November 06, 2012 Volume 08 Issue 41

Motion Control News & Products

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Palm-size XY/XYZ motorized stage is fast and precise

PI (Physik Instrumente), a top provider of precision motion control and positioning solutions for more than four decades, has released the low-profile M-122 motorized positioning stage. This stage has a very small footprint of 60 mm x 86 mm and a travel range of 25 mm, best suiting it for research and industrial applications, including fiber alignment, metrology, quality assurance testing, photonics packaging, test equipment, and micromachining.
Click here to learn more.

Toothed-belt linear axes in customizable sizes

To simplify product selection of maintenance-free, self-lubricating linear guides, motion plastics specialist igus has developed a modular construction kit for belt-driven DryLin ZLW linear axes. Using the new ZLW toolkit, customers can customize their own solutions, including rail widths, system length, etc. -- even for small installation spaces. Cross beams, rails, and/or carriages are available in either aluminum or stainless steel to suit a wider range of application requirements, especially food and lab settings. These systems were developed for high-speed applications with low loads and are better for high accelerations than ball bearings. Underwater applications are possible via a special toothed belt.
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Encoders: Rotary motion control in extreme environs

Novotechnik U.S. introduces the Vert-X 51 Series of rotary magnetic encoders, which feature up to 16-bit resolution and repeatability to 0.1 deg, depending on model. Measurement range in this series is 0 to 360 deg, and physical measurements of the housing are 30 mm x 50 mm. These encoders are ideal for harsh environments with ingress protection to IP 67, and stainless steel housing and shaft are available. Vert-X 51 Series is designed to operate with shock up to 50 g and vibration to 20 g as well as axial and radial shaft loads to 45 N. Ideal for marine propulsion, off-highway, and other applications
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High-torque DC mini motors

With high-torque carrying capabilities reaching up to 6.14 mNm, the 17DCT brush dc mini motor from Portescap provides outstanding performance with efficiency reaching up to 85 percent. This 17-mm diameter motor can deliver higher torque per ampere resulting in better battery life, making it ideal for demanding applications such as medical and industrial pumps, drug delivery systems, miniature industrial power tools, tattoo machines, mesotherapy guns, dental tools, watch winders, and more.
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Ultra-fast compact piezo nanopositioner

The new P-630 X-axis nano-positioning stage from PI (Physik Instrumente), with a large clear 30-mm diameter aperture, 0.1-nm resolution, and a small footprint and low profile, will ensure high accuracy and long life with travel ranges to 80 µm. Equipped with an internal capacitive sensor that allows for precise, extremely stable motion, the stiff flexure design enables exceptional responsiveness and accuracy. Vacuum version is available. PI piezo actuators are being utilized in research and industry microstructuring and scanning applications, precision positioning of optical elements, and micromachining.
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Custom-molded lead screws, linear motion components

Haydon Kerk Motion Solutions recently added SolidWorks Plastic Professional mold flow analysis software to help with the design of custom-molded lead screw and linear motion components. Haydon Kerk’s experience using over 60 molded materials, including the Kerkite composites, PEEK, and PPS base materials, combined with the capabilities of this new software, allows engineers to reduce the time required for the design and build process for custom molds. The combination of on-site tooling and molding machines also reduces the time to production for custom parts for existing Haydon Kerk polymers or customer-specified materials.
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Bosch Rexroth Resource Kits

Bosch Rexroth Corporation recently achieved a major milestone distributing 5,000 Resource Kits to U.S. engineers. Launched in 2013, the Resource Kits now cover six different topics: Lean Production and Automation Insights, Linear Motion & Mechatronics @ Work, Advancing Factory Automation, Hydraulics Performance, Mobile Hydraulics Solutions and Packaging & Printing Results. Resource Kits include handbook excerpts, case studies, technical papers, videos, and online tools.
Get your resource kits today.

Compact linear positioning stage driven by ultrasonic piezo linear motor

Ultrasonic piezomotors from Physik Instrumente are small and provide motion with high resolution, as well as an extremely wide dynamic range from microns/second to hundreds of millimeters/second. A significant advantage over magnetic drive technologies (such as voice coils, brushless, and 3-phase motors) is the self-locking principle: Once the motor reaches a target position, it acts like a ceramic brake and locks the platform into place, providing extreme long-term stability at zero driving current and heat generation.
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Mike Likes Robotics: Tiny powerhouse of a robot

The small-but-mighty KUKA KR 3 AGILUS is aimed at production applications where very short cycle times and maximum output are required, such as assembling small components and performing handling tasks, screw fastening, brazing, adhesive bonding, packaging, testing, inspecting, and more. Payload capacity is 3 kg; reach is 540 mm. This 600 mm x 600 mm (2 ft x 2 ft) little workhorse is characterized by impressive speed and precision.
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Aerospace: Custom modular cooling pumps

A new family of cooling pumps from Parker Aerospace shares a common core of basic motor and pump components. The pumps are compatible with a variety of dielectric fluids including PAO, fuel, Galden, and turbine engine oils and are available in fixed- or variable-speed configurations to accommodate a variety of flow rates. Both AC and DC motor configurations are available as 115 VAC at 400 Hz, 28 VDC, or 270 VDC. The wet-motor design allows the fluid to extract heat from the electronics or the sensor suite, while also removing heat from the pump motor itself.
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Linear Motion: Mini voice coil actuators

H2W has built its smallest moving magnet voice coil actuator (NCM01-04-001-2IB) to date, with an outside diameter of 0.40 in (10 mm) and a length of 0.735 in (18.8 mm). It has a stroke of 0.10 in (2.5 mm) and generates a continuous force of 0.10 lb (0.45 N) and a peak force of 0.30 lb (1.35 N). It weighs just 0.20 oz (5.7 g). This actuator uses a hardened shaft and sliding contact bushing to ensure long life and is ideal for oscillatory motion -- particularly in a number of handheld applications. Moving magnet voice coil actuators have built-in bearings, so there is no need for the customer to add mass or complexity to their motion system to integrate a bearing, and there are no moving leads to worry about cable management.
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Motion: Next generation of precision motion controllers -- V3.0

MICROMO launches the new MC3/MCS motion control family -- an extensive and versatile basis for the complete FAULHABER motion system. The new controllers are optimized for use with FAULHABER motors, offer electronics for simple operation with state-of-the-art interfaces for multi-axis applications, and provide a motion control system solution with the most compact integration into industrial grade housing. The Motion Controllers V3.0 are high performance, intelligent, networked drives optimized for OEM and automation applications.
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Cool Tools: Digital oscilloscope tests motors for damaging shaft voltages

Industrial motors controlled by variable frequency drives (VFDs) are at risk of electrical bearing damage. The new AEGIS Shaft Voltage Tester Digital Oscilloscope makes it easier than ever to check in-service motors for damaging VFD-induced shaft voltages and head off bearing damage and costly unplanned equipment downtime. A complete package, the two-channel, full-function 100-MHz digital oscilloscope comes with a special conductive microfiber-tipped probe for exceptional shaft contact, a probe holder with magnetic base, and a compact carrying case.
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Low-cost belt-drive actuator

Tolomatic’s family of MXB electric belt-drive actuators includes a new solid-bearing load-carrying design ideal for harsh environments. The trapezoidal solid bearing provides a rigid, long-lasting bearing system capable of operating in environments that roller bearings would not be able to withstand. With loads up to 520 lb, speeds to 100 in./sec, and strokes up to 230 in., the MXB-S belt-drive actuator is an economical solution for light- to moderate-loading applications requiring high duty cycle and high speeds over long strokes.
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Robotics: Robotiq camera for Universal Robots couldn't be more user friendly

Robotiq has just launched a new vision-guided pick-and-place solution for those oh-so-popular Universal Robots. This camera can be working on a shop floor in 5 minutes flat. No external PC is required to set up, program, or run the camera -- the camera’s user-friendly software is seamlessly embedded within Universal Robot’s graphical user interface. The compact camera design fits perfectly on the UR wrist and offers direct connectivity to the controller. Early users of the system say Robotiq’s Camera breaks down all the integration barriers we are used to seeing with vision systems in manufacturing automation.
Click here to learn more.

DARPA tests UAV-to-UAV refueling at 45,000 ft

DARPA completes close-proximity flight tests of two modified RQ-4 Global Hawk unmanned aerial vehicles, demonstrates technology enabling autonomous aerial refueling.

Global military aviation currently relies on a key enabler: aerial refueling. Fighters, bombers, reconnaissance, and transport aircraft use "flying gas stations" to go the extra mile.

Increasingly, UAVs are conducting combat and ISR operations, but they aren't designed to be refueled in flight. In 2007, DARPA teamed up with NASA to show that high-performance aircraft can easily perform automated refueling from conventional tankers, yet many unmanned aircraft can't match the speed, altitude, and performance of the current tanker fleet. The 2007 demonstration also required a pilot on board to set conditions and monitor safety during autonomous refueling operations.

But DARPA has been working to close this capability gap.

Global Hawk UAVs demonstrate close-proximity test flight.



DARPA's two-year Autonomous High-Altitude Refueling (AHR) program, which concluded Sep. 30, explored the ability to safely conduct fully autonomous refueling of UAVs in challenging high-altitude flight conditions. During its final test flight, two modified Global Hawk aircraft flew in close formation, 100 ft or less between refueling probe and receiver drogue, for the majority of a 2.5-hr engagement at 44,800 ft. This demonstrated, for the first time, that High Altitude Long Endurance (HALE) -class aircraft can safely and autonomously operate under in-flight refueling conditions.

The flight was the ninth test and the first time the aircraft flew close enough to measure the full aerodynamic and control interactions for unmanned-to-unmanned connections. Flight data was analyzed over the past few months and fed back into simulations to verify system safety and performance through contact and fuel transfer, including the effects of turns and gusts up to 20 knots.

Since HALE aircraft are designed for endurance at the expense of control authority, the program started with the expectation that only one in six attempts would achieve positive contact (17%). The final analysis, however, indicated that 60% of the attempts would achieve contact.

Multiple autonomous breakaway contingencies were successfully triggered well in advance of potentially hazardous conditions. Fuel systems were fully integrated and ground tested, demonstrating a novel "reverse-flow" approach with the tanker in trail. This approach opens valuable trade space for future developers to choose between various fixed and modular implementations of proven probe and drogue hardware.

"The goal of this demonstration was to create the expectation that future HALE aircraft will be refueled in flight," says Jim McCormick, DARPA program manager. "Such designs should be more affordable to own and operate across a range of mission profiles than systems built to satisfy the most stressing case without refueling. The lessons from AHR certainly extend beyond the HALE flight regime, and insights into non-traditional tanker concepts may offer further operational advantages."

Using this capability, U.S. military Global Hawk UAVS could fly nonstop for days or maybe even weeks.

Source: DARPA

SIDEBAR: Some basic Global Hawk stats courtesy of Northrop Grumman.

Q. How far can Global Hawk fly?

A. It has an inter-continental range (~11,500 miles). This means the aircraft can fly from New York and land anyplace in the world.

Q. How high can Global Hawk fly?

A. About 12 miles high -- an altitude almost twice that of airliners. From this height, you can see over 300 miles to the horizon.

Q. How long can Global Hawk fly?

A. More than 32 hours -- the longest of any high-altitude operational aircraft in the world.

Q. How much can Global Hawk carry?

A. It can carry equipment weighing 3,000 lb -- that's the weight of a Ford Focus.

Published November 2012

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