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Engineer’s Guide to
Advanced Motion
and Mechatronics

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TABLE OF CONTENTS

Are servo and stepper functionalities merging? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Six degrees of freedom give motion control a new perspective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How to be gentle and accurate with linear motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mechatronic linear transport system offers revolutionary possibilities to OEMs . . . . . . . . . . . . . . . . . . 13

How to transform rotary motion into linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Packfeeder pairs XTS with delta robots to sort bottles

with automatic format changeovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

New innovations in linear motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Mechatronic material handling for complex automotive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

AD INDEX

Beckhoff Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Are servo and stepper

functionalities merging?
How many differences still remain between these motors?

By Tom Stevic, contributing editor

W
ith the advancement of motor control and construction, the operational difference
between servo motors and stepper motors has become minimal. Theoretically, a servo
motor can move to an infinitely small fraction of a rotational degree, whereas a stepper
motor is limited by the number of individual stator windings that create each step. Practically, these
limitations do not exist.

In general, a servo motor is just a part of a servo system. The system consists of a motor, a drive and a
feedback device.

The drive, or amplifier, takes the incoming ac power and rectifies it to supply a dc voltage to the drive
circuitry. The drive can be a simple rectifier with power relays controlled by external control circuitry.
This type of drive relies on the external control device to perform all of the motor-control functions
such as speed, acceleration, PID tuning and so forth. Intelligent drives are also available from most
manufacturers that allow motion profiles to be stored, fault conditions to be detected and auto-tuning
of the PID loop. For these intelligent drives, a simple digital interface, such as EtherNet/IP, may be all
that is required from the central control device.

The feedback device may be an absolute encoder or resolver. An encoder outputs a pattern of
electrical signals that represent the servo motor’s position. In the encoder housing, various electronic

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components are combined to read an angular feedback to the control system. If the load is
position based typically on slots in a metal disk constant, such as with an x-y table or conveyor
or masked areas of a glass or plastic disk. A lane diverters, as long as the motor is sized
resolver is a rotary transformer that changes correctly, a stepper motor can operate in open-
the measurement of current through two stator loop mode. If the load is dynamic and correct
windings. A resolver’s only moving part is the positioning is essential, a feedback device can
rotor. This makes a resolver more rugged than be added to the motor shaft.
an encoder. In operation, the control device,
either an intelligent drive or the primary control As with servo drives, stepper drives can be
device, continually compares the commanded simple or complex. Stepper drives are typically
position with the measured position and adjusts powered with 24 Vdc, but other voltages are
the motor current or voltage accordingly. available. Stepper systems do not need to be

“The motor must be properly

paired with the drive.”

A servo motor may be designed to be an ac tuned the way that servo systems do. Using
or dc voltage style motor. The motor must be an intelligent drive will reduce the control
properly paired with the drive. The drive then system complexity. Intelligent drives are
supplies the correct type of voltage and current. also available from most manufacturers that
The ac style motors are often preferred in allow motion profiles to be stored and fault
constant speed applications. They require less conditions to be detected.
maintenance because they have no brushes to
wear out and can reach much higher rpm than Stepper motors produce high torque at low speed;
the dc style. The dc motors are often preferred however, if the commanded speed is too low, the
in variable-speed applications and require a motor may exhibit excessive vibrations. A natural
simpler control system. resonance occurs around 200 Hz. Usually, the
starting speed is much higher than 200 Hz, so
Stepper motors also require some type resonance should not be a problem. Vibration at
of drive to control motion. As with servo low or no load is also an issue with stepper motors.
systems, stepper-system drives can be simple Careful selection of the motor is essential to avoid
pulse generators up to entirely independent vibration. As the motors increase in speed, the
intelligent drives. Many stepper systems output torque decreases. At speeds above 1000
run in open-loop mode. There is no direct rpm, stepper motors begin to lose their performance.

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Servo systems can cost up to three times the engineer can’t answer a question, ask for a
price of a comparable stepper system. If the contact at the manufacturer’s corporate level.
system load remains relatively constant and the You might be advised to purchase the drive
operational speed falls within the range supported unit, the motor and the feedback device from
by a stepper system, it is worth evaluating. the same manufacturer. A person can surely
Knowing the mechanical characteristics the save some money by using different parts
system will be operating under is one of the most from different manufacturers and by building
important factors in developing a good design. your own cables. However, in the event you
If you are just beginning to design motion need to have a representative from one of
systems, make use of the manufacturer’s the manufacturers come in to assist in fixing
technical support. Local support is usually a problem, the trouble will always be with the
the best place to start. If the local application equipment from the other manufacturer.

Advanced Motion and Mechatronics 5

 : Agile machines
with adaptive automation
Flying 2D product transport with up to 6 degrees of freedom

Levitating 6D
planar movers motion

Scalable Velocities
kg payload up to 2 m/s

Individual Free system

product transport layout

www.beckhoff.com/xplanar
XPlanar enables new dimensions of freedom in product and material handling: Levitating planar movers
fly over flexibly arranged planar tiles accommodating nearly any track layout and path planning.
Individual 2D transport at up to 2 m/s
Processing with up to 6 degrees of freedom
Transport and processing in one system
Wear-free, hygienic and easy to clean
Free arrangement of planar tiles enabling totally customized machine and process layouts
Multi-mover control enables parallel and individual product handling
Fully integrated into the powerful and standardized PC-based Beckhoff control system
(TwinCAT, PLC IEC 61131, Motion, Measurement, Machine Learning, Vision, Communication, HMI)
For use across all industries: assembly, packaging, food/bev, pharma, laboratory, entertainment, …
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Six degrees of freedom

give motion control a
new perspective
by Jeff Johnson, Mechatronics Product Manager, Beckhoff Automation

C
ontrol Design talked with Jeff Johnson, mechatronics product manager at Beckhoff Automation,
about its new product called the XPlanar. It uses flying motion technology and the principles
of magnetic levitation to enhance flexibility and enable revolutionary, non-linear production
concepts. This is also Beckhoff’s first product to run on a gigabit network. Along with the use of high-
speed multicore processors, this power can run everything in one system. With almost infinite possibilities
to connect tiles and movers, it can accommodate many different applications with few limitations.

Q: Tell our readers about the XPlanar. This uses Beckhoff’s flying motion technology. What exactly does
that mean?

A: XPlanar is based on the principles of magnetic levitation. Think back to your first physics labs where
you played with magnets. You had two magnets with the red and green ends. When you put the red ends
together, they repelled, and when you put the green and red ends together, they would attract. XPlanar is
based upon similar principles. With trains, these magnetic levitation technologies have been around for a
long time: the train has two sets of magnets, one for lifting or floating the train and another one for pushing
it. So with the XPlanar, we add a second dimension to that concept as we don’t have any track to follow;
the movers move freely in the XY plane. There are motor tiles underneath that generate a varying magnetic
field, and that allows us to levitate the movers and then move in the XY plane in 6 degrees of freedom. The
tiles have a flat array of coils, so thus the XPlanar name comes from the planar array of coils, which generate
the magnetic fields. That gives us the motion control to propel and lift the movers.

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MAGNETIC LEVITATION
Beckhoff’s XPlanar uses the principles of magnetic levitation to power its flying motion technology.

Q: Let’s talk a little bit about some of what makes machine. So as we’re talking to customers, we
this technology unique. You mentioned the 6 can actually redesign the machine or the process
degrees of freedom. Why don’t you talk about what around those 6 degrees. We can do a wobbling or
that is, and how this differs from traditional designs? swirling motion for mixing product, but it also allows
us complete freedom to skip past optional stations
A: We arranged the coils and magnets to give us to get production down to a lot size of one.
the 6 degrees of motion, so we can move in the X
and Y direction up to 2 meters per second. We can Q: Our readers would be curious about overall
float or levitate above the surface of the tile by 0 to performance and compatibility. How does
5 millimeters. You can also rotate the mover around EtherCAT and PC-based technology factor into
the center of the mover: it can rotate plus or minus 5 XPlanar performance, and how does it fit in an
degrees while in motion, or in a stationary spot, we overall machine control platform?
could actually spin 360 degrees. We can also tilt in
XY. These capabilities give us multiple dimensions A: XPlanar uses our TwinCAT automation software,
for handling many different processes on the running on our industrial or embedded PCs, and

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then TwinCAT communicates to the tiles over hygienic and clean-room-type applications because
EtherCAT G. This is the first product that we’ve there is no mechanical wear on any of the parts.
released using EtherCAT G, which is a gigabit The tiles themselves are 240 millimeters square –
network versus the standard 100-megabit network. roughly, a little bit over 10-inch squares. But they
But you can also mix and match the fully compatible can be arranged in any format. So you can make a
EtherCAT networks, so we can use our traditional rectangle, you could do lanes with offshoots, you
I/O and servomotors alongside the XPlanar. We could do L-shapes, you can do all those. It really
have one programming environment and one accommodates however you want to connect the
industrial I/O network, meaning there are no black tiles together. Currently we can do up to 100 tiles
boxes. So all of your machine I/Os, safety, and with 20 movers, or 60 tiles with up to 40 movers.
other servo or stepper axes can run on standard We are working on some new features that we
EtherCAT networks alongside the XPlanar. We will release by the end of the year that allow us to
provide a software framework, so customers can handle basically a system of infinite size. We can
quickly get their system up and running, and we have systems that work together. We currently have
also take advantage of the multicore processors. 4 mover sizes, which are all squares ranging from
XPlanar does require more processing power 115-millimeter up to 235-millimeter. At the high end,
than some of our traditional products. But the the 235-milimeter mover carries a 4.2-kilogram
multicore processors in our IPCs allow us to isolate payload. At the low end, the 115-millimeter mover
cores specifically for the XPlanar, which runs at carries a 0.4-kilogram payload. We also have a
250-microsecond updates. So between the high stainless steel mover that will carry up to 1 kilogram.
speed I/O network and the high speed multicore And we’re working on other mover designs. But you
processors, it allows us to do everything in one can take and link movers mechanically together, or
system versus requiring multiple systems talking even via software to carry heavier payloads. We’re
asynchronously to each other. continuing to add many new features. We’ve been
shipping starter kits for a little bit over two years
Q: This product obviously has a lot of applications, now, and we officially released the products in the
but we’re also curious about the limitations. Does U.S. at the end of last year. And we’re seeing lots of
XPlanar have limits in regards to track layout or applications across all industries, including assembly,
the application or industry? packaging, lab automation, pharma, food, beverage,
intralogistics and entertainment. The whole feature
A: I look at it as the only real limitation on the system set fits well in all of those different industries.
is our imaginations. XPlanar offers a unique way
to design a new machine around all the benefits To listen to the conversation with Beckhoff’s Jeff Johnson,

of flying motion. Since we’re levitating tiles, there find the Control Intelligence podcast at controldesign.com or

are no moving parts to wear or break down, so it’s download via Apple Podcasts and GooglePlay.

typically maintenance-free. It’s easily adaptable to

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How to be gentle and

accurate with linear motion
Displacement in a given direction, at a velocity and acceleration
and after a period of time must all come to an end

By Dave Perkon, technical editor

W
hen discussing the physics of linear motion, rotary and oscillating motion often surface, as well.
Linear motion is more than just displacement; it has a start and a stop point, and compressed
air and rotary motion often drive the physics of the move and the resulting cycle time.

Fortunately, calculus is not needed to calculate linear motion as it is simplified by assuming a constant
acceleration. The equations for linear motion and the related variables including constant acceleration,
displacement, velocity and time are easily accessible.

Linear-motion automation components, such as pneumatic actuators and motor-driven actuators, all
operate within the defined physics equations. All motion starts and stops, but some are easy to create
multiples of such. Most provide the ability to adjust positions of the start and stop points, but accuracy
and repeatability vary, and some are programmable.

Linear motion, moving the part or tooling, is initiated and stopped in many ways. Compressed air and
rotary motion are two of the most common methods used on automated equipment, and each method
controls the motion in different ways.

The compressed air controlled through air-preparation units, solenoids, tubes and flow controls
actuates cylinders and pneumatic actuators. This pneumatic actuated linear motion usually only has
two positions, such as advanced/ returned, extended/ retracted, raised/ lowered or open/ closed.

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The advanced and returned displacement—the advanced or retracted position of an end-of-

start and stop position—can be adjusted, and travel stop by loosening a nut, turning a bolt and
the speed of the move can retightening the nut may require several tries to
be varied. get within a few thousandths of an inch of the
desired position.
Simple pneumatic linear motion literally runs
into hard stops at each end of travel; the Better control of the linear motion speed,
travel is often fixed. These hard stops can be acceleration and starting and stopping positions
built internally to the cylinder or actuator or is possible by adding rotary motion to an
mounted externally either to the device itself or appropriate linear motion actuator instead of
surrounding support structure. In any case, it’s compressed air. Improved precision and gentler
good practice to decelerate and even stop the operation can be had using rotary motion via
cylinder piston before impacting the end cap. a variable-frequency dive (VFD) and motor,
The stops are more like cushions as metal- stepper motor and servo motor. And there are
to-metal stops are loud and abrupt. As the other differences.
speed of the motion increases, external shock
absorbers or soft-bump stops are often used to To start, these motor-driven linear actuators are
control the stopping of the actuator at the end not supposed to run into hard stops. That would
of travel. be a crash condition, and certainly not a gentle-
stop method. It may even damage the actuator
System air pressure, solenoid valve and hose or the carriage and bearings in the device. The
size, and the air volume through a flow control controlling drives and automation controllers are
all combine to determine pneumatic-actuator programmed to move the carriage between the
velocity and acceleration. These actuators often hard stops in this case, without contacting them.
accelerate the whole motion before hitting the
hard stop. Obviously, machine cycle time drives Another difference is that end-of-travel
the actuator speed requirements, but the cylinder switches on motor-driven linear actuators
speed should only be set as fast as needed. If are not meant to be actuated during normal
the cylinder extends and waits or the cycle time operation such as advanced and returned
is faster than needed, adjusting the flow control sensors are on pneumatic actuators. Activating
to reduce the speed can greatly soften the end-of-travel switches on a motor-driven
abrupt stops at the end of travel. actuator will usually cause the motor drive to
perform an immediate stop before the physical
The repeatability of the hard-stop positioning end of travel is reached.
is well under 0.01 inch, but adjusting it to an
accurate position can be difficult. Moving the

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In more precise applications, such as moving The linear motion is stopped differently in
between two or more programmable points, a pneumatic actuators and motor-driven actuators.
home switch is part of the precise and gentle Both have methods to ensure gentle stops.
stopping performance of these motor-driven Cushions and shocks used in pneumatic
linear actuators. Open-loop control, such as step applications quickly and smoothly stop the load.
and direction signals to a stepper motor drive or With motor-driven actuators, the controller and
closed-loop control such as encoder feedback related program provide smooth stopping at many
to the servo motor drive, allow programming locations, precisely. All linear motion eventually
of target positions that are then reached via comes to a stop.
a discrete signal, analog voltage or controller
instruction block.

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Mechatronic linear
transport system
offers revolutionary
possibilities to OEMs

M
achine builders and manufacturers across industries need to meet demands for greater
throughput while increasing functionality, such as track and trace, customization down
to lot size 1 and greater implementation of IIoT and Industry 4.0 concepts. Dynamic
motion control solutions, such as the eXtended Transport System (XTS) from Beckhoff Automation,
can help to achieve these goals by leveraging mechatronics and software-based changeovers.

The U.S. launch of XTS this year coincides with the 20th anniversary of Beckhoff USA. The XTS is truly
a milestone, but it is just the latest success in a long line of PC-based automation technologies backed
by an efficient and effective engineering team in the United States.

Jeff Johnson, mechatronics product manager for Beckhoff Automation, answers important questions
machine builders have about XTS and key differentiators for selecting linear transport systems.

Q: Beckhoff says XTS combines rotary and linear motion principles.

What exactly does that mean?

A: In general, it’s a linear motor that drives in a circle—that’s the combination. The benefits of both
motion types are possible without limiting either. The XTS comprises motor modules, guide rails
and movers. The track configuration is extremely flexible, enabling straight, open segments, as well
as circles, rectangles, S-curves and custom shapes. This minimizes space requirements and can

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reduce machine footprint 25-50% depending necessary for operation are integrated directly
on the application. The wireless movers glide into the XTS. The system does not need
along the track in groups or alone, and they additional drive electronics or amplifiers in
can be automatically monitored and adjusted separate electrical cabinets. Electromagnetic
independent of the others. coils in the motor modules generate propulsive
forces with magnetic plates inside the movers,
Some real-world examples include assembly, enabling speeds of 4 m/s and acceleration up
bag filling, inline package assembly, product to 100 m/s2. The movers contain a mechanically
stream sortation and synchronization, and robust encoder flag that continuously
automated inspection using machine vision communicates its position to the motor modules
systems. In this last case, the movers can with high precision. The movers absorb and
speed up between stations, pause and compensate for attractive forces on both sides
undergo manipulation beneath the cameras to provide highly dynamic motion control with
without halting other processes. extremely accurate positioning.

Q: Regarding the control system, where are the Unlike other linear transport systems, the XTS
drive, electronics and feedback devices? does not require cables to be daisy-chained
or run to each individual track segment.
A: As a true mechatronic system, the power Every motor module plugs directly into the
electronics, communication and mechanics next to share power and communication via

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EtherCAT industrial Ethernet. Options for +/- heat reductions. Two tracks can even work
22.5°, 45° and 180° modules combined with together simultaneously, when stacked on top
reduced cabling offer greater flexibility and of each other to carry the top and bottom of a
customization to achieve the desired track part or pinch together to open a bag under a
design with minimal footprint. filling station. Harnessing the communication
flexibility of EtherCAT, the mechatronic XTS can
The only additional requirements are a PC- also work in concert with other systems, even
based controller that serves as the EtherCAT those networked over other industrial Ethernet
master and TwinCAT 3 automation software for protocols and legacy fieldbuses.
the programming and runtime of the XTS.
Beckhoff offers numerous industrial PC (IPC)
Q: How do EtherCAT and PC-based control options that are well-suited to the XTS. The IPC
technology factor into XTS performance? performance level can be scaled to suit track
A: EtherCAT and PC-based control from length, complexity and the amount of other
Beckhoff are foundational to the success processes and systems that are in the overall
of XTS. EtherCAT provides real-time, machine control architecture. However, one of
deterministic communication that ensures the keys to unlocking the significant benefits of
movers transport parts or tooling to the correct XTS is in the software.
position at optimal speeds. This translates into
exceptional precision, energy efficiency and

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TwinCAT 3 offers a standard

framework with built-in
software libraries and
preprogrammed functions,
such as station-to-station and
load applications. Intuitive
programming via IEC 61131-
3 and computer-science
standards make it easy to get
started on a new system. The
software treats each mover as
a normal servo axis with built-
in collision and jerk avoidance,
automatic buffering and
greater track-and-trace
capabilities. While mechanical
components are typically
obstacles to rapid product
changeovers, software machine footprint reductions, The convergence of electrical
addresses this challenge XTS eliminates expensive and mechanical technology in
for XTS, enabling greater components, such as chain the XTS has yielded proven,
implementation of Industry 4.0 drives, actuators, rotary real-world advantages in
concepts, including lot indexing tables or multi-station the field. However, because
size 1 production. conveyors. In addition, the this system incorporates
XTS reduces maintenance expertise from multiple
Q: What specific mechanical requirements. The motor engineering disciplines,
design and control methods modules contain no moving machine-builder OEMs
make XTS better than parts and are therefore not should make sure that both
traditional approaches? susceptible to wear, unlike mechanical and electrical
previous options. The rollers engineers are involved from
A: XTS provides greater on the individual movers are the very beginning of the
flexibility, adaptability and equipped with a particularly design process to ensure the
throughput than traditional wear-resistant synthetic highest possible success of
methods, but, most running surface. The lifetime the application.
importantly, it does all this with of the rollers depends on
fewer components. Beyond the payload.

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How to transform rotary

motion into linear
Think about the process when selecting feed-screw devices

By Tom Stevic, contributing editor

I
n the world of machine controls, linear motion is the name given to the process of moving some
object in a straight line, usually with a programmed speed and to a defined position. If a precise
speed is not a requirement of the movement and the distance moved is between two constant
points along the linear axis, one of the most straightforward linear-motion devices is a simple
pneumatic cylinder.

Air, like any gas, is compressible. The pressure and flow of air into a pneumatic cylinder is controllable, but,
if the load is not constant, or if the operating temperature changes or other environmental factors are not
constant, the speed at which the cylinder reacts will change.

The travel distance of the pneumatic cylinder can be controlled with hard physical stops or the designed
length of the cylinder’s pushrod.

When precise speeds and positions are required, pneumatic cylinders may not be the best choice. A
better solution may be a device that includes a feed-screw component to produce the applied linear
force required for movement, one or more linear bearings to maintain the straight line motion and a
motor to drive the feed screw.

In addition to the mechanical components, the linear-motion control system may include control
electronics to process movement commands into motor-control commands and sensors to provide

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position feedback to the control system. If the A lead screw has a much higher coefficient of
application requires the motion to be firmly held friction than a ball screw. For lighter loads, cost
once the desired position is reached, a brake efficiency favors a lead-screw-type device. For
may be employed to prevent unwanted travel of heavier loads, ball screws should be considered.
the feed screw.
A linear-motion stage consists of a mounting
Feed-screw devices change the rotary motion base, a carriage or platform that holds the end
of a motor into the desired linear motion. Two effector, linear bearings (or bushings) and drive
general types of feed-screw devices exist, hardware—lead or ball screw, drive motor and
although a significant amount of variation motor controls.
in design differences among different
manufacturers also exists. A lead-screw style is, Manufacturers can assist in selecting the best type
in effect, a threaded rod with a nut that moves of bearing style for the linear stage. Manufacturers
parallel to the threaded rod axis as the threaded will tend to specify solutions that use the products
rod rotates. A ball screw is similar in operation; they sell, but their expertise can be utilized to
however, instead of the face of the screw and narrow the field of choices.
nut threads contacting each other, the ball
screw uses ball bearings that reduce friction.

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Given the acceleration/deceleration rates, top of the lead/ball screw. When the motion required
speed, weight, distance of movement, duty cycle is variable, a servo or stepper motor along with a
and desired life-span, manufacturers’ design motor-control system offers variable speed and
tools will help to determine the most efficient positioning capabilities.
designs. This includes selecting the correct
type of linear bearing which is fundamental to a For a motion stage with two fixed positions,
successful linear-stage application. feedback signals may be simple proximity
sensors. When the motion stage must move to
A drive motor and its controls are selected variable positions, a linear position transducer
to complete the design of the motion stage. or motor feedback is used to determine the
The motor power will be determined by the actual position.
weight and direction of the load, along with
the frictional drag of the bearings and screw Servo- and stepper-motor controllers often offer
mechanism and with the desired acceleration/ an output that reflects the rotational movement
deceleration rate. of the motor. When the rotational output signal
is multiplied by the pitch of the threaded rod, the
If the required motion is a fixed speed and assumed distance of movement for the linear-
distance, a general purpose gear motor with or motion stage can be calculated. However, this
without a variable-frequency drive may be used to calculation does not take into consideration
supply the rotational force to the threaded portion feed-screw wear and backlash.

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Packfeeder pairs XTS

with delta robots to sort
bottles with automatic
format changeovers
The intelligent eXtended Transport System handles efficient and highly
flexible bottle unscrambling in the most demanding packaging applications

By Aleix Vives, Packfeeder

H
eadquartered in Barcelona with a global presence for sales and service, Packfeeder has
developed a family of highly automated, robot-supported systems for unscrambling and
positioning bottle-shaped containers. Such machines are frequently used in the cosmetics,
pharmaceuticals, food, household cleaner and chemicals industries where products must be filled into
bottles. Since its founding in 2002 by Tomàs Mulet, Packfeeder has focused on innovative machine
concepts with significant added value for end users. A good example of this approach is the Spanish
company’s new bottle-sorting system, Pickfeeder, which was developed with help from Beckhoff,
according to Packfeeder CEO Ferran Martínez.

“Having innovation as a basic objective requires technology partners that share our vision, which is
one of the reasons why we are working with Beckhoff to master such a technological challenge,”
Martínez says.

The Pickfeeder machine series uses the eXtended Transport System (XTS) from Beckhoff to implement
a highly flexible machine concept that is ideal for the most demanding sorting jobs in packaging with
virtually no changeover effort (Figure 1). By leveraging the highly flexible XTS, the new Pickfeeder
family of machines can sort bottles of various materials and vastly different sizes and shapes without
mechanical modifications to the production line. The use of XTS in combination with delta robots
eliminates the need for specially shaped parts normally needed for each individual bottle in a standard
machine and enables the Pickfeeder’s automatic changeover functionality.

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Figure 1: The bottle unscramblers of the Pickfeeder family of machines combine the extended
Transport System (XTS) with up to four delta robots. Source: Packfeeder; Ivan Raga, photographer

INTEGRATED SYSTEMS DELIVER HIGH “Conventional systems perform both of these

PROCESS EFFICIENCY steps with robots. Using the delta robots only
Depending on the performance requirements, the to grab the prone bottles, on the other hand,
Pickfeeder bottle unscrambler can be configured allows us to use smaller and less expensive
with up to four delta robots for a broad spectrum robots while still leveraging their speed to the
of sorting applications (Figure 2). The combination fullest,” says Martinez. “XTS is the ideal solution
of four-axis delta robots with the mechatronic XTS for accepting the bottles from the robots
makes the bottle unscrambler extremely versatile and handing them over upright and perfectly
with optimized throughput, very gentle transfer to synchronized to the conveyor for transfer to the
the exit conveyor and automatic format switching. next machine. This prevents bottles from being
positioned incorrectly or tipping over. Another
The machine’s most important innovation, Martínez benefit is the ability of XTS to be mounted in
explains, is the separation of the infeed area a diagonal position, which makes the system
where bottles arrive lying down from the outfeed particularly compact and straightforward.”
area where bottles are placed upright on the exit
conveyor. This separation was made possible by
the XTS as a central machine component.

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On the Pickfeeder
machines, the flexible XTS
employs the GFX guide
rail from HepcoMotion
and a Packfeeder-
developed gripper. This
innovative combination
of technologies forms a
universal solution that can
handle a broad range of
containers irrespective of
their shape, material, color
and fragility. In addition,
any format changes within
the filling line are easily
handled via the Beckhoff
multi-touch control panel. Figure 2: With its individually controllable movers, the XTS delivers the
ability to switch to different bottle formats quickly and easily. Source:
According to Packfeeder, this Packfeeder; Ivan Raga, photographer
capability represents a huge
advantage over mechanical
unscrambling systems, which
require several components
to be switched out for each
format change.

A FOCUS ON
FLEXIBILITY
While increasing the operating
speed of each robot was
an important objective of
the Pickfeeder project,
the main focus was on the
ability to switch formats
automatically. “The daily Figure 3: Packfeeder CEO Ferran Martínez (right) and Beckhoff Spain Sales
Engineer Lluís Moreno stand in front of the unscrambler machine and its
operations of our partners and easy-to-use multi-touch control panel in portrait orientation. Source: Pack-
customers demand maximum feeder

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machine flexibility in order to

accommodate the endless
container variations in terms of
geometries, colors, materials,
textures and refinements,”
Martínez explains. “The
successful launch of the
Pickfeeder series has met the
expectations of our customers
with the additional benefit of
optimizing the relationship
between throughput rate and
floor space requirements.”

For example, the Pickfeeder

Single 100, the smallest model
with only a single robot,
achieves an output rate of more
than 120 bottles per minute.
That’s a great improvement
over conventional systems
that offer 70 to 80 bottles per
minute, says Martínez.

The high degree of flexibility

that XTS provides makes the
intelligent transport system
ideal for this application, as
well as many others across
industries, says Lluís Moreno,
sales engineer at Beckhoff
Spain (Figure 3). “Packfeeder
appreciated from the start the
Figure 4: The XTS accepts the prone bottles from the robots and transfers flexibility of the XTS and the
them to the output conveyor belt perfectly synchronized and in an upright
position. Source: Packfeeder; Ivan Raga photographer
benefits of PC-based control
for the entire machine,” he

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explains. “We foresaw the huge potential for “The Pickfeeder series was developed from the
Packfeeder’s bottle unscramblers in our first start with these requirements in mind, and the
meeting. It was our clear goal to close this gap intelligent XTS transport system made it possible
that existed in the packaging market with a for these concepts to become reality,” says
machine that could unscramble random bottle Ferran Martínez. “This successful combination
sizes and shapes with exceptional flexibility.” has expanded the capabilities of Packfeeder’s
bottle unscrambling technology considerably
Industrial requirements are changing so rapidly (Figure 4). We haven’t been able to achieve such
these days that no one can ignore concepts a major increase in a machine’s efficiency and
such as Industry 4.0, support of lot-size-one flexibility in a long time.”
or setup changeover times approaching zero.

Aleix Vives is sales manager at Packfeeder. Contact him at info@packfeeder.com.

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New innovations
in linear motion
Expert panel describes some of the technology that will guide the future

By Mike Bacidore, editor in chief

N
ew technology is popping up all over. Be sure you know what’s what before you begin
implementing linear motion. The technology can bring accuracy and precision to many
applications, but selecting components requires a bit of forethought. Our panel of industry
experts discusses some new innovations.

WHAT ARE SOME OF THE NEW TECHNOLOGY INNOVATIONS

IN LINEAR MOTION TODAY?

Matt Prellwitz, Beckhoff Automation: We’ve seen a move toward electrical

actuators, rather than traditional hydraulic or pneumatic systems. For example,
new linear actuators combine integrated electronics and an actuator in a single,
compact, IP54-rated package. This solution offers a lifting height of 10 mm and
a peak force of 800 N. In addition, 150 N of continuous force means the linear
actuator is an ideal replacement for frequently messy hydraulic solutions or
inaccurate pneumatic systems in machine applications with thermoforming or fluidic control, for example.
Linear actuator accelerations of 7 m/s2 and speeds of 100 mm/s enable exceptionally short control
cycles, with response times typical of traditional hydraulic systems.
Matt Prellwitz is motion product specialist at

Beckhoff Automation.

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Brian Zlotorzycki, initial design was released in 2002, but the industry
Heidenhain: There’s has not seriously considered this as an enabling
a focus toward technology until recently (Figure 1). We can see this
streamlining the by the increase in competitive technology within this
manufacturing process space and the increase in marketing surrounding
to make it quicker them. SuperTrak is a fully mature technology in
and less expensive to manufacture. On the an emerging product market with a lot of lessons
performance side, manufacturers are always learned over the years that have led to optimizations
looking for ways to increase the coil density of and various technical improvements.
the motor so that the performance can increase
without increasing the size. Looped LLMs, such as SuperTrak, take advantage
Brian Zlotorzycki is Etel motors product specialist at Heidenhain. of the dynamic movements of linear motors and
the tight control of servos to have a highly flexible
Derrick Stacey, and high-performance motion system.
B&R Industrial
Automation: There’s This system gives users efficient and cost-effective
linear transport batch-size-one production capabilities. It is a highly
technology or long stator configurable system that allows each product that
linear motors (LLMs). the SuperTrak carries to have a different recipe.
B&R has worked very closely with ATS Automation Derrick Stacey is solutions engineer

to form a partnership on the SuperTrak, the third at B&R Industrial Automation.

generation of ATS’s LLM technology. SuperTrak’s

Josh Teslow,
Curtiss-Wright: There’s
the use of high-tech
plastics and easily
replaceable guide
bushings/anti-rotation
parts. And sensor technology is more active.
It’s still rare, but more companies are looking at
integrating additional sensors in their machines to
gauge health. A simple example is a temperature
sensor in a bearing block. If the temperature
SUPERTRAK suddenly rises, it’s an easy way to predict a
Figure 1: SuperTrak’s initial design was released in 2002,
failure before it happens. This will become
but the industry has not seriously considered this as an
enabling technology until recently. more and more common as sensors continue to

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“New linear actuators combine integrated electronics

and an actuator in a single,
compact, IP54-rated package.”

commoditize and controllers have additional low- Broc Grell, Nexen

cost inputs. And of course, the idea of integrating Group: Everyone is
drive, motor and roller-screw actuator all into one going faster and more
body/unit. It’s still relatively new and definitely a accurate with every new
game-changer. machine. Linear-motion
Josh Teslow is applications engineer at Curtiss-Wright. product manufactures
are doing everything they can to keep up.
Clint Hayes, Bosch Broc Grell is applications engineer at Nexen Group.

Rexroth: Higher-
force actuators and Aaron Dietrich,
components such as the Tolomatic: Design
planetary roller screws engineers typically
allow for electrification reach for two electric
of applications traditionally driven by hydraulics. actuator solutions:
Linear motor technology is becoming more electromechanical
affordable and available, allowing linear-motion- actuators that are screw-driven, ball or roller,
system engineers to achieve the speeds of belt- but are limited to a medium level of speed
driven actuators with precision and repeatability performance due to critical speed limitations; and
that rival the capabilities of ball-screw-driven tubular linear motors that can achieve speeds
actuators. There’s the integration of linear beyond pneumatic but tend to be very expensive
positional feedback into the linear guide rail due to their reliance on rare-earth magnets and
system with either incremental or absolute complexity. New technologies in belt-driven, rod-
feedback. And onboard sensor diagnostics style electromechanical actuators can meet the
within the linear bearings provide feedback on speeds of linear motors but at a lower cost. This
thermal properties, shock and acceleration. new technology helps to provide a more cost-
Clint Hayes is product sales manager, linear motion technology effective design vs. pneumatic cylinders but can
at Bosch Rexroth. achieve higher speeds, has much higher efficiency
and has the flexibility of position control.
Aaron Dietrich is director of marketing at Tolomatic.

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Jay Johnson, Sick: made innovative strides in magnetic working

Within the past few principles for feedback devices, especially
years, there has been in magnetostriction. This technology offers
great progress made very good precision at an excellent price-
in the hydraulically performance ratio. Traditional feedback
driven motion industry, signals such as quadrature, SSI, or HIPERFACE
especially with mobile machinery. Precise aren’t typically used in these applications
closed loop motion control of hydraulic because most mobile machine ECU controllers
cylinders helps to reduce the wear and tear generally use CAN or analog. Therefore,
on off-road equipment, automates the task of expect these sensors to operate on the J1939
making accurate repetitive movements, and CAN network or PWM.
provides safer operations. In this area Sick has Jay Johnson is national product manager at Sick.

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Mechatronic material
handling for complex
automotive assembly
Eclipse Automation deploys Beckhoff Automation’s eXtended Transport System to
deliver micron-level accuracy for multiple automotive part assemblies on one machine.

By Jeanne Schweder, Contributing Writer

L
ike a well-organized soccer team executing a precisely timed play on the field, linear transport
systems deliver the coordinated motion manufacturers need for complex assembly tasks. A good
example of this can be seen in the redesign of an automotive transmission pump assembly system
performed by system integrator Eclipse Automation for one of its clients—a tier-one automotive supplier.

By deploying the eXtended Transport System (XTS) from Beckhoff Automation, along with PC-based
control and high-speed EtherCAT industrial Ethernet communications, Eclipse was able to design
a new assembly system in a compact footprint to make multiple automotive parts on one high-
throughput machine with micron-level accuracy. With this new system, product changeover times
plunged from one hour to one minute.

The base system features four separate cells with more than 50 stations for pressing, soldering,
screwdriving, flatness checks with LVDTs (linear variable differential transformers), dispensing, plasma
treatment, leak testing, inspection, and other processes. Some of these stations also require precise
synchronization with robotics. With this setup, the new system can process two different pumps at the
same time.

XTS plays a crucial role in the system. The adaptive mechatronics of XTS allow the automotive
supplier to produce parts with different pitches without time-consuming changeovers or separate
tooling at each station.

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ELECTROMAGNETIC PROPULSION The mechatronic XTS has built-in EtherCAT

Eclipse constantly researches leading-edge communication and therefore does not require
solutions to help customers stay ahead of separate I/O hardware for system communication.
its competitors.
SHRINKING THE FOOTPRINT
“We test all kinds of new technologies, including This new XTS-enabled transmission pump
artificial intelligence, remote training, virtual assembly system is the second version Eclipse
reality for maintenance systems, and any built for this supplier. The customer had
components that add precision and flexibility,” requested the first system to replace several
says Jeff Werner, general manager for Eclipse, legacy machines that manufactured just one
headquartered in Cambridge, Ontario, Canada. product type.
“One technology that has proven particularly
important to us is linear transport systems.” Though the new system replaced multiple
older machines, the new machine could not
Combining the benefits of rotary and linear achieve the throughput and quality standards
motion, Beckhoff’s XTS technology uses the customer wanted to achieve for this high-
electromagnetic forces to propel movers along volume product, according to Matthew Kelly,
a track at high speeds with accelerations up to software design supervisor at Eclipse. “The
100 m/s2. Movers with encoder flags operate previous machines used rotary dial tables
individually or in groups, unlike rotary dial and similar components. Each station only did
tables. Because each mover appears as an one process and, if any station went down, it
individual motion axis, it offers better traceability impacted the entire line.”
for each pump in each step in the process.

Figure 1: The Eclipse machine can make

two different automotive transmission
pumps simultaneously.
Source: Beckhoff Automation

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Figure 2: Beckhoff’s XTS linear transport

system enables high-volume, precision
manufacturing in a compact footprint.
Source: Beckhoff Automation

The challenge for this new system was to create a SAVING SPACE
machine that could make two different pumps at the While increasing functional capabilities, the
same time. Working with the local Beckhoff team, updated system from Eclipse needed to minimize
Eclipse created a new concept relying on the fast footprint. “Floor space is always at a premium,
cycle times of EtherCAT and the flexibility of XTS. but this customer’s assembly and process
equipment is extremely consolidated. When we
“The system allows operators to quickly release proposed the system, they said, ‘We like the
and replace the pallet with a second type. This concept, but make it 25% smaller.’ We didn’t
new pallet indexes forward and its specific know if that was possible,” Werner says.
position is measured to determine an offset.
We apply those offsets to each individual pallet “XTS, along with the EtherCAT industrial
and make sure that components and parts line Ethernet system and PC-based automation from
up exactly for the processes. This allows the Beckhoff, allowed Eclipse to concentrate an
operator to easily load part type A, wait one incredible number of processes in a small area
cycle, and then load part type B with negligible and accomplish the dynamic motion control
downtime,” Werner says. necessary to create the machine,” explains Andy
Burleigh, Beckhoff applications specialist.
“Frankly, this design request seemed terrifying
when we first concepted it because of the high In the first three machine cells, operators place
accuracy requirements. When we presented the pumps on pallets attached to XTS movers.
the bold idea of suddenly taking a pallet off and The XTS systems are 12 meters long, with 18
putting on a different one, there was silence in movers in the first cell, six meters long with 12
the room,” he says. movers in the second cell, and 10 meters long

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with 18 movers in the third. The pallets’ carefully per part with the micron-level accuracy required.
calculated pitch enables micron-level positioning. Since commissioning finished in early 2021,
When all assembly processes are complete, the the system has produced roughly 1,000 parts
operator moves the pump to the next cell. At the per shift, running part A and part B in separate
third cell, a small conveyor moves the pump to batches. The easy release and attachment of
the fourth cell where a robot lifts the completed pallets, along with the instant automatic indexing
pump in front of two GigE cameras for a final of XTS, almost eliminated changeover times,
machine vision inspection, then places it on a pushing them down from more than an hour to
conveyor for outfeed. just one minute.

“XTS transitions products from station to station “The customer was absolutely overwhelmed
very quickly and accurately; if there’s an issue by the ability to perform that changeover
with a part at any point in the process, we can considering the system’s extreme compactness
bypass other stations and simply remove it,” and complexity of process,” Werner adds. “It
Kelly says. “We grouped multiple processes was a marvel of both controls and mechanical
into a single station, which helped us further engineering to ensure easy release of these
decrease footprint. With all the processes and pallets without removing a single bolt.” Pallets
tooling, it was the most condensed automation simply move to a storage buffer and, if one is
system I’ve ever seen.” damaged, the operator can easily replace it.

CHANGEOVERS: Because the XTS movers are not linked as in

FROM ONE HOUR TO ONE MINUTE traditional designs, they can freely move the
With the innovative design by Eclipse, the pallets around the track to specific process steps
updated transmission pump assembly system as needed, even if the order is different between
met the specified cycle time of 20.2 seconds the two pumps.

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