Anyone responsible for maintaining, upgrading or designing automation equipment would benefit from SERVO SIZING DEMYSTIFIED, a 40-minute no-cost webinar on Tuesday, March 9.
A leader in cutting edge sawmill equipment since 1954, Cleereman Industries in Newald, Wis. They started out owning and operating a sawmill business and now are a manufacturer of a wide range of sawmill equipment that includes Carriages, Track Frames, and Trim & Grading Lines.
Cleereman recently decided to redesign a rotary log kicker in order to increase its size range, as well as transition its hydraulic system to a fully clean electric system. The challenge was the overall size of the log kicker. The resulting machine inertia makes the 15 cycle per minute rate difficult to achieve. The machine’s inertia and cycle per hour requirement would have required a large braking package to dissipate the energy.
Cleereman turned to L&S Electric for a solution to their challenge.
Initial thoughts of a standard VFD and brake resistor were considered, but L&S representatives recommended a more energy efficient solution. Due to its power regeneration capabilities, a Yaskawa U1000 Industrial Matrix Drive was selected to control the 30HP electric drive system.
This solution allowed Cleereman to get away from the maintenance time and costs that are associated with hydraulic systems, and provided them a cleaner, more energy efficient solution in a smaller package.
Cleereman now can smoothly control the very high inertia log kicker. Whether motoring or regenerating, the U1000 Industrial Matrix Drive provides Cleereman with a clean power solution by maintaining ultra low input current harmonics.
In addition, the U1000’s inherent regenerative capabilities eliminated the braking resistors that dissipated heat from the deceleration of the load.
Cleereman now provides a solution that reduces their customers’ utility costs. The energy wasted using resistors is now diverted back onto the grid. Removal of the resistor package also increases machine lifetime and reduces machine maintenance requirements by eliminating another point of potential failure. Lastly, using the U1000 Industrial Matrix Drive eliminates fire safety concerns that come with using resistors in lumber mills to burn off regenerative energy.
Big week for Mike Adams in Baton Rouge. Monday, he filled up an 18-seat class of customers for Yaskawa A1000 drive training. And on Tuesday and Wednesday, he spearheaded the efforts at the Sugar Mill Show in Baton Rouge. Adams is shown here with Ron Dufresne, Yaskawa rep for Louisiana and southern Mississippi (left); Richard Lewis, Engineering Manager Houston IIDM (middle).Read More
Ever wonder how SkyCam really works? With a lot of help from Yaskawa servos and collaboration with Innovative-IDM engineers.
When choosing an Ethernet communication platform for industrial machine control, it’s hard to ignore the virtues of EtherCAT. Its ability to mix and match between various components from different manufacturers makes EtherCAT a popular choice among integrators and design engineers.
EtherCAT is the fastest industrial Ethernet technology and has unmatched bandwidth utilization. This makes it an excellent choice for machine control, according to the EtherCAT Technology Group.
Omron’s NJ machine automation controller offers EtherCAT as a built-in communication network. And thanks to EtherCAT Technology Group’s testing for device compliance, users are assured that a certified device will work with other certified devices. This means users can confidently mix and match vendor EtherCAT certified hardware.
For instance, you can pair an Omron NJ controller with Yaskawa VFDs and Yaskawa servomotors, both of which have received EtherCAT conformance certification. This type of multi-vendor system might cause headaches on many other networks. But with EtherCAT, a skilled integrator can have these devices talking very quickly.
How to connect an Omron NJ to a Yaskawa EtherCAT servo amplifier
- First, download and install the EtherCAT ESI from from Yaskawa. The ESI file is a free .xml format file Yaskawa created and published in accordance with EtherCAT standards. This file contains all the information needed by an EtherCAT master (the Omron NJ) to successfully control the EtherCAT slave (the Yaskawa amplifier).
- Next, add the ESI file into the Omron ESI library. It can now be used by Omron’s NJ programming software, Sysmac Studio.
- Inside Sysmac Studio you now need to add the Yaskawa device to your EtherCAT network map. This can be done by dragging and dropping the image form the library onto the network (this is only possible because you successfully loaded the ESI file). You will need to match the node address setting on the Yaskawa amplifier rotary switches to the node you assign in the software.
- Finally, you need to map the communication objects such as the control and status word. This is easily done using the Detailed Settings within the axis of Sysmac Studio using the drop down lists provided.
That’s it. Within minutes, you can have functioning communication and control between an Omron NJ controller and a non-Omron EtherCAT device.
Matt Meeker is one of our customers' most highly-sought after resources for automation and controls systems advice. Matt also teaches classes on PLC programming at all of our branches or onsite at manufacturing facilities. You can reach Matt at email@example.comRead More
One of our clients needed a solution for automatically adjusting his horizontal extrusion die. The die controls the thickness of a plastic web about 72 inches wide.
Previously, the 72 bolts across the top of the die were adjusted by hand by an operator. The worker would compare the readings on a nuclear micrometer to what the set point was. This was labor intensive and required a lot of the operator’s attention, time he should have been dedicating to watching the machine and its operation.
Our solution was to incorporate a Yaskawa multi-axis servo controller with four servo amplifiers and motors and Modbus communication to interface with their micrometer.
A brief explanation: Two motors are mounted on two “heads.” Each head consists of:
- A position motor with a gear reducer that travels on a linear gear across the die
- And, an adjusting motor with a socket mounted to the motor shaft that pneumatically lowers down on a bolt to adjust it.
Each head is taught the position of the first bolt by moving it manually to that position. The distance between each bolt is inputted into the system through the Parker HMI. Then each head travels across the die, learning the positions of every bolt and the rotational position of each bolt head. In case of vibrations or other external influences to the bolts, the system has the ability to relearn on the fly the rotational position of any bolt.
The micrometer will message the servo controller via Modbus when a portion of the web is out of tolerance. The servo controller is told which bolt is causing the error and by how much. The “head” closest to the offending bolt will move to a bolt 3 bolts away. Then, alternating between bolts on either side of the offender, the head start adjusting the bolts. The outside bolts receive minor adjustments working up to a full adjustment on the center (and offending) bolt.
Result; the operator can manage the machine and not have to micromanage a bunch of bolts.
Productivity up. We do solutions like this for customers every month. If you tell us y
our problem, we probably can help your efficiency.
Stewart Bissell is a Field Applications Engineer in Innovative-IDM's Dallas office. He can be reached at firstname.lastname@example.org