EtherCAT Benefits Production of Green Energy Lester Shaw, Elmo Motion Control, Inc.
Pioneers in green energy Photovoltaics characterized by long production lines Elmo servo controllers are installed in hundreds of production lines of this type.
Much higher throughput Improved yield Greater efficiency Migration from CANopen to EtherCAT Highest density of power and intelligence Install the servo drive anywhere Modular build and test of subsystems Scalability Flexibility
Operating in harmony Richness of motion control and programming capabilities standard communication protocols Interface with a large number of motor types Support wide range of power ratings (50 W to 7 kw) Support for different operating voltages Support for wide variety of feedback types Installing the servo drives anywhere Advanced networking capabilities Electromagnetic compliance Reliability Throughput
Elmo Servo Drives Incorporated in the Application I Gold Whistle: PCB-mounted, extremely lightweight. The Gold Whistle is the smallest and lightest EtherCAT servo drive available. Gold Solo Whistle: Integrated solution for applications that require a small footprint, high efficiency, and without the need to integrate it on a specific PCB. Gold DC Whistle: A closed and protected case (IP42) in an industrial enclosure, with full size connectors. It is ready for use. Gold Duo: An industrial enclosure that that integrates two Gold Whistle drives in a single product. The case is closed and protected (IP42) and the drive is economical. Customized Gold Duo: A dual axis solution tailored to the customer s specifications. It enables a simple and quick interface to the additional control units in the system. It is an ideal solution for multi-axis machines.
Elmo Servo Drives Incorporated in the Application II Gold Trombone: PCB-mounted for integrating directly into an application. It is very compact and economical. Gold DC Trombone: A closed and protected case (IP42) in an industrial enclosure, with full size connectors. It is ready for use. Elmo Duet: An intelligent motor that combines a servo controller in one integral unit. The servo unit is super compact and full of advanced features. It is an ideal solution for multi-axis applications that require high levels of synchronization in a deterministic communications network. The Duet is closed and protected (IP65) in an industrial enclosure, and it can withstand extreme environmental conditions including vibrations and temperature. It saves the need for electricity boxes and extra wiring.
Gold Line Servo Drive Performance The servo drives in the Gold Line have very impressive loop performance ratings: Current loop: up to 40 µs Velocity loop: up to 80 µs Position loop: up to 80 µs Advanced filtering for performance optimization. Additional performance features are as follows: Advanced servo tuning and gain scheduling. High power density. Very high efficiency (approximately 99%). Support for many types of feedback. Compliant with standard communication protocols.
High efficiency: negligible heat High electromagnetic immunity: negligible disturbance Proprietary FASST Technology (Fast and Soft Switching Technology) Minimizes the need for heat sinks Industrial Medical Elmo Gold Drive
The FASSTechnolgy: Provides fast and highly efficient switching Keeps process soft with no stress on power device with very low EMI The FASSTechnology is realized in Elmo s fully customized analog/digital IC designed for the Optimum Drive of power for MosFets and IGBTs.
The efficiency of Elmo s servo drives is around 99% and the EMI is significantly below the regulations requirements. This contributes to the compactness of the overall machine, minimizes the need for bulky heat-sinks, and eliminates the need for heat dissipation using unreliable fans or cooling systems. It is also unnecessary to reduce noise that would otherwise increase the overall cost of the system. Thus, the Green Energy Machine is itself green, due to Elmo s servo drives.
Elmo s highly advanced motion control algorithm allows the best solution for any motor and feedback combination, from a simple rotary and Hall-only motor up to the most precise linear motor in the submicrometer range. Motor Types DC Brush Motors Brushless Motors Moving Coil Linear Motors Options Incremental Encoders Absolute Serial Encoders Digital Hall Effects Analog Hall Effects Torque Motors Stepper Motors Encoder Sin-Cos 1V ptp Resolver Tachometer Potentiometer
Self tuning with the following tools: Nichols Plot Bode Plot Low Pass and High Pass filters Notch and Anti-notch filters. Fixed frequency filters Position and velocity scheduled filters
Position based addressing eliminates the need to set switches or preload configuration data before placing units on the network EtherCAT permits tuning software to access the drives while on the network using EOE and FOE No need to connect to each drive directly
Full compatibility with standard protocols Maximum flexibility and interoperability Easily add or switch servo drives Fast and efficient interface with host computer Support for: EtherCAT CANopen Ethernet (Ethernet/IP, Modbus, TCP/IP, UDP, Telnet) USB
Intelligent Use of Network Efficiency The EtherCAT protocol allows for the following network features: Remotely download firmware (FoE) Automatically download configuration files (FoE) Automatically set the EtherCAT address after a drive has been replaced on the network. Synchronization level is H/W controlled, down to < 1 µs Flexible network topology. You can combine star and loop topologies, mixed Daisy chained networks can be made redundant by connecting the last drive s EtherCAT out port back to the EtherCAT master Many data objects can be mapped from each drive Remote access is possible while the system is operating: Monitor and change axis parameters (EoE) Update settings on the-the-fly (EoE) Evaluate diagnostic variables (EoE).
Summary I Elmo s Gold drives have allowed the OEM to achieve their goals: Much higher throughput Improved yield Greater efficiency Modular build and test of subsystems Scalability Flexibility Elmo s Gold drives have the highest density of power and intelligence of any drive in the market. Their compact size and flexible packaging options permit the installation of the servo drive anywhere on the machine. In long production machines such as these, a significant reduction in the size of the machine, the saving in cooling factors, heat dissipation and EMC compliance, together with the simplicity of installation, lead to a great reduction in the machine s hardware infrastructure.
Summary II Utilizing a networked solution allowed the OEM to construct the machine in a modular fashion. The ability to build and test subsystems increases the efficiency of manufacturing. The modular nature of the machine also permits scalability and flexibility. More modules can be added to increase capacity or modules can be exchanged or added for new processing methods. The green energy machine is an exception in terms of its size and complexity, however, it is very representative of the multiple advantages that Elmo s servo drives offer in a network setting. When using the right servo drives, any machine that has more than four axes can be implemented much more effectively when using our distributed network topology.