servo-actuator platform from Wittenstein is an uncompromising flexibility from the viewpoint of the user. Motors and gearboxes with application related graduated performance characteristics can be configured modularly to individual motor/gearbox units. The result is a modular system that is significantly more versatile and more individual with regard to performance for the most diverse applications, that meets almost all the challenges of automation, integration and industry specification.

The core of the motor/gearbox unit is a torsionally rigid precision gearbox with low backlash and excellent torque density in conjunction with the equally powerful, permanently excited synchronous servo motor, which guarantees low cogging and a constant speed through the distributed winding.

The Premo actuator generation opens new dimensions in terms of performance with doubled power density and minimal installation space requirements. The Premo boasts increased productivity and optimised energy efficiency thanks to digital, single-cable technology providing more freedom during planning, design and storage as well as lower investment costs.

Typical fields of application:

–  Delta robot (axes 1-3, swivel axis)
–  Handling portal (Z axis, swivel/rotating)
–  Machine tool reaming
–  Tubular bag packaging
–  Folding carton packaging
–  Plastic thermoform (tool axis)
–  Intralogistics (AGV)

For more information on Wittenstein products contact Micromech sales on 01376 333333 or sales@micromech.co.uk

 

Disclaimer
The use of these images came with permission from Wittenstein.

Success Story from Kollmorgen – Peening extends life

Kollmorgen - Success Story - Peening extends lifeFreymatic is building shot peening plants for the construction of aircraft engines – and, to do this, it’s opting for Motion Control by KOLLMORGEN to achieve high quality requirements

Kollmorgen - Success Story - Peening extends life

The shot needs to hit accurately. This is the only way for their power to be optimally deployed. This power does not do any damage. In fact, with each hit it makes the target stronger, more solid and tougher. And this is why accuracy, air speed and the right quantity with the right measurements are so crucial. Freymatic AG from Switzerland builds shot peening systems which extend the life of heavy-duty components including those in aircraft technology. To do this, the process, similar to a blacksmith’s hammer, produces precise compression stress on the surface. Motion Control by Kollmorgen ensures that sufficient shot reaches the target – the single cable connection technology saves valuable installation time.

“When we have a breakdown, we can’t just pull over.” Those in the know describe in one sentence the safety thinking in aviation. Anyone with a broken drive shaft managing to end up relatively unscathed with their vehicle in a field or ditch would have much further to fall if they were in a similar disaster while in the air. In the face of the serious consequences of technical faults in civil aviation, all parts of an aircraft are supplied with an abundance of safety margins. One way to make heavy-duty components even tougher against the prevailing powers is using shot peening. This process is used mainly in the construction of engines.

A chain mail made of tension forces

Using pressure, the drag is able to resist a potent force. Figuratively speaking, components are placed into chain mail. The links in the chain mail consist of compression stress which the shot peen with their kinetic energy during impact with the atomic lattice. Fatigue damages only become clear later on. “Fissures in the material occur where tensile stress is prevalent,” explains Martin Hunziker, CEO of Freymatic. The connection between tensile forces and the formation of fissures is particularly critical in the construction of aircraft since it is here that lightweight construction is required. Despite their size, the blades in an engine need to be very light. This is why they are made of a titanium alloy. The next generation of engines will be even lighter – amongst other things due to the use of titanium-based compounds. But in automotive construction, too, the process is an established manufacturing practice – specifically where fatigue resistance is required.

When it comes to shot peening, manufacturers often use Roxor systems by the Swiss firm Freymatic AG. To do this, the system builders from Domat-Ems in the canton of Graubünden place an industrial robot into a hermetically sealed chamber and fully automatically equip its wrist with up to six different spray nozzles via a mechanical exchange during the machining job. While the robot takes on the motion control along the components being blasted inside the soundproofed chamber, the pressure supply and dosage unit remain outside. The shot quantities can be selected anywhere between 1 and 10, thus achieving control deviations below three percent. This precision is necessary since it is not possible to carry out inline quality monitoring for shot peening – at least not without destroying the tool. The system operator must therefore be able to rely on the adherence to process parameters – which is why, in the field of servomotor driven dosage units, maximum precision and repeat accuracy is required. This range is achieved with a speed-controlled worm gear. The conveying screw is driven by synchronous servomotors from the KOLLMORGEN AKM series which in single cable connection technology are combined with their own AKD servo inverters.

The connection between the servo drive and the servo motor using just one cable is also an advantage for this application since the systems can be wired up more quickly while also saving space. This is because the cable typically used for feedback signals is not required.

Kollmorgen - Success Story - Peening extends life

KOLLMORGEN opts here for a slender hybrid cable for motor and feedback.

What is special about it: The single cable connection technology works even without laborious and expensive multiturn encoders. The specialists in Motion Control and servo drive technology have developed the digital resolver SFD3 for this. The interface translates the analog data of the resolver into one digital signal which it then transfers via one cable to the drives.

Tight tolerances in the dosage

Back to the peening system by Freymatic: In terms of construction, this consists of two pressure containers which act as a sluice between the unpressurized blasting shot store and the dosage which is under high pressure. The dosage powered by the AKM servomotors in the single-cable version represents a core function of the Roxor systems and, when operational, delivers shot quantities of between 0.1 and 12 kilograms per minute with an accuracy of /- 5 percent. In the mixing tube and up to the spray nozzle, the shot is accelerated up to the exit speed. This speed forms the two significant process parameters and is indirectly regulated via the spray pressure in a tight window of tolerance. The pressure thus lies between one and seven bar.

Accompanying the high adjustment range in the drive control designed by TBM Automation is above all the challenge of being both delicate and fast. To do this, the drive axles regulate the speed of the dosing screw via the signals from throughput sensors. “If there is too much material, the speed drops and vice versa,” explains Silvester Tribus, managing director of TBM Automation AG. The company from Widnau, south of Lake Constance, has been working closely with Freymatic for some time already as a system integrator. The specialists in Motion Control and servo drive technology belong to the group of certified system and distribution partners of KOLLMORGEN with highly specialized engineering competence.

Precision from zero speed

To ensure that the adjustment is carried out swiftly and precisely, Urs Tobler, from the TBM management team and specializing in control technology in blasting systems, has equipped the Motion Control with a few special features. “After all, we want the system to start up quickly and need a correspondingly short amount of time until the quantity and pressure have precisely engaged.” Urs Tobler looks back to make a comparison with a time when dosage drives were still driven by DC motors which were hard to regulate, especially with small quantities, and only delivered reliable values in the upper speed range. With an additional linearization of the control performance with analog values, using the KOLLMORGEN AKM motors, it has now been possible to “be precise even from zero speed upwards.” This control quality is said to make the process reliable across the entire adjustment range. This aspect is particularly relevant for shot peening since, after peening, it is not possible to carry out a quality analysis without damaging components.

Shot firing which is too low also results in poor values, following the motto “more is more”. To determine where the optimum value lies, system operators can only do this with “Almen strips”, thus measuring the effect of the shot impact by the distortion of a standardized surface. The Almen values determined by the distortion of a metal measurement strip then provide conclusions as to the effectiveness of the process. This must later precisely and continuously follow the previously determined key values so that the desired effects of the compression stress is set. In a further consequence, this process only functions in conjunction with regular calibration.

Conclusion

The complex processes in the mechanical strengthening of metal components using shot peening shows what a significant role the precise and, above all, repeat accurate servo drive technology plays. The automation conceived by TBM Automation AG for Freymatic AG is also set up in a user-friendly way for the operator and offers a cleanly structured visualization.

Author: Martin Zimmerman, Key Account Manager, KOLLMORGEN Switzerland

 

Disclaimer
The use of this news article and images came with permission from Kollmorgen.