June 26, 2018 Volume 14 Issue 24

Motion Control News & Products

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Brushless slotted flat motor weighs only 15 grams

The 20ECF brushless slotted flat motor is the latest motor to join Portescap's flat motor line. The motor's 19-mm rotor diameter is notably smaller than the 20-mm diameter of competitive solutions. At 15 grams, the 20ECF provides a mass savings of at least 30% when compared to competing motion solutions. The motor's design optimization also helps it achieve a 50% improved motor regulation factor relative to standard available solutions. Applications include surgical and service robotics, lab automation, premium tattoo machines, electric grippers, LiDar, and pumps.
Learn more.


Efficient, reliable and flexible robot gripper optimizes machine tending operations

To continuously deliver high-quality results to its customers, WEFAG AG not only invested in new CNC machines, but also deployed a collaborative application with the 3FG15 gripper from OnRobot to tend the CNC machines. This makes it possible for the Swiss family-owned company to meet extremely short delivery times and smaller batch sizes confidently, while also reducing the workload of employees, who can now focus on more demanding tasks.
Watch how the 3FG15 delivered an ROI in 2 months.
Learn more: How to automate machine tending.


Differences between types of multi-axis positioning stages -- parallel vs. stacked

According to the experts at PI (Physik Instrumente), stacking individual motorized stages is a fine approach for assemblies of just a few axes, but as applications become more complex a 6-axis stage design based on parallel kinematics could be the best option. Learn about stiffness, inconsistent dynamics, size and weight fragility, and even cabling considerations for multi-axis applications. Lots of good info here.
Read this informative PI blog.


Universal Robots' new UR20 Cobot makes its U.S. debut at IMTS 2022

Attendees at North America's leading machine tool show (IMTS) are experiencing how the all-new collaborative, industrial cobot from Universal Robots delivers the longest reach and payload in its class, offering the ability to automate even more hard-to-staff tasks in a market struggling to hire. Also learn about cobot grippers, machine tending, robo welding, and more.
Read the full article.


Miniature voice coil servo motor with 1-micron resolution

The miniature GVCM-016-019-01M Linear Voice Coil Servo Motor from Moticont is smaller in diameter than a dime and features a high force-to-size ratio of 1.5 N (5.3 oz) continuous force and 4.6 N (16.6 oz) of peak force. These brushless mini linear servo motors are clean, quiet, and feature high acceleration/deceleration, high speed, high reliability, and cog-free linear motion. An ideal choice for haptic feedback, pipetting in medical devices, machining and drilling, scanners, laser beam steering, sorting, assembly, and more. Can also be a low-cost replacement for pneumatic linear actuators.
Learn more.


MAHLE claims new EV motor is most durable -- can run indefinitely with high performance

Automotive supplier MAHLE says it has developed "the most durable electric motor available" for electric vehicle (EV) applications. Unique to the market, the traction motor -- with a continuous output of more than 90% of its peak output -- can run indefinitely with high performance thanks to a new cooling concept.
Read the full article.


What are Crossed Roller Bearings?

Learn all about HIWIN Crossed Roller Bearings that are three to four times more rigid than standard bearing solutions and are capable of handling loads in the axial, radial, and moment directions. They consist of an outer ring, an inner ring, and a plurality of rollers and spacers. The roller lies between the inner and outer ring with the spacers placed between the rollers to prevent the mutual friction between them, thereby decreasing the torque resistance for rotation. Many options are available depending on the level of rigidity needed.
Learn more.


Compact electrically controlled hydraulic actuator

Bosch Rexroth has expanded its range of standardized self-contained actuators by adding the CytroMotion system solution. With the help of the new compact actuator, linear movements involving forces up to 110 kN can be achieved in a range of machines and systems in smaller spaces -- more efficiently and more sustainably. These benefits can be seen over the entire life cycle. Thanks to fully electric control, CytroMotion makes engineering and commissioning easier. The efficient, power-on-demand drive and the maintenance-free, hermetically sealed design also minimize operating costs.
Learn more.


Belt-driven actuators for harsh environments

Rollon's newly enhanced Plus System lineup of belt-driven linear actuators can be integrated seamlessly with industrial machines. Combining sturdy construction, protective features (sealed), and high-performance characteristics for load, moment control, speed, and acceleration, the Plus System family features an anodized aluminum structure and steel reinforced driving belt. Three types available: Plus System ELM completely enclosed unit, Plus System ROBOT for multi-axis or SCARA robots, and Plus System SC for vertical motion in gantry applications.
Learn more.


Linear positioning and motion systems at IMTS 2022

SCHNEE-BERGER Linear Technology will spotlight its precision positioning and motion systems at IMTS 2022 in September. On display will be a fully functioning demo of a complete linear motion technology system featuring the company's leading and most innovative linear motion components. When linear tech components are designed to work together to create the most effective solution for machine movement, OEMs can accelerate design and manufacturing, reduce assembly time and labor, and achieve a lower TCO.
Learn more.


Micro-sized FlexPro servo drive

ADVANCED Motion Controls' new 60-A continuous FlexPro servo drive model FM060-60C-RM is the third "machine embedded" version in this power range, adding RS-485/232 communication to the previously released EtherCAT and CANopen versions. This drive can operate at its 60-A peak rating continuously with no need for current foldback -- impressive because the micro-package size means up to four units can fit within the footprint of a business card. Applications include cobots, AMRs, AGVs, portable devices, lab and warehouse automation, military equipment, and more.
Learn more.


NSK's new Active Casters help robots move effortlessly

NSK has developed new Active Caster technology for service robots and mobility drive applications. The compact, electric-powered turning unit provides both drive and steering functions based on the difference in rotation between two motors. The developers say it generates less vibration compared to an omnidirectional mobility unit using Mecanum wheels.
Read this informative NSK article.


Hybrid stepper motor with 8-pin integrated connector

Lin Engineering's NEMA 23 (57-mm) hybrid stepper motor can be ordered with an 8-pin integrated connector that allows for multiple connection options. Standard and customized windings and shaft options are available to match your performance requirements, as well as customizable leads and wire harness. This high-volume-availability motor may be the perfect drop-in replacement for your designs if you are experiencing supply chain issues.
Learn more.


IronHorse jet pump and stainless steel motors

Automation-Direct has added the new, economical IronHorse MTRJ series of jet pump motors to their AC motor lineup. They come in a TEFC enclosure with a 56J frame that has a threaded shaft for direct connection to a jet pump, and are available in 120/230 VAC from 1/3 to 2 hp and in 208-230/460 VAC from 1/3 to 3 hp at 3,600 rpm. AutomationDirect has also added the MTS series of IronHorse motors that offer premium efficiency (EISA compliant) and come with an IP69K-rated stainless steel construction that can survive the harshest of environments. They are available in sizes from 1/3 to 20 hp in 208-230/480 VAC 3-phase and in speeds of 1,200, 1,800, and 3,600 rpm.
Learn more.


Machine learning eliminates cogging for linear motors

The highly dynamic AL8000 linear motors from Beckhoff now meet even greater requirements for accuracy and synchronization with the new TwinCAT Cogging Compensation software, which compensates for cogging forces. Cogging forces in linear motors are caused by the magnetic attraction between the iron core in the primary part and the permanent magnets in the secondary part. AL8000 linear motors are particularly suitable for high-precision applications such as milling machines or laser cutting machines.
Learn more.


All-time record smashed: Volkswagen makes history with the all-electric I.D. R at Pikes Peak

[All images © 2018 Copyright Volkswagen]

 

 

Volkswagen and its special, all-electric I.D. R Pikes Peak racer have made history at the finals of the Pikes Peak International Hill Climb held in Colorado this past Sunday, June 24.

Driving the 500-kW racecar, Romain Dumas defeated a field including cars with conventional drivetrain technology. In doing so, Dumas not only broke the previous record for electric vehicles, but also bettered Sébastien Loeb's all-time speed record from 2013 -- by a full 16 seconds. Dumas' new record of 7m 57.148s is now top of the list of Pikes Peak champions, which includes such acclaimed drivers as Loeb, Walter Röhrl, Michèle Mouton, Stig Blomqvist, Nobuhiro Tajima, and Rod Millen and his son Rhys.

"With a combination of outstanding engineering skills, passion, and commitment, the team has managed to create a fantastic racing car in just eight months," said Dr. Frank Welsch, Member of the Board of Management of the Volkswagen Passenger Cars brand with responsibility for Technical Development. "The Volkswagen I.D. R Pikes Peak has now set the fastest time in the history of this hill climb, which spans more than 100 years. That speaks volumes for electric mobility."

Volkswagen I.D. R Pikes Peak driver Romain Dumas claims victory at the 2018 event.

 

 

Held in a Rocky Mountains area just 16 miles west of Colorado Springs, the race is a climb of 4,720 ft from the start at Mile 7 on Pikes Peak Highway to the finish at 14,110 ft on grades averaging 7.2%. It is 12.42 miles, 156 corners, and just one attempt. Romain Dumas claimed his fourth overall victory at the Pikes Peak International Hill Climb this year, which has now been held 96 times since 1916.

VIDEO: VW's record run.

With the I.D. R Pikes Peak, Volkswagen has created an extraordinary racing car, specifically tailored to the demands of the most famous of hill climbs: a combination of minimum weight, as much downforce as possible, and maximum power -- all coalescing to achieve the best possible performance. Including its battery cells, the I.D. R Pikes Peak weighs less than 2,425 lb. When evaluating performance, Volkswagen employed simulation software to calculate exactly how to achieve the optimum in energy demand and performance for the record attempt on the famous racecourse.

"There is one big advantage of having an electric car in the Pikes Peak International Hill Climb -- the power remains constant over the entire 20-kilometer route," said Dumas. "By contrast, vehicles fitted with combustion engines lose a significant amount of power in the thin mountain air."

With its two electric motors, which together generate 671 hp, the I.D. R avoids the cooling issues that combustion-engine vehicles face. This made it possible to reduce the size of the intakes in the chassis, which are traditionally aerodynamic drawbacks.

As far as aerodynamics, the key was to compensate for the loss of downforce caused by the thin air on the mountain. The design result could be seen from afar: the flat, streamlined chassis and huge rear wing.

"The altitude on Pikes Peak means that the air we are driving through is on average 35 percent thinner. As a result, we lose 35 percent of our downforce compared to a racetrack at sea level. The huge rear wing allows us to compensate for some of this lost downforce," said Willy Rampf, technical consultant to the project with years of Formula 1 experience. "The imaginative aerodynamic development means that we still achieve maximum downforce greater than the weight of the car during the hill climb."

Volkswagen Motorsport used a half-scale model to test a host of different variants of the Pikes Peak racer in the wind tunnel. The final touches were then put to a full-size chassis on the rolling-road wind tunnel in the Porsche development center in Weissach, Germany.

New components were often produced in quick time on a 3D printer. "We printed about 2,000 parts. In doing so, we saved a lot of time," said Dr. Hervé Dechipre, who, as a CFD engineer at Volkswagen Motorsport, is responsible for the aerodynamics on the I.D. R Pikes Peak.

Inside the driver cockpit.

 

 

Lithium-ion batteries are used as the energy storage system, similar to production EVs, as their power density is the crucial factor for the system when producing high voltage. Roughly 20 percent of the electric energy required is generated during the drive, so the key here is energy recovery. When braking, the electric motors act as generators, converting some of the braking energy into electricity and feeding this into the battery.

Volkswagen also struck out in a new direction when it came to the car's charging technology. The goal was to charge the car as quickly as possible with minimum environmental impact. The time for charging was defined by the regulations: In case of the race being suspended, it must be possible to completely charge the car in under 20 minutes. The electricity required was provided by generators at the foot of Pikes Peak. Glycerol, which in chemical terms is a sugar alcohol, was selected as the generator fuel. A by-product of the manufacture of biodiesel, Glycerol combusts with virtually no harmful exhaust fumes or residues. Glycerol itself is non-toxic and is even permitted as an additive in the food and cosmetics industries.

Volkswagen's latest Pikes Peak project started on Oct. 18, 2017, meaning very little time was allotted for the development of the thoroughbred prototype, including innovative fully electric drive technology, specific demands on the batteries, aerodynamics, and chassis. The effort was centered at the VW Motorsports facility in Hannover, not too far from VW's headquarters in Wolfsburg, Germany.

Volkswagen has had some strong partners on its side for the record attempt on Pikes Peak this year, notably Volkswagen R, ANSYS, Michelin, Integral e-drive, and OMP. ANSYS made a vital contribution to the success of the project by providing support with the software simulations.

Volkswagen last entered the Pikes Peak hillclimb in 1987 with a particularly noteworthy dual-engine Golf that generated an impressive 652 hp. However, the Wolfsburg-based manufacturer narrowly missed out on success.

Dumas' last winning Pikes Peak run was in 2016 driving a Honda-powered Norma M20 RD Limited up the course in less than 9 minutes -- at the time, it was only the second ride in the event's history to break that mark.

Source: Volkswagen Motorsport

Published June 2018

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