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How to Build Robotic Positioning Systems for Long-Stroke

Applications

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q  This webinar will be available afterwards at www.designworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar

Before We Start

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Lisa Eitel Motion Editor — Power Transmission and

Motion Control Design World Magazine

Jean-Paul Beyak Regional Manager, Midwest/Eastern USA & Canada

Director of Sales, Latin America Nexen Group Inc.

How to Build Robotic Positioning Systems for Long-Stroke Applications

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Gantry and robot-positioning systems perform myriad functions:

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RTUs — Sold as pre-engineered assemblies, as custom-engineered systems from integrators, or built from motion components

TranTek

ABB

Milwaukee MachineTool

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Gantry and robot-positioning systems need components that deliver:

High speed •

High positional accuracy •

Low backlash •

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Otherwise, alternative designs also called robot-transfer units (RTUs) use adaptive control to prioritize flexibility …

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RTUs for gantry and precision robot-positioning systems necessitate:

• Low maintenance • Long life • Safety

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The long-stroke applications can use drives with: Belts

Rack-and-pinion sets Linear motors

Ballscrews

... and all drive types have benefits and limitations.

Gantry and robot-positioning RTUs use an array of drive setups

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Check out this example — an RTU that lets one robot automate a whole machine-tool operation:

Gantry and robot-positioning systems abound

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Robot gantries traversing mid-range linear distances use motor+ belt designs— belt drives are quite common on H robots and other gantry setups…

... especially those with shorter strokes

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… so are more common on shorter axes … but there are exceptions to the scalability caveat.

Belt drives in long-stroke applications can be subject to limitations

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— these use framing and linear tracks in various orientations to get more precision from belt drives …

Belt-driven gantry and robot-positioning RTUs exist —

Stroke — 30 ft Payload — 3,000 lb Repeatability — ±0.001 in.

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... So what are some benefits and caveats? Long-stroke applications can also use drives with ballscrew axes …

Peak Analysis & Automation — robot track with ballscrew or linear motor option

Thomson linear ballscrew-driven axes exceed 10-meter strokes

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Long-stroke applications with ballscrew-driven axes must address the challenge with more supports, appropriate diameter, and speed limits …

On longer axes, the main problem is whip—

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Long-stroke applications with screw variations … … just another option:

There are other iterations of screws in seventh-axis setups—

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Consider this option — using linear

actuators driven by servomotors instead

of hydraulics for vertical platform lifts.

One manufacturer decided it was the

only option.

Long-stroke vertical arrangements are also seeing alternative designs

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Motor-driven actuators on the lifts ensured a clean environment for the composite aircraft-hull manufacture.

Electric actuators may come to displace hydraulics for aerospace

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Pneumatic robot transfer units (RTUs) — low-cost solution for A and B

Not to say that fluid power is completely out …

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Accurate though expensive • More common is average-sized gantry setups

Linear motors … always an option

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Eight meters long … reproducible accuracy of ±0.01 mm

Linear motors … here, for a specialty application

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• Higher accuracy; more controllability

Rack-and-pinion sets excel on seventh-axis designs (RTUs)

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Stroke — 30 meters with repeatability to ±0.2 mm!

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• Standard for the longest setups • Length exceeds 50 feet

Rack-and-pinion sets — for the longest RTUs

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• Racks assemble together • Rack-pinion sets maintain accuracy

More rack-and-pinion sets (though note difference in guides + bearings that keep tracks aligned and supported)

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Quick note on software considerations — Programming

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Another quick note on software considerations — Calibration

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Now we’ll hear from Jean-Paul Beyak, regional manager for our sponsor on this topic.

Beyak will explain some of Nexen’s product offerings, including:

• A zero-backlash roller-pinion system in linear-rack and rotary-gear forms • A high-speed PRD Precision Ring Drive indexer

• A compact HG Harmonic Gearhead

Jean-Paul Beyak Regional Manager, Midwest/Eastern USA & Canada

Director of Sales, Latin America Nexen Group Inc.

Precision Motion Control Solutions for Gantry and Robot Positioning

Systems

Jean-Paul Beyak Eng. BIE, MBA Regional Manager

jbeyak@nexengroup.com

Gantry and Robot Positioning Systems

Gantry and Robot Positioning/Transfer Systems require components that provide some or all of the following attributes: high speed, positional accuracy, low backlash, low maintenance, long life and safety. Nexen offers numerous innovative Precision Motion Control products that provide these benefits and integrate well into these types of systems.

Precision Motion Control Products

RPS Roller Pinion System

The Precision Roller Pinion System converts rotary motion to linear motion.

Its revolutionary design makes it an excellent choice for applications that require a linear drive system.

Linear Drive Technologies

•  RPS Roller Pinion System •  Linear Motors •  Ball Screws •  Rack and Pinion •  Lead Screws •  Chain Drives •  Belt Drives

Roller Pinion System (RPS) •  High Positional Accuracy (up to 30 µm) •  Unlimited Travel Distances (modular) •  Extremely High Speeds (up to 11 m/s) •  Near Zero Backlash (≤3.2 µm) •  Low Maintenance/No Maintenance •  Long Life (60,000,000 pinion revs) •  Efficient (>99%) •  Quiet (≤75 db) •  No Magnetic Field

RPS Pinion Bearing & Roller

Typical Applications

Robot Transfer Unit-RTU

Flow Waterjet and RPS

Theabilitythatitprovidesforournewmodularwaterjetsystem(anindustryfirst)tobeexpandedbycustomersastheirbusinessneedschange,hassingle-handedlywonusthreeorderstotalingoveronemilliondollars.Besidesthesethreeorders,otherpost-salesinterviewswerequicktoiden5fytheNexenRPSsystemasTHEKEYDRIVERoftheirdecisionto"goFlow".OngoingaccuracytestshaveconBnuedtobefantasBcandthesemachinesareturningoutthemostaccuratewaterjetpartstheworldhaseverseen.WeconBnuetobeimpressed,asweincreasinglyseethebenefitsofahigh-precision,backlashfree,highlyefficient,modularmoBonsystemisabletodo.

TIMFABIAN

Manager,GlobalProductMarkeBng

FlowWaterjetAmericas

Rotary RPS Systems •  Accurate Positioning •  Near Zero Backlash •  High Speed •  Arc Segments, Rings &

Fully Programmable Ring Drives

HG Harmonic Gearhead Industry’s Shortest and Most Compact Automation Gearhead

•  Compact-Replace Larger,High-Ratio Planetary Gearheads

•  Zero Backlash, Extremely Accurate Save up to 70% or more in Gearhead

length

Aerospace Gantry Riveting System

Thank you

www.nexengroup.com

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How to Build Robotic Positioning Systems for Long-Stroke Applications

Questions?

Lisa Eitel

Design World @DW_LisaEitel

Jean-Paul Beyak

Nexen Group Inc. @NexenGroup

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