Designing a Motion-Control System…Software in 2015 Makes It Easy

Designing a Motion-Control System ... Software in 2015 Makes It Easy

q  This webinar will be available afterwards at www.designworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar

Before We Start


Wednesday • June 23, 2015

Submit your questions!

?

Designing a Motion-Control System ...

Software in 2015 Makes It Easy Presenters:

Lisa (Elisabeth) Eitel Senior Engineer Editor Design World Thomas Worsnopp Product Manager Servo Pneumatics and PLCs Festo Corp.


1. Enabling technology landscape in 2015: Better processors than ever (thank you, Moore’s Law) and configurability of physical components play synergistic role with software in eliminating busy work of motion design. 2. Design software: More interoperability is driving dynamic collaboration. 3. Selection software: An array of increasingly powerful tools make short work of virtual prototyping. 4. Example from Festo: One engineer from Festo walks us through the use of advanced sizing and selection software. 5. Programming software: The trend towards standardization on IEC 61131-3 continues as more engineers recognize the benefits of open-source languages.

Once, machines were mostly mechanical …

So now there’s an industry migration to electronically controlled systems.

But with that type of motion designs no longer efficient enough, industries have abandoned it …

Even in this department there’s been a design evolution …

… so today, motion-control systems use suites of compatible tools, components, and modular subsystems:

Suites of compatible components + modular subsystems:

Mechatronics are the extension of this trend

Microwave sensor for pneumatic actuators

Maker-grade Synthetos TinyG six-axis CNC controller

Firgelli’s miniature actuators in Youbionic hand

SolidWorks Interference and Clearance Detection

… and some direct-drive technologies are mechatronic designs in motion:

NSK Megatorque Motors

for positioning

Schaeffler IDAM INA MDDS-002 X-Y stage for optical scanning

Moog Animatics SmartMotor for multi-axis

coordination

LinMot linear-rotary motors for pick and place, stacking, or

aligning

Proprietary programs to setup, tune, and run motion hardware abound

Here you see software for parameterization, commissioning, design, and programming from Ace Controls, Aerotech, Rockwell, Fanuc, National Instruments, Galil, AutomationDirect, TI, PMD, ABB-Baldor, Lenze, and Fanuc.

On physical level, motion builds are often from scratch

Tweet to #DWwebinar • @DW_LisaEitel

Separate mechanical-drive, gearing, and motor design needs careful calculation to avoid oversizing

Sizing and selection software to the rescue

Go to motioncontroltips.com and search Motor Selectors

Sizing and selection software to the rescue

Tweet to #DWwebinar • @Festo_US • @DW_LisaEitel

Lets designers unify programming in multi-controller automation

Side note: Libraries in programming software

• Rockwell’s RSLogix Architect lets hardware and tag synchronize with RSLogix 5000 and EPLAN Electric P8

• Keeps controls and electric drawings updated

• EPLAN models for 26,000 of this particular manufacturers’ components, so engineers can drag and drop into designs

Even CAD software simplifies selection with part libraries …

Besides part libraries, there’s more interoperability in 2015:

One specific example from Festo

Result: List of working options, motion profile, single-axis drive bill of materials

Designing a Motion Control System...Easier How?

Tom Worsnopp Product Management – Electric Automation / Advanced Handling / Servopneumatics

•  Global automation company •  Supply components and systems solutions, including:

•  Pneumatic actuators •  Valve manifolds •  Electromechanical actuators •  Motors and drives •  PLCs, motion controllers, and HMIs •  Handling systems

Festo Company Overview

1.  Sizing and selection of solutions

2.  Ordering components and systems 3.  Configuration of stepper/servo drives 4.  Programming

Software automates the process

Designing a Motion Control System...Easier How?

1.  Engineer consults catalogs

2.  Engineer manually calculates viable solutions

3.  Engineer weighs cost versus performance

Sizing and Selection in the Past

m

L

JRJioInertiaRat 2=

ηπρ⋅⋅

⋅=2FM

1.  Input application requirements 2.  Software automatically determines solutions that works

Sizing and Selection Now PositioningDrives for sizing a single axis

Handling Guide Online (HGO) for sizing a multi-‐‑axis gantry

1.  Input application details: •  Load mass •  Stroke length •  Location of center of gravity •  Detailed motion profile •  And so on…

PositioningDrives for Sizing and Selecting a Single Axis Load mass

Stroke length

2.  List of solutions is generated •  Performance of each solution is available •  Listed from lowest price to highest price

PositioningDrives for Sizing and Selecting a Single Axis

3.  Automatically generate a bill of materials 4.  Configure additional options 5.  Export bill of materials to the online shop or save for later

PositioningDrives for Sizing and Selecting a Single Axis

Software tool on the Festo website to size gantries (1-axis, 2-axis, 3-axis) 1.  Input application data 2.  Select from suggested list of gantry solutions 3.  Configure additional options 4.  Download CAD models and documentation immediately 5.  Order gantry in the online shop

Handling Guide Online (HGO) for Sizing and Selecting a Gantry

•  Save Time •  Eliminate time spent comparing technical specifications in catalogs. •  Explore a broad range of products that you may not have otherwise considered. •  Focus on a narrow range of products that meet your application needs.

•  Save Money •  Festo software tools are free to download and/or use. •  Properly size the components (actuators, motors, drives) for your application.

Oversized components cost more to purchase up front and to maintain in the long run.

•  Increase Performance •  Find solutions that are guaranteed to work together with a long service life.

Benefits to Sizing and Selection with Festo Software Tools

Thank you, Tom! Put into context …

So, just to review:

• Motion technologies in 2015 include hardware that’s easier to configure

• New software for parameterization, commissioning, and design

• Programming options in a state of evolution … with proprietary offerings

incorporating more universal tools for interoperability

After selection of axis components, motor controller needs configuration …

But what if the motion design needs more customization? Programming software ……………….. Such as CoDeSys:

Tweet to #DWwebinar • @Festo_US • @DW_LisaEitel

Leading the charge in programming-software simplification in 2015

IEC 61131 …

• Originates from the International Electrotechnical Commission (IEC)

• Took root thanks in part to increasing affordability of PLCs

• As a controller-languages standard, it specifies the syntax, semantics, and displays for programming languages that include:

PLC Ladder Diagrams (LDs), Sequential Function Charts (SFCs), Function Block Diagrams (FBDs), Structured Text (ST), and Instruction Lists (ILs)

Controller Development System supports all five programming languages and C for easier setup

One tool for programming IEC 61131-3: CoDeSys

• Unlike other IEC 61131 offerings, CoDeSys generates native machine code for common processors … for fast and reliable code

Analysis • Design • Construction • Testing • Validation • Operation• Maintenance

IEC 61131-3 simplifies:

Improving maintenance yields high returns for end users

IEC 61131-3 controls also work independently on distributed controllers … useful for even fairly complex automation tasks

Data types are Real, Byte, Word, Boolean, Integer, Time of Day, Date, and String data; user-defined also possible

IEC 61131-3 doesn’t directly define motion control standards, but is framework for PLCopen

PLCopen

✓ PLCopen function-block libraries for single and multi-axis motion

✓ PLCopen like IEC 61131-3 is hardware independent so defines no block implementation

✗ Some PLCopen Motion Control software doesn’t produce compatible programming

✗ A few features of advanced motion controllers sometimes missing

Hardware connectivity complements software

Point-to-point connection at the field level with IO-Link:

• Standardized IEC 61131-9 IO for communicating with sensors and actuators

• Based on familiar three-wire sensor + actuator connection (not a fieldbus or special cabling)

Example:

More interoperability at motion-system device level

More interoperability at higher levels

Software for design, integration, and programming are leading time-savers today

Design software in 2015 has more interoperability for more collaboration and tools and parts libraries to save engineers time.

Some programming software is moving towards standardization on IEC 61131-3’s open-source languages.

Selection software comes in increasingly powerful tools make short work of virtual prototyping. Festo’s

PositioningDrives offering is one good example.

Designing a Motion-Control System ...

Software in 2015 Makes It Easy Questions?

Lisa (Elisabeth) Eitel Senior Engineer Editor Design World [email protected]

Thomas Worsnopp Product Manager Servo Pneumatics and PLCs Festo Corp. [email protected]

Thank You q  This webinar will be available at

designworldonline.com & email

q  Tweet with hashtag #DWwebinar

q  Connect with Design World

q  Discuss this on EngineeringExchange.com


Thank you for your time!