SPS IPC Drives Italia Smart Servo Sensing in Industry 4.0 Tomer Goldenberg Elmo Motion Control

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Dominic Russell
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1 SPS IPC Drives Italia 2017 Smart Servo Sensing in Industry 4.0 Tomer Goldenberg Elmo Motion Control

2 Motion Control in the Age of Industry Overview The significant role of Motion Control in Industry 4.0 The motivations behind the new industrial revolution Why are Servo considerations so critical for today s factory challenges? What is Pure Power, and how can it be achieved? Smart Servo Sensing and how it can help achieve the same goals promoted by Industry 4.0 Big Data and Predictive Maintenance how are they related? 2

3 The Fourth Industrial Revolution What is Industry 4.0 (mainly) all about? Improved Asset Utilization Optimized Supply & Demand Improved Throughputs Reduced Time to Market Improved Process and Product Quality To do so, factories are: Automating Sensing Clouding Monitoring Digitizing Big Data Analysis 3

0, is essential in achieving some of its main goals But How?

4 Motion Control in the Age of Industry 4.0 Motion Control, although less talked about explicitly in the context of Industry 4.0, is essential in achieving some of its main goals But How? Consider the following two Surface Mount Technology (SMT) Pick & Place machines: 1200kg Both: High Throughput Uncompromised Quality Double Gantry Structure Z-Axis Mounting head (Z/θ) Similar PCBs, high density placement 2000kg 3.0m 3 5.2m 3 4

Pure Power To understand the difference between both machine, as well as the relation to Smart Servo Sensing, we must first understand the concept of: Pure Power Machines are dealing with Pure Power

5 Pure Power To understand the difference between both machine, as well as the relation to Smart Servo Sensing, we must first understand the concept of: Pure Power Machines are dealing with Pure Power when: Power is consumed almost entirely by machine functionality Minimal power is consumed by wasteful overheads such as cables, connectors, heat-sinks, cable guides, fans and more. Smart Servo Drives High Resolution Sensing & Monitoring System with Pure Power Huge Advantage in the Industry 4.0 Ecosystem 5

6 Pure Power Servo drives, In addition to high performance motion control, with advanced algorithms and high precision sensing can: Sense Monitor Analyze Movements Reactions Parts & Devices Pure Power facilitates Real-Time analytics necessary for monitoring and accurately controlling force, torque, velocity and position 6

7 Phase I: Achieving Pure Power As 80-90% of the power consumed is Pure Power, high-sensitivity, high resolution monitoring may be achieved. Qualitative Power (none more, none less) Light & Agile Mounting Heads Smart Servo & Control Algorithms Unique Gantry Control 7

8 Phase I: Achieving Pure Power 1) Qualitative Power Ideal Motion Control : Input Electrical Power = Mechanical Power Load The closer a servo drive is to the ideal scenario, the better the machine operates, and the more Pure Power is retained in the system Real Life: Input Electrical Power > Mechanical Load Power Mechanical / electrical interferences wasted energy fixing it requires even more energy 8

Physical Complexity Excessive Network Load Lean Distributed Control

9 Phase I: Achieving Pure Power 2) Unique Gantry Control Traditional approach: Complex Centralized Architecture Requires Master Control Physical Complexity Excessive Network Load Lean Distributed Control (machine B) 2 Drives Only (no Master Control required) Significant Overhead Reduction 9

Phase I: Achieving Pure Power 3) Pick & Place: Light and Agile Mounting

design and allowing drives to travel with mounting head 16 miniature

less power needed to carry cables, cable carries and connectors into

attuned to the load itself (Pure Power Monitoring) Sensor-less Force

10 Phase I: Achieving Pure Power 3) Pick & Place: Light and Agile Mounting Heads Agile machine B was also realized by minimizing servo drive design and allowing drives to travel with mounting head 16 miniature servo drives were directly mounted to the XY stage (Z,θ) Drives consume less power needed to carry cables, cable carries and connectors into the machine (since drives inside) x4 Drives are more sensitive and attuned to the load itself (Pure Power Monitoring) Sensor-less Force Control in the range of 0.3N to 10N (with 4kHz control bandwidth / 2000:1 Dynamic Range) 10

11 Phase I: Achieving Pure Power 4) Smart Motion & Servo Control P&P machines must be extremely dynamic to reach high performance and throughputs. These dynamics can be understood with the help of: Smart servo drives that are small enough to be mounted deep within the machine and that have high resolution and sensitivity, and act as high precision telemetry devices Vertical head units (Z-axis) oscillations, measured in response to high speed XY motion (during no command for Z) Intensive parasitic mechanical oscillations and system non linearity is evident 11

Phase I: Achieving Pure Power 4) Smart Motion & Servo Control Machine builders often resort to traditional methods to overcome such undesirable behaviors: Heavy and bulky mechanics to stiffen the

12 Phase I: Achieving Pure Power 4) Smart Motion & Servo Control Machine builders often resort to traditional methods to overcome such undesirable behaviors: Heavy and bulky mechanics to stiffen the system This leads to larger motors, gears, higher power drives Ultimately it means heavy, less agile machines (like machine A) A better approach embraces light and agile mechanics, monitors consequential behaviors of high dynamics, and reacts to resonances and jerks with smart motion control and advanced servo control Cannot reach highest dynamics and throughputs 12

Phase II: Utilizing Pure Power 1) High Precision (Sensor-less) Force Control Promptly and accurately monitor the component mounting force of the placement process in real time, based on pure power

3N-10N Faster process with higher CPH throughput Real Time Analysis and Reaction Short and long term deviations in mounting force may be detected and lead to conclusions about mechanical wear out,

13 Phase II: Utilizing Pure Power 1) High Precision (Sensor-less) Force Control Promptly and accurately monitor the component mounting force of the placement process in real time, based on pure power through drive No external sensors needed High sensitivity/wide range: 0.3N-10N Faster process with higher CPH throughput Real Time Analysis and Reaction Short and long term deviations in mounting force may be detected and lead to conclusions about mechanical wear out, component failure, or a bad batch of components Initial Distance - 4 mm First Impact after ~16.3 mili-sec Position/ Position Command [cnt] Switch to Torque mode at ~ -0.5 mm (after ~16 mili-sec) Retract head unit to upward position Profiled Torque [Amp] Impact of 1.25 N for ~4.5 mili-sec. Force stabilizes at 1 N for ~ 30 mili-sec. Long term, Big Data analysis Velocity/Velocity Command [cnt/sec] Load Cell [mn] 13

Phase II: Utilizing Pure Power Predictive Performance & Operation Smart servo drives can also monitor the short and long-term load stability, repeatability, and control performance of the XY table

14 Phase II: Utilizing Pure Power Predictive Performance & Operation Smart servo drives can also monitor the short and long-term load stability, repeatability, and control performance of the XY table (Gantry axes) Data can be analyzed to detect future risks: Malfunctioning Mechanical wear-out Mechanical problem (Predictive Maintenance) The drives can correct and/or prevent failures before damage to the process or components occur, or before a machine halt is reached 14

15 Conclusion An innovative motion-control approach has been demonstrated to provide an SMT machine with high-quality and stable throughout, by introducing it to intelligent I4.0 capabilities: Servo Sensing Monitoring Analyzing Predictive maintenance Pure Power is achieved as a "bonus" due to intelligent motion and servo control, aimed at machine performance optimization by means of control rather than (costly) mechanical design. 15

16 THANK YOU Smart Servo Sensing in Industry 4.0 Tomer Goldenberg Elmo Motion Control SPS IPC Drives Italia 2017

Smart Servo Sensing in Industry 4.0

SPS IPC Drives Italia 2017 Smart Servo Sensing in Industry 4.0 Tomer Goldenberg Lead Technical-Marketing Engineer, Elmo Motion Control Abstract In a revolution aimed at transforming factories, the less