Motion Control News

Hard drives ''built like a tank'' for extreme driving conditions

Hitachi has been working with the automotive industry for nearly a decade to develop the right hard drive products for use in cars. Even beyond the wider temperature and altitude ranges, the requirements for an automotive-class hard drive are quite different than those of hard drives designed for personal computers or other stationary consumer electronic devices.

For example, cars could be in operation for a number of years, so the hard drives that go into them must compare to the reasonable lifespan of other automotive parts. In addition, automotive hard drives must have long-term supply for replacement and repair purposes, far beyond what's expected in IT applications.

Automotive hard drives are being implemented in predominantly three ways — as manufacturer options, dealer options, and after-market installations. A number of high-end luxury car manufacturers are beginning to offer hard drives as factory built-in options.

Hitachi Global Storage Technologies has introduced two new automotive hard drives that are tough enough to take on the harshest roads — even those less traveled. The Endurastar J4K50 and N4K50 are Hitachi's fourth-generation hard drives geared for automotive applications, such as navigation, digital entertainment (music/books/video), and telematics.

Featuring a wider temperature range and an industry-leading altitude range, the new Endurastar drives also incorporate impressive shock-absorption technologies to take on potholes and other surface vibrations. The J4K50 and N4K50 feature the highest storage capacity in an automotive-class hard drive with a top capacity of 50 gigabytes (GB). Luxury manufacturers and the dealer-installed options typically employ the higher-temperature range Endurastar, the J4K50. After-market installations tend to use the Endurastar N4K50, which offers a slightly lower temperature and altitude range.

The Endurastar J4K50 offers an operating temperature range of -22°F to +185°F, while the N4K50 sports a slightly lower range of 3°F to 158°F. This means the Hitachi Endurastar drives can operate at below freezing and near boiling temperatures. In terms of the road, the J4K50 would be able to travel from Antarctica to the Sahara Desert. The Endurastar products employ a technology called Thermal Fly-height Control to keep the read/write head at an appropriate distance from the surface of the disk as needed, which can be affected by extreme temperature variances.

In addition, an industry-leading altitude range of -300 to 5,000 meters allows the J4K50 to successfully store and retrieve data from the lowest point on earth, near the Dead Sea (-394 m), to the highest paved road in the world in the Andes Mountains (4,818 m). The N4K50 can travel to a slightly lower altitude with an upper range of 3,000 meters.

To traverse hills, mountains, and other bumpy terrain, the drives can survive as much as 3.0 G operating vibration and up to an 800 G drop shock.

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Hitachi Global Storage Technologies

Motion Control Products

Increase flexibility, decrease development time

The new ION™ Developer’s Kit is an easy-to-use digital drive and software package that makes setting up and testing motion systems quick and accurate.

The ION Digital drive is a fully enclosed module that provides high-performance motion control, network connectivity, and amplification in a compact package for DC brush, brushless DC, or step motors. The ION Developer's Kit consists of an ION Digital Drive, communication, and I/O cables, easy-to-use Pro-Motion development software, and documentation. There is also an optional heat sink and DIN rail adapter available. Designers only need to connect a motor and DC power supply to implement a complete motion system.

The all-digital ION drive module provides serial and multiple CAN interface communications and features user-selectable profiling modes including S-curve, trapezoidal, velocity contouring, and electronic gearing. ION’s small, powerful package has a 500W capability and performs at 8A RMS continuous, 15A RMS peak current. ION uses high-efficiency MOSFETs and offers 102 μsec servo loop rate and field-oriented control.

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Performance Motion Devices

Aries drive with resolver feedback

Parker Automation now provides a resolver feedback option in its successful Aries family of low-cost, all-digital servo drives. Now users can choose the versatile Aries drive for use with resolver feedback in addition to smart encoders, quadrature encoders, and Heidenhain EnDat absolute encoders.

The new resolver option adds the capability of solving applications requiring the advantages that rugged resolver technology can offer. A resolver feedback device is essentially made out of the same materials as the motor and contains no electronics; thus, a resolver-equipped motor is less susceptible to the effects of temperature, humidity, dust, vibration, and shock.

In addition, the Aries family now features a total of seven distinct power levels ranging from 100W up to 3,000W of continuous motor shaft power. That equates to 16A RMS continuous and 48A RMS peak current to quickly accelerate even the largest loads.

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Parker Electromechanical Automation

Modular, bus-compatible three-phase motor control

The new BL20 xStart motor starter modules allow three-phase motor control to be connected to the same rack as standard I/O. BL20 xStart motor starter modules are mounted directly next to other BL20 modules, and are controlled by the same gateway. This allows the motors to be controlled via DeviceNet, PROFIBUS-DP, or CANopen fieldbus protocols.

BL20 motor starters contain a base and power module, and are available in direct online and reversing (with and without trip indication) versions. The module’s base contains the I/O and communication electronics, and can be configured to allow power modules of various ratings to be used. The power module contains a motor-protective circuit breaker, as well as one or two contactors. Power modules are also hot-swappable, and enable the connection of motors rating up to 7 horsepower at a rated operational voltage of 480 VAC.

BL20 xStart modules comply with industrial switchgears standards IEC/EN 60947-4-1, and carry an IP 20 protection rating. The modules are fully compatible with existing BL20 terminals, and include free I/Oassistant configuration software.

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Turck

Stepper motor provides up to 40% more torque

Portescap, a Danaher Motion company, introduces the Portescap h3 Stepper Motor. When compared with similar step motors, these housed hybrid motors provide industry-leading torque output with increased performance, improved heat dissipation, and higher side and radial load capability, according to the company. These 1.8-degree step motors are available in NEMA 17, 23, and 34 frame sizes. Various stack lengths are available in each frame size, and windings can be customized to suit individual application needs.

The h3 series offers several upgrades when compared with standard hybrid step motors. The aluminum housing provides superior heat dissipation to create higher output torque during operation, and stator-enhanced magnets deliver up to 40% more torque in the same footprint. Neodymium iron boron magnets offer optimized torque density, while the bearing retainer and o-ring help reduce motor noise. Larger bearings enable the motor to effectively handle higher side and radial loads

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Portescap

Electronic position sensor for cylinders

Festo has added to its sensor product line the SMAT electronic position sensor for cylinders. The new SMAT can continuously monitor the position of a cylinder piston within a range of 50 mm.

This innovate cylinder position sensor is ideal for use in gripping, clamping, and part-selecting applications. Features and benefits include:

50 mm measurement range with analog output
Contactless, magnetic measurement principle
Mount in size 8 cylinder slot
Independent of magnet polarization
Space-saving — direct mounting in T-slot
Easy installation — insert into slot and lock into place with an Allen key
Reliable and accurate by design

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Festo Corp.

Highly durable electromechanical actuators

Duff Norton’s industrial duty TracMaster electromechanical linear actuator excels in demanding applications for load capacities up to 500 lbs. Load-dependent travel speeds are available up to 143 in. per min. Standard stroke lengths range from 3 in. to 18 in., although custom lengths can be accommodated. Load ratings are the same for both tension and compression applications.

The Duff-Norton TracMaster actuator features an aluminum housing outer tube and a plated inner translating tube with double clevis ends. The model also features dual adjustable internal limit switches with potentiometers or a load limiting clutch; AC or DC motors come with thermal overload protection, which resets automatically. All metal gears deliver strong performance for the most demanding applications, and help lower maintenance requirements. The drive system uses double-lead acme screws, which provide for the actuators speed and long life.

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Duff Norton

System-on-a-chip motion controller

The M3000 Motion Controller, from System Semiconductor Inc. in affiliation with Intelligent Motion Systems, is a highly integrated, mixed-signal system on a chip combining the major building blocks necessary to control and position multi-phase step motors. The device also works as a high-speed general purpose microcontroller incorporating extensive communication, analog, and system functions. The M3000 is offered in 160-pin quad package (LQFP), 128-pin quad package (TQFP), and 128-ball grid array (TFBGA).

The M3000’s patented phase current control circuits enables increased speed and smoothness while lowering audible noise and vibration. And with advanced acceleration, velocity, and position control circuits virtually eliminating corresponding time critical tasks, the CPU is freed to perform other system control functions. This allows system throughput rivaling high-end DSPs costing more.

Incorporation of the M3000’s extensive communication and general analog functions provides the user the capability to control a large variety of systems without additional circuits. A wide temperature range makes the M3000 ideal for commercial and industrial applications.

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System Semiconductor Inc.

Brush DC motors with 7-slot skewed armature

Series 8000 brush-commutated DC motors feature a 7-slot skewed armature design ideally suited to minimize magnetic cogging (reluctance torque) and promote smooth and quiet motor operation. This family of brush DC motors offers performance, reliability, and long life for a wide range of power applications in industries such as data storage, medical and biotech, semiconductor, and automation, among many others.

Series 8000 motors are available in three lengths (2.070 in., 2.445 in., and 2.915 in.) and can achieve peak torques up to 16.8 oz-in. and speeds up to 10,650 rpm for standard motors at rated voltages. Speed, voltage, current, and torque characteristics can be varied to satisfy particular application needs.

Motor commutators are diamond-turned after armature assembly to promote optimum concentricity and long brush life. Windings are resin-impregnated for greater reliability in incremental motion applications. Copper graphite brushes are standard. Modular construction enables the motor assemblies to be customized with alternate brush materials, encoders, timing belt pulleys, brakes, cables, connectors, modified shafts, and RFI suppression or other special configurations to meet application demands.

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Pittman

Miniature linear guide

A new linear motion company is introducing their unique combination of costs and capability to the U.S. market via their relationship with The Precision Alliance (TPA). Chieftech Precision of Taiwan is combining state-of-the-art German production equipment, a creative snap-together bearing design, and their new low-cost production facility in Taiwan.

The product line covers all sizes and bearing block types in both standard and wide series from 3 mm to 15 mm. All dimensions are directly interchangeable with the industry leaders and will drop directly into nearly any existing application. All sizes are made from German stainless steel extrusions and come in three precision grades and three preload classes.

TPA offers designers a wide variety of motion components and, when desired, complete subassemblies at either end of the accuracy spectrum.

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The Precision Alliance

Drivetrain system selection made easier

AxleTech International has launched a totally redesigned website that places a wealth of information and services literally a click or two away from its global customers.

Customers can locate products by industry — agriculture, construction, forestry, aircraft ground support, materials handling, military, mining, or specialty vehicle. They can also find a product by family — axles, independent suspension axle systems, transfer cases, brakes, or axle options. Individual sections of the new site contain product guides, application sheets, service manuals, and warranty information.

Entry to the Aftermarket section, which features genuine AxleTech, Rockwell, and Off-Highway Meritor Parts, is also one click away from the home page.

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AxelTech

Hollow motors now available from Empire Magnetics

Empire Magnetics introduces custom Hollow Series Motors. These pancake-style motors are available in large bore or hollow shaft configurations for vacuum, radiation, and other harsh environments. They are available with a power range of 25 to 2,500 watts in sizes ranging from 8 to 60 in. in diameter; with maximum bore size of 20% to 25% of the motor diameter. Comprehensive design services are available.

Magnetic and other computer modeling methods allow the envelope and performance to be accurately predicted in advance of fabrication. This allows the engineer to customize his design with a high degree of confidence.

Hollow motors are useful in beam line applications where a clearance hole at the centerline is vital to proper machine operation. Hollow motors are also useful in cable, fiber optic, and other continuous process manufacturing equipment where high strength and lightweight glass or graphite fibers are wound into complex coverings as the core passes through the center of the motor. Manipulator and robot arm designers benefit because a linear actuator can pass through the motor to perform mechanical functions in a very compact space.

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Empire Magnetics

Linear encoder for low-cost motors

For straightforward motion applications where simple and fast mounting of a small encoder is decisive, HEIDENHAIN now offers a new high-quality, low-cost exposed linear encoder package, the LIDA 200 series. These new exposed linear LIDA 200s offer two ways of simple mounting and are perfect for the low-end linear motor market.

HEIDENHAIN’s new LIDA 200s maintain the high-quality graduations, accuracy, and reliability of the LIDA 400 but offer a perfectly desirable grating period of 200 µm for analog systems (for digital systems, signal periods of 5 µm, 1 µm, and 0.5 µm are available).

The LIDA 200 linear encoders also actually operate at higher speeds (10 meters per second) than the LIDA 400, and boast even more resistance to contamination like scratches and fingerprints because of the coarser grating.

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HEIDENHAIN Corp.

Motion and logic controller with integrated servo drive

Reduce your total system cost by replacing a standalone PLC and single-axis motion controller/drive with the SMLC-SA, ORMEC’s new single-axis controller that combines high-performance drive technology with IEC 61131-3 programming capabilities in a compact, cost-effective package. The single-box solution reduces wiring complexity, panel space requirements, and programming effort.

The SMLC-SA uses the same development and commissioning tools as the entire SMLC product line. These tools provide seamless scalability from one to 16 axes. The CoDeSys Integrated Development Environment (IDE) and runtime engine are robust, full-featured tools with extensive diagnostic capabilities. ServoWire Pro is an easy-to-use, integrated suite of configuration, tuning, diagnostic, and maintenance utilities to assist in the commissioning of the drive. PLCopen standard motion control function blocks plus powerful ORMEC extensions reduce your software development costs and bring new levels of motion performance and machine control to single-axis applications.

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ORMEC

Servo motor feedback systems

SICK STEGMANN, INC. introduces SinCos SRS 64 Motor Feedback Systems with Hiperface interface. These single-turn servo motor feedback systems are well suited for applications requiring high resolution, or the Hiperface interface, in an industrial housing suitable for mounting external to a servo motor. They provide precise absolute positioning with 32,768 steps per revolution. In addition, they provide 1,024 sine/cosine cycles per turn, which after A/D conversion in a servo drive produces up to 4 million counts per turn.

The SRS64 Series offers reliable operation in temperatures ranging from -20º up to 110ºC with high resistance to shock (100/10 g/ms) and vibration (20/10 to 2,000 g/Hz). Hollow shaft bores are available for up to 14 mm shafts. An IP65 rating ensures trouble-free operation in a wide range of industrial applications.

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SICK STEGMANN, INC.

Microcontroller targets time-critical control apps

A new, unique industrial SoC (system on chip) microcontroller DCIC9907 is available from Saelig that contains two ARM 946E cores, two CAN channels, two 10/100 Mbit Ethernet MACs with HW extension for real-time protocols, and a versatile motion control logic capability, specifically designed for time-critical and other industrial control applications. DCIC9907 is destined to be the central digital element of advanced Servo System Platforms, since one of the two ARM cores can be used for complex real-time control tasks and the second for time-variable OS support and system overhead.

Although optimized for motion control applications, DCIC9907’s key features will find application in a wide variety of industrial communication situations, such as: Field bus controller node (CAN 2.0B, ETHERNET Powerlink); Field bus-to-Ethernet Network (bridge/firewall, gateway/TCP/IP, web server, firewall); Real-Time Ethernet control node (EPL Manager Node[Master] or control node [slave]); or Real-Time data acquisition and measurement (precision time/capture and intelligent ADC/DAC interfaces).

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Saelig Co. Inc.

Torque inserts add infinite position control

Reell Precision Manufacturing, a developer and major supplier of torque hinges for laptop computers that allow users to position the screen at any angle, has created a new and versatile product category they have called the “torque insert.” Design engineers who are looking for the same kind of smooth control they feel while positioning their laptop computer screens can now apply this technology in other areas without having to bolt on a hinge.

The torque insert is essentially a very compact torque control device that can be easily adapted to both new and existing applications without compromising a product’s design elements. Catalog products and custom derivatives are suitable for office equipment, medical devices, accessories for automotive interiors, computer peripherals, flat panel monitors, access panels, industrial enclosures or equipment guards. All of these versions feature Reell’s patented “ReellTorq™” torque clip technology that is designed to provide a smooth, quality feel and consistent torques over a life of more than 10,000 cycles.

The product is designed to be over-molded with plastic or pressed into a keyed cavity to add the feature of constant torque to positional parts. This allows manufacturers to create unique position-control devices by incorporating the insert into their molded or extruded parts.

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Reell Precision Manufacturing Corp.

Slide-Rite Gearboxes in new configurations

TOL-O-MATIC now offers its popular Slide-Rite® Gearboxes in new 3:2 and 2:1 gear ratios and metric versions in 1:1 ratios. Slide-Rite Gearboxes feature TOL-O-MATIC’s unique product design and manufacturing philosophy with Endurance TechnologySM for the most rugged products available that perform reliably right out of the box.

Slide-Rite Gearboxes consist of two 45° helical gears that mesh at right angles and turn power at 90° degrees. The industry-proven slide-through shafting allows the device to slide axially along keyed shafts in either direction, limited only by the length of the keyway. This type of floating design allows for easy installation and fast changeover. Slide-Rite Gearboxes also maintain perfect alignment, eliminating the need for dangerous chain sprocket drives and additional adjustments required for chain drive applications.

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TOL-O-MATIC, Inc.

Low-profile, direct-drive, air-bearing rotary stages

Aerotech's ABRS series rotary air-bearing stages provide angular positioning, velocity stability, and error motion performance in an exceptionally low-profile package. The ABRS is designed to meet the exacting requirements of wafer inspection, high-precision metrology, x-ray diffraction systems, optical inspection and fabrication, and MEMS/nanotechnology device fabrication.

To maximize positioning performance, the ABRS series utilizes Aerotech's S-series slotless, brushless motor. The motor uses an advanced magnetic circuit design to produce high-torque output with minimal heat generation. The slotless design is inherently zero cogging and torque-ripple free. This makes the ABRS stages ideal for applications requiring smooth scan velocities at low or high speeds.

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Aerotech