5 keys to “mechatronics made easy”

 

5 keys to “mechatronics made easy”

By Mark Huebner, Market Development Manager, PBC Linear & 3DP Unlimited
“使机械电子变得容易”的五个关键点

Bringing together mechanical, electrical, programming, and control engineering is not effortless. But integrating technology advances, and focusing on these five areas, can simplify the process and ensure that mechatronics is made easy.

把机械工程、电气工程、编程工程和控制工程结合起来并不容易。但集成技术的进步,紧扣这五个方面,可以简化这个过程,确保使机械电子工程变得容易。

Today’s fast paced product development cycles and rapid advances in technology have pushed the need for greater cross-disciplined engineering. Where once the mechanical engineer could solely concentrate on the hardware, the electrical engineer on the wiring and circuit boards, and the control engineer on the software and algorithmic programming, the field of Mechatronics brings these areas together creating a focus for a complete motion solution. Advances in, and the integration of all three fields together, streamline mechatronics design.

当今快速的产品研发周期和迅速的技术进步推动了更多的跨专业的工程需求。过去机械工程师仅仅专注于硬件,电气工程师仅仅专注于布线和电路板,控制工程师仅仅专注于软件和算法编程,而机械电子领域把这些领域结合起来为完整的运动方案建立了一个重点。所有这三个领域的进步以及集成,简化了机械电子的设计。


crt ugt rail end

ivt vs profile rail

Newer parallel rails feature pre-engineered alignment, which reduces the overall cost and improves movement precision. Newer linear guide systems integrate support structures into the linear rail itself. The shift from individual component design to engineered one piece designs or integrated sub-assemblies reduces the number of components, which also cuts cost and labor.

新型的平行导轨设有工程预制的校准,从而降低了整体成本,提高了运动精度。新型直线导轨系统把支撑结构集成到了线性导轨本身。从单个部件设计到工程整体设计或集成子系统的这种转变减少了部件的数量,从而也减少了成本和劳动力。

It is this simplification that is driving advances in robotics and multi-axis Cartesian systems for industrial uses and manufacturing, automation for consumer markets in kiosks and delivery systems, along with the rapid acceptance of 3D printers into mainstream culture.

随着人们快速的接受3D打印进入主流文化,正是这种简化推动了机器人技术进步和多轴笛卡尔系统的工业应用与生产,推动了服务停或交付系统消费市场的自动化。

Here are five key factors that, when put together, result in easier mechatronics design.

这里有五个关键因素,把它们结合到一起,使机械电子的设计更容易。

1. Integrated linear guides and structure

1.集成的线性导轨与结构

In machine design, bearing and linear guide assemblies have been around so long, that often the mechanics of a motion system is treated as an afterthought. Advances in materials, design, features, and manufacturing methods, however, make it worthwhile to consider new options

在机器的设计过程中,轴承和直线导轨部件已经使用了很久,运动系统的技术经常被视为是事后的想法。然而在材料、设计、功能和制造方法的进展,使它值得认为是新的选择。

For example, pre-engineered alignment built into parallel rails during the manufacturing process means less cost because of fewer components, greater precision, and fewer variables in play over the length of a rail. Such parallel rails also improve installation because multiple fasteners and manual alignment are eliminated.

例如,生产过程中,把预制校准内置于平行导轨中,由于部件较少,精度较好,以及作用在导轨长度上的变量较少,这就意味着成本更低。因为省略了多个紧固件和手动校准,这种平行导轨也提高了机器的安装进度。

In the past it was almost a guarantee that whatever linear guide system an engineer selected, they would also have to consider mounting plates, support rails, or other structures for the needed rigidity. Newer components integrate support structures into the linear rail itself. This shift from individual component design to engineered one-piece designs or integrated sub-assemblies reduces the number of components, while also cutting cost and labor.

在过去,无论工程师选择什么样的直线导轨系统,为了所需刚度,他们还必须考虑安装板,支撑导轨或其他结构,这几乎是一个保障。新型部件把支撑结构集成到线性导轨本身。从单个部件设计到工程整体设计或集成子系统的这种转变减少了部件的数量,同时也降低了成本和劳动力。

2. Power Transmission Components

2.传动部件

Selecting the right drive mechanism or power transmission components is also a factor. The selection process, which involves balancing the right speed, torque, and precision performance with the motor and electronics, begins with understanding what results each type of drive can produce.

选择合适的驱动机构或动力传动部件也是一个要素。选择过程涉及平衡电动机和电子设备恰当的速度,力矩,以及精度性能,在选择之前首先要了解各种类型的驱动会产生什么效果。

motion control components comparison chart

Selecting drive mechanisms or power transmission components involves balancing the right speed, torque, and precision performance with the motor and electronics. This chart gives a rough idea of the capabilities of various motion control components.

选择驱动装置或动力传动部件涉及平衡电动机和电子设备恰当的速度,力矩,以及精度性能。这个图表给出了各种运动控制部件大致的功能。

Much like the transmission in a car operating in fourth gear, belt drives suit applications where top speeds over extended length strokes are required. On the opposite end of the performance spectrum are ball and lead screws that are more like a car with a powerful responsive first and second gear. They offer good torque while excelling at quick starts, stops, and change of direction. The chart shows the differences between the speed of belts and the torque of screws.

就像一辆四档运行的汽车的传动一样,皮带传动适用于高速,对于延长冲程是必需的。在性能范围的另一端是滚珠丝杠,像一辆有强大响应第一档和第二档的汽车。它们在快速启动,停止和转变方向同时能提供良好的扭矩。图表显示了皮带的速度和丝杠扭矩之间的差异。

lead screw designw  

Lead screw design can deliver high repeatability in dynamic applications, but attention should be paid to the motor and screw alignment. In some cases, you can eliminate a coupler and affix the screw directly to the motor, eliminating components, increasing rigidity and precision, while cutting cost.

丝杠设计可在动力学应用中提供高的可重复性,但要注意电机和丝杠的校准。在某些情况下,可以消除耦合,把丝杠直接固定在电机上,这样降低了成本的同时,省去了部件,也增加了刚度和精度。

Similar to linear rail advances, pre-engineered alignment is another area where lead screw design has advanced to deliver greater repeatability in dynamic applications. When using a coupler, pay attention to the motor and screw alignment to eliminate “wobbling” that reduces precision and life. In some cases, the coupler can be eliminated completely and the screw affixed directly to the motor, merging directly the mechanical and electrical, eliminating components, increasing rigidity and precision, while cutting cost.

类似于线性导轨发展,预制校准是丝杠设计的另一个领域,丝杠设计已经发展到在动力学应用领域中实现更高的可重复性。当使用联轴器时,注意电机和丝杠的校准,以消除“摆动”,这种摆动可降低设备精度和寿命。在某些情况下, 联轴器可被完全消除,丝杠直接固定到电机上,机械和电子直接耦合, 这样降低了成本的同时,消除了部件,增加了刚度和精度。

torque of screws chart

The chart shows the differences between the speed of belts and the torque of screws

图表显示了皮带的速度和丝杠扭矩之间的差异


3. Electronics and Wiring

3.电子设备和接线

Conventional configurations for the electronics in motion control applications include complicated wiring arrangements, along with the cabinets and mounting hardware to assemble and house all of the components. The result is often a system that is not optimized along with being difficult to adjust and maintain.

在运动控制应用的电子设备的常规配置包括复杂的线路布置,连同机柜和安装硬件的组装以及将内部所有部件装进柜子里。结果往往是未优化的接线系统难以调整与维护。

wiring

wiring 2

Smart motors simplify and eliminate a lot of wiring.

Emerging technologies offer system advantages by placing the driver, controller, and amplifier directly onto a “smart” motor. Not only is the space needed to house the additional components eliminated, but overall component count is trimmed and the number of connectors and wiring are simplified, reducing potential for error while saving cost and labor.

新兴技术通过将驱动器,控制器,以及放大器直接安装到“智能”发动机上,为系统提供了优势。不仅节省了安装额外部件的所需空间, 减少了整体部件数,也简化了连接器件的数量和线路, 节省成本和劳动力的同时减少了可能出现的错误。

4. Designed for Manufacturing (DFM)

4.制造设计(DFM)

• Bracketization

支架化

Along with easier rail assembly of integrated designs, experience and emerging technologies such as 3D printing increase your ability to create prototype mechatronic and robotic assemblies to DFM standards. For example, custom connector brackets for motion systems have often been costly and time consuming to process through a tool room or fabrication shop. Today, 3D printing lets you create a CAD model, send it to the 3D printer, and have a useable model part in a fraction of the time and at a fraction of the cost.

随着导轨组件的集成设计以及经验越来越容易,新兴技术如3D打印提高了根据DFM标准创建机械电子模型和机器人装配的能力。例如,运动系统的自定义连接支架经过一个工具间或制造间往往是成本高昂的且非常耗费时间的。如今,3D打印可以使你创建一个CAD模型,将其发送到3 D打印机,在很短的时间内和需要一小部分成本就可以打印出一个可用的部件模型。


custom connector bracket

3D printers can help deliver custom connector brackets for motion systems at a fraction of the time and cost of sending designs out for tooling.

• Connectorization

接头连接

Another area of DFM that has already been covered is the use of smart motors that put the electronics directly on the motor, making assembly easier. In addition to this, newer technologies that integrate connectors, cabling, and cable management into one package, simplify assembly and eliminate the need for traditional, heavy, plastic chain type cable carriers.

DFM包括的另一个领域是智能电动机的使用,把电子设备直接连接在电机上,简化装配。此外, 集成接头、布线,、模组化设计到一起的新技术,简化了装配以及省去了对传统的,重型的,塑料链类型电缆载体的需求。

connectors

Newer technologies integrate connectors, cabling, and cable management into one package, which eliminates the need for traditional, heavy, plastic chain type cable carriers. Photos courtesy of igus and Cicoil

5. Long Term Maintainability

5.长期的可维护性

Newer technologies and advances in design not only affect the up-front manufacturability, but can also influence the ongoing maintainability of a system. For example, moving the controller and the drive onboard the motor simplifies any troubleshooting that may be needed. Access to the motor and electronics is uncluttered and straightforward. Additionally, many systems can now be networked allowing for access from virtually any location to perform remote diagnostics.

新技术和先进的设计不仅影响前期工艺性,也可以影响系统的可持续维护性。例如,通过移动控制器和发动机板上的驱动器简化一些可能需要的故障诊断。集成后的发动机和电子设备的使用简洁明了。此外,许多系统现在几乎允许网络可以从任何位置访问来执行远程诊断。

motion controls

Moving the controller and the drive onboard the motor simplifies any troubleshooting that may be needed. Access to the motor and electronics is uncluttered and straight forward.



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