Issue 8

Applications › Healthcare positioning › Glass decoration › Cut-to-length

News › The Ethernet Revolution MMotionotion IIntelligencentelligence › Stainless steel servos aadvancedd v a n c e d mmotiono t i o n ccontrolo n t r o l ttechnologye c h n o l o g y fforo r mmachinea c h i n e ddesignerse s i g n e r s › Stepper motors/drives › Eurocard drives › AC drives

Pin-Point Precision for Protons

motion control system capable A of positioning patients to within A Novel Control Solution 0.5mm/0.02inch, is about to enter commercial The novel eight-axis control system inside operation at the Rinecker Proton Therapy the machine has been designed by IPG of Centre in Munich. The system will be used for Switzerland. It is based on motion control As IPG had a considerable experience with proton beam irradiation - a therapy offering components from Baldor, and Baldor’s Mint- Linux, The result gave IPG a very flexible motion considerable advantages over X-rays as it does language motion commands - specially ported software environment, with a library of high-level less collateral damage. to run under Linux for this project to provide an commands providing sophisticated movement open and maintainable system. functions. The proton beam machine consists of a Ultra Smooth Movement large steel cylinder housing a gantry with very Among the advanced features IPG employs large magnets that guide the accelerated proton in the control system are Mint’s BLEND, Take a giant step - with beam. The patient is driven into the path of the CONTOURING and S-RAMP commands. These beam by means of a table with control of X, Y, allow moves to be overlapped with no jerky Z, rotation, pitch and roll axes based on closed- n innovative transitions - in this instance to ensure ultra- loop BSM servo motors. The table itself weighs solution for smooth movement and positioning of the A over 4 tons, to provide the stiffness required for implementing patient. accurate and repeatable positioning. machinery and Continued on page 2 motion control Linux Based Platform systems using At the heart of the control system is a PC fitted the industry- with Baldor’s multi-axis motion controller, › Application Summary standard NextMove-PCI. Control is provided by a Linux- Application: ETHERNET Powerlink (EPL) protocol is now based application written in ‘C’. This issues Precision patient positioning available. Consisting of servo motor drives, a motion commands to NextMove-PCI using Motion controller: full-function machine controller that will also Baldor’s library of ‘C’-compatible Mint functions. NextMove-PCI manage over 200 axes/devices, and a license- IPG needed to use Linux for the project in order FlexDriveII and BSM motors free software environment, it provides machine to obtain open access to the source code Key Design advantages: builders with the platform to make radical - but in order to do this, a new Linux driver for Rich programming language progress. Baldor’s Mint-compatible ‘C’ library had to be simplified the movements required written. See inside for more detail or access - Linux support www.baldormotion.com/epl2

1

2

system”. simplify this complex project” notes Alexander Alexander notes project” complex this simplify steps. smaller of sequences into

overall control control overall “Mint’s sophisticated motion functions helped helped functions motion sophisticated “Mint’s down movements dividing by problem this

and on the the on and the magnet gantry. magnet the simplified IPG mountings. its from extension

movements, movements, and a heavy-duty industrial motor that adjusts adjusts that motor industrial heavy-duty a and the on depending occurs that flexing slight

positioning positioning nozzle as it is set up for a treatment session, session, treatment a for up set is it as nozzle the and table the of non-linearities the

underpin the the underpin control the linear extension of the proton beam beam proton the of extension linear the control for corrects also which and positioning,

algorithms that that algorithms Two further axes on the card are also used to to used also are card the on axes further Two patient three-dimensional the for required

the application-specific application-specific the six Baldor FlexDrives and BSM servo motors. motors. servo BSM and FlexDrives Baldor six coordinates Cartesian the into coordinates

efforts on developing developing on efforts PCI card plugged into the PC, connected to to connected PC, the into plugged card PCI polar converts that program control complex

Ferro of IPG. “It allowed us to concentrate our our concentrate to us allowed “It IPG. of Ferro The motion subsystem consists of a NextMove- a of consists subsystem motion The a is however, motion, smooth this Behind

1 page from Continued

multi-tasking features multi-tasking

the background processing and geometric geometric and processing background the glass the to tape the bond to pressure as such Simple programming using Mint's Mint's using programming Simple

MintNC also automatically manages all all manages automatically also MintNC functions support provide that pneumatics

packages

the required real-time motion commands. commands. motion real-time required the miniature tape, the trims that knife’ ‘pizza a MintNC toolkit for interface to CAD CAD to interface for toolkit MintNC

industry-standard CAD formats and generates generates and formats CAD industry-standard including required accessories other controls

Key Design advantages: Design Key

environment that imports information in in information imports that environment that I/O the incorporates also NextMove-ESB

and BSM motors BSM and FlexDrive II

This facility relies on MintNC, a PC-based PC-based a MintNC, on relies facility This direction. changing for facility rotational a with

NextMove-ESB

streaming real-time motion commands. commands. motion real-time streaming combined positioning X-Y providing - toolhead

Motion solutions: Motion

programs, and automatically convert these to to these convert automatically and programs, multi-function a incorporating gantry a drives

Tape laying machinery laying Tape

conventional CAD CAD conventional that system

features than we originally planned” originally we than features

Application:

drawings from from drawings positioning

and allowed us to introduce more more introduce to us allowed and

› Application Summary Application

ability to accept accept to ability servo three-axis

platform for this new kind of automation, automation, of kind new this for platform

A key feature is its its is feature key A precision a

“NextMove has given us an economic economic an us given has “NextMove

operator interface. interface. operator controls box

host that provides the the provides that host compact This

interface is employed to interface with a PC PC a with interface to employed is interface controller. NextMove-ESB standalone the on

. USB subsystem’s motion real-time The windows. based Baldor, by engineered subsystem a Powerlink version, NextMove e100 NextMove version, Powerlink

the creation of Georgian-style doors and and doors Georgian-style of creation the by provided is machines both for Control NextMove-ESB is also now offered in an ETHERNET ETHERNET an in offered now also is NextMove-ESB *

designed for applying lead tape, and speeds speeds and tape, lead applying for designed control. motion

time to market.” says Ron Baker of CADRAM. of Baker Ron says market.” to time is machine LYNX-2 top-of-the-line The novel to thanks patterning of flexibility great offer

level software required, substantially shortening shortening substantially required, software level system. operating multitasking free and processes, hand-application traditional with

allowed us to focus our efforts on the higher higher the on efforts our focus to us allowed license- a including features, control machine compared increases productivity substantial

“The engineering support provided by Baldor Baldor by provided support engineering “The general with functionality control motion of deliver They tape. Accentrim 3M prismatic-effect

standard RWB files via USB. USB. via files RWB standard choice rich a combines which language, or lead using glass, window to decoration

The machine will alternatively accept industry- accept alternatively will machine The Mint the using written is software control The applying for solutions automated first the

T

the required number of rows and columns. columns. and rows of number required the feed. tape motor-based DC a and reel, providing are Sondermaschinen R&R and

complex pattern with crossings, and inputs inputs and crossings, with pattern complex the from tape cuts that guillotine a and surface CADRAM partners from machines novel wo

edges of a piece of glass, or a more more a or glass, of piece a of edges

frame design for applying tape to the the to tape applying for design frame

The operator selects either a simple simple a either selects operator The

following a simple configuration process. process. configuration simple a following

tape application program is generated generated is program application tape

by a local HMI connected via CAN. The The CAN. via connected HMI local a by

Here, operator control is provided provided is control operator Here,

beveling. beveling.

- LYNX 1 - which provides effects such as as such effects provides which - 1 LYNX -

the machine for applying Accentrim tape tape Accentrim applying for machine the

subsystem is employed on the variant of of variant the on employed is subsystem

The same basic machine control control machine basic same The

lots of custom software. custom of lots

the tape laying process without writing writing without process laying tape the

R&R to add a great deal of versatility into into versatility of deal great a add to R&R

software toolkit allowed CADRAM and and CADRAM allowed toolkit software

changing tools and direction. This This direction. and tools changing Mint - The Clear Choice Clear The - M Mint e c i o h C r a e l C e h T - t n i computation functions required when when required functions computation Take a Giant Step

radical new solution for implementing application - even those requiring very large A machinery and motion control systems is numbers of motion axes. now available, thanks to the industry-standard “We are implementing ETHERNET Powerlink ETHERNET Powerlink (EPL) protocol. Consisting in such a way that users can implement hybrid of servo motor drives, a full-function machine systems with a mix of digital and analog drives controller that also manages over 200 axes of if they wish, and continue to exploit low-cost motion, and a license-free software environment, technologies such as CANopen for cost-sensitive the range provides machine builders a platform parts of the machine control system. This to make radical progress. gives OEMs the freedom to exploit Ethernet immediately with migration-friendly technology”, Among a very broad range of gains made says David Greensmith of Baldor. as a fundamental tool for progress: “As with possible by this new Ethernet-friendly machine everyday speech, the degree of articulation that control architecture are the means to provide Bill of Materials Savings a language offers determines how elegantly end users with machinery that will link Greensmith goes on to estimate the hardware and efficiently problems can be solved. We seamlessly into local and wide area networks, savings possible by the reduced wiring believe the incredible richness of motion control and simpler system design, building and requirements of EPL to be as much as 100 functions available in Mint compared with commissioning. These are complemented by the Euros/$130 per axis. However, open industry software, possibility of major hardware system level gains are where gives engineers a real bill-of-materials savings the main benefits lie, and in edge in the new Ethernet from reduced wiring, and this arena Greensmith points to compatible machine the ability to use a single Baldor’s unique Mint language automation development.” controller for almost every

› Benefits of Using Baldor's EPL Solution COST SAVINGS > PERFORMANCE GAINS > CAPABILITIES >

> Reduced cabling and infrastructure > No analog signal issues or limitations > 16 axes of interpolated motion > Shorter design cycles > Precise, pure digital demands > DS402 Positioning Drives for > 200 axes > Faster build times > Dynamic control of drive parameters > CANopen manager integrated in the drives > Simpler commissioning > Communications between all devices > Remote access possibilities > Reduced hardware requirements > All control loops auto-tuned in one step > Access ALL drive functions from motion > No additional Fieldbus required > Scalable and flexible architecture controller using Baldor's ‘redirection‘ system > No software license fees for Baldor products > Improved reliability > Powerlink I/O and absolute encoders

3 What is ETHERNET Powerlink?

THERNET Powerlink (EPL) is a proven real-time Ethernet solution for automation applications. E The protocol provides deterministic data transfer with cycle times down to 200μs, and ultra precise timing (<1μs jitter). The technology is managed by an independent group (ETHERNET Powerlink Standardization Group (EPSG - www.ethernet-powerlink.org) and has won worldwide support from industry.

100% Ethernet Compliant Precise Timing EPL is compatible to IEEE 802.3u standard for EPL is the only real-time protocol on standard Fast Ethernet. So all IP protocols TCP, UDP and Ethernet which is compliant to IAONA real-time http can coexist with the isochronous time- classes 3+4 (www.iaona-eu.com). No matter how critical data, allowing seamless IT integration many stations are connected, or if the cycle time from the management level to the drive and is 200μs or 10ms: timing-precision is always sensor. Another benefit of standard compliance guaranteed with tolerance below 1μs (jitter). is the use of standard wiring - 100BaseTx, CAT 5e shielded cable - for up to 100m (330ft) Future-Proof Technology segment length and 100BaseFx (fibre optic), for Ethernet is the most widely deployed networking Ease of Use up to 2000m (6600ft) segment length. technology in the world, and is described by Simple wiring and configuration is important an ever evolving set of standards managed by for machine manufacturers. EPL allows any wiring topology like line, star and tree. Unlike real-time Ethernet systems which are based on switches, EPL not only offers superior timing, but a network which adapts to the machine’s need and not vice versa. Integrated hubs in EPL devices facilitate simple daisy chain connections and drastically reduce infrastructure costs and complexity.

Cross Traffic Between All Nodes EPL allows information exchange between any two or more nodes in a network, unlike some fieldbuses or Ethernet approaches where all information has to go through a master.

Network Security In Protected Mode, EPL incorporates network EPL precisely manages the exchange of data between all devices, in real-time. An asynchronous time period provides for service data exchange and communications with external IT networks. security by design. The real-time segment of the network is separated from the open IT network by an EPL router to avoid network collisions. Firewall and features such as MAC address filtering techniques, ensure security for a Deterministic Communication the IEEE. Currently Fast Ethernet with 100Mbit machine network in an IT environment. Guaranteed bandwidth is in common use. With 1Gigabit Data collisions are the ‘Achilles heal’ of emerging and working groups having already standard Ethernet. EPL avoids collisions by defined 10Gigabit Ethernet, Powerlink's future is simply managing the exchange of information secure. on the network, precisely controlling the order and timing of each exchange. Hence EPL can No Custom Silicon guarantee there will be no collisions ensuring EPL utilizes standard Ethernet chips only. precise timing and deterministic behavior. No special ASICs are required to achieve microsecond cycle times and precision.

4 15 Axis Pipe Bending is a Breeze

aldor's ETHERNET Powerlink control B solution is providing a breakthrough in the performance of tube bending machinery - allowing multi-stage bending operations to take place in parallel, while also reducing the electrical bill of materials and machine footprint. e c The technology is installed on Unison’s new n

machine, Breeze Uniflex, which provides modular e

multi-stage bending with automatic feeding, g i positioning and clamping to progress tube l l

components through the process. e t n I Intelligence

15 Axes of Motion Control

In the first production version of Breeze Uniflex, n

a machine Unison configured to produce o i condenser tubes for diesel engines, a single t

NextMove e100 machine controller manages o

a total of 15 motion axes powered by Baldors M Motion MicroFlex e100 servo drives, combined with Baldors high performance BSM servo motors, as well as numerous I/O channels and “Baldor’s ETHERNET Powerlink absolute encoders. On this application, tubing sequential operation of a multi-head bender. solution provides such a leap components progress automatically through Unison has also managed to reduce the size in motion control performance four separate bending stages, with operations at of the electrical control cabinet dramatically, that it makes this new multi- each stage happening simultaneously. by an estimated two thirds. This benefit was a stage bending machine Four axes perform bending operations combined result of much simpler wiring, and feasible,” says Mike Kay, the and eleven axes feed, rotate and clamp tubing the ability of the machine controller - Baldor’s Unison engineer responsible for the control components. In addition, a number of I/O NextMove e100 - to manage and synchronize all system. “The machine operates at several times devices are controlled via the network, including the motion axes and I/O required via the high- the productivity that would previously have been absolute encoders for automatic bend angle bandwidth (100Mbits/second) Ethernet network. possible, and in a space that’s probably half the verification on each bend axis. The centralized machine controller has comprehensive real-time control of each drive, size of the last generation.” Low Cost CANopen Expansion allowing it to deterministically control parameters such as motor torque and speed, as tube For cost effectiveness, and to maintain the “The benefits of all-electric components move through the machine. The machine’s modular architecture, many of tube bending machinery are machine’s simpler architecture, with its single the I/O components are connected locally now strongly established, Ethernet-based controller, also reduced software to the controller using the CANopen fieldbus, and the technology is taking complexity. In fact, Unison managed to get a an architectural possibility opened up by the a substantial slice of the prototype of the control program working within decision of the Powerlink standards group to use market,” notes Unison’s just one week of receiving the machine control CANopen device profiles, and the availability of a Managing Director, Alan Pickering. “We believe software - Baldor’s Mint programming language. CANopen port on the Baldor drives. all-electric technology now accounts for a fifth The parallel processing multiplies of the high-end tube bending market - which productivity compared with the more typical Modular Multitasking Software is around ten times the share of five years ago Programming speed was aided by the Mint - and with this technology, we expect market software’s built-in multitasking kernel, which share to double again in the next five years.” › Application Summary allowed Unison’s development team to divide Application: the real-time control program into a number of More information: Multi-head Tube Bending discrete software modules. Programming the www.baldormotion.com/epl2 Motion solution: core bending control program was simplified www.unisonltd.com NextMove-e100 by using a single bend task throughout the MicroFlex e100 and BSM motors machine, of which there can be several Key Design advantages: instances. The instances all run concurrently, ETHERNET Powerlink providing simultaneous control however many Mint's multi-tasking capabilities bend stations are required; the first machine has CANopen expansion for I/O control five, but adding a further station would simply Networked Absolute Encoders require the duplication of that code.

5 Baldor's EPL solution

EPL Machine Controller he NextMove e100 control platform offers a T real-time core that can control over 200 EPL devices such as drives, encoders, I/O, gateways etc - up to 16 of which can be interpolated axes - and also an extensive complement of general machine control and connectivity features. These include onboard analog and digital NextMove e100 MicroFlex e100 I/O and a USB port for simple connection to PC 16-axis stand-alone motion controller with DS402 Positioning Drive with ETHERNET hosts - with free ActiveX components. ETHERNET Powerlink and CANopen. Powerlink and CANopen The controller additionally includes support for three traditional analog controlled servo axes and four stepper or open loop axes for maximum In addition NextMove e100 can manage connection, plus a CANopen interface for I/O system design flexibility, giving OEMs the freedom EPL devices such as absolute encoders and expansion. The range currently offers users a to remain with conventional control technology if distributed EPL I/O banks to provide a complete choice of drives capable of delivering continuous Ethernet versions are not yet available. networked solution. output currents of 1, 3, 6 or 9A.

Elegant Expansion EPL Servo Drive DS402 Positioning Capability A CANopen interface provides a low-cost MicroFlex e100 is an EPL compatible single- Support for the CiA DS402 positioning drive means of adding local or remote I/O or other phase servo motor drive family based on the profile, provides system builders with an elegant components into the machine control system. company’s successful MicroFlex single-axis drive means of off loading the host motion controller, Users have the option of controlling any concept, a lean-and-smart drive that is now allowing simple commands to activate remote additional independent axes using the DS402 installed in many systems around the globe. functions such as absolute or incremental positioning drives on Powerlink, extending The drives provide a dual-port Ethernet moves, changing target positions on the fly, and beyond the 16 axes of interpolated motion. hub interface to support simple daisy-chain performing homing sequences.

Mint Machine Control Language The unique Mint language offers a fundamental tool for progress in any automation application involving motion. This high level language makes it easy to write and develop modular programs, and in addition to support for HMI, communications, I/O handling and complex mathematical functions, Mint offers probably the richest motion control programming facilities available worldwide. The incredible range of Mint’s motion control functions compared with ‘open’ industry software - which includes several hundred ‘keywords’ providing software functions for all common motion/movement related functions, which greatly simplifies complex machine design projects. The software also comes with its own license-free multitasking operating system.

For more information contact your local Baldor office or visit: www.baldormotion.com/epl2

6 Digital Servo Drive: Twice The Accuracy

y equipping a high-speed cut-to-length drive needs to move the knife at a consistent B machine with an advanced digital servo rate, and stop as repeatably as possible with no drive, Baldor managed to double its accuracy. overshoot. Goodman was typically achieving a Since most manufacturers of downstream figure of 200μs with its existing servo systems. cutting machines – and their customers However, even obtaining this level of – regard cutting accuracy as the single most performance was time-consuming, because important parameter, the improvement is highly the servo drive used analog potentiometers for significant and likely to lead to increased tuning, which only provide limited resolution and machine sales. offer no confirmation of performance. The machine that Baldor upgraded is Compared to the earlier servo used, designed to cut plastic tube extrusion into 2inch the Baldor FlexDriveII offers much faster I/O (50.8mm) lengths, at a rate of more than 300feet and servo loop update response times, and (91m) per minute. It is produced by GF Goodman considerably more control over operating & Son of Pennsylvania. GF Goodman asked parameters such as stiffness and overshoot. Baldor to investigate whether the accuracy of The software also features auto-tuning wizards › Application Summary its tube cutting machines could be improved and a Windows-based graphical user interface without major redesign. to help minimize set-up time, together with an Application: These machines are installed downstream oscilloscope facility which provides engineers Cut-to-length machinery of extrusion systems, forming one of the final with instant visual feedback of the effect of any Motion solutions: stages of fully automated production lines. changes to tuning parameters. This particular FlexDriveII servo drive Goodman’s existing cutting machines employed feature proved key, enabling the performance of BSM servo motors an earlier-generation brushless servo drive and the entire servo drive and motor system to be Key Design advantages: motor to control a rotary knife head. optimized very quickly and easily, halving the Faster servo loop and I/O response Accuracy of cut depends primarily on the response time from 200μs to just 100μs. Build-in tuning support response of the drive. To maximise accuracy, the

Small is Beautiful, Advancing AC Drives Tiny is Magnificent aldor has introduced an advanced he DSM Series of new family of adjustable-speed B micro-stepping AC drives, with an initial choice of T motors come powers up to 45kW. Designated H2, with onboard the drives feature a modular expansion drives. Their bus and option range that allows users compactness is to configure optimum solutions for ideal wherever space saving or every application, from simple speed simplicity of installation is important - such control to advanced positioning and as in instrumentation, test, medical devices sophisticated movements - with local and machinery adjustment applications. The I/O and networking communications range can greatly simplify both development for integration including Ethernet. They and machine building for OEMs, eliminating have been engineered for reliability the need to find space in the equipment for and ease of use, and offer a choice of drives, and drive-to motor-cabling - reducing open- or closed-loop control, including potential problems from electrical noise. inverter, encoderless vector, and There are three choices of NEMA frames, closed-loop vector operational modes. each in three lengths, offering a choice of nine torques spanning 22.6 to 749N-cm (32 to 1061 oz-in).

7 Clean As A Whistle he new SSBSM Series of all-stainless-steel servo motors provides T optimized protection for the most demanding applications in clean environments. The new 25-strong range allows OEMs to deliver higher speeds, accelerations and positioning accuracies in clean-in-place machinery and automation. Among the protection features is a 304 stainless steel housing protected to IP67, which will easily withstand cleaning using caustic materials at pressures to 103bar (1500PSI). Further protection includes an FDA shaft seal to comply with food industry and BISSC (US Baking Industry) standards; a potted stator for environmental protection and high voltage protection; an internal thermal switch to safeguard against overheating; and a laser etched nameplate to ensure there are no areas for process media and bacteria to cling to.

› Available in sizes 0.45 to 32 Nm (3.9 - 283 lb-in)

Spring 2006

Applications: News › Healthcare positioning › The Ethernet Revolution › Glass decoration › Stainless Steel servos › Cut-to-length › Stepper motors/drives MMotionotion IIntelligencentelligence › Eurocard drives aadvancedd v a n c e d mmotiono t i o n ccontrolo n t r o l ttechnologye c h n o l o g y fforo r mmachinea c h i n e ddesignerse s i g n e r s › AC drives › Office Locations World Headquarters (U.S.A.) United Kingdom Baldor Electric Company Tel: +44 1454 850000 Tel: +1 479 646-4711 Fax: +44 1454 859001 Fax: +1 479 648-5792 E-mail: [email protected] E-mail: [email protected] Singapore Germany Tel: +65 744 2572 Tel: +49 89 905 08-0 Fax: +65 747 1708 Fax: +49 89 905 08-490 E-mail: [email protected] E-mail: [email protected] Australia Italy Tel: +61 2 9674 5455 Tel: +41 91 640 9950 Fax: +61 2 9674 2495 Fax: +41 91 630 2633 E-mail: [email protected] E-mail: [email protected] India Switzerland Tel: +91 20 25 45 95 31/32 Take a giant step - with Tel: +41 52 647 4700 Fax: +91 20 25 45 95 30 Fax: +41 52 659 2394 E-mail: [email protected] ETHERNET Powerlink E-mail: [email protected]

For all current motion control brochure and flyers visit our web site, www.baldormotion.com/literature

Copyright © Baldor 2006. All trademarks recognized. Specifications subject to change without notice NL1250- 04/06 USA 8 5000 Litho For office locations visit www.baldor.com