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Automation for the Future
Moving forwards:
Emerging simulation techniques could help machine builders design complex automation systems more efficiently.
Bob Lloyd, simulation manager at specialist machine builder Amtri, told delegates at Eureka’s ‘Automation for the Future’ Design Day that projects like PhysVis could help to design complex products in parallel with the production process and production machinery.
Around 60 delegates attended the event at the Kaetsu Centre in Cambridge last month. After a morning of technical presentations, the afternoon split into four hands-on workshops, led by event sponsors Copley Motion, Delta Tau, Heidenhain and Oriental Motor.
During the event, Lloyd showed how a flag could be simulated to drape over a spherical surface, and said that smart composite parts were a potential beneficiary of the technique.
“They are becoming more widespread – but their production will have to be automated at some point in the future,” he said.
Tim Court, operations director at design agency PDD, spoke about running a successful automation project.
“There are countless ways to manage an automation project,” he said. “There is probably no absolute management method, but in this project we benefited from a detailed understanding of the assembled product.”
PDD chose Modular Automation to build a machine to automate production of a disposable syringe, used by client Belron to inject resin into a damaged windscreen.
One challenge faced by the team was to develop a way of feeding and placing two small ‘O’ rings. It ended up ‘floating’ the rings using compressed air to prevent them twisting as they passed down the linear track.
“If you understand your components and assembly you can reduce the risk of redesign, re-work and escalating costs,” said Court.
The workshops took delegates through several aspects of new technology: encoders; linear motion; motion control; and stepper motors.
Heidenhain’s Stuart Jenkins explained the importance of encoder signal output.
“The quality of the sine wave is crucial,” he said. “The more data you have, the tighter you can control speed and position.”
Its demonstration showed how a current ripple caused by a poor signal led to noise in the drive, as it had to keep re-adjusting itself.
Adam Brierley of Copley Motion covered the importance of ‘object orientation’ to linear motion. “It is not commonly associated with motion control, but the concept is simple: to apply trusted, reusable solutions to problems.”
Event feedback
“A very well organised, managed and attended event, resulting in some interesting leads”
Steve Hickman,
Copley Motion Systems
“Incredibly useful and applicable”
Steven Puckey, TWI
“The best paper was from Tim Court: funny, informative and concise”
Ben Harker,
Harker Systems
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He cited a gearbox test rig for a truck manufacturer. It had to be rugged, deliver accurate force feedback and be powerful, yet sensitive to jams. Its linear motor actuator was used over a belt-driven stage and ballscrew.
Delta Tau’s Andy Joslin compared different control architectures: distributed control, centralised control and distributed power and pointed to an “elegant” example of distributed power/centralised control in an inspection machine for Airbus wings.
Oriental Motor said that its alpha step motor, a closed loop stepper system, can eliminate mis-steps and avoid loss of synchronisation to offer “a competitive alternative to servos”. It demonstrated their ‘Smoothdrive’ (low vibration) capability.
To see the programme, click here.
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