PBA Systems December 2012 Newsletter

19 Dec 12

In This Edition:

  • Product Updates
    • New Models for CVCA and RVCA Voice Coil Actuator Series
    • PBA Systems Motors Now Run With Customized Mitsubishi Drivers
  • Case Studies
    • High Precision Positioning for Multi-layer Ceramic (MLC) Stacking
    • Large-sized High Precision LCD Panel Assembly Machine for Flat Panel Industry
    • Low Cost RS-232 Control Using PBA MaxTune and ELMO Servodrives
  • Events & Other News
    • Season's Greetings from PBA Systems

Product Updates

New Models for CVCA and RVCA Voice Coil Actuator Series

PBA Systems introduces its new line of CVCA Voice Coil Actuator Series which uses cross roller bearing instead of normal linear guides for better precision and rigidity. Powered by CVC Circular Voice Coils, the CVCA is Ideal for high speed positioning applications with short stroke.

On the other hand, the new RVCA Voice coil Actuator Series features an improved design with reduced mass. The RVCA is ideal for high speed pick-and-place applications.

Other features of both actuator series are:

  • Direct drive, cogging free
  • Low moving mass, fast response
  • Integrated linear encoder
  • Ease of use, plug and play
  • Excellent reliability

For more information about these products, click here: CVCA / RVCA.

You can also download 3D drawings of the new products from the PBA Systems Website Downloads.

With the introduction of these new models, old CVCA and RVCA models will be discontinued.

 CVCA40-HF-6.5-CRX

RVCA-S12B

PBA Systems Motors Now Run With Customized Mitsubishi Drivers

PBA Systems has collaborated with Mitsubishi to enable compatibility between PBA Systems DX Motors and Mitsubishi PLC and servo drives. Now customers can combine the reliability and robustness of Mitsubishi PLC systems with the excellent dynamic response of PBA Systems Direct Drive Linear Motors.

The Mitsubishi PLC system is highly expandable with many modules and firmwares for various functions. One of the more useful function would be it's gantry solution which PBA Systems has implemented in a H gantry application.

Control Motor
  • Q Series PLC System
  • 0.1um incremental encoder
  • Acceleration of 0.1G, Velocity of 1m/s
  • PBA Systems Ironless Linear Motor Module
    DX65B-C5P for Y1, Y2 and X

The H-Gantry consists of PBA Systems DX65B-C5P Ironless Linear Motor on the two Y axes and X axis. Mitsubishi motion control solution has separate PID for the two Y axes which ensures that both axes track the motion well with improved repeatability.

To improve accuracy, the error mapping function can be used to store the position error on the axes which can be measured using a laser interferometer. This will greatly increase the accuracy of the system without solely relying on mechanical quality of the system.

Mitsubishi PLC

Case Studies

High Precision Positioning for Multi-layer Ceramic (MLC) Stacking

This machine is used for stacking ceramic sheets to produce Multi-Layer Ceramic Capacitors (MLCC). The motion requirements are high speed, accuracy, repeatability and reliability in order to achieve high yield rate and productivity.

300 to 500 ceramic sheets are stacked for every MLCC. Any layer failure will cause the product to fail.

The machine has one 1000mm axis with a motor carriage weight of 300kg. For this axis, the customer was initially using ball screw. However, due to backlash and large friction, the customer was unable to achieve the above requirements and the cycle time was 13 seconds.

Looking for better performance, the customer has decided to switch to PBA Systems DX B Series Ironless Linear Motor.

Earlier Configuration Current Configuration
  • Japanese brand Ball-screw
  • Rotary servo motor
  • Controller - PLC
  • PBA Systems Ironless Linear Motor Module
    DX65BT-C10P
  • Driver - Elmo TUBA 20/230
  • Encoder - Renishaw TONiC, 1 um
  • Controller - PLC

PBA Systems DX B Linear Motors have met all the above requirements, and cycle time has been reduced to 9 seconds and the machine is now used in production.

 Multi-layer Ceramic (MLC) Stacking Process

Large-sized High Precision LCD Panel Assembly Machine for Flat Panel Industry

This machine is used for backlight assembly of 60-inch LCD modules in a clean room. The machine has one XY table carrying around 140kg load.

The customer requires high accuracy, high speed and high precision motion on the XY stage. For a cost-effective solution that meets all these requirements, the customer has decided to use PBA Systems XY table. The XY table uses PBA Systems LMS Linear Motor Actuators which are powered by the DX B Series Ironless Linear Motors.

High Precision LCD Panel Assembly Machine High Precision LCD Panel Assembly Machine 

Advantages of PBA Systems XY Table Disadvantages of Using Ball Screws
  • High speed, high accuracy and high repeatability
  • Ideal for long stroke motion
  • High carriage load
  • Suitable for clean room application
  • Easy installation and maintenance
  • Short lead time
  • Poor accuracy due to backlash and high friction
  • For long axes, the ball screw shaft will deform under gravity
  • Not suitable for large loads because of wear and tear caused by friction, which also adds to maintenance costs
  • Not suitable for clean room applications because of particle generation

Current Configuration
  • PBA Systems LMS Linear Motor Actuators
    • For Top Axis : LMS65DG-XYS-C4-S700 with DX65B-C4P coil (Actuator length – 1000mm)
    • For Bottom Axis : LMS65DG-XYS-C6-S1400-1.0 with DX65B-C6P coil (Actuator length – 2100 mm)
  • Driver – Elmo COR 9/230
  • Encoder - Renishaw RH200, 1.0 um
  • Controller - PLC

With the PBA Systems XY stage, the customer requirements have been met and the machine is now used to produce LCD TVs of a famous Japanese brand.

Low Cost RS-232 Control Using PBA MaxTune and ELMO Servodrives

Being able to control a motor directly through a PC using simple RS-232 or CANOpen command can be very attractive for applications with either single axis or simple multiple axis motion. All that is needed is a PC, MaxTune or ELMO range of servodrives and PBA direct drive motors. When using CANOpen, you will need a CAN Interface.

With this minimal configuration, it is easy to create a GUI (Graphical User Interface) in Windows.

PBA Systems MaxTune Servodrive can simply accept ASCII command from RS-232 and CANOpen. The programmer will just have to refer to the command list available (see PBA Systems Website Downloads) and send it in ASCII format using any programming language.

ELMO Servodrive has provided a library for Visual C++ to send commands to the servodrive through either RS-232 or CANOpen. It even supports synchronization between multiple axes using "Position, Velocity, Time" (PVT). However it is not recommend to use PVT since Windows is not real-time and due to the bandwidth limitation of CANOpen.

PBA Systems has implemented many GUIs for its customers. An example GUI is shown on the right for the Dip-Coating Machine done using ELMO Cornet and PBA DX20B-C3.

Contact PBA Systems if you are interested in implementing this highly convenient and low-cost solution.

 

GUI

GUI

RS232 and CANOpen Control with PBA MaxTune RS-232 and CANOpen Control with ELMO
  • PBA Systems MaxTune Intelligent Servodrive
  • Supports Any Programming Language
  • PBA Systems Direct Drive Motor
  • PC with RS-232 Port or CAN Interface (Check with PBA Systems for compatibility
  • ELMO Servodrive
  • Visual C++ (MFC Programming)
  • PBA Systems Direct Drive Motor
  • PC with RS-232 Port or CAN Interface (Check ELMO Interlude manual for compatibility)

Events & Other News

Season's Greetings from PBA Systems

To our clients, distributors and business partners who have made our progress possible, we extend our warmest wishes for the Holiday Season and a prosperous and peaceful New Year!

Please note that PBA Systems will have a holiday shutdown from Dec 24, 2012 to Jan 1, 2013. Business will resume as usual on Jan 2, 2013.

e-Greeting
 

For more information on any of the products featured above, please contact:

PBA Systems Pte Ltd
2, Woodlands Sector 1, Woodlands Spectrum 1, #03-23, Singapore 738068
Tel +65 6576 6767 | Fax +65 6576 6768 | Email This email address is being protected from spambots. You need JavaScript enabled to view it. | Website www.pbasystems.com.sg

Disclaimer: Every care has been taken to ensure the correctness of the information contained in this newsletter but no liability can be accepted for any errors or omissions. Copyright reserved. This newsletter or parts thereof may not be reproduced without PBA Systems' permission.