Automation & Control Products

Kollmorgen has announced the latest update to its AKD2G servo drive that includes support for Profinet IRT and EtherNet/IP with CIP Sync alongside CANopen, EtherCAT and FSoE time-synchronized communication protocols. Each protocol is tested and certified by industry standards organizations. The AKD2G servo drive update allows for synchronized motion between multiple drives using a variety of control architectures. The drive features power density in a compact package, as well as simple mounting with one- and two-axis variants available. Engineers can choose from a wide range of feedback devices. The drive also features an optional SafeMotion Monitor firmware with a safety level of SIL3/PLe.

Schmalz introduced two of its latest CNC wood processing vacuum blocks with a time-saving grid-to-nesting table-switching capability.

The automation solutions expert Schmalz announced the release of two innovative vacuum blocks, the VCBL-R and VCBL-N, for grid and nesting-based computer numerical control (CNC) wood processing applications. Depending on the desired use case, both vacuum blocks can be used interchangeably between grid and nesting tables. Adding or removing a nesting insert reduces time and manual labor when switching between applications. The flexibility offered by this functionality is intended to save woodworkers valuable time, reduce material waste, and improve production.


According to Schmalz, the laborious and time-consuming task of modifying setups when switching from grid tables to nesting tables during CNC wood processing is over. Image used courtesy of Schmalz

Switching from Grid Mode to Nesting Tables

Over the last twenty years, there has been a significant advancement in CNC wood processing in terms of automation, accuracy, and productivity. Modern CNC machines are outfitted with advanced software for automating toolpath planning and execution, integrating with CAD/CAM systems (Computer-Aided Design/Computer-Aided Manufacturing), performing multi-axis operations, and optimizing design-to-production processes.

In contrast to earlier systems, which mainly relied on manual setup and calibration, today's CNC machines are highly automated. Technological advancements like multipurpose vacuum tables, interchangeable suction systems, and intelligent sensors have significantly reduced setup times, improved adaptability, and facilitated faster project changes.

The key draw of Schmalz’s upgraded vacuum block series is the ability to switch from grid to nesting table via adding or removing a nesting insert. Tedious manual intervention must be performed to switch between suction cup-based grid clamping and sheet-vacuuming nesting fastening. To maintain pressure, technicians have to remove and reinstall suction cups when transferring between processes, position them for particular product layouts, and seal any unneeded vacuum zones. The complexity and time needed for setup modifications may increase if the CNC machine needs to be reset due to variations in elevation and flatness between grid and nested setups.


Schmalz’s VCBL-R and VCBL-N vacuum blocks provide a membrane-coated suction plate to protect parts. Image used courtesy of Schmalz

Using vacuum blocks that can fluidly transition between grid and nesting tables can increase productivity by minimizing the need for human interaction. Operators can transition between grid fastening and nesting more rapidly because of these blocks' quick repositioning and adjustment capabilities, eliminating the requirement for complete removal and reconfiguration. These blocks simplify setup, remove the need to seal unneeded zones, and reduce downtime by automating vacuum zone control and sustaining suction in all necessary places. As a result, the process becomes more effective, enabling faster transitions and increased throughput for CNC operations.
 
Features and Benefits

First in the lineup is the VCBL-R, designed to accommodate grid-based CNC wood applications and nesting table-based applications via an optional nesting insert. This insert allows customers to adhere the suction cup to the nesting plate. This flexible tool is ideal for conventional grid setups with dimensions 30 and 40 mm, groove widths between 6 to 7.5 mm, and groove depths of 6 to 7 mm.

Along with the VCBL-N, the VCBL-R features height (25 to 132 mm) and dimensional flexibility to suit specific workpiece requirements and an optional accessory hose connection for grid table positioning, even if the suction cup is without a suction point. Both vacuum blocks are designed for 3-axis and more intricate 5-axis machining.

The VCBL-R and VCBL-N incorporate a membrane covering the suction plate to protect from the ingress of dirt, ensure maximal frictional forces, optimal sealing, and improved workpiece protection.

The VCBL-N accommodates working heights between 32 to 132 mm and, like the VCBL-R, facilitates sensitive unloading and loading of heavy, extensive parts via an optional lifting system. This system also helps to protect the suction plate’s sealing edge from wear and tear.

With its edge edition, Kassow Robots has launched 7-axis cobots in which the controller is integrated into the base of the robot. These 7-axis cobots are available in two versions: one with a separate controller and the Edge Edition. The controller is miniaturized so that it now only occupies around 10% of the volume of the external controller. The Edge edition’s base is extremely compact, at 160x200mm. These cobot models can be directly connected to any DC power supply. The cobots also feature 60 easily accessible I/O connections.

Helukabel has enhanced its AS-Interface (ASi) bus cable offering by adding a round cable design for use in drag chain applications. This new round ASi bus cable provides is capable of being inserted into a drag chain with other round cables and hoses. Under part number 11009063 the A-Bus Round PUR (polyurethane) Chain cable has four polypropylene-insulated conductors that are twisted into a star quad configuration. This type of construction enables better resistance to EMC interference when compared to other round ASi bus cables with four conductors. The PUR outer jacket is resistant to oil, flame and is halogen-free. It is capable of being used in temperatures ranging from -40°C to +80°C, and meets U.S. and Canadian safety standards according to UL Std. 758 (AWM) Style 20233 and CSA 22.2 No. 210 AWM I/II A/B.

ABB has introduced various features to its GoFa series cobots to enhance their accuracy, operational efficiency, and applicability.

ABB's new features in the GoFa series of cobots are unlike any other advancements in the market. With the new Ultra Accuracy feature, ABB claims that the path accuracy within the GoFa series will be increased tenfold. Users will also benefit from a full range of motion, as GoFa cobots offer full 6D motion across the entire workspace.

In many cobot applications, the tasks must be simple, require minimal weight, or be geared towards entertainment scenarios, such as a robot fetching alcoholic beverages at automation showcases. ABB aims to enhance cobots' accuracy to meet the demands of applications where precise positioning is crucial, such as gluing and sealing in consumer electronics production, laser welding, composite material layering in aerospace manufacturing, and precision laser fabrication processes.


An image of a GoFa series cobot in use. Image used courtesy of ABB
 
How does the Ultra Accuracy Feature Work?

A statement such as a tenfold increase in path accuracy might make many potential users wonder if it's too good to be true or sprout curiosity on exactly how it works.

The Ultra Accuracy feature enhances the cobot by upgrading components and algorithms, as well as the technology behind the software. It incorporates high-resolution sensors that provide real-time feedback on the cobot’s position and movements. These sensors use advanced algorithms to adjust the cobot’s path precisely, ensuring it follows the intended trajectory with extreme precision.

The cobots are also equipped with improved actuators that execute precise movements as directed by the algorithms, minimizing deviations from the desired path. Additionally, advanced calibration techniques reduce errors and ensure consistent accuracy across different tasks and environments. This combination of technologies allows the GoFa cobots to achieve a path accuracy of 0.03 mm, making them ideal for applications that require high precision and rigorous safety standards.

ABB demonstrates a GoFa cobot performing an electronic application by picking and placing circuit breakers. Image used courtesy of ABB

GoFa Cobots Vs. Gantry Systems

The GoFA cobots from ABB Robotics offer several key advantages over traditional 2D gantry systems. They can move in six dimensions (X, Y, and Z axes plus roll, pitch, and yaw) rather than only two dimensions.

Upon delivery, GoFa cobots are ready to operate with full 6D motion without extra calibration. This reduces setup time and cost, making them efficient and more easily integrated into existing workflows. The ability to move in six dimensions means these cobots can handle a wider variety of tasks, from simple pick-and-place operations to more intricate assembly processes. The 6D feature makes the GoFa cobots a more adaptable and efficient solution for modern manufacturing needs.
 
Offline Cobot Programming

When GoFa cobots are equipped with the Ultra Accuracy feature and used with ABB’s RobotStudio software, users can program the cobots’ tasks and movements in a virtual environment. This combination also ensures the simulations are incredibly close to real-world performance, with a 99% match. This high level of accuracy means that what you see throughout the simulation is almost precisely what you will get. Because the simulation is so accurate, there is no need for additional adjustments once the cobot is deployed, saving time and ensuring that implementation is both precise and efficient.

The Ultra Accuracy feature is an optional upgrade that can be integrated into existing GoFa cobots, enhancing their precision and performance.

SMC, a leading company in pneumatics, has recently introduced two new products to its portfolio: a new guide cylinder for improved linear motion and suction cups for handling delicate items.

Two standouts of SMC’s catalog are the new HF3A-ZP3F Series suction cups and the MGPK Series compact guide cylinders. These products have exceptional utility and reliability, with features and design improvements that set them apart.

MGPK Series Compact Guide Cylinder Upgrades

SMC has significantly improved the new MGPK Compact Guide Cylinders to enhance their durability and accessibility. These cylinders are designed to be highly compact, making them ideal for use in confined spaces. With a remarkable 28% reduction in volume and multiple mounting and piping port location options, users can easily plan to integrate these cylinders into existing applications. Additionally, SMC has addressed weight concerns by reducing the cylinder's weight by 41%, making it a more viable option for applications like end-of-arm tooling for robotics.



Although the cylinders are now more compact, SMC has also increased the rigidity by raising the plate thickness by up to 33%, depending on the selected plate material. Customers can choose either carbon steel or an aluminum alloy for the pusher plate. One material prioritizes durability, while the other focuses more on weight.

The MGPK Series Compact Guide Cylinders can be used in many applications. Their compact design and high rigidity make them ideal for precise positioning and movement in an automated assembly process. They can also be used in packaging machinery with their flexibility in mounting and port options, where space is often limited. Lastly, as mentioned, the lightweight and compact nature of the MGPK series makes them suitable for use in robotic arms and other automated systems that require precise control and minimal weight.
 
Suction Cups for Delicate Items

SMC has also added the HF3A-ZP3F Series suction cups to its product portfolio. These suction cups are suitable for various applications such as automated bread handling, pastry and confectionery production, and fruit and vegetable packaging. They address the harsh pressure typically applied by suction cups and are made of materials compliant with the FDA dissolution test, EC directives, and Japan Food Sanitation Act Standards.


Although these suction cups don’t apply harsh pressure, they still have excellent cushioning. The materials used and the design of the suction cups ensure that only a small amount of pressure is needed to apply the suction force. This light force allows workpieces to be handled without crushing delicate items.

The HF3A-ZP3F suction cups are made from a metal compound compatible with metal detectors. This compatibility is essential for maintaining stringent safety and quality control standards in food processing environments. The specific metal compound allows for quick identification and address of potential contamination, preventing compromised products from reaching consumers.

SMC's dedication to delivering solutions to various industries is evident in the addition of these products and other newly introduced components to its portfolio. This expansion demonstrates SMC's commitment to consistently providing tailored solutions to meet the needs of multiple industries.

Siemens is extending its drive portfolio in the extra-low-voltage range for 24–48V EC motors with its new Simatic Micro Drive.  The new product line with UL- and CE-marked components consists of the PDC (Profidrive Control) servo drive in conjunction with a flexible range of motors and connecting cables from product partners, along with the TM (technology module) format with servo and stepper drives in a compact 20mm width that can be used with distributed or open controllers. Connectivity to Siemens PLCs helps reduce the engineering workload, while integration into Siemens automation technology via its TIA Portal makes for simple commissioning and servicing. Attributes such as smart encoders and one-button tuning add to its plug-and-play startup. Communication takes place over Profinet using Profisafe and Profidrive profiles. The new Safety Integrated function SLT limits torque by monitoring motor current in running operation.

Weidmuller’s new WI-I/O-9-U3 Wireless Transceiver combines long-range, scalable, secure mesh networking multiple I/O node and gateway into a single device. Features include a scalable, simple to complex and point to multi-point network design; flexible, native Ethernet support and comprehensive gateway capabilities for Ethernet and serial protocols, including Modbus TCP/RTU, DNP3 I/O and MQTT + Sparkplug B; and secure AES encryption, advanced IP filtering, multi-level authentication and comprehensive user access and change event logging.

Version 2.7 of Aerotech’s Automation 1 motion control platform introduces extra support for drives and laser scan heads. Allowing laser scan head users to achieve higher peak speeds, version 2.7 features enhanced scanner control, along with 3D data visualization,  new HMI customization tools and improved development tools. Also available are an HMI builder for custom HMI modules, Autmation1 Studio’s new program variables tab and global string variable support, custom belt-driven stages, cutter offset compensation support, INI file support, user defined task errors and warnings, CNC features and support for Modbus TCP/IP.

New variable frequency drives from Rockwell can power motors up to 500 hp while retaining panel-mount capability. They are programmed with Studio 5000 and offer predictive maintenance with FactoryTalk.

Using variable frequency drives (VFDs) to control motor start-up and running speed has become an industry standard within the automation community, especially when dealing with large motor sizes. Motors this size will draw an enormous amount of current during the start-up process. By using a VFD such as a PowerFlex 755TS, this start-up current can be reduced.
 

A variety of different PowerFlex 755TS sizes. Image used courtesy of Rockwell

The PowerFlex 755TS lineup consists of many drives capable of driving motors from 1 hp to 500 hp while still having panel mounting functionally. All of the drives within the 755TS series support up to five expansion cards for I/O, communication, or auxiliary power supply. A corrosive gas protection option can be added to any of the 755TS drives which protects the drive when used in environments with corrosive gas.

Recently Rockwell Automation also announced the PowerFlex 755TS family will now support frame 7A sizes which are motors up to 500 hp.
 

Image of the PowerFlex 755TS Fram 7A. Image used courtesy of Rockwell
 
PowerFlex 755TS Frame 7A

The new PowerFlex drive from Rockwell Automation is a reduction in overall footprint size but not power. The 755TS low voltage model comes in a panel mount version instead of the typical floor-mounted variety and can drive motors up to 500 hp. Designed for system integrators in the oil and gas and power generation industries the 755TS is said to be easier to maintain and commission.

The 7A model has all of the same features as the other sizes within the 775TS catalog, including CIP safety communications, built-in dual gigabit ethernet ports, compatibility with Studio 5000 programming interface, and TotalFORCE technology.


A mixing tank would likely use a VFD for motor control. Image used courtesy of Unsplash

VFD Programming

Today, programming your PowerFlex VFD is even easier because you can use Studio 5000 software. Once connected, drive parameters can be set, and commands to start, stop, or command frequency can all be sent from within the PLC logic that is written with Studio 5000 software. The TotalForce technology gives the end user of the VFD more precise control and monitoring capability, which is made possible with its digital platform. Combined with FactoryTalk Guardian AI, a predictive maintenance software, maintenance staff can prepare for downtime and prevent unpredicted stoppages before they happen.

 
Processing plant using large pump motors. Image used courtesy of Unsplash
 
FactoryTalk Guardian AI

Predictive maintenance software monitors sensors, real-time values, and input from operators to determine which equipment will need to be maintained. The FactoryTalk Guardian software interfaces with Rockwell’s PowerFlex family of the VFDs to capture the warning signs of asset failure and hopefully prevent unexpected downtime of equipment.

Multiple assets can entered into the system and monitored at one time, your entire plant can be analysed from one installation of FactoryTalk Guardian. When FactoryTalk Guardian determines an anomaly within your assets, you get a notification about the cause of failure and the severity of the risk. FactoryTalk Guardian is designed to be installed on edge computing systems that often reside on the factory floor, and it is designed to interface with Rockwell Automation’s full portfolio of products.