Motion Product Overview

Transcription

1 SPECIALTY I/O POSITION SENSING MOTION CONTROL Motion Product Overview Advanced Micro Controls Inc Specialty I/O Position Sensing Motion Control

2 Today s Agenda 1. Introduction 2. AMCI stepper products 3. Applications and Installations 4. When is a stepper the right solution? 5. Other Considerations 6. Questions on Motion Products

3 Motion Basics Why Customers Use Servo Performance Ideal for high speed and demanding applications Programming Integration into the Rockwell Automation PLC is critical to maximize machine performance Institutional Knowledge Implementing and programming a servo is known quantity It s what we use It works, why mess with it

4 Motion Basics Why Consider Steppers Performance A great choice for applications where speeds are less than 1500 RPM and load requirements do not change from cycle to cycle Programming Integration into the Rockwell Automation PLC makes implementing stepper control quick and easy Institutional Knowledge Forget what you know about steppers. Advances in stepper technology and features eliminate many of the challenges of using steppers in sophisticated motion applications Take a look at what s new Advances in product integration makes stepper a great choice for many applications where you use servos

5 Motion Basics Stepper vs. Servo Stepper systems DC current generates a magnetic field. It is a constant current system. Torque drops off as a function of speed due to the number of rotor poles. Advantages Simple design/control Excellent low speed torque Excellent low speed smoothness Lower overall system cost Disadvantages Torque decreases as speed increases Constant current regardless of requirements* No method to overcome position loss* Servo systems Three phase AC current generates a magnetic field. The system continuously monitors position relative to commanded position and adjusts current and voltage accordingly. Advantages Closed loop control Higher torque at higher speed Very Efficient lower motor heating Better choice for variable load systems Disadvantages More complex control tuning required Position feedback required- increases cost Higher overall system cost

6 Motion Basics Stepper vs. Servo Motor Performance - Let s take a look at a general torque vs. speed curve of a stepper motor and servo motor of comparable size(nema 23) Motor-Size 23-three stack stepper motor servo continuous Stepper System cost Less than $800 Servo System cost Over $2000

7 Integrated Stepper Products Take Advantage of the PLC Integrated Motion Products - Efficiency without Sacrificing Performance Integrated motion products use the PLC as the central control for the motion and combine two or more functions to simplify installation and save time/money. Drive + Motor Drive + Controller Drive + Motor + Controller

8 AMCI Motion Products Integrated Motors Many of the less demanding or high volume applications can benefit from component integration. In 2004 AMCI designed the integrated motor/drive package in response to customers need for performance and quality in a low cost package. Stepper Motor Integrated Drive/Motor SMD23 Stepper Driver

9 AMCI Motion Products Integrated Drives In an effort to provide customers with cost effective solutions AMCI has developed a complete line of integrated solutions. These solutions combine 2 or more of the basic system components in one package. Saving money in both initial cost and installation. Stepper controller Integrated Drive/Controller Stepper Driver

10 ANG1E Integrated Stepper Motor Drive/Controller Expandable and Flexible Stepper controller & 4.0A stepper drive in one package 1-to-6 Axis of motion control Buy what you need > Expand later without penalty! Works Open or Closed Loop All PLCs/PACs using EtherNet/IP Easy programming via the PLC/PAC software Single network connection conserves bandwidth Works with any two phase stepper motor DIN rail mounting + = List Pricing: $625(US$) ANG1E master w/ network interface $545(US$) ANG1 expansion module

11 Integrated Drive Applications Packaging Print & Paper Medical Conveyors Automotive Vision Systems Handling and many more

12 Customer Application Filling Application A nationally recognized manufacturer of art supplies is undergoing product line improvements on a paint filling line. Current pneumatic solution is producing inconsistent fills resulting in under and over filling of product. The first product selected to manage the control failed due to communication delays. Requirements Must integrate into current control architecture (1756 PLC) Already purchased linear actuators to produce linear motion size 23 motors 6 axis and 10 axis control, depending on product run Solution AMCI (2) ANG1E and (8) ANG1 The Ethernet/IP connectivity and integrated control was key for this application. The integrated components eliminated the need for multiple control modules in the PLC as well as reducing component cost. Other solutions considered would have required up to 10 individual network connections where as this solution only required two, reducing communication bandwidth

13 SMD2XX Series Motors All-In-One Motion Control Integrated Stepper Drive + Motor + Controller Compact, all-in-one design for complete motion control Eliminates cabling between Controller and Drive and Motor Direct communication with PLC through the network Programs using the PLC s software (nothing new to learn) Standard cabling and interface M12 connectors Available in standard motor sizes Gearboxes and linear slides available Most efficient method to add sophisticated motion Available for most industrial networks Stepper Controller Stepper Driver Stepper Motor Fully Integrated Stepper Motion

14 SMDXXE2 2 nd Generation All in One Motion Control Product Highlights Standard Nema23 and NEMA34 frame sizes Absolute, Multi-turn Encoder Virtual Axis Following Embedded Ethernet switch Device Level Ring (DLR) IP65/67 Rating Optional EDS files/aois for Studio5000 Benefits Easiest integration into the PLC No need to home after a power cycle Reduction of hardware Lower cost option to integrated servo Encompass partner you can count on

15 SMDXX Series Accessories Cables and Connectors Power Cable CNPL-5M 5 meter cable Network Cable CNER -5M 5 meter cable Power Connector MS-29 Network Connector MS-28 Gearheads 5:1 Gearhead add GB5A to part number 10:1 Gearhead add GB10A to part number Consult factory for other gear ratios

16 SMDXX Series Applications Packaging Print & Paper Medical Conveyors Automotive Vision Systems Handling and many more

17 Automatic Conveyor Guiderail Adjustment SMD23E2 with absolute encoder Slitter Positioning SMD23E with gearhead

18 SMD23E Customer Application Medical Equipment Design Machine builder serving pharmaceutical industry designed table top metering machine to dispense anesthesia. Table top design required a compact, PLC-based motion control solution for an Allen-Bradley CompactLogix; all controls must reside within the enclosure. Requirements Compact size & EtherNet/IP compatible Cost less $$$ than an equivalent servo Integrate with PLCs quickly/easily. Must offer better value/reliability than other steppers Solution AMCI SMD23E-130 (RJ45 connectors) The Ethernet/IP connectivity and integrated control was key for this application. The integrated components eliminated the need for multiple control modules in the PLC as well as reducing component cost. The ability of AMCI to provide several hundred units in a small delivery window allowed the custom machine to be delivered in a standard product time frame.

19 Motion Basics Selecting the Right Product Consider using a stepper when your application meets any of these requirements. High torque, low speed Short, rapid, repetitive moves Simple control is desired Low speed, high accuracy Benefits of stepper Rugged construction High reliability means no maintenance No system tuning is required Low system cost Some considerations of stepper systems Torque decreases as a function of speed(this is improved using AC powered drives) Current setting of drive is continuous current. Use idle current reduction to reduce motor heating(new Hybrid Motion was designed to improve performance) If a system is sized improperly there is no feedback to detect motor stall(encoders Optional)

20 Why AMCI? Advantages Other Cannot Match Products are designed with the PLC as the heart of the solution Programming developed with PLC ladder logic in mind Data structure similar amongst all controller products No third party programming language Engineering and Manufactured by AMCI No outsourcing of production or engineering. Designed and manufactured in our Connecticut facility Complete control of quality and delivery Tech support and Application support using factory personnel Encompass Program Proven Partnership Only company manufacturing stepper products for the Rockwell Automation program AMCI stepper products are designed to complement not compete with Rockwell Automation s line of motion products

21 SPECIALTY I/O POSITION SENSING MOTION CONTROL For additional information please visit AMCI s web site. Thank you.