Overview
The production of curved, profiled stainless steel clamp components to aircraft standards has undergone a revolution with the introduction of a new machine from Kidderminster Engineering Services (KES)
Eaton Aerospace selected KES to develop an improved process for the production of a range of clamp components, seeking lower production costs, higher throughput and a substantial reduction in turn-around times between different types of component. Employing a Trio MC 206 Motion Coordinator, the new machine was developed jointly by Eaton, KES and software specialist LMS ServoTechnics. The ring roller features quickly-replaceable profiling roller assemblies, through which the steel strip is passed before reaching the innovative bending and cut-off unit. The results are “U” or “V” shaped components curved and cut to length to very high standards of accuracy.
Engineering Highlights
MC206
1 Frequency inverter & 3 servo axes
150 rpm
Mitsubishi drives
Replaced Mitsubishi controller
Overview
This machine is used to bind the stators used in air-conditioning motors.
The control loop gains were optomised to achieve a very stable performance from the inverter.
The effect was an energy saving of 40% on the machine. We were able to increase the machine speed from 120 to 150 rpm over the Mitsubishi controller.
Overview
Machine is used to make photo album pages with plastic pockets either side of a centre paper.
Ultra Sonic sealing is used to form the plastic pockets and a mechanical CAM used to operate the cutter for the pages as the web stops.
This is an unusual configuration because the first servo motor is controlled by a Mitsubishi PLC and the second is controlled by the MC202 using CONNECT referenced to the infeed motor encoder.
The infeed and outfeed motors are made to keep tension in the web by using a CONNECT ratio slightly less than 1 varied depending on the material.
Overview
Leading packaging machinery rebuilder, Daco Engineering Services, discovered hidden benefits when the company standardised on Trio Motion Technology Motion Coordinators for its range of flow-wrapping machines. Established in 1985, Daco Engineering was the brainchild of Dave Harris, an engineer with a lifetime’s experience in the development and maintenance of food processing machinery.
Concentrating on the reconditioning and upgrading of flow-wrapping machinery, Daco rapidly earned a reputation for high quality work and personal service. The company specialises in solving individual problems at economic prices, building often highly complex machines from existing plant.
Engineering Highlights
MC206
CAN 16-I/O modules
Overview
Newtech Ltd. has designed and produced a machine to accurately mix a two-part epoxy glue and dispense the mixture into glass-filled nylon end caps for a heat exchanger assembly.
Critical requirements were for an inherently safe machine with full automation of the epoxy dispense into two end caps at a time, and capable of reliable, consistent production output at around 90 units per hour. The machine was designed with two mirror image working areas. One side at a time is alternately operator accessible for loading and then I/R safety-guarded during the automated dispense routine.
Newtech selected Trio’s MC206 Motion Coordinator to control three axes of stepper motors, with two additional CAN 16-I/O modules and a Membrane Keypad for operator input and machine information displays.
The machine consists of a dispensing unit with two pressurised epoxy storage tanks, a four-chamber pump driven by a ballscrew and stepper motor for precise volume control, and a cabinet containing the automated mix and dispense systems. Dispense heads are carried on a travelling carriage suspended above the workpieces and driven in x-y planes by two further stepper motors. The heads are raised and lowered to fixed points by a pneumatic cylinder. The dispensing system was provided with an auto-purge routine, allowing up to five cycles if the machine is left unattended before an automatic shut-down. Disposable mixer tubes at the dispense points ensure that solidified epoxy is easily removed should the machine stop for any reason.
Engineering Highlights
Supplier: Trio China
MC206
3 servo axes
Yaskawa Drives
250mm/sec
Replaced Siemans 840D CNC
Saved $14,000 per machine
Overview
Machine used to grind rolls for the sheet steel and aluminium manufacturing industry.
Rolls are up to 2m in length and have a “barrelled" profile formed by using 60 to 120 degrees of a sinusoidal CAM profile.
The diameter in the middle of the rolls is approx 3mm greater than at the ends.
CAMBOX is used to generate the Sinusoidal CAM profile by linking the grinding wheel In/Out and linear travel to the rotation axis.
Engineering Highlights Supplier: Trio China
MC206 1 servo axis
2 Reference Encoders
High speed registration
30m/min
Yaskawa drives
Overview
This application is based at one of the largest producers of glass fibre insulation in China.
Here transfer of Glass Fibre rolls from one side to the other is required for the next production process.
The MC206 does this by linking the robot linear axis with the two encoders on each side.
Engineering Highlights MC202
2 CAN 16-I/O modules
1 CAN Analog Input module
Overview
A revolutionary can inspection machine offers exceptional programming flexibility and low maintenance costs through the use of a Trio Motion Technology Motion Coordinator.
The X-Seam Double Seam Analyser from Sencon uses X-ray technology to inspect the vital joint between filled food or beverage can ends and sides, eliminating the need to perform manual, destructive testing. A sophisticated image processor linked to the X-ray camera measures each critical point and produces a report based upon pre-determined standards. Typically, measurements are made to 0.001mm and have excellent “R & R” standards of better than 20%.
Sencon chose an MC202 Motion Coordinator, 2 CAN 16-I/O modules and one CAN Analog Input module to control the entire mechanical elements of the X-Seam Analyser. These consist of two can conveyors, a vacuum lift mechanism which moves cans from the input conveyor to the measuring point and then removes them to the output conveyor, and a chuck assembly which clamps the can firmly and moves it to the X-ray generator head.
During measurement, the chuck assembly is rotated by a stepper motor to four accurately pre-set positions, providing four images of each can seam for analysis. A second stepper motor drives the ball screw to move the chuck into position. All other movements, including vacuum pick-up and can transfer, are actuated pneumatically using limit switches and controlled by the MC202. The whole assembly is therefore completely “stand-alone”, needing only the manual input of a start signal to begin operation and an indication of how many cans are to be tested.
Engineering Highlights MC206
300 ppm
Single touch screen user interface
Overview
Harland’s labelling machines find applications in many industries, with customers ranging from small local suppliers to blue-chip internationals. The diverse needs of this global customer base are met by the adoption of a modular approach which employs a number of standard systems modified as necessary to suit the precise requirements of each application.
The application of pressure-sensitive labels requires very high precision of initial placement, accurate control of the pressure system which bonds the label to the container, and effective product handling. Even the smallest and simplest of Harland machines is still a remarkably complex engineering achievement. Such machines are expected to perform reliably for many years with minimal maintenance, requiring very high standards of design and build quality.
Engineering Highlights MC206
Fast registration
Single touch screen user interface
Overview
JD Innovation specialises in retrofitting carton-folding machines. An MC206 Motion Coordinator controls a servo motor connected to a hook. The carton position is recorded using the fast-registration input on a separate incremental encoder input. The system uses the CAMBOX motion command to position the hook relative to the incremental encoder.
For up to 2 hooks the system is designed with one MC206 as shown in the picture. The MC206 is equipped with an Ethernet Daughterboard for communication with a Pro-Face touch screen. For machines with more than 2 hooks the same Ethernet network allows the MC206 Motion Coordinators to communicate.
Overview
Leading packaging machinery rebuilder, Daco Engineering Services, discovered hidden benefits when the company standardised on Trio Motion Technology Motion Coordinators for its range of flow-wrapping machines. Established in 1985, Daco Engineering was the brainchild of Dave Harris, an engineer with a lifetime’s experience in the development and maintenance of food processing machinery.
Concentrating on the reconditioning and upgrading of flow-wrapping machinery, Daco rapidly earned a reputation for high quality work and personal service. The company specialises in solving individual problems at economic prices, building often highly complex machines from existing plant.
Engineering Highlights MC206
Overview
This application is an X-Y-Z system using the MC206 for interpolating 3 servo axes. The MC206 communicates with a PC over the USB to download the required positions. A Motion Coordinator MERGE function allows the movements to be smoothly connected at high speed.
Overview
When TMS (Tissue Manufacturing Service S.r.l) required an urgent upgrade for failing and obsolete motion control equipment on aged Italian manufactured tissue wrapping machinery, they turned to Trio Motion. An MC224 Motion Coordinator controller was combined with a new six- axis brushless servo system to provide a drop-in replacement that seamlessly mimicked the machine’s web tension, electronic cam, and registration functions. As a bonus, it improved system performance and reliability.
The TMotionS is mechanically interchangeable with the old system, having the same mounting configuration and featuring a front faced interfacing panel with an identical DB connector arrangement. Installation involves simply bolting it into the existing panel and connecting cable assemblies for the existing brushless servomotors and encoders, and hooking up the interfacing cables to the wrapping machine’s PLC.
Behind the interfacing panel, six interconnected brushless servo amplifiers provide the power and precision to drive the servomotors with simple +/- 10 V control from two MC224 Motion Coordinators. From the outset, it was important that rather than reprogram the tissue wrappers main PLC, the controller must provide functionally identical performance as the existing servo controls.
The MC224’s uses a 32-bit floating point DSP that handles up to 24 axes of synchronized motion with machine I/O and communications. Each MC224 includes 4 processor slots and a system of axis expansion modules. The processor slots can be populated with any combination of axis, fieldbus, and digital-drive daughter boards and the axis expanders by any combination of axis daughter boards.
For the TMotionS, the two MC244’s are linked via an axis expander and house six servo encoder cards and a master reference encoder card with the existing PLC logic triggering pre-programmed events through the Motion Coordinator’s built-in I/O using Trio BASIC to handle electronic cam and axis-synchronized registration on the machine. Trio’s programming language includes motion and event handling commands with multitasking and subroutines. It lets engineers create modular programs quickly.
Thanks to its processing speed, multi-tasking architecture, and control capabilities, faster cycle times helped optimize machine performance. Consequently, the MC244 and the new servo drives together provide smoother motion and higher process speeds. Additionally, Trio’s inherent safety protocols completely removed the previous tendency for axes ‘running away’ on error conditions.
The MC244 also improved print registration accuracy, enhancing finished product quality and yield; and higher acceleration/deceleration characteristics with less vibration helped contribute to faster production throughput.
Other benefits of the TMotionS’s fit-function approach is that machine commissioning is fast – with virtually no downtime and no PLC reprogramming, making the installed costs to replace the old web registration system predictable. As all the equipment used in the solution is new and modern, the element of future proofing is restored for these wrapping machines, extending their useful life even further.
Engineering Highlights Details to follow
Overview
As customers often say about projects with John Brooks Limited,” It’s a win/win relationship”. This is certainly true of the motion control solution John Brooks Ltd supplied to rejuvenate the electron beam welding machine located at the Air New Zealand Gas Turbines’ Auckland facility. The savings were significant as the upgraded technology cost only 20% percent of the original suppliers’ estimate.
Engineering Highlights
MC224
SLM Daughter Board
Feedback resolution of > 8.3 million points per turn
50 nano seconds
synchronisation between axes
Overview
Control Techniques SLM technology uses high resolution SIN/COS encoder with a speed loop processor coupled directly to the motor. In this way a digital network consisting of the Motion Coordinator, SLM and Drive is able to achieve a feedback resolution of over 8.3 million points per turn, 50 nano seconds synchronisation between any axis, local intelligence in the motor, up to 50% less wiring, and elimination of the +10V analogue reference signal.
“The exceptional performance provided by Trio Motion Coordinators equipped with SLM Daughter Boards in standard motion control applications can now also be utilised as a very flexible CNC “ said Bill Drury, Executive V.P. Technology of Control Techniques Ltd.
Control Techniques announced a policy of close partnerships with multi-axis motion control manufacturers from 1998. Trio Motion Technology has been an active participant in this partnership, producing an SLM Daughter Board for use with its own range of Motion Coordinators. The Trio MC224/SLM offers 125us loop control regardless of the number of axes in the system.
On top of the increased performance, one of the aims of the partnership is to provide “Plug and Play” capability to a servo system. Bill Drury commented: “It has been seen in the field that the Intelligent Drive set-up provided by Trio’s MotionPerfect software is one of the simplest servo-commissioning systems in the industry”.
The combination provided the spur to offer an enhanced system to CNC machine tool builders which would also offer substantial advantages when retrofitted to older machines. The Control Techniques Research and Development Department retrofitted a conventional CNC machining centre using MultiAx and an MC224 Motion Coordinator. Accuracy of table movement is assessed using a Renishaw Ballbar® system, which permits the user to capture data to a computer for detailed analysis. The whole procedure, including initial set-up, takes about 10 minutes of machine time. The high resolution feedback combined with full digital interface to eliminate any delays, synchronisation jitter and offsets leads to high dynamic and static stiffness, enabling the system to provide better accuracy and repeatability.
Early tests with a variety of Drive/Motor combinations revealed that under 10µm circularity error at speeds in excess of 3m/sec can be achieved with virtually no speed reversal spikes at the four points where the table drive motors reverse. Machine tool operators are, of course, familiar with the potential for error which derives from the mechanical and electronic characteristics of the machine, and will take these effects into consideration when programming each component.
Engineering Highlights
MC206
TrioBASIC
Fast product test cycle>
Overview
Greenwave Electronics Ltd on behalf of Total Motion Systems Limited has developed a product testing strategy for its new GSD1x drives around the MC206 controller.
The parallel process and machine control capabilities of the Trio Motion Coordinator platform are exploited successfully to provide a full product test. The product test cycle completes in less than 2½ minutes compared to at least 30 minutes that would be required to complete the test with individual non automated lab test equipment.
Engineering Highlights Carpet tufting machinery
Needle bar control
Infeed and outfeed control
Overview
Tufted carpet is usually produced by the equivalent of a giant sewing machine, equipped with anything up to 600 closely-spaced needles mounted on each metre of rapidly moving bars. The first tufted carpets were made in the late 1940's, at a time when there was considerable demand for low-cost yet hard-wearing carpet. Gradually as the market matured, a growing need for more sophisticated pattern designs and sculptured finishes prompted the steady development of manufacturing techniques with an associated increase in machine complexity.
Overview
Garrandale systems specialise in turnkey systems to meet the demand of process, engineering and manufacturing industries and needed a solution to control welding machines.
"All of our product welding systems must be capable of welding to a tollerance of 0.5mm, with close control of welding speed to avoid damage to thin sheet metal. Consistency and reliability of operation are vital charactoristics, along with a minimal maintenance requirement and exceptionally sturdy construction".
All functions are comtrolled by the Trio DAC modular controllers in automatic mode, with an optional manual mode from a handbox controller.
Aircraft
Engineering Highlights Details to follow
Overview
As customers often say about projects with John Brooks Limited,” It’s a win/win relationship”. This is certainly true of the motion control solution John Brooks Ltd supplied to rejuvenate the electron beam welding machine located at the Air New Zealand Gas Turbines’ Auckland facility. The savings were significant as the upgraded technology cost only 20% percent of the original suppliers’ estimate.
Overview
Carbon brake discs typically take about 6 months to make. The discs are made from layers of high purity carbon fibre matting ‘stitched’ together into a wad to form a blank roughly the size and shape of the finished item.
The carbon fibre wad is then put in an oven at around 1,000°C where it is exposed to an atmosphere rich in hydrocarbon gas for hundreds, or even thousands, of hours. This causes the layers of felt-like material to fuse together and form an extremely strong, solid carbon blank virtually free from voids and inclusions. The resultant blank is then machined to finished size.
Engineering Highlights Carpet tufting machinery
Needle bar control
Infeed and outfeed control
Overview
Tufted carpet is usually produced by the equivalent of a giant sewing machine, equipped with anything up to 600 closely-spaced needles mounted on each metre of rapidly moving bars. The first tufted carpets were made in the late 1940's, at a time when there was considerable demand for low-cost yet hard-wearing carpet. Gradually as the market matured, a growing need for more sophisticated pattern designs and sculptured finishes prompted the steady development of manufacturing techniques with an associated increase in machine complexity
Overview
London based Windmill Studios provide audio-visual solutions for the conference, live events and attractions industry and when Trio Motion launched its recent special offer for evaluation kits, it seemed an ideal opportunity to try out the MC206X motion controller whilst saving costs for a special effects project that involved animating Daleks in a visual panorama of synchronised graphics and motion for the phenomenally popular Dr Who Up-Close Exhibitions.
Overview
Trio Motion Technology’s MC206X motion controller is being used to provide position and stability control for a 30 metre camera mast that provides sweeping high-angle aerial shots for film and TV.
The Vortex Aerial Mount Camera System, developed by professional cameraman Matthew Gladstone of Cammotion with the help of automation specialist Machinery Control Systems (MCS), is completely portable and can be rigged and de-rigged in minutes - making it suitable for a wide range of spectacular shots for outside broadcast and film studio work.
Engineering Highlights Stage machinery
Laser/light displays
Ride control
Overview
Diablo is a large scale, fully automated moving yoke search which utilisies a 7kW Xenon light source with internal closed loop cooling to provide a light beam which is visible for up to 40 miles. The light can be moved through a 240 degrees tilt and 420 degrees of pan at a finely controlled speed varying from 4 rpw to 4 rpm and a resolution of 0.0001 degree. This meansthat the searchlight can achieve the remarkable repeat positional accuracy of 872mm at 10km.
Essential services are housed in the base unit, including pumps and heat exchangers. The smooth motion is controlled by the MC204 equipped with SSI daughter boards and programmed from a custom built computer desk.
“It is vital that the position of the beam is precisely known before the xenon arc is fired”, commented Fineline Managing Director, Darren Wring. “So we chose to use the SSI Daughter Board to provide absolute position feedback. This eliminated the need for a lengthy homing sequence at start up and minimised set-up times.”
Having successfully developed the Diablo, Fineline turned their engineering design team to increasing the functionality and application possibilities of the new light. Current work centres around colour light generation, using DMX technology controlled through a modified version of Trio’s Motion Coordinator, and a radio link system to allow remote operation.
“We have a vigorous new product development policy which, I am happy to say, is fully matched by Trio’s own attitude,” said Darren Wring. “The company is continuously producing new products which meet our requirements. I am really impressed with their quality, service and technical support”.
Engineering Highlights Video screen control
800 stepper axes
Overview
100 Euro209 controllers are loaded with a cam table that is synched to a large 3D video display.
More detail to follow.
Engineering Highlights 2 x MC206 (1.5 axes used each)
2 Servo Axes + Reference Encoder
4 Frequency Inverters via I/O
14 Temperature Control Feedbacks via RS485
High Speed Registration
30m/min
Yaskawa Drives
Machine aimed at replacing Tetra Pak
Overview
This s a vertical fill milk packaging machine. It is the first machine of it’s type in China and is aimed at replacing Tetra Pak.
The special “environmentaly friendly paper “ used to package the milk has been developed in China and has 6 layers of plastic and paper.
The advantage over Tetra Pak is that the milk packages can be put directly into a microwave (ideal for the Chinese market where hot milk is very popular). NOTE: Tetra Pak has aluminium inside the paper.
MOVELINK and registration functions are used in conjunction with a reference encoder on the material to facilitate a vertical fill. Seal & cut machine.
This machine uses 2 x MC206 to allow up to 14 temperature control signals to be fed back via RS485.
Overview
Leading packaging machinery rebuilder, Daco Engineering Services, discovered hidden benefits when the company standardised on Trio Motion Technology Motion Coordinators for its range of flow-wrapping machines. Established in 1985, Daco Engineering was the brainchild of Dave Harris, an engineer with a lifetime’s experience in the development and maintenance of food processing machinery.
Concentrating on the reconditioning and upgrading of flow-wrapping machinery, Daco rapidly earned a reputation for high quality work and personal service. The company specialises in solving individual problems at economic prices, building often highly complex machines from existing plant.
Overview
Machine is used to grind the edges of mirrors used in projection TVs.
It has improved the output from 1pc to 7pc per minute.
Engineering Highlights MC206
2 Servo Axes
Overview
In this application, a Trio MC206 Motion Coordinator with 2 servo axes controls x-y motion to cut a 2D pattern from a sheet of glass. A PC running a Visual Basic (VB) program serves as the HMI and pattern generator.
Other machine functions such homing and diagnostics are also handled. The PC communicates to the MC206 via serial Modbus. The user enters process data such as overall glass size, and pattern dimensions to cut. Enhanced functionality included curves and tangential cutter control.
Controller functions...
CAMs, Software Gearbox and Linked Moves
Print Registration
64 bit precision (MC464)
Machine types...
Flexo-graphic, both full servo and semi (shaft driven)
Web Offset
Inkjet
Finishing...
Slitting
Cut to length (flying cutter)
Stack and batch
Overview
Trio multi-axis Motion Coordinators use web processing fucntionality to control printing machines all over the world. Printing machines with up to 10 colours, infeed, take-up and finishing stages have been designed and manfactured with Trio Motion Coordinator technology as the central controller.
Engineering Highlights
MC202
Optimised cycle times
Overview
The A-Series printers have earned an excellent reputation for reliability, typically operating successfully for up to 50,000 hours without major servicing. Their remarkable performance is a direct result of Domino’s approach to design and the rigorous testing of all new products by an independent test house.
The printers are used in many industries around the world to individually mark products such as frozen and fresh food, dairy products, beverages, photographic film, pharmaceuticals, and even vehicle and electrical components.
Engineering Highlights Stereo lithography
Metal powder printing
Polyurethane mouldings
Overview
In this application, a 4-axis Trio MC206 Motion Coordinator is used to control the scanning head of a 3D rapid prototyping Machine. A PC running a Visual Basic (VB) program serves as the main interface, and shapes library.
Images are developed off-line and saved to the PC. Trio's ActiveX component is used with VB to communicate with the MC206 and download the 3D images profiles. Communications from PC to the MC206 is via Ethernet TCP/IP. All coordinated motion is handled by the MC206 system which includes scanning, part-cleaning and maneuvering around to clean off dust and debris.
