Intelligent Motion Control Ltd (INMOCO)

Absolute encoders provide surgical robots with positional control in a demanding environment. Requiring performance in dexterity and ergonomic flexibility that enhances human skill, combined with faultless reliability, its crucial to select feedback technology that delivers across these areas. Celera Motion’s latest through-bore inductive angle encoder has been designed specifically for surgical robot applications.

Gerard Bush of INMOCO discusses the needs of surgical robot application encoder feedback.

Robots are increasingly used for surgery, from treating forms of cancers to gallstones, as well as heart and thoracic procedures. While patients may have natural nervousness in replacing a surgeon with a robot, the technology is designed to improve the surgical outcome, with benefits including reducing the length of the hospital stay and recovery time, as well as lowering the risk of infection.

Of course, it’s not the case that the surgeon is replace by the robot, rather that their surgical capability is augmented as a result. Using a robot for surgery provides greater vision, with a magnified and detailed resolution of the procedure. The surgeon’s control of the robot can also increase dexterity and range of motion, usually achieving greater precision or function than would normally be humanly possible.

A mode of robotic operation involves the surgeon remotely controlling joints and limbs including wrists and finger movements to perform minimally invasive surgery. Precision of robotic motion depends upon a feedback sensor, and an encoder is used to provide closed loop control by detecting and relaying the rotational angle of motors that in turn power the robot’s limbs.

The encoders are installed in the manipulator arms and joints of the multiport surgical robot. Their dexterity and precision demand compact dimensions and light weight, particularly for applications such as keyhole surgery. Robot designs also need to be flexible to various surgical tasks. An encoder such as Celera Motion’s IncOder® CORE is designed for integration into manipulator arm rotary joints. It features a hollow bore stator and rotor, allowing for simple integration within a robot, with wiring and components that can pass through the encoder’s centre. The sensor itself is contained within a low-profile PCB form factor that also offers light weight.

To enhance surgical performance, a robot needs to combine precision, accuracy, and repeatability. The IncOder® CORE provides angular granularity of measurement in 17 bit resolution over each 360° rotation. The accuracy with which this level of measurement is achieved has a difference as low as +/- 0.1°. This performance is also repeatedly confirmed over a single power cycle at 1 lsb (least significant bit).

The encoder also has a measurement update rate of 10 kHz and an internal position update period as low as 100 μs, giving it a reaction rate that can respond to virtually any status change. This performance is also offered in control of a maximum speed of up to 10,000 rpm.

The robot and its components have to provide this level of performance against the regular practical rigours of the surgical setting. To ensure reliable performance during a critical surgical procedure, as well as offering long-term durability that reduces downtime and maintenance requirements, the IncOder® CORE involves an inductive measurement technique. The non-contact position sensor uses field proven technology that is impervious to contamination and as a result delivers repeatable, reliable, temperature-stable measurement performance. The bearing-free design also means the encoder is maintenance-free.

For ease of use, absolute encoder technology is important in the surgical setting as it enables the device to know the position of each joint and its position in three dimensions at power-up. Awareness of the true angular position of the axis removes any configuration requirement and the IncOder® CORE also speeds up production time for the robot OEM as no precision tolerances are required for calibration. For simple installation to the robot host, the through-bore encoder is screwed into place with M2 mounting holes and optional dowels. Meanwhile, communications flexibility is offered with integration options including SSI, BiSS-C, SPI, and Async Serial.

As each robot application differs, Celera is also able to integrate bespoke design considerations from OEMs, which INMOCO can facilitate. Surgical robot use is set to proliferate, but what will remain the same is the need for accurate, precise and reliable control. Absolute encoder technology, such as Celera Motion’s IncOder® CORE, can help OEMs achieve these outcomes.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Linear motion control specialist, Tolomatic, has released a new multiaxis actuator system, providing rigidity and accuracy for OEM machine designs. The two or three axis Twin Rail Stage (TRS) is an enclosed design, profiled rail actuator system, saving assembly time for OEMs that require multiaxis linear motion. TRS enables precise control with a choice of roller nut or ball nut. Typical to Tolomatic design, the actuator includes features that provide long service life.

Tolomatic’s new TRS is a multiaxis actuator system for two or three axis applications. Suited to X, Y, Z axis deployment, the Tolomatic TRS is ideal for OEM design of gantry systems, pick & place applications, and machine centres.

Specifically for metal machining, actuators must provide a secure hold on workpieces and control them with precision and stability to achieve accurate drilling and cutting. Actuator control also has to prevent deflection, which would cause the cutting axis to move, resulting in an imprecise finish. To overcome these challenges, the TRS system has been designed with high rigidity and delivers accurate control.

The TRS actuator’s extruded body ensures resistance to flexing and can handle loads up to 6 kN. Available with a strokesup to750mm or 1,100mm depending on frame size, the actuator system is suitable for maximum bending moments up to 294 Nm. A choice of screw technologies gives precision control, including a roller nut that provides accuracy of ± 0.0102mm/300mm, as well as a cost efficient ball nut that achieves accuracy of ± 0.051mm/300mm.

Applications such as metal machining require high durability, and the TRS actuator system has been designed with Tolomatic’s Endurance Technology principle to provide extended service life. This includes stainless steel dust bands that keep contaminants from entering the actuator interior, protecting components for reduced maintenance and increased uptime. Similarly, breather/purge ports are available as standard and can be leveraged to provide positive pressure with air lines and filters, ensuring that contaminants do not enter the interior of the actuator. Meanwhile, the wiper and seal are integrated with the carrier design to enable clean and smooth operation.

Pre-assembly by Tolomatic in multiaxis configurations saves the OEM time in assembly and installation. The design means that the TRS system can be mounted carrier to carrier with no additional mounting plates. Optional slots and clamps also provide flexibility and added security for mounting in addition to the dowel pin holes and threaded mounting holes that are available as standard.

The TRS multiaxis actuator system can be used with your choice of motor. Thanks to Tolomatic’s ‘Your motor here’ specification option, the OEM can inform of their motor and gearbox choice, with in-line or reverse parallel mounting, and the TRS actuator ships with the proper mounting hardware.

Tolomatic actuators are distributed in the UK by INMOCO. INMOCO’s engineers can work with OEM designers to guide sizing and specification for existing and new machine designs.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Celera Motion has released a new range of miniature PCB-based ring encoders for robotic joints. Ideally suited to surgical applications with a hollow bore design to fit into rotary actuators, the IncOder Core non-contact absolute encoder is metal-free and extremely lightweight. In addition to providing the accuracy, resolution and repeatability required for surgical applications, it features a design that is immune to contamination.

Distributed and support in the UK by INMOCO, Celera’s new absolute encoder is fully contained within a printed circuit board kit. Free from a metal housing, the rotary through-bore encoder is an ergonomic fit within robotic joints and is extremely light weight. Each sensor includes a passive rotor target, coming in at 11.8g, that is combined with an active stator comprising all the required processing electronics weighing just 2.8g. The lightweight package helps increase robotic precision and control.

Surgical application accuracy of 0.1° is combined with a resolution of 10 - 17 bits and a repeatability of +/- 1 LSB. This high level sensor performance is achieved using tried and tested inductive technology, chosen for its reliability during surgical procedures.

Highly durable for use in demanding environments, the encoder is impermeable to ingress, and neither liquids or debris impact sensor readings. It can operate in all expected temperature ranges, from -20 to +85 °C, and has a temperature coefficient of <1 ppm, giving it temperature-stable measurement performance. The bearingless design also means the encoder is maintenance-free.

Minimal dimensions make the encoder flexible for a range of compact robot layouts, intended to enhance the ease and speed of OEM design and integration. The rotor has an outside diameter of 36mm with the stator having an outside diameter of 56.8mm, while the unit has a hollow bore of 10.4mm across. With no precision installation tolerances required or need for calibration, this reduces installation time and speeds up production for the robot OEM. The angle sensor is installed into the host assembly by M2 mounting holes and the unit can be screwed (and optionally doweled) in place for fast and reliable installation.

The encoder is flexible to communication needs featuring integration with SSI, BiSS-C, SPI, and Async Serial. To connect the device, the stator features a 10-way Molex PicoClasp connector for power input and data outputs and the IncOder CORE can be supplied with an axial or radial connector.

INMOCO’s engineers are available to work with OEM design teams in application development and support, as well as providing the backing of Celera Motion when required for projects.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A linear actuator is usually needed to move an object in a straight line, from a conveyor to a metal press. While some applications requiring the highest forces and longest strokes might need hydraulic actuation, in the majority of cases, electromechanical actuator technology provides both machine builders and machine users with significant advantages.

Gerard Bush, INMOCO, compares electric and hydraulic actuator technology.

Electric actuators today provide mechanical outputs sufficient to span a wide variety of applications previously considered achievable only with hydraulic power. Compared to hydraulic, they offer a comparable bore size, extending from 25mm up to 127mm, with force reaching as high as 222.4kN. While achieving the same mechanical output, the more compact size of an electric system also enables a smaller machine footprint.

One of the clearest benefits of electric actuator technology is the higher level of control it provides. Coupled with a servo drive and motor, an electric actuator gives real time motion control over position, speed, acceleration and deceleration. Whereas a hydraulic system must maintain a constant oil temperature, which can otherwise cause fluctuating viscosity that impacts performance, an electric system provides greater consistency of operation.

Constant torque monitoring means control over force that single digit percentage points can consistently measure. High accuracy position control with closed loop operation means that multiple positions can be achieved with precision without additional external sensors.

Position and speed control can be achieved with hydraulic systems but this requires the addition of servo valves. Their integration adds significant cost and complexity compared to electric systems to achieve a comparable outcome.

As a result of the risk of leakage and contamination, some industries cannot use hydraulic actuation.Stringent regulations surrounding the food and beverage industry and pharmaceutical sector make electric actuators the only choice. Hydraulic actuators leak at some point in their lifetime and the fluid can damage produce. Alternatively, electric actuators remove any concerns of leakage or contamination and they also provide far quieter operation.

Electric actuators are sealed and once installed they operate maintenance-free, aside from periodic addition of grease via a port. This operation also makes them more reliable while the relative complexity of a hydraulic system takes longer to install and demands regular maintenance.

Despite the advantages of electric actuators, perception of cost is the main reason for resistance to conversion. They are more expensive in initial capital cost and some OEMs consider this prohibitive. However, true cost over the lifetime of machinery is the total cost of ownership and these benefits can be presented to the primary beneficiaries: the end users.

Substantial energy savings can be made over a machine’s lifetime. Electric actuators are more efficient, operating at up to 80% efficiency, whereas it’s not uncommon to find hydraulic actuators that provide less than 50%. More significantly, hydraulically powered machines are less productive than their electromechanical counterparts as a result of increased downtime, combined with longer machine changeover times.

When converting to electric, the biggest mistake is to oversimplify the force calculation process. While over-sizing a hydraulic system is common, because allowing a headroom of force required comes at relatively low cost, it’s key that an electric system is sized with greater accuracy to minimise energy costs. The traditional method of sizing, the system pressure method, is not recommended because it will likely lead to oversizing. Instead, determining the true peak and continuous working force of the existing hydraulic cylinder is ideal.

The most accurate sizing can be achieved by using a load cell or temporary installation of an electric actuator. INMOCO provides a sizing service and can work with designers to achieve the optimum specification for application requirements. Tolomatic, which manufactures electric actuators, also offers customisation to provide machine builders with the flexibility they need.

Hydraulic actuators aren’t going away. The stroke length of electric actuators is limited to around one meter, whereas hydraulic actuators extend further. Similarly, hydraulic actuators feature bores up to 203mm and are able to provide nearly 500kN of force. Below these requirements, providing the actuator is accurately sized with the proper assistance, electric power provides the highest performance and most cost effective operation.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

When assembling prefabricated metal components and frames, exacting accuracy is consistently needed to ensure a productive work rate and to avoid rejects. To achieve this, drills, routers and cutters have to provide a controlled action that ensures precision and avoids deflection during high speed operation. This relies on the rigidity and precision provided by the actuators, and a multi-axis linear system can help OEMs design more productive, high performance machines.

Gerard Bush of INMOCO explains the key considerations in actuator selection for metal machining.

When metal framework is assembled onsite, such as aluminium frames for doors and windows in construction projects, it’s vital that the prefabricated pieces are delivered with holes drilled and pieces cut with precision. These projects demand speed of installation and if the framework includes inaccuracies or defects, this means time onsite to rectify the issue or the introduction of waste through rejects.

As a result, a key requirement for metal working machines from routers to drills is precise control and stability in the automation process to enable accurate positioning throughout the machine’s operation. Without consistent accuracy, this results in poor fit and finish of the completed framework that can impact the quality of construction and efficiency of build.

A major cause of inaccuracy in metal machining is deflection. A common problem when machining with high speed drills and routers on aluminium framing, as the material moves through the machine, the cutting axis can bite, bend or wobble. Crucial to avoid deflection, it’s imperative that the machine’s actuators securely hold the drill or withstand the force of the press to prevent misplaced drilling or cutting.

The more exacting the specification or intricate the operation, the more crucial this becomes. If the actuator system can’t provide rigidity to sustain secure retention amid high paced machining, the pace of manufacture has to slow accordingly, impacting productivity. Alternatively, the machine risks inaccuracies and defects, affecting product quality and introducing waste.

To combat deflection, ideally the actuator requires a single body frame with a thick aluminium base, factors that contribute to high rigidity. Smooth action and control of the rail stage will also optimise control, and actuators specific to the task, such as Tolomatic’s TRS, provide high positional screw accuracy with the roller nut model providing ± 0.0102mm/300mm.

Combined with a controller and its software program, a multi-axis approach to metal machining of prefabricated framework can increase productivity by speeding up production. On such an approach, material can be automatically moved into position. A three-axis linear actuator system operating across X, Y and Z planes of movement can drill and route the top, bottom and front sections. High-speed tool sets can be mounted on multi-axis actuator system and cut holes and shapes according to the controller and software with a 90-degree upcut saw cutting the product to the required size. Introducing Tolomatic’s TRS actuators can achieve a three-axis configuration, mounted carrier-to-carrier with no additional mounting plates required.

The generation of swarf and fine particles is an inevitable by-product of metal machining applications. To avoid this material entering and fouling the actuators and impacting their service life, adequate sealing is required. A retained exterior dust band will keep contaminants from entering the actuator interior, protecting components to provide reduced maintenance and increased uptime. In addition, positive pressure with air lines and filters will ensure that contaminants do not enter the interior of the actuator. Ideally, the body of the actuator should be constructed from fatigue and corrosion resistant stainless steel. The wiper and seal on the actuator’s rail stage surface should also be integrated into the carrier design to provide consistently smooth and controlled operation.

OEMs might have their own choice of motor to power the actuator and INMOCO’s engineers can also advise on the optimum combination according to the application’s requirements. Tolomatic’s TRS can be delivered with mounting hardware specific to the required motor with in-line or reverse parallel mounting. In combination with the actuation system, INMOCO can also specify control hardware and assist in the selection and development of motion programming to optimise throughput and control accuracy for the desired application.

Removing deflection combined with high positional accuracy will ensure precision cutting and drilling across metal machining applications. Adequate sealing and protection of the actuator system will not only ensure smooth, service free operation, it will also reduce the total cost of ownership and enhance the lifetime of the machine.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

When the Covid pandemic struck in spring 2020, the world faced a global shortage of face masks to help contain infection spread. Existing mask-making machines were running at capacity and new machines were required that could adapt to manufacturing requirements. Motion actuation was a vital aspect of the new machines and contributed to flexible, compact and productive mask manufacture.

Gerard Bush of INMOCO discusses the vital role of electric actuators for mask making machines.

When the Covid pandemic gained pace in April 2020, masks to limit infection control became an integral part of the regulations and practices adopted by many countries. The ensuing demand created a global shortage, so much so that the UK government delayed compulsory public use for fear that the shortage would extend to hospital settings. Though mask making machines were at full capacity, the favourable option was not just to recreate existing designs.

Many machines were based on 20-year old designs, often developed to manufacture a single type of mask. They generated high throughput but were inflexible to manufacturing various mask designs. They were also expensive to produce and they were large, occupying a significant footprint. The need for the rapid build of multiple machines that could quickly handle manufacturing changes required a new design.

One such mask machine project took place in the US with a consortium of machine builders and automation vendors taking part. Typical of the situation, companies diversifying from their traditional fields were involved, such as Boyce Technologies, which works within urban technology for safety, security and communication. The company set about developing a mask manufacturing machine that would fit a compact footprint and provide high throughput. It also had to be able to manufacture various types of masks involving diverse designs and materials.

Projects like this were made possible by involving a foundation of specialist expertise. For Boyce Technologies, reliance on an actuation specialist was indispensable as the operation of actuation would provide the accuracy and speed required for fast throughput, so the company turned to Tolomatic.

The mask machine has three primary stages: material feed, form and cut, and assembly, and each station includes specific motion control requirements across multiple axes. Following infeed, the machine operates form pressing, cutting, and fabric welding. A Tolomatic B3W rodless belt-drive actuator moves and supports the material, pulling in the material sheet and then supporting a heated form press that’s applied. It’s crucial that the actuator provides high moment-loading capabilities as well as supporting the press’ weight of more than 65kg. Meanwhile the actuator’s entire unit, including the internal carriage support and bearings, is completely sealed, essential to prevent fabric particulate from penetrating the actuator and impeding its motion.

The formed masks are then transferred to the machine’s assembly stations where straps and nose pieces are cut, shaped and added to the mask moulds. Here, the B3W actuator provides fast positioning in the move and support function of the press that cuts and welds the masks. The rodless actuator’s speed of movement of up to half a meter per second enables high production cycle times and Tolomatic’s actuators are also stroke-configurable, a vital aspect for the machine’s manufacturing flexibility.

The actuators then move the pre-formed masks to a robot that transfers them for assembly, cutting and applying straps as well as gluing, cutting and applying nose pieces. At this stage, a pair of Tolomatic GSA linear slide actuators, chosen for their accuracy and resolution, assist in motion control of the ultrasonic welding function that applies loop elastic for placing around ears. The masks are then unloaded, ready for packaging and shipping.

Each actuator is also sized with a motor mount developed specifically to fit the choice of servo motor. To size the actuator according to motor dimensions, the OEM can add the relevant data to Tolomatic’s ‘Your Motor Here’ configurator, which is pre-loaded with an extensive range of motor types, speeding up the procurement process.

Going into service, the resulting machine has achieved its design goals and in particular the actuators have facilitated high throughput and widely configurable manufacturing options. For Boyce Technologies’ mask manufacturing machine, despite rapid design the machines will meet FDA standards, the equivalent of the UK’s Medicines and Healthcare products Regulatory Agency (MHRA).

While the actuators carry a wide range of options, Tolomatic customizes around a third of its orders meaning that individual machine build requirements are easily handled. INMOCO’s engineers are well placed to advise on machine integration for similar projects in the UK.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new linear actuator provides OEM applications with up to 100% duty cycle for repeated use, a total which is significantly higher than comparable electric actuators says the manufacturer. Thomson’s Electrak® LL also offers long life thanks to its brushless motor and ball screw assembly, which makes it last up to 375 miles of travel according to the brand, an advance of up to 10 times longer compared to other actuator models capable of the same load and speed.

Distributed in the UK by motion control specialist INMOCO, the Thomson actuator features a maximum static load of 18 kN and a maximum dynamic load of 6 kN. With a maximum operating speed of 30 mm/s, the Electrak LL has a maximum ordering stroke length of 500 mm and a minimum of 100 mm.

Electrak LL’s duty cycle, the function of the on-time operation of the actuator's motor, is 35%, which Thomson says is up to 20% higher than comparable electric linear actuators. However, the key benefit of the Electrak LL is that it can extend duty cycle to 100% at reduced load, which increases operational productivity without having to use forced cooling. This total duty cycle potential removes the need to use a higher power actuator for the same frequency of use, enabling the OEM to achieve a more cost effective and compact design. The system also provides constant speed regardless of the load.

Combined, the actuator has been designed for long lifetime operation, including a long-life ball screw and nut assembly increases resistance to wear. This is powered by a brushless DC motor that enhances lifetime relative to brush and alternative motor types, and is paired with a built-in brushless motor drive system. The assembly features a long-life manual override and the load-bearing design of the Electrak LL includes two bearings to handle bidirectional load. To protect the system, Thomson’s integrated Electronic Monitoring Package removes the need for separate controls and provides real time internal monitoring of parameters including end-of-stroke, voltage, current and temperature.

To ensure long lifetime under harsh environmental conditions, the actuator is protected within a highly corrosion-resistant casing and the adapters also made from stainless steel. Electrak LL’s housing is also coated, painted and sealed, pushing the protection up to IP69K (static) and IP66 (dynamic) standards, meaning it resists corrosion from UV radiation and water jets, and prevents the ingress of dust. The actuator can also withstand temperatures from -40° to 85°C and is CE and RoHS compliant.

Designed for OEMs developing machinery for applications with heavy duty demands that could also require a higher duty cycle, the Electrak LL is ideal for material handling applications. This includes conveyors, as well as door, hatch and valve control, as well as picking, placing and sorting. Suitable to withstand washdown and abrasive detergents, the actuator can also be used in environments where the risk of hydraulic contaminations cannot be accepted.

The actuator has also been designed for railway applications and is able to withstand harsh weather, heavy vibrations and high-pressure washing over prolonged periods. Its characteristics make Electrak LL ideal for opening and closing gravity bins or controlling a pantograph, and the actuator complies with railway standards EN 50155, EN 60077 and EN 45545.

INMOCO’s engineers can advise on specification dependent on application requirements and customised variations are also available for high volume OEMs.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Food production safety detection and rejection systems demand accuracy and control sufficient to ensure not just an effective system, but one that maintains throughput and uptime. This combines a need for optimum motor control that can integrate with an automated system with real time data sharing to guarantee that standards are met.

Gerard Bush, INMOCO, discusses motion control system requirements to ensure food production standards are achieved.

Whether controlled by regulators such as America’s Food & Drug Administration or the UK’s Food Standard’s Agency, food manufacturers are acutely aware of the need to follow stringent production regulations. For reputable manufacturers, it’s also important that they follow the obligations of hygiene and safety, not only to ensure the wellbeing of consumers and provide a high quality product, but also to protect their brand and consumer confidence in it.

As a result of food safety demands, end user food manufacturers rely on inspection systems. The inspection process is used both to identify and remove imperfect products from the line to ensure batch quality, but also to capture and share data to improve upstream quality control over the long term, as well as enabling downstream product traceability.

Today’s demands mean inspection of every single item in a batch, and for food manufacturers to ensure safety but maintain throughput, inspection equipment such as machine vision systems, X-ray, metal detection and weighing sensors are automated to the production line. Imperfect products are then using flaps, pushers and arm diverters. Control over the motion required to actuate and accurately position equipment such as sensor gantries and inspection systems is vital in order for the detection and rejection systems to effectively operate.

Direct drive motor technology is often favoured in these applications because of the high dynamic performance it provides. Not requiring a coupling between the motor and the load, a direct drive motor minimises lag or backlash associated with a device such as a gearbox. Resulting performance advantages include load acceleration, reduced system inertia, and higher precision, as well as reduced power consumption. Another advantage is the highly compact footprint of the motor itself, which combined with the removal of the transmission, creates a smaller machine. As transmission devices are prone to wear, removing the transmission also creates a more robust, reliable system.

Direct drive motors are available with a housing, enabling them to be easily installed into an existing machine. Alternatively, a frameless direct drive motor comprises the rotor and stator alone, meaning that they can be designed into a machine to reduce footprint and improve flexibility, particularly relating to installation options.

Kollmorgen has been involved with direct drive motor design since the birth of the concept and today the company’s engineers combine with partners such as INMOCO, as well as directly with the OEMs themselves, to develop motion solutions for applications including food manufacture safety systems. Kollmorgen’s framed motor range includes both housed and cartridge models that combine the advantages of direct drive in an easy to install package. Combined with high torque density, control is ensured with an integrated high resolution feedback device.

Alternatively, Kollmorgen’s frameless designs are embedded directly within a machine, using the machine’s own bearings to support the rotor. The advantages include high performance motion control combined with a long life, maintenance free motor. The frameless design also means that an exact fit for the application can be used, enabling compact and efficient machine design and also helping create a faster machine build.

The inherent benefit of direct drive motors, particularly frameless versions, is the ability to customise according to specification requirement. Working with integration partners such as INMOCO, Kollmorgen’s direct drive motors cover an extensive range and are flexible enough to enable a range of modifications to ensure best fit. Customisation options mean that features such as leads, windings and stack lengths can be specified to suit.

Combined with control accuracy, data sharing is also key for food manufacturers in order to demonstrate quality, improve future processes and enable traceability. Cloud-based systems enable the advantages of Industry 4.0 and Kollmorgen’s direct drive motors can communicate with the company’s AKD2G drives, which also include built in functional safety. The drives share data in real time to communicate status, diagnostics and predictive maintenance, providing information to enhance process productivity and reliability.

Integrating AKD2G drives, process data can be relayed to the controller as part of the Kollorgen Automation Suite, and Kollmorgen’s controllers also support I/O terminals and HMI integration. This means that real time production data can be managed and recorded, as well as being shared where required thanks to cloud connectivity. This provides visibility at all stages across the process to ensure that safety standards are maintained.

About Kollmorgen

Kollmorgen has more than 100 years of motion experience, proven in the industry’s highest-performing, most reliable motors, drives, linear actuators, gearheads, AGV control solutions and automation platforms. Kollmorgen delivers breakthrough solutions that are unmatched in performance, reliability and ease of use, giving machine builders an irrefutable marketplace advantage.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new type of linear motion technology is, literally, giving hydraulics a run for its money. Electromechanical actuators can provide superior performance over hydraulic cylinders in many applications – through improved precision, flexibility and reliability.

This webinar will cover:

• Considerations for making a change from hydraulics 
• Benefits of electric linear motion systems 
• Total cost of ownership 
• Important tips for converting from an existing hydraulic system to an all-electric solution 
• Resources & tools

      Register

Throughout the Covid-19 pandemic, OEMs have been challenged to provide solutions from design adaptions through to completely new machines. Particularly in the medical field, many of these machines rely on high accuracy, meaning high demand on servo system design. In addition to providing a precision motion control capability, reliance on holistic engineering partnerships have been brought to the fore.

Gerard Bush, INMOCO, explains the need for a collaborative approach in motion control development.

The Covid-19 crisis has increased demand across a wide variety of medical sectors, not least imaging and diagnostics. As a result, CT (computerised tomography) scanners, used in the diagnosis of conditions impacting the lungs and circulatory system, among other organs and biological processes, have been heavily relied on. As a result, the motion system on which CT scanners are based, being integral to provide control accuracy, have also faced a strong requirement.

A CT scanner generates a 3D representation of the body by taking a wide series of X-ray images from a range of angles surrounding the patient. To optimise the patient outcome, the key attribute of a CT scanner includes high image resolution, where the more detail and clarity that the scanner presents, the higher the potential of analysis and diagnostics by the medical practitioner. This capability is the result of the speed and accuracy of the scanner’s servo drive and motor control, and the servo package also has to combine control precision with speed of operation in order to minimise the time the patient is subject to the X-ray procedure.

Precision motion control

To achieve these benefits, a medical imaging OEM partnered with Kollmorgen for the supply of its servo drive, motor, cable and supplementary motion control equipment. The AKD servo drives form the basis of precision motion control and are selected by the CT scanner OEM as a result of their high bandwidth torque and velocity loops, combined with real time performance feedback.

The servo drives are matched with the AKM servo motor that offer low cogging to provide smooth and controlled motion, required for precision across multiple X-ray frames per second. High motor power density also ensures a more compact footprint for a smaller overall machine.

Ease and speed of motion application development and programming is also crucial for a faster time to market – especially crucial during the peak demand that the Covid crisis has presented. Combined, drive and motor compatibility ensures fast and reliable integration, which is made easier thanks to the simple to operate graphical user interface and wizard-based autotuning.

Motion solution specification assistance

As part of Kollmorgen’s global service, its capability is supported locally by country-based distributors and solution partners. In the UK, INMOCO, a motion specialist, supplies and supports Kollmorgen’s products to OEMs, advising on a variety of aspects to facilitate effective machine design. Based on an OEM’s known specification needs, INMOCO can guide engineers through product selection combined with Kollmorgen’s selection tools.

If specification criteria for application requirements, such as torque and speed, are as unknown by the OEMs design engineers, INMOCO can provide an OEM with servo sizing along with a detailed review of all potential application design aspects. This service extends through to a co-engineering capability, where INMOCO’s engineers will interface directly with the OEM and Kollmorgen to develop the optimum motion package.

This could range from identifying aspects such as voltage requirements and the windings best able to suit application needs, through to calculating servo braking speeds. Machine design is also assisted with Kollmorgen’s 3D image CAD library, which serves 50,000 product options for fast and simple motion solution integration within the overall machine.

Engineering partnership

If the partnership needs to extend further than the motion solution surrounding the motor, INMOCO can also work alongside Kollmorgen and the OEM to focus on software application development for the motion solution. This could range from programming motion profiles across the machine, through to the integration of third-party devices. These solutions may also require start-up assistance, including commissioning and on-site debugging, through to full training and ongoing field support.

The covid pandemic has brought to prominence the need to adapt or build new machine designs at a time of crisis. The reality however is that in general, OEMs typically benefit from a level of service above simple hardware procurement, whether to achieve faster time to market or an improved machine design. From servo sizing through to full application development and ongoing support, machine builders are increasingly relying on the presence of partners in engineering.

About Kollmorgen

Kollmorgen has more than 100 years of motion experience, proven in the industry’s highest-performing, most reliable motors, drives, linear actuators, gearheads, AGV control solutions and automation platforms. Kollmorgen delivers breakthrough solutions that are unmatched in performance, reliability and ease of use, giving machine builders an irrefutable marketplace advantage.

[Image Source: iStock-1168752174]

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Celera Motion’s IncOder Series inductive encoders can be designed to work in ATEX environments, ideally suited to measure ¼ turn valve position in explosive conditions. Aimed at industries including petrochemical and oil & gas, the encoders are highly durable and designed for continuous and reliable operation. Celera Motion’s IncOder Series of inductive angle sensors are distributed in the UK by INMOCO.

The IncOder Series rotary encoders can accurately measure full-scale positions between 10 and 100° of motion that can be measured at more than 1,000 points. Fast and simple to set-up, points on the scale can be selected with a simple push-button. Encoder size and resolution is designed to meet application requirements. Celera Motion’s established IncOder™ Series inductive angle encoders are built for precision and durability, and can be custom ATEX rated.

These encoders have been successful in providing precise, automated control for valve diagnostic systems in the oil and gas and petrochemical industries. The valve systems analyse data to provide real-time results on valve health status, without the requirement for operator intervention or process shutdown. The IncOder Series provides required feedback accuracy, combined with continuous operation in demanding conditions.

Custom ATEX rated IncOders have been tested and proven intrinsically safe. This means that the rotary encoder can be used in hazardous, explosive environments without causing a spark or reaching a high temperature that could ignite an explosive atmosphere. Application of the ‘Ex’ mark demonstrates ATEX approval and intrinsically safe operation.

Custom IncOders are rotary encoders and are fully sealed with IP68 rating, providing total protection from dust and water ingress. Operating with a low temperature co-efficient and designed with corrosion-resistant materials, the inductive encoder achieves a high mean time between failure (MTBF) rate. Installed in suitable certified enclosures, the IncOder can be used in tough environments with no impact on accurate, reliable performance.

Experience easy set up – wiring is protected with a flying lead to remove exposed connections. The encoder is rated at 28 V DC and can integrate with a wide variety of third-party motors and actuators. INMOCO’s engineers are well placed to establish application requirements and work with Celera Motion in the development of the customised encoder designs.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new PCB-mountable digital drive with full programmability has been released for control of DC brush, DC brushless and stepper motors to speed up development time. With a compact footprint, Performance Motion Devices’ (PMD) ION®/CME N-Series amplifiers are targeted at OEMs in applications in the medical, mobile, scientific, semiconductor, and automation markets. PMD products are distributed in the UK by INMOCO.

Three power ratings are available, including 75 W, 300 W and 1 kW and motion control performance is achieved through 20 kHz position and current loops. In DC brush motor control mode, the 1kW version operates at 19A continuous current up to 33A peak duty. Motion control profile generation includes with S-curve, trapezoidal, velocity contouring, electronic gearing profiles. Onboard control features including servo compensation, stall detection, field oriented control (FOC) and electronic camming also increase performance and control flexibility.

Instead of designing control boards from scratch with multiple IC components, the ION®/CME N-Series drives allow fully functional custom boards to be designed and produced in weeks instead of months or years. Engineers need only select their desired motor power and type, then attach the digital drive to the PCB with their choice of connectors and form factor.

At just 38 mm x 38 mm x 17 mm, the highly compact digital drives are fast and easy to install. Flexible to integrate, they include support for quadrature, sin/cos and BiSS-C encoders and communicate via Ethernet, CAN, serial, and SPI (Serial Peripheral Interface) communications.

In addition to the performance of the ION®/CME N-Series amplifiers, their onboard intelligence makes them fully programmable. The C-Motion® Engine allows users to directly run their application on the digital drive and PMD’s Magellan motion control chip speeds up development through compatibility. Applications previously developed on Magellan can be easily migrated to the new ION®/CME N-Series amplifier with support for the same programming libraries.

New application development is fast and simple and thanks to PMD’s Pro-Motion® Windows-based interface, which can also graph and analyse motion control performance to optimise the application. Autotune also speeds up commissioning time.

With a robust design, the ION®/CME N-Series drives also include pulse width modulation (PWM) switching frequencies from 20 – 120 kHz. This minimises ripple current and avoids heat build-up, optimising the compact, high power density design.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Celera Motion has launched a new frameless motor that provides high torque density in a compact form factor, combined with smooth motion. The Omni+™ motor series, distributed to the UK by INMOCO, improves thermal management with lower power dissipation and decreased temperature rise. The Omni+™ Series is well suited for medical robotic joints and industrial applications that demand high power density in a compact footprint.

Pre-engineered in a variety of axial lengths and winding options, the Omni+™ Series are currently available in 60 and 70 mm diameters with additional size options coming soon. Large rotor inner diameter to stator outer diameter ratios provides thin cross-section form factors, allowing design flexibility for cable routing, optics or other system elements. The frameless motor kits easily integrate with geared robotic joints, direct drive rotary stages or actuators – efficient for compact requirements.

The Omni+™ 60 mm version generates up to 5.29 Nm pulse duty and 1.61 Nm continuous duty. The 70 mm version has a maximum torque of 6.38 Nm pulse duty and 1.96 Nm continuous duty. While increasing power density, smooth motion is delivered due to reduced cogging, achieved through a high pole count and efficient electromagnetic design with a compact winding arrangement.

Decreased cogging also reduces torque ripple, resulting in high heat dissipation, a crucial requirement to enable high power generation in a compact design. Celera Motion’s frameless motor kit technology provides high speeds and accelerations, with superior mechanical stiffness that reduces settling times and increases performance.

Enabling ease of integration, the Omni+™ is offered in standard diameters and stack lengths that easily match with strain wave gears, and motor windings pair with drive current ratings – making all models compatible with a wide range of drives. Celera Motion’s Everest Series and Capitan Series miniature servo drives can be combined for optimal control, while Celera Motion also provides a range of optical encoders and inductive encoders for precision feedback – including the Zettlex inductive encoders.

Custom windings and form factors are also available, and INMOCO can provide application integration support to UK-based design engineers.

“Advancing on the success of Celera Motion’s Omni series, the Omni+™ frameless motor creates increased torque from a highly compact unit,” says Gerard Bush, INMOCO. “Combined with simple installation and easy cable routing, the Omni+™ is specifically for design engineers that need high power density with smooth motion performance.”

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Celera Motion has released a servo drive for your next generation applications that is ‘the smallest, most powerful servo drive in the world’. The Capitan Series servo drives is just 10.3 mm in height and 18g in weight, designed for applications in robotics and autonomous vehicles. This product is distributed in the UK by INMOCO. Experience high efficiency for battery-powered machines with a very low standby current.

Providing 10 A continuous current, the Capitan operates with an input ranging from 8 to 60 VDC. The drive supports multiple motor types including DC brushed and rotary brushless – suited to pair well with Celera Motion direct drive frameless motors.

The very low profile and light weight allows Capitan to easily integrate in compact footprints including robotic joints, flat actuators, end-effectors, surgical robots, exoskeletons, gimbals and haptic applications. Crucial for mobile applications, power control techniques and standby power consumption down to 1.12 W, combine to deliver up to 99% efficiency. Multiple Capitan servo drives can be connected together on the fieldbus to create multi-axis systems, and as a further benefit of the compact size, the drives can be mounted very close to the axis – minimising the cost of wiring and time of installation.

The Capitan Series optimal heat dissipation is vital to attain the high power density required for miniature applications. This is achieved through a transistor bonded to a ceramic film and attached directly to the heat sink, rapidly expelling excess temperature. Standby power has also been reduced to minimized the heat generation, and firmware architecture has been designed to accommodate PWM frequencies up to 200 kHz.

Communication options include SPI, CANopen or EtherCAT. EtherCAT update rates include low latency down to just two cycles, significantly faster than most servo drives. The high-speed SPI bus communication features a command update of just 20 kHz. Combining performance with safety, Capitan integrates functional safety STO SIL-3 Ple.

Simple to commission, the Capitan is programmed with Celera Motion’s Ingenia Motion Lab software that is used to set-up other drives in the same range. The Motion Lab software also includes autotuning and monitoring features to rapidly achieve motion performance.

The Capitan XCR is ready-to-use, enabling quick install and system commissioning. The pluggable module versions, Capitan NET and Capitan CORE, allow easy integration into a carrier board without soldering, providing the continuous current is below 10 A.

Supplied to the UK through INMOCO, the Capitan Series servo drives are well suited for OEM design engineers integrating motors, drives and control solutions into their applications.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new absolute encoder for PCB surface mounting has been released by Celera Motion, a business unit of Novanta. At just 9 x 7mm, the Aura™ Absolute Encoder Series is compact and low power, designed for applications where tiny form factor is critical. Distributed in the UK and Ireland by INMOCO, the Aura™ delivers optimum feedback performance in an easy to install package.

The Aura™ series is designed for OEM applications such as surgical robots, cobots, robot joints and grippers, exoskeleton and wearables, and semiconductors.

Absolute position decoding is achieved by a short wave-length LED, featuring 18–22 bit high resolution interpolation. This is the result of an incremental scale track that reflects pure sinewave signals detected by an advanced sensor with run speeds over 80k rpm on an 18mm track.

Aura’s™ absolute position feedback is highly accurate, measured to +/- 0.01° for precision control requirements with high repeatability of just 1 LSB (least significant bit). Accuracy is augmented by built-in eccentricity compensation for minimal angle error, achieved by a compensation algorithm that eliminates the effects of off-centre scale mounting. This technology also removes the requirement for a second encoder, alternatively added to achieve dual average concentricity and accuracy, which reduces power consumption, footprint and cost.

Highly compact dimensions and low heat dissipation enable easier PCB design. The Aura absolute encoder is also fast and simple to install. Standard scale sizes include 18mm outside diameter (OD) / 7 mm inside diameter (ID) and 33mm (OD) / 21mm (ID), while custom scale sizes are available from 16mm to 45mm (OD).

Wide alignment tolerances remove the need for exacting, time consuming positioning of the track and sensor head, while maintaining accuracy of measurement. The Aura™ series encoder is highly efficient, requiring low power and 5 V DC input voltage.

Real-time BiSS-C continuous mode interface means high speed communications and minimal latency for high bandwidth control loops. SSI, SPI and ABZ interfaces are also available, providing a wide range of connectivity options. The ABZ interface also provides incremental encoder capabilities for the lowest latency,and can be used to provide secondary position information.

The Aura™ absolute encoder series is calibrated, aligned and provides status monitoring managed via Celera Motion’s intuitive SmartPrecision™ III software. To simplify installation, custom hubs with pre-mounted encoder scales can be offered. Encoder data be downloaded in an easy-to-use CSV file format.

Celera Motion provides global application support and customisation to meet specific OEM requirements, with UK and Ireland applications supported by INMOCO.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

As OEMs strive to develop ever more mobile and compact machines, the trend is forcing miniature motion control manufacturers to maintain pace. Miniature motors and controllers are enabling precision performance control with an increasing need for reliability in demanding applications. The field is answering the demand with a shift towards embedded, decentralised architecture.

Gerard Bush of INMOCO explains how in meeting the demands, miniature motion technology is moving towards decentralised control.

The increased need for applications which are mobile, lightweight and compact has passed on these same requirements to designers of miniature motion control systems. Answering these demands, miniature motion solution development has also facilitated the reorganisation of machine architecture, allowing OEMs to decentralise motion control to local, embedded positions. As a result, in addition to machines with highly compact footprints, this trend is enabling improved performance, increased reliability and helping to reduce costs.

Reducing the size of the motor.

Brushless DC motors remain in favour for their high power to weight ratio and their ability to generate a constant torque up to high RPM. Alternatively, stepper motors are frequently used in portable applications as a result of their high torque to weight ratio. Despite the once detracting effect of a lowered effective torque because of their tendency to oscillate, the stepper servo technique has resolved the issue and uses an encoder to enable higher torque across the operating range of the motor, eliminating mid-range instability.

Particularly for steppers, as motor size reduces it becomes harder to add sensors without impacting the overall footprint. This explains the trend in sensorless operation for some applications using control techniques such as electronic stall detection for stepper motors as well as back-EMF for Brushless DC motors.

However, the challenge for sensorless techniques in many uses, such as electronic stall detection, can be to match the required level of reliability. This is pushing the trend for even very small motors to upgrade their sensors or to include encoders where they were not previously used. This demand for more robust sensors has also seen an increased trend for magnetic rather than optical encoders, especially when deployed in harsh conditions and medical applications.

Miniature motion control.

Whether using a motion control IC or a module, the most significant contributor to the size reduction in electronic motion controls is the performance increase of digital switching amplifiers. Most frequently, this means the metal–oxide semiconductor field-effect transistor switch, or MOSFET. Today, MOSFETs are reliable and compact, with significant improvements in energy losses to increase their efficiency.

Another advance has been in heat flow management and a new, specialized PCB, known as a metal clad printed circuit board (MCPCB) is gaining prominence for use in motion control amplifiers. It involves a traditional copper PCB which holds the integrated circuits onto a relatively thick aluminium or copper substrate. This layer acts as a dielectric layer which efficiently transfers the heat from the PCB. The MCPCB thermal transfer technology has accelerated the power density of motion control amplifiers and the latest generation devices achieve results of more than 100W per cc³.

The closer the better.

The more compact the motion control device, the greater the potential to deploy it locally or embed the motor and controller into the host machine. These embedded controllers can take the form of cable connected modules or an application specific control board built from PCBs or ICs. The control advantage of these devices, particularly those that integrate analogue sensors such as sin/cos encoders, is more accurate signals while the reduced length of physical communications means higher speed servo loops. These gains are augmented for ultra-high accuracy systems where performance is measured in nano or picometers.

As a result, the trend shifts closer towards the advantage of embedded motion control solutions versus those which are remotely mounted, especially for smaller machines requiring miniature motion control systems. Even though the current technology may not represent significant performance gains for large machines, even for these applications a single PCB-based embedded motion solution creates a more compact footprint compared to an external device.

Cost-wise, embedded control can be less expensive than module-based control providing a sufficiently high volume of devices are involved, but at the same time a new motion control device is easing the barrier to building application specific embedded control boards. Known variously as an intelligent amplifier, programmable amplifier, or motion control module, these PCB-mountable devices simplify custom control board design and development.

PCB-mounted motion control modules can run user application code, generate motion profiles, control servo positioning and drive the motor with an on-board amplifier. These devices can also interface via serial, CAN and Ethernet. Crucially they maintain the advantages of small size, measuring just 3-5cm in length and they can be interconnected, plug-and-play style.

Ever-shrinking motion control systems.

From drones to robots to patient treatment devices, compact and mobile applications continue to increase in number while the machines themselves decrease in size. Along with miniature motors, motion control electronics have not only reduced in size and weight but have increased in performance capability. Performance has also been able to advance with the greater potential of distributed architecture that local, embedded motion allows, at the same time increasing reliability with the potential to reduce cost.

“To get deeper technical insight, read the paper “Motion Control Goes Small” written by Chuck Lewin of Performance Motion Devices, Inc. (pmdcorp.com)”

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new range of electric linear actuators provide high power density in a compact package. Thomson’s Electrak MD actuators achieve up to 2 kN force in a housing being shorter than a pencil. The actuators feature a range of onboard electronics which extend control capability in a highly robust package with IP69K ingress protection.

The new Electrak®Electrak MD is based on Thomson’s established Electrak HD actuator. This means that the Electrak MD is still designed for use in demanding environments but is more compact. Electrak MD actuators are ideal for small space, mobile applications such as AGVs where the use of larger actuators or hydraulics aren’t possible. For smart packaging applications, the Electrak MD is easy to control while for agricultural use the actuators are highly robust and energy efficient.

The high power density of the compact Electrak MD actuators achieve 250 N to 2 kN force, combined with a stroke length of 50mm at 1.1kg to 300mm at 1.6kg. Actuation speed is up to 45 mm/s and the 1 kN version has 10% higher power density than the competition.

Easy to use control is achieved with Electrak MD’s onboard electronics, which reduce the cost and footprint of external relays and switches, and also speed up installation. Functions can be used to select end-of-stroke limit switches, with or without potentiometer feedback. Motor speed control can also be achieved using pulse width modulation (PWM). Extending capability, the optional Electronic Monitoring Package improves diagnostics for increased reliability. Functions include current, voltage and temperature monitoring as well as end of stroke dynamic braking to remove coasting.

Control functions can be extended further still with the optional Electrak Modular Control System, which includes J1939 CAN bus connectivity. Analogue output for position and direction feedback as well as end of stroke indication output are joined with low-level switching. These inputs increase safety, energy efficiency and smoothness of motion.

Designed for demanding environments, the Electrak MD’s IP rating is tested for IP69K statically and IP66 dynamically and the highest available. The actuator is sealed against high pressure water jets, dust and high temperature, meaning that it can undergo rigorous washdown. The Electrak MD has also passed a 500-hour salt spray test and can operate in temperatures from -40 to 85°C. The unit meets heavy duty shock and vibration levels and adheres to EMC safe levels.

The actuator has been designed for long life and achieves 25% longer life on the 1 kN 300mm variant than competing models. A strong, reliable motor powers a high quality self locking acme screw, protected by a stainless steel extension tube. Meanwhile, the actuator housing is E-coated for greater protection.

The sealed electric unit also means that the actuator is maintenance free and additional advantages over hydraulic or pneumatic variants include reduced noise and cleaner operation. The electric actuator is also significantly smaller, making it the better choice for applications which demand low footprint.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Performance motion control is a crucial aspect for the reliable automation of laboratory analysis equipment. Effectively commissioning servo systems to overcome real-world challenges such as vibration can be achieved by application of the most appropriate motion control technique.

Gerard Bush of INMOCO discusses a variety of techniques to enable accurate and reliable motion control for automated laboratory analysis equipment.

Accuracy and reliability in motion control are key requirements to optimise automated laboratory analysis equipment such as blood analysers and DNA sequencers that receive, process and analyse samples. Repeatedly and safely moving the objects which hold the liquids through the process is not only important for efficiency and machine uptime but also to protect the media itself, especially where its value can be very high.

At the most fundamental level, an intrusion into a conveyor mechanism or wear of a component could disrupt controlled movement. For this reason, a position encoder is usually deployed and connected to the motor – including stepper motors which wouldn’t normally require the assistance of an encoder device - and when required, an encoder can sometimes be connected to the load itself. The feedback of an encoder ensures that control changes which could lead to mechanical disruption are detected in advance.

Vibration is another challenge to the reliability and accuracy of movement of liquid sample containers such as slides, test tubes or microplates. The heavier the load and the wider the range of motion, the greater the potential issue. Vibration can be controlled by applying a force, equal and opposite to that of the driving motor, to the mechanical structure supporting the end effector. Conducting a Bode plot scan, the motor operates in a sinusoidal motion from low to high frequency. Doing so, it’s possible to observe the vibrating resonant point responses of the supporting mechanics and end effector. Even without a sensor located at the load, the closed loop response of the servo motor with an encoder will show the resonance points, reflected as energy back into the motor.

When the vibration points have been identified, it’s then possible to control the motion profiles which minimise jerk, the representation of the changing rate of acceleration. The motion profile comprises the acceleration, coast and deceleration stages, and changing it from a trapezoidal profile to an S-curve increases the intervals of incremental speed change and as a result reduces vibrational energy. Adding incremental changes at a time will reduce mechanical vibration while not unduly lengthening the duration of the move overall.

For large apparatus involving servo-based control systems such as a gantry, biquads can be programmed to create a variety of filter types including low pass, notch and band pass. Most motion controllers offer frequency-domain filtering capabilities via biquad filters, which can be applied to help reduce specific resonances and smooth the overall system response. Also based on Bode plot analysis, implementation involves open and closed loop axes from which it’s possible to identify resonance points or areas where the phase margin difference is slight, which can result in oscillation.

Inertial forces must also be considered on the basis that during acceleration the load will lag; while coasting the contribution will be zero; and during deceleration the load will lead. To offset inertial forces, feedforward can be applied. It’s possible to calculate feedforward though it can be quicker and more effective to trial application settings before honing in to the optimal value. This process is achieved by combining a PID loop and motion oscilloscope to capture the servo error over the entire move.

If velocity-proportional forces are present, velocity feedforward can be used to compensate. Similarly, if there is a constant directional force on the axis, such as a vertical axis under servo control, a motion controller’s PID bias setting can feedforward a constant value to counteract the constant force.

Despite the techniques applied, for systems with complex linkages between the motor and load, the resonances and mechanical inaccuracies may still generate vibration. Reducing the mechanical linkage itself, for example switching a geared motor to a direct drive, is an option but this can add cost. An alternative technique therefore is to use the dual loop, where an encoder directly measures the load position as opposed to the final position and is used to stabilise the servo loop.

Ultimately, the most effective method of motion control within a laboratory analysis machine depends on the characteristics of the application. INMOCO is the sole UK distributor for Performance Motion Devices chip-based motion control products and can advise on the right motion control for your embedded application.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Patient fluid processing in particular has contributed to the development in precision fluid pumping. Application requirements determine the type of pumping system required, which must be combined with a matched motion control system.

Gerard Bush of INMOCO explains the technology involved with precision fluid pumping.

Patient fluid processing, including dialysis, drug infusion, plasma & platelet extraction, has driven the developments of precise liquid pumping. Amongst these applications, a piston or syringe pump is one of the most commonly used. The liquid is dispensed by moving a sealed plunger through a tube and these pumps are capable of very high precision. Using a lead screw, the higher the motor's positioning resolution, the higher the dispensing precision.

With a piston pump, liquid can be ejected or drawn in. A single-piston pump has a fixed total displacement, which means that the total volume of liquid transfer is limited to the volume of the syringe. To achieve continuous flow, two or more pistons have to be controlled to ensure that as one dispenses, the other draws in fluid. Check valves coordinated with the pistons are used in combination to manage flow direction to create accurate, effective continuous dispensing.

The accuracy of piston pumps is dependent on position control. This means that stepper or servo motors are used with a position encoder and in the case of servo, a PID (proportional, integral, derivative) loop. To move the position of the piston from point to point, a profile generator is required and trapezoidal rather than s-curve motion profiles are generally sufficient.

An alternative to the piston pump is the diaphragm pump. Instead of a piston, a seal is used to dispense the liquid. The difference is that the seal is driven in a reciprocating manner, alternately drawing fluid in and dispensing fluid out. Again, check valves can be used to maintain fluid flow in a single direction. This reciprocating motion can be easily generated by a spinning motor.

The challenge of diaphragm pump motion control is that constant rotary velocity doesn’t deliver a constant volume of liquid. This is because the drive-motor linkage at the bottom and top of the motor arm stroke the rate of fluid delivery will be essentially zero, and at the mid-point the flow will be greatest. A cam profile can be used to remedy the issue, translating input from a master encoder; alternatively, the input can be time-based.

Another variety is the peristaltic pump, which uses a roller to squeeze a liquid-containing tube, dispensing the liquid in the direction of the roller movement. The most notable advantage is the separation of the pumping mechanism from the medium. This is crucial for applications where liquid has to be pumped without contacting the contents of the packaging, such as dialysis and blood transfusion machines. The constraint however is a lack of accuracy. The flexible tubes mean that the volume of delivered liquid for a programmed amount of motor rotation may vary and liquid can be pulsed, rather than a continual smooth flow.

Motion is created by a direct drive or geared servomotor and a profile generator and PID controller control the rotor angle. A challenge is torque variation caused by position of the roller, which can exacerbate the pulse effect. Where patient-specific variables exist, such as the effect of blood pressure, it’s also imperative to use a motion control system to handle the impact on flow output velocity.

As with peristaltic pumps, seal-less centrifugal pumps are also hermetically isolated. With an inlet, magnetic coupling, impeller, and outlet, as liquid enters, the centrifugal force of the rapidly rotating impeller forces the exit of the liquid via the outlet. Magnets inside the impeller couple to rotating magnetic fields driven by a motor shaft external to the impeller assembly.

This design also means durability because of the lack of wear on components such as the tube found on the peristaltic pump but centrifugal pumps are though relatively inaccurate and are mainly used where variables can be measured with a separate device.

For precision fluid handling, it is also possible to use general purpose air pumps with sensors. Sensors measure the actual air pressure imparted by the pump, and to determine the amount of liquid transferred, the air pressure is monitored at regular intervals. A lookup table converting pressure differential to flow rate is used to calculate the volume of transferred liquid. An outer control loop is also often combined to precisely maintain a desired pressure profile.

The advantage of this arrangement is a compact footprint at a relatively low cost. In addition to controlling pressure, outer loops are also commonly used to control temperature, liquid level and reaction rates. As a result, a variety of off-the-shelf IC and module products can integrate a complete outer loop control function.

It’s important to note that all of these pump types can also be used in non-precision applications and the crucial factor to ensure accuracy is also the type of motion control and sensors used. As sole UK distributor for Performance Motion Devices chip-based motion control products, INMOCO can advise on the right motion control for your embedded application.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Rod-style electric actuators with integrated servo motors are reducing machine footprint and extending service life. INMOCO is supplying Tolomatic’s high force Integrated Motor rod-style Actuators to the UK. Tolomatic’s IMA actuators have been developed for OEMs requiring high force in a compact, highly durable and long lifetime package.

Tolomatic IMA provides up to 30.6 kN push and pull force in a highly compact, integrated servo motor and actuator design. This design reduces the overall footprint of the machine by removing the need for an external motor. The integrated approach also simplifies machine design and installation which can be further extended with a single cable option if a Hiperface DSL encoder is used.

Tolomatic’s IMA utilizing roller screw technology is ideally suited for pressing applications, where high force and long life are required. Efficiency, accurate positioning and quick response also makes the IMA ideal for valve management, as well as process control applications such as fluid dispensing. In these applications repeatable force with smooth velocity are necessary. IMA has also been designed for resistance spot welding applications It’s light weight and compact construction are ideal for pedestal and robotic applications in addition to very repeatable and consistent force. IMA is also a cost effective option for welding applications with a competitive price point.

IMA has been specifically designed and tested to maximize service life. A grease port means lubrication can take place without the need for removal from the machine. This increases the potential for regular, simple lubrication extending the screw service life. The roller screw supports this by applying force over a large contact area, reducing concentrated wear thus increasing force and minimizing the space required to do so when compared to conventional ball screws. Should applications not require the extended force or durability provided by the roller screw, ball screws are available for increased cost efficiency.

The IMA’s robust construction is further enhanced with an IP65 rating. This provides ingress protection from dust and water spray, supported by a replaceable rod wiper preventing contaminants from entering the actuator. An IP67 option is also available, protecting from water immersion up to 1m depth for 30 minutes. Internally, the steel thrust tube supports extremely high force capabilities and its salt bath nitride treatment provides high surface hardness, corrosion resistance, and other hazards like weld slag, water or other potential contaminants. Meanwhile, bumpers protect the screw and nut assembly from damage at the end of stroke in the event of an uncontrolled impact.

Tolomatic IMA generates actuation speed up to 1,334 mm/sec with a stroke length up to 457 mm, in face sizes ranging from 63.5 mm to 142 mm. Integration with leading robot manufacturers is made possible through wide array of feedback types, resolutions, and protocols. The recent addition of the Hiperface DSL option also enables a single cable solution integrating power and feedback, for a more compact footprint and simpler installation.

IMA is quieter and cleaner than hydraulic systems, as well as removing the possible emission of hydraulic fluid. Also included in the IMA range is a white paint option. This adds options that are very desirable for food manufacturing and processing applications. With a painted exterior, an IP67 option, stainless rod and food grade grease, it is a cost effective solution in a very compact package. The newest addition to the IMA family is the IMA-S. An all 316 stainless steel solution with IP69k sealing is the premier solution for the most aggressive wash down and caustic environments.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Kollmorgen has released a new servo drive, motor and cable motion package, designed to increase machine performance and reduce footprint. The new Kollmorgen 2G Motion System, distributed by INMOCO and aimed at OEMs and system integrators, features integrated safe motion and is easy to install for existing and new machine designs.

The 2G Motion System has been designed to work together for optimal performance in a compact package. The AKM2G single cable motors have improved power density with an average torque increase of 30% over the first generation AKM motors of equivalent size. Compact, dual axis AKD2G drives provide up to twice the power density and include integrated I/O which can be expanded without increasing panel space requirements. The drives also feature integrated SafeMotion, reducing the cost and footprint requirements of an additional external safety controller.

The AKM2G servo motor provides high torque density, decreased indexing time and increased responsiveness, and the lower inertial feature also makes AKM2G a better fit with high dynamic applications. Performance ranges from 0.65 Nm continuous torque at stall at 8,000 RPM rated speed with 0.0930 kg-cm2 rotor inertia, through to 72.1 Nm continuous torque at stall at 3,000 RPM with 88.6 kg-cm2 rotor inertia. Feedback options include Kollmorgen SFD3 as well as HIPERFACE DSL and EnDat 2.2, both of which support functional safety. Dual-cable resolver feedback is also a standard option and customer-specified feedback devices are available through co-engineering. Standard winding choices range from 120 V to 480 V.

The AKD2G servo drive, at just 76 mm wide and 235 mm high for 110-230 V drives and 75 mm wide and 272 mm high for 230-480 V drives, achieves twice the power density of single axis drives thanks to its dual axis capability at 20% less space than competitors’ dual axis technology. With 16 I/O ports onboard including Safe Torque Off (STO), this can be expanded to 28 without increasing the size of the drive. Control technology comprises Servo on a Chip with Dual-Core ARM A9 and the AKD2G boasts rapid, accurate motion control. Performance characteristics include 1.28 us current loop, 62.5 us velocity loop and 250 us position loop.

Easy to use, the AKD2G servo drive features plug and play compatibility with Kollmorgen controls and motors, as well as full colour display for easy access to commissioning data. Kollmorgen’s WorkBenuch GUI software tool includes one-click autotuning as well as wizard-based manual tuning when required. Meanwhile, communications integration includes EtherCAT, FSoE and CANopen.

The AKD2G servo drive’s integrated safety includes SafeStop, SafeSpeed and SafePosition functions. Amongst the full range of functions, examples include Safe Brake Test, Safe Brake Control, Dynamic Braking, Safe Speed and Safe Direction. The integrated safety functionality increases productivity by reducing unnecessary machine stops and removes the footprint and cost requirement for an eternal safety controller.

Faster machine development and easy integration is achieved with drop-in motion performance and no need to change the existing machine design. Motors are available with a wide range of frame and stack length combinations as well as electrical configurations. If required for bespoke or specialized applications, co-engineering is achievable with Kollmorgen, facilitated by INMOCO’s engineering expertise.

For complex, multi-axis machines, the Kollmorgen Automation Suite (KAS) is available to develop a full automation system. This takes Kollmorgen’s capability from individual or small groups of independently controlled axes through to complex synchronized motion on multi-axis machines. KAS includes controller hardware, I/O devices, HMI and an additional safety controller.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new stainless steel integrated electric actuator has been released for the food and beverage market. The Tolomatic IMA-S rod-style servo actuator, distributed in the UK by INMOCO, has been designed for demanding hygienic requirements in a robust, long-life package.

Designed to prevent corrosion and withstand clean-in-place washdown, the IMA-S integrated actuator enables open machine design, removing the requirement to use shrouding to protect the actuator and shield the production area. The actuator is designing for food and beverage applications including volumetric pumping and dispensing, slicing and cutting, grating, sorting and diverting.

The Tolomatic IMA-S integrated actuator is constructed from food grade 316 stainless steel. This prevents corrosion which could harbour bacteria from saline and acidic substances commonly used in food and beverage production. Welded, polished joints create the most hygienic seams and Hex head fasteners also prevent the build-up of potential contaminants. FDA-approved rod wipers and seals are also available as options.

316 stainless steel construction gives the IMA-S the capability to withstand regular clean-in-place washdown using caustic detergents. Hygiene is also enhanced as the IMA-S features IP69K ingress protection, meaning that the actuator can withstand high-pressure, high-temperature, close range water spray during washdown.

The integrated electric actuator design is inherently cleaner and quieter than hydraulic systems and removes the potential emission of hydraulic fluid, which can contaminate the hygienic production environment. The hollow rotor servo motor is also integrated into the actuator housing, creating a compact and hygienic design, removing the footprint required for an external motor.

The IMA-S has also been designed for durability and long service life. The roller screw applies force over a larger contact area, reducing wear and extending lifetime, and a ball screw option is also available for a focus on cost efficiency. Lubrication takes place in situ via the grease port, removing the need to dismount the actuator from the machine and encouraging regular lubrication.

Automation integration is compatible with a wide variety of vendors, thanks to a range of feedback types, resolutions and protocols. Feedback options include multi-turn absolute encoders (Hiperface DSL, Hiperface Sin-Cos, EnDat 2.2), and the Hiperface DSL option enables a single cable solution integrating power and feedback. Motor files for Rockwell Automation (Allen Bradley) Kinetix motion platform are also available for quick integration.

The hygienic IMA-S series offers forces up to 11.1 kN (2500 lbf) and stroke lengths up to 450 mm (18 inches).

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

A new range of mini inductive angle encoders are now available for ultra precision measurement of angle or angular speed in harsh environments. Non-contact inductive technology makes Celera Motion’s Ultra IncOders, now in 37mm and 58mm diameters, more reliable than capacitive and magnetic encoders. The Ultra IncOders, distributed in the UK by INMOCO, are pre-calibrated and offer up to 19 arc-seconds accuracy and 22 bits resolution.

Celera Motion has released the new Mini Ultra IncOder, providing reduced diameter options for applications demanding the lowest footprint, including mobile robotics applications such as unmanned ground vehicles. The Midi Ultra IncOder series, which has a larger outside diameter range of 75mm to 300mm, has been augmented with a duplex option – providing redundancy for safety-critical applications such as surgical robots, a feature that is also included in the standard Mini IncOder.

Measuring via induction, the IncOder’s accuracy is unaffected by moisture or particulates. This also means that measurement performance is largely independent of installation tolerances. Combining expansion options, the Ultra IncOders can be used to measure weight, vibration, strain, shock, tilt, pressure and temperature. Ingress protection up to IP67 is also available.

As a result of these features, Celera Motion’s Zettlex Ultra IncOder series is highly suited for outdoor, rugged environments, and applications where optimal accuracy is needed. Satcom, UAV, defense, industrial robotics, CNC machining and surgical applications have integrated the IncOder product as a result.

The flat ring design comprises a powered stator that measures the absolute angular position of the passive rotor, relative to the stator, with no motion required. The lightweight design features simple, screw-in mounting for OEMs. Cabling, through-shafts, slip rings, and pipes can also be integrated through the IncOder’s bore, reducing space requirements to achieve a compact footprint. Inductive technology removes the need for bearings, bushes or seals, and entails the IncOders are fit-and-forget, maintenance-free.

Celera Motion’s Ultra IncOders communicate over ASI, SSI, SPI, BiSS-C and A/B/Z pulses, and operate on 5, 12 and 24 VDC. The product series integrates with a wide variety of drives and controllers – but is well matched with Celera Motion’s Omni and Agility direct drive, frameless motors, and Celera Motion’s Ingenia servo drives. Combined, it creates a highly compact, lightweight, motor, controller, and positioner precision motion control package.

“Even if subjected to grease, debris or moisture, the Ultra IncOders will continue to provide highly accurate, consistent measurements where other encoder types cannot,” says Gerard Bush, engineer at INMOCO.

“High accuracy and resolution are combined in a highly compact package, now made smaller still with the release of the Mini Ultra IncOder diameters.”

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

New rod-style electric actuators achieving force up to 222.4 kN have been released. INMOCO is now supplying Tolomatic’s RSX Extreme Force actuators to the UK market, which also provides high accuracy and long lifetime. Aimed at OEMs, the RSX electric actuators are an ideal replacement for hydraulic cylinders.

The Tolomatic RSX Extreme Force actuators provide force ratings from 80.1 kN to 222.4 kN with 100% duty cycle operation in both the push and pull directions. The range includes the newly released RSX128 actuator which provides an increase of 60% from the 178 kN total provided by the RSX096P press-model.

The actuators have been designed for a wide range of extreme force applications including pressing, riveting, injection moulding and sawmill equipment. Also targeted at upgrade from hydraulic cylinders, the RSX electric actuators provide enhanced control of speed and position achieving a roller nut screw accuracy of ± 0.01mm/300mm. Control is also more consistent, removing the fluctuations caused by temperature and pressure changes associated with a hydraulic system.

The new RSX128 extreme force linear actuator operates up to a maximum speed of 500mm/second at a maximum stroke length of 665mm and comes standard with an anti-rotation thrust rod should the application not provide external restraint.

The RSX is designed for long life and achieves operational durability as a result of the planetary roller screw mechanism. As opposed to a ball screw, the roller screw mechanism applies force over a larger contact area, reducing concentrated wear and resulting in a higher load capability and longer life. The RSX096P Press model, designed for the highest force actuation, further extends operational durability with oversized tie rods, a bearing system optimised for high force extension, as well as a reinforced strength steel front flange.

For optimised durability, Type III hard coat anodized aluminium housing increases surface hardness to withstand demanding environments while steel components are black or clear zinc plated for corrosion resistance. The actuator also includes the option of stainless steel upgrades for the motor mount, tie rods, front flange and thrust rod to further increase durability for applications in corrosive environments. With ingress protection from dust and water spray up to IP65 as standard, IP67 is optionally available providing resistance to water ingress up to 1m deep for up to 30 minutes when static. The RSX actuator is also designed to withstand cold conditions.

Compared to hydraulic systems, Tolomatic’s RSX Extreme Force electric actuators are also quieter in operation as well as cleaner, without the unwanted possible emission of hydraulic fluid. The Tolomatic actuators are also available with a food grade white epoxy resin coating and stainless steel thrust rod, designed for use in food and beverage processing applications.

The Tolomatic RSX is compatible with a wide range of servo motors and gearboxes up to 215mm frame size under Tolomatic’s Your Motor Here® program. Meanwhile, INMOCO can provide the RSX with Kollmorgen servo motors as a package.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.

Direct drive, smooth motion motors are moving light payloads in arc and full 360-degree rotary profiles. Designed for OEM equipment that needs to deliver precision motion, the Celera Motion Infinity Series motors enable flexibility and accurate motion that is not possible with conventional motor designs. INMOCO in the UK are distributing these motors that achieve high accuracy control in an ultra-low profile and lightweight construction.

The Infinity Series low-profile direct drive motors are targeted at applications including lightweight gimbals, broadband communication antennas, medical scanning, diagnostic imaging, inspection and metrology equipment. Ultra-thin, arc-shaped motor segments can be used individually or combined to create a greater motion circumference, up to 360 degrees. This enables design flexibility within a highly compact, lightweight construction. The Infinity Series delivers modular construction for large diameter motion up to two meters and features large through holes for ease of installation of cables, optics and sensing elements.

The ironless design of the Infinity Series direct drive motors provides high accuracy with zero cogging. This generates highly accurate control across the entire range of motion. High power density also enables a compact footprint, with axial heights as low as 20mm are possible, particularly compared to large and heavy traditional direct drive motors. Generally suited to continuous duty applications, Infinity can also be used for dynamic, peak duty purposes. Celera Motion encoders delivering rotational position feedback, can be easily integrated alongside Infinity motors, and accuracy up to +/- 2 arc-seconds can be achieved with the Optira Series encoders.

Medical diagnostic imaging systems, for example, benefit from Infinity’s wide diameter form-factor, which can suit an aperture of 900mm. The ironless, direct drive motors deliver smooth precision motion required for accurate scanning. Quiet operation ensures quality of patient experience and Infinity’s low profile design enables a small machine footprint to minimise floorspace.

Customisation of winding and form factors are available from Celera Motion to meet a variety of application requirements. The Celera Motion engineering team can collaborate on bespoke projects with OEMs and development of a complete mechatronic system with motors, encoders, servo drives, and integrated motion control technology. INMOCO’s engineers in the UK, can work closely with the Celera Motion applications team for solution development, and are available to provide engineering and design consultation.

Infinity Series provides up to 63.4 Nm continuous torque and 190.2 Nm peak torque at five amps. Infinity is also compatible with a wide range of drives and controllers.

About INMOCO

Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.