TMC-3D, the Technosoft multi-axis motion controller, is now adapted to execute G-code commands. Today, a lot of industrial applications are defined with these types of motion. G-code is a language, used in numerical control programming, that executes various movements as: piece cutting, profile shaping or drawing, etc. In order to achieve these particular kinds of movement, the numerical control uses basic blocks which carry one or more words, each word consisting of a letter—detailing the function to be performed—followed by a number that assigns value to the function (e.g., N0001 G90  G00 Y125 X2 A23 B-1).

The G-code information is translated into TML commands through the G-code to TML converter integrated in the EasyMotion Studio software. The G-code files are imported into EasyMotion Studio and translated to TML commands. After the conversion process, TMC-3D will send the motion sequences to the drives / motors which execute the movements. The TML converter allows you to set the basic movement parameters specific to the G-code: linear axes, cycle start button, choose the measure units, set the Traverse and Feed rates. Technosoft's G-code–to–TML converter supports various G-code words, letters and parameters together with unary and binary operands.

TMC-3D is able to control two other Technosoft intelligent drives and also includes a 640 W servo drive that may be used to command one of the application axes. The motion programming can be done using PC or PLC motion libraries, or directly at controller level in TML language. EasyMotion Studio automatically generates all the TML instructions, so you don’t need to learn or write any TML code. Powerful TML instructions as: motion commands, program flow control, I/O handling, arithmetic and logic operations are executed / controlled by TMC-3D. Its role is primarily a managerial one, with responsibilities that include network or slave management. It can perform predefined actions as: stopping the motion on all slaves in case of a node failure, or commanding different homing procedures and other motion profiles on each slave.

For further details (on how to set up a multi-axis project, how to import a G-code file or execute a G-code application), see the ‘Executing G-code commands with TMC-3D Motion Controller’ application note at:
http://www.technosoftmotion.com/products/OEM_PROD_TMC-3D.htm.

Eaton Corporation announced it is helping control panel builders to construct control panels that improve safety while preventing application errors. Helping panel builders meet a wider range of short circuit current ratings (SCCR), the newly tested combinations of Eaton’s molded case circuit breakers and power distribution blocks are Underwriters Laboratory® (UL) listed for SCCR up to 65 kiloamperes (kA) at 480 volts.
 
“Eaton is committed to increasing safety, and is able to help customers design industrial control panels, navigating both UL 508A and National Electrical Code requirements,” said Zari Talebi, marketing manager, Eaton. “Ultimately, we are able to help prevent application mistakes, and provide solutions that address a variety of fault current levels, resulting in safer, more cost-effective installations. The new ratings offer several options for distributing power within a control panel through feeder- and branch-circuit taps.”
 
The new high SCCR for power distribution blocks, when used in conjunction with Eaton Series G® molded case circuit breakers, offers industrial control panel builders the flexibility of power distribution blocks, along with small size, reset capability, and add-on accessories of circuit breakers, without sacrificing the overall short circuit rating of the panel.
 
Previously, a branch circuit in a UL508A control panel with an unmarked power distribution block was assigned a maximum value of 10 kA. This rating limits the overall SCCR the panelbuilder can achieve. Using tested combinations of Eaton’s molded case circuit breakers and power distribution blocks, the default rating of 10 kA is able to be increased substantially, to as high as 65kA, depending on the breaker and block used. The new ratings allow for many configurations that make it easier to select the breaker and block to meet the desired short circuit rating for the control panel.
 
Panel builders for industrial control panels, industrial machinery electrical panels and HVAC equipment have several options when distributing power within a control panel through feeder and branch circuit taps:
    •    Listed and tested power terminal blocks and molded case circuit breakers with high short circuit current ratings
    •    Multi-wire terminals mounted on the load end of the circuit breaker
    •    Multi-equipped molded case circuit breaker terminals
 
For additional information for panel builders, visit www.eaton.com/UL508A.

TCP/IP-compatible servo drives from Baldor Electric Company have simplified the construction of an innovative automotive component tester.  

Developed by a leading builder of structural and custom test equipment, Dynamic Testing & Equipment (DTE), the new machine fully automates the accelerated life testing of the flexible boot seals used to protect ball joints in automobile steering assemblies. The use of programmable AC servos - instead of conventional hydraulic actuators - provides an unprecedented level of control flexibility, enabling test parameters such as joint articulation angles to be varied on the fly.

Capable of testing up to six boot seals simultaneously, testing regimes can include continuous articulation of the ball joints, hot and cold brine sprays, elevated humidity levels and air temperature cycling from -25 to +80 degrees Celsius.

DTE's boot seal testing machine employs two motorized movement axes - one vertical and one horizontal - each driven by a Baldor MotiFlex e100 3-phase servo drive and servomotor fitted with a multi-turn absolute encoder. The precise feedback signals enable both axes to be programmed to absolute zero, facilitating optimal positioning of the machine's tooling for parts loading and unloading, and ensuring ease of start-up.

The servo drives are connected via industry-standard Ethernet to the test machine's host computer, which runs National Instruments' LabVIEW software, and are controlled via TCP/IP using the built-in ActiveX commands in Baldor's Mint programming language.

According to DTE machine designer Glenn Siddens, "We were looking for servo manufacturers who could support ActiveX. Baldor was also able to supply 3D CAD files for the motors. As we use SolidWorks' 3D CAD software for much of our design work, the availability of these files was a major time-saving advantage. What's more, Baldor has proved to be extremely supportive. As well as helping us with ActiveX/LabVIEW integration, applications specialists from the company visited our facility on several occasions to help set up and fine-tune the servo systems."

Designed primarily for automotive component manufacturers, DTE's boot seal testing machine can be used to influence component design, or to demonstrate conformance with end customers' performance standards.

At EMO 2009, the CNC controls vendor NUM will launch a ready-integrated tool head for sophisticated plasma, laser and waterjet cutting machinery applications, and exhibit an advanced 3D simulation package combining workpiece simulation with collision monitoring for the first time.

The new head design brings many technical advantages to the cutting machinery sector. Novel mechanical design means that the head provides the versatility of movement and stiffness required to implement precision cutting motion, but with the unique advantages of very low mass, and the elimination of cabling runs that must flex with the tool head movement and can cause failures. Due to its unusually light weight, the new head can be assembled easily on existing CNC machines in the plasma- and waterjet-cutting market often without additional mechanical adaptation - providing a very simple means of extending the capability of machinery from 2D to 3D applications, with precise multi-axis interpolation.

NUM will also publicly exhibit a new 3D simulation package for the first time. It combines workpiece simulation with collision monitoring and other powerful features. The computer-aided engineering software allows machine builders to offer new generations of optimisation tools with their machines - to help users to maximize manufacturing throughput and productivity. Designated True 3D, the software tool is a general-purpose version of NUM's well-known 3D simulator for multi-axis grinding applications.

NUM's True 3D is one of the first commercial CNC software simulation tools to combine both workpiece simulation and collision monitoring facilities. Also worth mentioning is the fact that the new software is not only emulating, but is simulating the actual CNC commands, hence the name True 3D, and subsequently provides an output as close as possible to the actual machined parts. It allows machinery users to virtually prototype and optimise the entire machine production process, to yield significant gains including improved machine productivity, reduced tool wear, and faster project completion.

The new frequency converter from ABB is designed for machine applications that require a high level of protection. Because no special enclosures and cabinets are required, the closed design speeds installation, saves money, and gets the drives into operation quickly. The ACS350 General Machinery Drive – with UL Type 4X (IP66) protection – is offered in a 0.5 to 10 Hp (0.37 to 7.5 kw) range.

“This high level of protection is suitable for indoor applications, such as screw conveyors, mixers, pumps, fans and lifts that are used in places where the machines operate in a load of dust, moisture, high-pressure washing and cleaning chemicals,” said Kathleen Watson, the product manager for the series. “These applications typically occur in, but are not limited to, the food & beverage, textile, ceramics, pulp and paper industry and water / wastewater industries,” she noted.

The design and materials used in the drive’s construction comply with current National Sanitary Foundation (NSF) standards. The drive’s sleek design does not provide any nesting places for bacterial, and all components are protected from ingress of water. The control panel is designed for use in humid environments, and is protected against infiltration of dust by a plastic window; the fan is integrated into the housing of the unit. This design does not have an external fan, which reduces the chance for failure in harsh environments.

According to the company, the drives series is designed specifically for hygienic environments. The die-cast aluminum chassis of the units is painted white, and is manufactured with a cover made of fiberglass-reinforced polycarbonate. The enclosure has rounded edges for easy cleaning, and the surface shape is designed so that water drains off and away quickly. The heat sink ribs are constructed in a vertical design, so that they are freely accessible and easily can be cleaned of dust or debris. The housing is adhered to the chassis with a specially shaped seal that defends the drive against dirt deposits. Units can be wall mounted in close proximity to processing machines, and within easy reach of operating personnel.

The ACS350 UL Type 4X (IP66) offers an optional integral disconnect switch, when there is a need to isolate the motor and enable a safe working environment for maintenance and servicing. Features include:
-- Patented FlashDrop technology (fast, safe & easy parameter programming);
-- Eight (8) state Sequence Programming (PLC-like functions);
-- Control Panel for easy start up and assistance;
-- High-speed Communications, including
        Modbus TCP, Ethernet IP, DeviceNet, PROFIBUS-DP, CANopen;
-- Cabinet-compatible Hardware;
-- EMC Filter; and
-- Built In Brake Chopper

The drives have comprehensive control connections: there are two bipolar analog and five digital inputs (of which one can be configured for pulse train), and one analog, one relay and one digital output. The drives feature a totally new generation of Fieldbus, with small, enclosed, plug-in adapters that offer high-speed communications. The drives feature embedded Modbus RTU, including several small, enclosed, plug-in Fieldbus adapters, offering high- speed communications, such as DeviceNet, PROFIBUS-DP, CANopen & Ethernet IP / Modbus TCP.

Eaton Corporation today announced the availability of the DS6 line of reduced-voltage, solid-state, soft-start controllers designed for customers who require reliable and efficient soft starting of three-phase motors.

“Soft starting minimizes shock to mechanical components, thereby extending the life of a system, increasing reliability, reducing downtime and lowering costs,” said Ram Tenneti, soft starters product manager, Eaton. “Reducing the shock to products on conveyors and material handling equipment reduces the costs associated with damage to handled products. Lower in-rush current causes less stress on electrical components and junctions, further maximizing system life. Additionally, a soft-starting device reduces slippage, squealing and stretching, and extends belt life two to six times that of a traditional across-the-line starter. In pumps, the DS6 can soft stop the motor, thereby alleviating what is commonly known as the water hammer effect.”

The DS6, which is available for current ranges from 40 to 180 amps, can be used to upgrade existing systems that are currently using wye-delta, autotransformers or across-the-line National Electrical Manufacturers Association (NEMA) and International Electrotechnical Commission (IEC) starters. Because of its small size, the DS6 can provide customers with the benefits of soft starting, without necessitating a change in enclosure sizes or additional assemblies.

The DS6 is designed to be wired in the three-phase line feeding the three-motor input leads as is done for typical across-the-line starting. Using silicon controlled rectifiers (SCR) to ramp the voltage to the motor, the DS6 provides smooth acceleration and deceleration of the load reducing wear on belts, gears, chains, clutches, shafts and bearings. Used often with high-friction loads, soft-stop control is often critical for applications where an abrupt stop of the load may cause system or product damage.

Once the motor is started, the internal run bypass contactor closes, resulting in the motor running directly across the line. The internal-run bypass contactor significantly reduces heat generation when compared to non-bypass starters, thereby reducing enclosure sizes and cooling requirements while maximizing the life of all the devices in the enclosure. The bypass contactor directly connects the motor line and improves system efficiency by reducing internal power losses.

The DS6 family includes a variety of additional benefits and features:

• Light-Emitting Diode (LED) displays device status and provides fault indication

• Variable ramp times and voltage control (torque control) settings provide unlimited starting configurations, allowing for application flexibility

• Minimizes the peak in-rush current’s stress on the power system

• Minimizes peak starting torque to reduce mechanical system wear and damage

• 24 volts of direct current control module enhance personnel and equipment safety

• Multiple protective features, including over/under temperature and bypass dropout

New quick clamping shaft collars from Ruland are easily installed. The collars slide on the shaft smoothly. They have easy finger access to the handle that allows them to be removed or positioned without tools, using only the strength of the finger. The handle can be locked, fixing the collar in place. When installed, the handle is flush with the outside diameter which makes them suitable for rotating and stationary applications alike.

They are ideal for printing, packaging, medical, machine vision or semi-conductor manufacturing equipment to retain frequently adjusted items such as rolls of media, guide rails or other setup fixturing, or everywhere the need for tools is not practical.

The design features a tension-adjustment screw which makes the collar compatible to wide shaft tolerances and also adjust the axial holding power on the shaft. The collars work well on split hubs as well as on solid shafts. They can be modified by mounting holes to allow them to face-mount other components to the shaft.

Quick clamping collars are made from aluminum for light weight and low inertia and have an anodized finish. The hardware on the collars is made from stainless steel which makes them suitable for wash-down applications, medical applications and some food applications. Quick clamping shaft collars are available with bore sizes from 5/16 " to 1 ½ " in the inch series and 8 mm to 35 mm in the metric series.

Ruland says that a patent is pending on the design.

Called a model ACS310, ABB’s new drive is designed for extremely fast installation and commissioning -- particularly for pump & fan applications. The addition to ABB’s AC Drive family ranges from 0.5 HP to 30 HP (0.37 kW to 22 kW). The drive is fitted with a powerful set of features that fulfil pump & fan application needs – complemented with advanced, energy efficient functionality built into every unit.

Built-in PID controllers are used to vary the drive’s performance, in response to changes in pressure, flow or other external data, which modifies drives’ performance according to the needs of the application. The controllers can eliminate the need for an external PLC, and helps to save energy and up-front costs.

A pump and fan control (PFC) feature modulates the speed of the main pump or fan, and brings any auxiliary pumps or fans on line as necessary. The drive even can manage switching between pumps or fans to ensure that they all are used to the same extent (working hours) over time. In addition, the drive includes soft pump and fan control (SPFC), which further reduces unwanted pressure peaks in pumps and pipelines.

Among the standard energy efficiency features is an energy optimizer that helps to make adjustments in areas such as noise and efficiency. The drive’s internal fan is controlled by software to reduce losses, further improving energy efficiency. Energy savings can be monitored easily, using the built-in energy counter, which displays energy savings in kWh, or local currencies.

“It is impressive to be able to see, in real time, the energy these drives are saving a customer,” said Kathleen Watson, the product manager for the ACS310 series. She continues, “That’s a feature ABB has added, to that end users visually can see how their installations impact their bottom line, in terms of energy consumption.”

The user interface of the new general machinery drives also are designed to give users greater flexibility -- and the possibility to cut costs. The control panel is needed only for commissioning or troubleshooting, so no panel is included with the drive as standard. Users who require a panel can select between two types: basic and advanced.  Both are detachable, so an end-user could acquire a single panel to swap between, and use across, a number of drives.
 
A short parameter menu view means that only the most-used drive parameters are shown on the drive’s parameter view. A complete parameter view can be changed by setting one parameter; this saves time, as the user quickly can see the most important parameters – critical to fast drive commissioning.

The drive also has pre-programmed application macros for common tasks. The user is helped by an intuitive user interface with several assistant screens, including: a start-up assistant to guide the user through all essential settings; a maintenance assistant that helps to set criteria for preventative maintenance; and a diagnostic assistant that finds the root cause of a problem. A timer assistant offers help for setting timed functions, while the PID assistant helps in setting up sensor feedback.

The drive has embedded Modbus RTU interface as standard (RS-485/RS-232). Well-known Modbus protocol, integrated and compact design simplifies the commissioning of the drive.
 
The drive is based on a robust hardware and software platform. It is resistant to supply voltage drops and sags, improving the reliability of the application. Flying start enables picking up a spinning load without waiting for it to stop. Full output current is available at up to 50 °C ambient temperature.

Installation and commissioning is further speeded with the help of a User’s Short Manual, which provides basic information on the mechanical and electrical installation; start-up and control with I/O; and actual values and parameters in the short-parameter menu view.

All the units are equipped with a built-in EMC filter. And the drives are extremely compact: the 480 V drives over 1 HP are the smallest available in their category. And only the width of the drives increases with increasing power, which facilitates easy installation into cabinets, or stand-alone configurations.

Cable tunnels can be arranged in a straight run, and all screw holes can be drilled in a line. DIN-rail mounting of the all ACS310 units also is provided for, and the drives can be mounted side-by-side, without the need for air gaps. When cabinet depth is very limited, the drives even can be mounted with one side to the back of the cabinet. At only 9.7 lbs, handling and installation of the 30 HP units is easy. The drives’ own housing provides IP20 protection.  And the drives can be configured before start-up, using ABB’s FlashDrop configuration tool. This feature is particularly useful for serial manufacturing, where time per unit for programming parameters is critical.

Automatic Functions for Pumping

-- The drive has a variety of commonly needed functions for pump installations, such as:
-- Pump and fan control (PFC) and soft pump and fan control (SPFC) functions for controlling pumps in parallel
-- Supervision of inlet / outlet pressure conditions
-- Soft start and stop (pipe-fill function) to reduce mechanical stress and water hammer effect
-- Detection of under load and overload
-- Pump cleaning sequence for prevention of pump jamming

The motor-control software features a tool to analyze the loading of the drive, so that users more accurately can dimension the drive and motor for the specific application. This Load Analyzer tool comprises an Amplitude logger and a Peak Value logger. The data of both loggers must be able to restore itself should there be a power failure and, as such, the data is stored within a Flash memory.
In addition, the drive features software-controlled phase inversion, which provides a fast and easy  way to change the phase order of motor rotation; this saves time, as there is no need to change the output cable manually.

The drive is EMC compliant to second environment, as standard. First environment compatibility is available as an option. AC output chokes enable use of long motor cables. AC input chokes reduce total harmonic distortion, making the drive compliant with EN61000-3-12.

The enclosure class is IP20, with UL Type 1 (NEMA 1) kit available as an option. The interface has five digital and two analog inputs, accompanied by one digital and one analog output. The drive features a relay extension module (optional) that offers an extra three FORM C relay outputs, providing improved I/O interfaces. The drive also has embedded Modbus RTU with RS-232 and RS-485 connections.