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MOTION CONTROL A look into the products, technologies and solutions shaping the market
Your move? Factory of the Future
Technology Handbook | MOTION CONTROL
GATEWAY TO A SMARTER FUTURE
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he Internet of Things is transforming manufacturing operations on the factory floor – and we’ve developed a solution to accelerate its adoption. The benefits of internet enablement in manufacturing industries are well known. The Internet of Things (IoT) can bring production equipment online so that, once isolated machinery, can now be interrogated, monitored and managed remotely or from a central control point on-site. However, many industrial plants haven’t caught up with the digital age yet. What’s needed is a simple and streamlined approach to the introduction of this new technology – and that’s just what the IoT Gateway from Rexroth aims to provide. The IoT Gateway works with OPC UA, the open Industry 4.0 standard. It sits between devices such as sensors and process controllers on the one hand and processing applications on the other. It’s a building block that enables machine builders to add knowledge and connect equipment that can then be sold to their manufacturing customers.
Using the IoT Gateway
The technology is already being applied or tested in several sectors, including automotive, furniture and consumer manufacturing. One of our customers in the packaging industry, Bosch Packaging Technology, has been using the IoT Gateway to monitor equipment performance and make small remote adjustments to improve productivity, quality and efficiency. 2 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
A team of experts scoped the project, embedded the sensors, installed the IoT Gateway, configured the network, tested connections and commissioned the solution. The IoT Gateway itself, comprising the host hardware, bus housing and peripherals, gathers the sensor and controller data, filters it as required and forwards it to a central control point for analysis of parameters including torque, safety clearances, acceleration data, humidity and temperature. The system then compares performance against target production values and recommends a course of action as required: for instance, the callout of an engineer for service or repair. This analysis is conducted not just for live data but over time, so trends can be identified to make continuous improvements.
Looking ahead Our plan is to provide connectivity to machinery in all areas of factory automation, and we have a worldwide infrastructure of experts, services and support that can work with equipment manufacturers everywhere to make IoT enablement a reality. “Now machine builders will be able to offer something new to their customers that’s powerful, productive and smart,” says Hans Michael Krause, our Director of Market and Product Management PLC and IoT Systems. Article by Hans Michael Krause Director of Market and Product Management PLC and IoT Systems
You're ready. We're set. Let's move. Single Source Motion Control Solutions
Your move? Factory of the Future Complete motion control solutions - from Mechatronics, Conveyance, Assembly Handling, and Tightening Systems, to Linear and Electrical Drives and Controls Technology Rely on Bosch Rexroth, the world leader in drive and motion control technologies that power today’s most advanced manufacturing systems. Our automation solutions drive your manufacturing performance with fast throughput, precision, repeatable efficient motion control with maximum uptime. We’re set to help you achieve this with the industry’s most advanced conveyor technologies, electric drives and controls, linear motion components and systems, as well as production tools and tightening systems. All equipped for fast changeovers, and ready for Industry 4.0. Smarter, more productive automation starts with the right technology. Make your move to Rexroth’s motion control solutions today. We Move. You Win!
Order your free Factory Automation Resource Kit: www.boschrexroth.ca/factoryautokit For expert advice call 1-855-REXROTH (739-7684) or email us at info@boschrexroth.ca
Technology Handbook | MOTION CONTROL
Two great ideas to simplify and accelerate putting a handling system in your machine
H
Watch the video. Click here.
ow much time does your company spend incorporating a gantry or other robotic handling system into your project – from designing and ordering it, assembling it and connecting the motion control components, then parameterizing it and programming specific tasks for it at a PLC? Let’s not count the interval between order and delivery. Would you say several days, even weeks? The entire process can be lengthy, cumbersome, delay-prone and disruptive to the entire project timeline. Festo saw it as ripe for significant streamlining from conception through commissioning, which it accomplished with a pair of innovations: the Handling Guide Online (HGO) and the Festo Motion Control Package (FMCP). Taken together the HGO and FCMP are changing how OEMs incorporate a handling system into a new machine. All things being equal, using the Handling Guide Online to design the best Cartesian robotic solution can reduce time-to-market for projects by as much as 70%. All it takes is a few minutes to complete the design phase. The engineer specifies a single axis, 2D or 3D Cartesian robot, then inserts basic application data such as load, cycle time, load voltage, and the available workspace size. The HGO calculates and suggests appropriate solutions. The planner selects the most suitable, and almost immediately can import its data sheet and CAD model into his or her design engineering system, without obligation. Festo supplies a quote within two business days on average. That robot can be ordered fully as-
Check out our video tutorials. Click here. sembled, pre-parameterized and pretested or as disassembled modules.
Learn about the Handling Guide Online. Click here. The HGO is integrated into Festo’s online product catalogue, so these application-specific handling solutions are composed entirely of standard parts. That helps assure competitive pricing and fast delivery – usually three weeks or less. Next up, installation and commissioning is greatly accelerated when the motion control package is ordered at the same time. The FMCP is a comprehensive motion control solution matched for the robot – servos, motion controller, power supply, gateway to the PLC connectivity of the OEM’s choice along with safety and circuit protection. The FMCP can coordinate motion of up to six axes for pick and place and other precision Cartesian robotic applications, including advanced kinematics like H-portal, T-portal, 2D and 3D Festo standard gantry systems.
4 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
The motion control package comes in its own cabinet, pre-wired and pre-tested – ready to be installed. All the OEM has to do to get the Festo robot up and running is connect power, Ethernet, IO and quick-connecting cabling to the gantry motors, then use the FCMP’s software function blocks at the PLC to configure the robot for specific motion tasks – no specialized or manufacturespecific programming knowledge needed. Basic motion can be taught through a webserver or IOS/Android app. The FMCP also offers a solution for end-ofarm-tooling. By including an IO-Link connection, it can control eight external digital inputs and eight digital outputs available in the function block. “Speed is of the essence and guaranteed with the handling guide and motion control package, says Ben Hope, Head of Business Development – Electric Automation & Industry 4.0, at Festo Canada. “The OEM can count on getting a solution that isn’t over- or under-engineered for the tasks to be performed. And it can choose a Festo handling system without having to worry about a lengthy or complicated process to get it to work with brand name PLCs. That means never having to settle for second best in a handling solution.”
HGO+FMCP = Breakthrough in machine design Learn more
5300 Explorer Drive Mississauga, ON. L4W 5G4 Phone: 1 877 GO FESTO festo.canada@ca.festo.com • www.festo.ca
One integrated platform for all your automation needs One platform for electric automation means seamless connectivity. From electromechanical actuators when joined with servo motors and servo drives to complete positioning systems, motion control solutions as well as entire handling systems and decentralized control solutions - always with the right software and interface. festo.ca/ea
Technology Handbook | MOTION CONTROL
N
Harmonic Planetary® Gears Offer Low Backlash for Life.
ew models are being added to our planetary Quick Connect® gearhead line. Building a high precision actuator is easily achieved by coupling any servomotor to one of our precision Quick Connect® servo gearheads. Planetary gears have simultaneous meshing between the sun gear, planet gears, and the internal ring gear. Harmonic Planetary® gears use a precision engineered elastic ring gear which compensates for interference between meshing parts. This proprietary Harmonic Planetary® gear design provides smooth and quiet motion and maintains ultra-low backlash for the life of the reducer.
Harmonic Planetary® Gears • Ratios: 3:1 - 50:1 • Peak Torque: 3.9 N•m - 3940 N•m • Sizes: 40mm - 230mm • Output Configurations: Hollow Shaft, Flange, Keyed Shaft, Smooth Shaft HPN Planetary gearheads are priced to deliver a great value. They feature a robust design utilizing helical gears for quiet performance and long life. These gearheads are available with short lead times and are designed to couple to any servo motor with our Quick Connect® coupling. HPN gearheads are suitable for use in a wide range of applications for precision motion control and positioning. HPN Harmonic Planetary® gears are available in 5 sizes: 11, 14, 20, 32, and 40, with reduction ratios ranging from 3:1 to 50:1. Plus, they are dimensionally compatible with popular gearhead models. This new value series of planetary gears carry the reputation for quality and reliability for which Harmonic Drive® products are known throughout the world. High torque HPGP and standard torque HPG Quick Connect® gearheads offer high precision and low backlash (standard: < 3-arc-min, optional: <1 arc-min). Harmonic Planetary® HPG gearheads are also available with helical gearing and low reduction ratios. The new models, HPG-R, offer lowspeed ratios from 3:1 through 10:1 including all integer ratios in between. Two stage ratios are currently offered in HPG standard and HPGP gearheads, and will be available soon for the new HPG-R. HPG standard torque gear is also available in three sizes as a right-angle configuration for use when space is limited. Innovative ring gear ensures consistent, low backlash for the life of the gearhead.
The HPF Harmonic Planetary® gear unit delivers hightorque and high-accuracy with a hollow shaft design. The gearhead incorporates continuous backlash compensation that ensures low backlash throughout the life of the gear. An extralarge cross roller bearing serves as the output flange and can directly support large loads with exceptionally high moment stiffness. The large coaxial hollow shaft allows cables, shafts, ball screws or lasers to pass directly through the axis of rotation. Harmonic Drive LLC has a dedicated website for its Harmonic Planetary® gearheads, offering users a quick and easy way to choose the best product for their application. Developed with the design engineer in mind, the website features a robust product selector tool, PDF and DXF drawings, as well as downloadable 3-D solid models. The Product Selector Tool enables the design engineer to quickly filter through Harmonic Drive product specifications to find the right gearhead to connect to their servomotor. Electromate is the exclusive Canadian distributor of Harmonic Drive products (except the Province of Alberta)
6 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
Harmonic Drive and Harmonic Planetary are registered trademarks of Harmonic Drive LLC.
HARMONIC DRIVE LLC 247 Lynnfield Street, Peabody, MA 01960 Toll Free: 800-921-3332 Phone: 978-532-1800 www.HarmonicDrive.net
ELECTROMATE 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 Phone: 877-SERVO98 Email: sales@electromate.com www.electromate.com
Servo Mount Gearheads Low Backlash For Life!
HPN Harmonic Planetary® value series provides a low cost solution without the need to compromise on quality or performance. This new value series of planetary gears carry the reputation for quality and reliability for which Harmonic Drive® products are known throughout the world. • Helical Gearing • Available in 5 frame sizes • Peak Torque: 9Nm to 752Nm • Ratios: 3:1 to 31:1, new two-stage ratios available soon • Quick Connect® mounting system
• High Efficiency • Backlash: <5 arc-min (single stage), <7 arc-min (two stage) • Fast Delivery • Shaft output available with key and centertapped hole or with center-tapped hole
Harmonic Drive LLC 247 Lynnfield Street Peabody, MA 01960 800.921.3332 www.HarmonicDrive.net
Electromate 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 (877) SERVO98 (737-8698) www.electromate.com
Harmonic Drive®, Harmonic Planetary® and Quick Connect® are registered trademarks of Harmonic Drive LLC. Electromate is the exclusive Canadian distributor of Harmonic Drive® products (except the Province of Alberta).
Partners in Precision
Technology Handbook Motion Control · MANUFACTURING AUTOMATION 7
Technology Handbook | MOTION CONTROL
L
afert NA is your best source for Metric Motors, Gearboxes and Coolant Pumps. We have supplied Metric Motors to the North American market since 1989, providing an extensive range of quality products with exceptional service. If you’re designing a system for the North American market or with a global platform in mind, the value of our IEC design motors is immeasurable.
to be mounted on or inside the motors, we have an extensive history in all customizations. Bring us a challenge - we are ready for it!
Lafert Brushless Servo Motors are so Dependable, We Use Them Ourselves!
What level of performance do you require from your IEC metric motor? AC motors have a significant impact on the total energy operation cost for industrial, institutional and commercial buildings. Lafert embraced the challenges and brought a combination of IE3 Premium Efficiency in a high reliability product to service this market. Lafert has an innovative range of High-Performance Permanent Magnet Motors, achieving IE4 & IE5 Super Premium Efficiency levels, offering enhanced efficiency while maintaining reduced operating costs.
Does your motor have special requirements? With our professionally engineered product designs, we can build to requirement. Our diverse range of products in our local inventory allows our knowledgeable sales team to pinpoint specific needs, while maintaining an industry leading turnaround time, whether off the shelf or factory built. Our ability to quickly adapt to meet our customers’ needs with a unique personal touch is one of our greatest strengths. When you need it, Lafert either has it or will build it for you!
Customizations available in volume from our factory, or on low quantity from our NA facility. With a focus on specialized electrical requirements for diverse applications, we have designed and built three phase motors ranging from 72V to 690V. Even with the proliferation of drives in all applications, we still maintain a high demand for multi-speed and two speed motors of all combinations. We have designed various three speed and four speed motors, with a wide variation of connections. When we turn to the mechanical characteristics of our motors, we have an even higher demand for customization. Lafert offers the widest range of (off the shelf) adaptor flanges in the industry and we are extremely adaptable with custom flanges and shafts to match any specialized application you can bring to us. We also build a variety of alternate adaptor brackets for our motors. Besides the basic electrical and mechanical requirements, Lafert can adjust to any other special features you may require; whether it be environmental or additional controls 8 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
Lafert, an industry-leading expert in the production and design of permanent magnet motor technology has its foundation in twenty-five years of brushless servo motor manufacturing. The complete range of AC servo motors are manufactured with an application oriented approach, at our Italian facility and are perfect for applications such as textile, laser cutting, welding machines, robots, packaging, glass (cold end) and injection molding. The “pancake” design allows for direct-drive applications with high torque or low speed. Our high overload, dynamic performance and power dense servomotors’ have one of the most complete ranges available on the market, with torques from 0.25 to 390Nm, spread across 14 different UL certified motor series. Direct Drive motors cover torques from 10 to 510Nm in three additional motor sizes and have vast capabilities to match both European and Asian mechanical designs. The full range is available with ATEX Certification – Zone 2-22, with speeds ranging from 0 – 6,000rpm. All compact design servo motors have an optional brake execution and are IP65 protected, with TENV or TEFC construction.
5620 Kennedy Rd, Mississauga, ON Canada, L4Z 2A9
www.lafertna.com
Technology Handbook | MOTION CONTROL
T
maxon drives set the world in motion
he maxon motor combines electric motors, gears and DC motor controls into high-precision, intelligent drive systems that can be custom-made to fit the specific needs of customer applications. maxon motor helps provide innovative solutions at competitive prices for numerous applications in various markets, such as industrial automation, medical technology, security technology, instrumentation, communications, and consumer applications, among others.
Offering solutions that fit your customized needs maxon motors manufactures small, high-quality brush and brushless DC motors ranging in size from 4 mm to 90 mm. maxon’s rhombic wound ironless rotor motors provide exceptionally high efficiency, low EMI emissions, fast acceleration, no preferred rotor position, torque constants and long service life. The drive components are assembled and designed within our modular system according to your individual needs. You can combine, according to your requirements, motors with 10 different product classes with planetary, standard or special gearheads, feedback devices, brakes and control electronics.
Brushed and brushless configurable DC motors more versions, more power
speeds of up to 120,000 rpm. They run very smoothly and are highly efficient in standard or sterilizable versions (up to 2,000 autoclave cycles). Ideal for use in hand-held surgical tools and industrial spindles. maxon motor’s X drives are extremely powerful and are now available in maxon’s online shop, where customizing the drives is easy. Customers can fit the drives with specific mechanical and electrical components specific to their application needs. It is possible to customize the shaft lengths, winding types, ball bearings and much more. When combined together with maxon encoders and planetary gearheads, you form a high-precision, robust drive system ideal for any application from aerospace to medical to robotics. In fact anywhere that requires a compact, powerful, quiet and strong drive system. The X program is a lean and automated process which ensures that all configurable drives are ready for shipment within 11 working days. In addition, detailed product data may be viewed immediately online and 3D CAD data for the configuration is available for downloading. Visit dcx.maxonmotor.com for more information.
Now even stronger, more efficient and with yet more combination options: There are new additions to the maxon family of X drive products. Several long versions of brushed DC motors, with higher torques and more power, have been added to the product range along with matching planetary gearheads. Each of the 3-stage versions can now be combined with the next smaller motor. This saves space, weight and costs. In addition, maxon launched a brushless DC motor (ECX) line to its configurable online program. These motors are available with diameters of 8, 16 and 19 mm achieving 10 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
ELECTROMATE 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 Phone: 877-SERVO98 Email: sales@electromate.com www.electromate.com
TRA CONFIGURABLE
Gearhead, motor and encoder tailored to your needs.
11DAYS
READY IN
Assemble your individual maxon DC drive: You can configure the gear stages, the motor bearings, the shafts, the encoder and much more. Design your custom drive online today and your finished drive will ship from Switzerland in 11 working days.
dcx.maxonmotor.com
Technology Handbook Motion Control · MANUFACTURING AUTOMATION 11
Technology Handbook | MOTION CONTROL
ENI58IL Incremental Rotary Encoders with BlueBeam Technology BlueBeam technology allows Pepperl+Fuchs to offer a portfolio of standard industry rotary encoders with the precision and accuracy required for rotational speeds of up to 12,000 RPM. This is achieved by implementing a blue emitter LED and the corresponding receiver diodes. When used in conjunction with a powerful sensing chip, a highly efficient utilization of light is possible. The benchmark for signal quality of incremental rotary encoders
Compared to the long-wave infrared light that is typically used in conventional rotary encoders, the blue light from the new emitter LED has a shorter wavelength while at the same time featuring identical splitting width. This allows sharper imaging. Due to the optimized functional principle, users can expect a new benchmark for signal quality. With BlueBeam Technology, the tolerance of phase position A:B is reduced to far below 10 %. Compared to the values that can be reached with conventional infrared technology, this more than doubles the signal quality. Because the high-frequency sampling is less prone to interference, BlueBeam Technology also keeps signals stable when exposed to mechanical force like shock and vibration. Another advantage is the improved calibration of the code disk, which goes above and beyond standard manufacturing procedures. During the production of ENI58IL rotary encoders, the precise insertion of the disk is verified on a microscopic level. This step leads to improved absolute accuracy for applications in which even the smallest deviations cause a noticeable loss of performance.
servo, square) and connections (axial and radial M23 or M12) are also available. With the ENI58IL series, Pepperl+Fuchs introduces a well-thought-out portfolio of industry-standard encoders covering applications that have so far only been possible in special high-performance encoder solutions. ENI58IL incremental rotary encoder and motion control
There are many motion control applications where you can use the ENI58IL incremental rotary encoders because of their compact, accurate, and robust design. BlueBeam Technology improves the resolution, signal amplitude, harmonic distortion, and jitter performance of optical encoders. This allows better position and speed performance for your motion control applications.
Incremental rotary encoder with interlocked bearings
ENI58IL with Blue Beam Technology Advantages at a Glance:
In addition to the high measuring quality achieved with BlueBeam Technology, the ENI58IL series also sets itself apart in terms of reliability and durability: interlocked bearings withstand high loads and protect the ball bearings. Special EMC circuit protection prevents damage from electromagnetic interference. Global use of rotary encoders often entails requirements that surpass minimum CE standards. For that reason, Pepperl+Fuchs quadrupled regular test levels to ensure accurate operation even under the most challenging conditions.
• Unmatched precision even at rotational speeds up to 12,000 rpm • A complete portfolio of shaft, flange, and connection options offers the optimal solution for a wide range of applications • Heavy-duty design ensures long service life • High shock and vibration resistance for maximum system and process reliability
Versatility bundled into one rotary encoder portfolio
Due to one-piece flow production, ENI58IL incremental rotary encoders can be purchased in quantities as low as “1” and with a wide variety of features. Along these lines, various types of shafts (solid, hollow, or recessed hollow), flanges, (clamping, 12 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
Robert Pasho Product Manager, Encoders rpasho@us.pepperl-fuchs.com
www.pepperl-fuchs.com
Advancing technology. Improving precision. Setting the standard. ENI58IL Incremental Rotary Encoders with BlueBeam Technology BlueBeam Technology: unmatched precision even at
rotational speeds up to 12,000 rpm A complete portfolio of shaft, flange, and connection
options offers the optimal solution for a wide range of applications Heavy-duty design with interlocked bearings ensures long service life
www.pepperl-fuchs.com/news-eni58il
Technology Handbook | MOTION CONTROL
Closed-Loop Motor Feedback with the Absolute Advantage
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OSITAL has expanded its line of kit-style encoders for position feedback in servo and stepper motors. The new models utilize the same mounting form factor as popular incremental kit encoders. • Mechanical drop-in replacement for easy upgrade to absolute position control • Same Footprints as US Digital E5 models and Broadcom (Avago) HEDS-5500 models • Identical assembly procedure - no training required • Hub diameters from 4 mm to 10 mm (plus 1/4 to 3/8 inch) • Magnetic technology, which is generally more robust than optical • Improved connectivity via M12 connector available See our Cross Reference Guide
However, with the introduction of POSITAL’s absolute kit encoders at prices more in line with incremental devices, system designers don’t have to work around the shortcomings of incremental feedback in an absolute position world. Incremental encoders are effective for speed control. However, to monitor absolute position, the controller needs to keep count of the number of pulses received from the encoder. If the pulse count becomes corrupted during a power outage, or if the control system fails to update the pulse count when the machine moves, positional accuracy is lost. The operator must “re-home” the machine by returning it to a known reference position and zeroing the pulse counts. By contrast, absolute encoders measure position directly. After a power outage, the controller can re-establish complete knowledge of the position of mechanical components by simply polling the sensors and reading their rotational position.
POSITAL Kit Encoder for Stepper- and Servo-motors
The Absolute Advantage POSITAL kit encoders provide absolute position feedback so that the control system always has complete information on the physical position of the mechanical components that it is directing. “Absolute position feedback is a natural way of providing accurate position control” comments Jim Stevens, market specialist for robotics at POSITAL. “Almost any position feedback application could be absolute-based.” Many current systems were designed around incremental encoders because incremental feedback devices were historically much less expensive than their absolute counterparts. 14 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
POSITAL-FRABA Inc. 1800 East State Street, Suite 148 Hamilton, NJ 08609, USA Phone: 609-750-8705 info@fraba.com www.posital.com
ELECTROMATE Inc. 6221 Highway 7, Unit #15 Vaughan, Ontario, L4H 0K8 Phone (905) 850-7447 sales@electromate.com www.electromate.com
KIT ENCODERS
Innovation in Motor and Robot Control Feedback POSITAL’s magnetic kit encoders are a rugged and versatile alternative for absolute position feedback in motors and robots Multi-turn capabilities based on POSITAL’s innovative energy-harvesing system eliminate the need for backup batteries Easy installation with built-in self calibration Compact and robust design Resolution of up 17 bits; revolution count range 16 bits
www.posital.com
Technology Handbook | MOTION CONTROL
How Smart is your Screwdriver? By John Miewald
M
ost consumer goods are assembled with small screws by hand. This close hand-eye work is prone to error. SMAC Moving Coil Actuators, out of Carlsbad, California, has come up with a solution that removes human error and replaces fallible pneumatic screwdrivers with what they call the “Smart Screwdriver.” Using a pneumatic handheld auto-feed screwdriver to install screws is dramatically more productive than manually picking up a screw, inserting it into a part, and driving it home, but simple pneumatic screwdrivers are not an ideal solution either. Workers using pneumatic tools with compressed air and dials to estimate the amount of torque for the screw can strip or misalign the threads if an incorrect torque or angle is used. For some manufacturers, a misaligned critical screw could result in stopping an assembly line. There is little or no feedback on the work until the device goes to QA. If QA misses the critical screw, it could lead to faulty products, angry customers, and the one word no manufacturer wants to hear- particularly in the automotive and aerospace industries: recalls. When you add this all up, a small screw could cost big money. A common problem with screws and lug nuts is crossthreading. Cross-threading means the threads on a lug nut or screw are not aligned with the threads on the stud when you start to screw them together. To avoid cross-threading, many assemblers will start lug nuts or screws by hand, turning the screw the wrong way until he feels a bump and hears a sound. This is the screw falling into position. The assembler would then turn the screw several rotations before using a wrench or screwdriver to “snug” it into place. Up until now, this process has been difficult to automate, performed by human operators only. This is how the Smart Screwdriver automates the process. First, it performs a fast approach, then finds the surface with our patented Soft-Land capability. Then, it turns counter clock-wise and the screw moves up and drops as the first thread is found. This is, in effect, “thread matching” and prevents cross-threading. The linear rotary actuator then starts rotating clock-wise. A “snug” torque can be applied. This is useful when there are a number of screws holding a part on the
clamping surface and they need to be snugged evenly, then a final torque is applied. The entire time, the Smart Screwdriver is monitoring the torque and pitch verification. Good, shallow, cross/no-threads, and the precision of the thread are detected through feedback of positon & torque off both axes. The SMAC Smart Screwdriver performs the same work as a pneumatic auto-feed tool electronically. There is no compressed air, no mechanical parts, and no need for oil or recalibration. On top of being maintenance free the Smart Screwdriver also has a high degree of programmability, so that you know the screw is correctly inserted, when linear height, degrees of rotation and the desired torque have been reached. The smart screwdriver monitors the linear position and force, rotary torque and degree of rotation while simultaneously driving the screw. These parameters are all completely programmable with the capability to have feedback sent to a PLC or database in real time. This ability to perform work and verify all in one move eliminates the need for down the line quality checks that are costly and time consuming. The SMAC Smart Screwdriver is intended for a wide range of screw sizes, including but not limited to 1.4 millimeter or less, like those found in watches, eyeglasses, cameras, consumer electronics, cell phones, power tools, etc. SMAC Moving Coil Actuators tend to be small but the Smart Screwdriver is so small that it could be attached to a larger robotic arm for special applications, providing 100% quality every time. Of course, the reverse could also be done. The Smart Screwdriver could be used to automatically disassemble a device, quickly, efficiently, and carefully.
16 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
SMAC Moving Coil Actuators 5807 Van Allen Way Carlsbad, California, 92008 Phone (760) 929-7575
ELECTROMATE 6221 Highway 7, Unit #15 Vaughan, Ontario, L4H 0K8 Phone (905) 850-7447 sales@electromate.com www.electromate.com
Technology Handbook Motion Control · MANUFACTURING AUTOMATION 17
MOTION CONTROL
The
competitive Hand tool maker commits to domestic manufacturing with new equipment investment
edge
BY ALYSSA DALTON
I
n today’s aggressive business environment, a number of factors can make it challenging for Canadian manufacturers to succeed, such as global competition, rising costs and difficulty finding new skilled labour, but hand tool maker Gray Tools Canada was determined to overcome these obstacles, ultimately deciding to invest $300,000 in a new vertical machining centre (VMC), fixtures and tooling last fall. “We needed to find a new way to remain competitive and overcome key uncontrollable challenges. The only certainty was any solution needed to include domestic manufacturing,” says Paul Dean, VP operations. “It was a long and sometimes frustrating process, however now that the equipment has been installed and is producing tools being sold worldwide, I am extremely proud and pleased because of what it represents to Gray Tools, its customers and Canadian manufacturing as a whole.” As the country’s only broad line manufacturer of hand tools, Gray Tools of Brampton, Ont., has been servicing industrial customers since 1912. It currently offers more than 6,000 different products — the total SKU count includes products it buys and resells, as
well as its import brand of tools which it engineers and develops. It also operates three warehouses in Brampton, Edmonton, Alta., and Delta, B.C. Selecting a solution The company explored waterjet and plasma cutting, automatic cold broaching, as well as horizontal and vertical milling machines before choosing a solution. “We looked at a ton of different options from different technologies to outsourcing to doing nothing at all,” says Dean. After an 18-month process that involved countless hours of project planning, equipment identification, creation and proof of the machining concept, consultation with partner Elliott-Matsuura of Oakville, Ont., and tooling build and integration, Gray Tools selected an Elliott-Matsuura
18 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
VX-1000 VMC. “It was a long road to [reach this decision] where we thought this would be the best way to achieve what we wanted: a reduction in cost and cycle time, and an improvement in part performance and quality,” he adds. Of the $300,000 project cost, approximately half the investment was in the machine cost, the rest went toward installation, training, tooling and fixturing. A change in operations The machine was installed in September 2016 with proof out, trialing and process refinement done over the following four to six weeks. With full production commencing in November, the VX-1000 makes large combination wrenches — wrenches that have one
open-end and one box-end with a hex of two inches and up — for use in heavy industrial applications, such as oil rigs and gas refining. “There has been a pretty steep learning curve because we have completely changed the way we make the product in every aspect,” notes Dean. The old way of making the large combination wrenches involved multiple steps and work centres before a finished product was produced. “Now, you put the forging in the machine — and for some of the [product] families, there’s a little more finishing that is needed — then you activate the program and you have the finished product.” The company says it has retained all employees and redeployed those who were displaced by the decommissioning of other processes in favour of the new technology to other functional areas. Dean says this includes movement to the CNC department, as well as other areas. Early, yet promising results As a result of the revised manufacturing process required to make the wrenches, processing lead times have dropped, says Dean, adding that it is now possible to produce them with a reduced lead time of up to one week if required. “When we look at the total product cycle time, we’re achieving things much faster and are making a better quality, better performing product. It’s a strong product.” He says the company’s future plans include determining what other existing products could be run on the new
equipment, exploring new products that could now be offered due to more efficient processing, and possibly exploring the implementation of other equipment within the CNC area. Along with boosting internal efficiencies, Dean explains the Elliott-Matsuura VX-1000 VMC is expected to increase product volume, distribution and the company’s international presence. “We’re probably going to need to hire in our distribution area and, as we continue to upgrade our CNC department, I can see more jobs there,” he says. Keeping manufacturing at home Of the products Gray Tools manufactures and finishes, 100 per cent
of the manufacturing is done within the Brampton facility — a detail that is “near and dear” to the company owners and the entire executive management team, says Dean. “There are a lot of pressures for us to do things offshore, to outsource things, but our president is committed to domestic manufacturing. It is part of who he is as a person, he really wants to keep manufacturing within Canada.” It can be difficult for businesses to keep their manufacturing operations in Canada, says Dean, but continuous investment in people, processes and equipment is something every manufacturer should pursue in an effort to remain competitive. “In order to maintain that product line being made here, in this facility and in Canada, we had to find ways to take process steps out to reduce the cycle time and internal costs so we could remain competitive internationally. We believe this is an investment in our people and in producing products here domestically,” he says. “This is an old industry. Not a lot has changed in the hand tool industry over the years, and we’re trying to be innovative, but at the same time continue to have a domestic presence, and continue to make products in Canada with Canadian people using Canadian companies as our integration partners. It’s onward and upward for us.” | MA
Technology Handbook Motion Control · MANUFACTURING AUTOMATION 19
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OPTIMIZING OPERATIONS How touchscreens can motivate assembly line workers to do quality work BY ANTHONY BORGES
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hen UTC Aerospace required a solution to manage assembly line workers with no previous manufacturing experience, it decided to try something new that set a precedent for its future manufacturing operations management (MOM) strategy. Using
manufacturing software from PINpoint Information Systems that features situational awareness graphics on plant floor touchscreens, the manufacturer was able to train an unskilled workforce to build safety critical electronics without defects, which actually helped ramp up production within days, said UTC Aerospace.
The touchscreen user interface and software help foster a team-based approach that instills a new culture, and closed-loop accountability in the factory where all manufacturing stakeholders are made accountable for what they contribute. 20 MANUFACTURING AUTOMATION · Technology Handbook Motion Control
With the software monitoring and controlling the hundreds of process steps needed to build the products, problems and defects could not go unchecked so error-proofing was maximized. How do touchscreens motivate assembly line workers to do quality work on time? All manufacturing stakeholders become accountable for the quality of the product, and the efficiency or timing in which it is assembled when individuals report to their own workstation touchscreens. The information created through an individual’s interactions with the touchscreens is also broadcasted to large plant floor displays for all team members to see, critique and act on. This manufacturing methodology emphasizes every line worker’s and supervisor’s own responsibility to contribute positively to the overall goal of manufacturing products of high quality in an efficient way, with the least amount of waste produced. Assembly line workers and area
supervisors become fully accountable for the finished product the moment they log into the user interface software with their own unique login and password. Figure 1 is an example of the SmartScreen user interface with various situational awareness graphics reporting the details and real-time performance of the individual line worker/workstation. The information includes the scheduled production time, the real-time status of the Goal Planned Actual (GPA), and Overall Equipment Effectiveness (OEE) which helps ensure the line worker is made aware and of their progress within the cycle time. Since each manufacturing stakeholder is identified by her/his own credentials, they must succumb to the first level of assembly line error-proofing. The software behind the user interface touchscreen identifies the worker and then confirms – before any work can start or tools are enabled – whether that person is actually qualified to do the work. The software, PINpoint describes, ensures quality by authenticating that the person has received the proper training to perform the process steps and that they are aware of the latest quality alerts and safety requirements unique to their workstation or process. At the heart of the user interface software is a manufacturing execution system (MES) and multi-dimensional database containing all the information required to build the product, along with the record of the line worker’s credentials, their
Figure 2: Fastening operation SmartScreen showing tolerances data visualization.
training and up-to-the-second historical assembly line performance data. Once the line worker is verified, the user interface presents the relevant work instructions so they can begin performing the steps to build the product. In the case of the common fastening operation, the user interface displays the tolerances required for the fastening operation. Figure 2 shows a SmartScreen example where the line worker has progressed to Process Step 4 requiring them to perform 20 fastening operations within the parameter set (PSet) of 5.00 – 7.00Nm at an angle of 5 - 7°. PINpoint believes the worker is motivated to perform each process step carefully and quickly since they are made aware of the cycle time remaining to complete the operation by way of the
Figure 1: Assembly line touchscreen user interface featuring situational awareness graphics.
cycle time gauge shown at the bottom left side of the main screen. Along the bottom of the screen are coloured bars that can also be configured to visually indicate and further re-enforce how they are progressing. Once the worker begins performing the fastening operation, the touchscreen displays their Fastening Results step by step with textual data and graphics that shows the worker’s progress. Not only does the touchscreen help guide the worker in each fastening operation, the system monitors their performance and can halt their progress and even turn off their tools should any operation be performed outside the set parameters. The touchscreen user interface and software not only motivate line workers, they help foster a team-based approach to manufacturing execution that instills a new culture, and closed-loop accountability in the factory where all manufacturing stakeholders are made accountable for what they contribute, describes PINpoint. The data generated by the line workers’ activities and the data recorded from the machines also becomes indispensable as business and manufacturing intelligence reports become increasingly essential for optimizing manufacturing operations. | MA Anthony Borges, marketing manager at PINpoint Information Systems, offers over 14 years of manufacturing optimization knowledge, with an aptitude for solving problems which increase business and manufacturing efficiency. Headquartered in Burlington, Ont., PINpoint services industry internationally from its offices in Canada, the United States and China.
Technology Handbook Motion Control · MANUFACTURING AUTOMATION 21