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MCMA Technical Conference

MCMA Technical Conference Sessions with Detailed Descriptions



MONDAY, OCTOBER 16, 2017

OPTIONAL Pre-Conference Training Workshop (fee applies)

8:00 am to 12:00 pm

Permanent Magnet Fundamentals
Stan Trout, Spontaneous Materials

This course will provide an understanding of the many complicated and subtle features of permanent magnet materials. The course is well-suited for people with a technical background, with little or no previous experience with permanent magnets. Covered topics include magnetic theory, ferromagnetism, permanent magnet processing, thermal effects, magnetizing and magnetic measurements.
Course Outline:
I. Magnetic Theory
II. Electromagnetism
III. Ferromagnetism
IV. Permanent Magnets

8:00 am to 12:00 pm Introduction to BLDC Motor Design
Brad Frustaglio, Yeadon Energy Systems

This course will provide a better understanding of brushless DC motors, electric motor selection, mechanics and performance.
Course Outline:
I. Magnetics
II. Magnetic Circuits
III. Electromagnetic Forces
IV. Mechanics of Motors
V. Selecting the Proper Motor Type
VI. Performance Equations
1:00 pm to 5:00 pm Introduction to PMDC Motor Design
Brad Frustaglio, Yeadon Energy Systems

This course will teach attendees about permanent magnet DC motors and how to calculate motor performance, select motor size and materials, analyze motor performance problems, and reduce engineering and production costs and enhance market responsiveness.
Course Outline:
I. Theory
II. Performance Calculations
III. Practical Design Considerations
1:00 pm to 5:00 pm

Fundamentals of BL Motor Control
Dal Ohm, Drivetech, Inc.

This course provides fundamental concepts and knowledge necessary to design and apply brush and brushless DC motor drives. This course is intended to help clarify basic principles. The course includes a brief discussion on the magnetic and mechanical structure of the various motor types to understand torque production mechanisms and to derive a circuit model. The content will cover most of the basic skills in designing brush and brushless DC motor drives including power electronic circuits, analog and digital motor control hardware, gate drive and feedback sensors, with particular emphasis on motor control algorithms and servo systems. Practical and useful procedures in selecting components and methods, rule-of-thumb design rules and performance versus cost trade-off will be discussed.
Course Outline:
I. Motor Control Basics
II. Power Electronics and Analog Motor Drives
III. Drive Configuration
IV. Servo Systems and Motion Control
V. New Technologies in Motor Control


TUESDAY, OCTOBER 17, 2017

8:15 am to 9:00 am Why Speed, Agility, Insight and Innovation are the New Competitive Advantages
Jeffrey Phillips, OVO Innovation

This presentation examines the concept of competing based on speed, agility, insight and innovation rather than mindless head-to-head competition. Using case studies, Mr. Phillips will demonstrate that maneuver strategy helps you achieve more and win more at less cost. He’ll also introduce the basic analysis and frameworks you and your team can use to gain speed and insight and use innovation techniques more effectively.
9:00 am to 9:45 am The Design of Safe Machine Motion
Mark Nehrkorn, SICK, Inc.

Machines can inflict injuries to workers. A properly designed machine which incorporates the risk reduction strategies during the concept phase of the machine design allow the automation engineer to properly build a machine that can be both productive and safe. Key to implementing a proper safety system for a machine is to consider all the motion necessary for the process that creates hazardous conditions, the task requirements which require access or exposure to these machine movements, and how to safely separate man and machine by space and/or time. Too often systems are over-engineered making them costly and less productive. In this session you’ll learn what constitutes “safe motion” and the techniques to properly control them. By implementing the 6 Steps to a Safe Machine, an engineer can methodically apply a safe design strategy that considers all operator and maintenance tasks necessary for the machine to function. During this process, consideration includes exposure to hazards during assigned tasks, the performance level required for the SRP/CS for hazardous motion, and a validation process to ensure all aspects of the applied risk reduction measures have been properly achieved. With a little planning and a roadmap of how to apply this 6 Step process to the design, machines can be productive and safe.
10:15 am to 11:00 am Design for Manufacturability - Optimizing Designs and Reducing Costs
Chris Ras, Dexter Magnetic Technologies

Would you like to get more torque with less weight and cost, plus reduce cogging torque, harmonics and compensate for non-idealities of the permanent magnet rotors? The method of assembly and manufacture of a rotor has a significant impact on these properties. This session will review fundamental rules to improve manufacturability and final performance of multicomponent magnetic assemblies while maximizing value. It will cover alternative ways to achieve an optimized magnetic performance of the final assembly without overly tight tolerances on components. Also discussed will be the impact of different coatings on component level tolerances and adhesion; especially for high reliability applications. Best practices for designs when specifying coating will be offered. Unanticipated air gaps in magnetic circuits due to tolerance stack up of arcs built around a diameter is a significant issue for overall motor performance. The unknown nature and unpredictability of size and location of the air gaps is both significant and, often, difficult to quantify. Different manufacturing methods that cause these issues will be discussed along with recommended methods for assembly to guarantee performance. Understanding how component and assembly prints can impact the function and cost is essential for motor designers in today’s market. This session will provide the key concepts to improve manufacturability and reduce costs.
10:15 am to 11:00 am Thinking Outside the Box with Decentralized Drives
Craig Nelson, Siemens Industry

This session will look at the expanding applications using decentralized drives and servos. The difference between a central and decentralized approach to drive systems will be explained. It will explore the benefits of moving the inverters out of the control cabinets and placing them on, or near the motor as well as the precautions and limitations that need to be considered. You will discover some of the more common applications that use decentralized drives, including the fast growing Automatic Guided Vehicles which are being quickly adapted in many industrial plants. You’ll learn what type of drive applications make good candidates for decentralized landscape and what options exist to tailor solutions for the best fit.
10:15 am to 11:00 am Deplying IIoT with Raspberry Pi and Arduino Platforms
John Davis, ThreeML
IIoT is a connectivity revolution with roots in the commercial Internet - roots that took seed from technologies such as Linux, SOAP, XML, REST, and HTTP. Properly applied, commercial prototyping hardware such as the Raspberry Pi and Arduino offer engineers open and highly extensible platforms for data collection, simple machine control, and other Internet-centric tasks that - while ill suited for PLCs - are nearly purpose made for this type of hardware. In this session you’ll learn how to safely use and apply commercial prototyping hardware in an industrial environment. How to apply security best practices for configuring and accessing Linux-based IIoT devices will also be covered. Simple state machine construction in an easy-to-learn language called Python will be discussed. You’ll learn how to interface with and read data from a PLC or other sensor device, plus the pros and cons of real-time motion control with Linux, and how to (quickly and easily) gather, store, and present production data using a fully open source programming toolchain.
11:00 am to 11:45 am Achieving Better Power Density with an Electric Motor and its Associated Electronics
Dan Jones, Incremotion Associates

There are many motor types that have the potential for high-power density. Increasing torque or speed or the combination of the two is necessary to reach the high-power density objectives. Both these parameters are also impacted by the drive and control electronics. This session will overview three major motor types: the brushless PM motor; the squirrel cage induction motor; and the switched reluctance motor. Each type possesses strengths and weaknesses and this session reviews them and matches them to some current applications.
11:00 am to 11:45 am Energy Recycling Inside a Motion System
George Bennett, Optimal Motion Inc.

When multiple motors drive heavy inertial loads, energy buildup can be a problem. Energy recycling is a third alternative to re-gen and dynamic braking. It has the advantage of making the machines invulnerable to a power loss and able to restart after a power loss easily and safely. Recycling also reduces the cost of the drivers. In this session you’ll learn how to quickly determine if your system can use this technique, especially if you're already using re-gen or dynamic braking. Also discussed will be how to implement recycling, what kinds of things can be done with it and why it should be done, plus system advantages and disadvantages.
11:00 am to 11:45 am Upgrading Automation Without Replacing Existing PLCs and Machine Controllers
Matt Zupan, Micron Manufacturing

Based on Industry 4.0 concept, Micron Manufacturing will present a practical case study on how they upgraded their factory automation without replacing existing PLCs and machine controllers. Factory machines and equipment are connected to upload field data to back-end ERPs or the cloud, facilitating data acquisition and connections among machines and devices on factory floor to the cloud networks wirelessly. Using available industrial hardware and a web-based configuration tool, you will learn how to pre-configure a wide-scale deployment using a simple innovative, intuitive drag and drop tools without any tedious programming. Also covered will be how to configure your own IoT dashboard.
3:00 pm to 3:45 pm Injection Molded Sensor Magnets and their Use in Electric Machines
Thomas Schliesch, Max Baermann GmbH

One major advantage of injection molded magnets is the high variety of field distributions which can be realized. This is of major importance for sensor applications for rotating electrical machines and related systems. Sensors for electric commutation, speed determination or positioning often demand specific spatial distributions of magnetic field components, which need to be tailored for the sensor in use. Such requirements can be met adequately either by field oriented injection molded magnets or by Rare Earth magnets with artful polarization patterns. This session will provide an overview of the manufacturing process of injection molded magnets, the different sorts of polarization, materials, magnet geometry and shaft positions, as well as the physical principles of the related sensors. Also covered will be a detailed explanation of the different methods to keep the angular error as low as possible, as well as the methods of designing respective magnets. Calculated results will be compared to measurements.
3:00 pm to 3:45 pm A Comparison of New Rotary Encoder Technology and Advances
Jarrod Orszulak, Everight Position

Recent advances in rotary encoder technology are presenting designers with a seemingly endless number of options for motion control in drives and motors. Optical, capacitance, inductive and magnetic technologies now all compete to offer each unique application the right blend of performance and cost, while being mindful of other considerations such as weight, power consumption, size and ease of installation. This session will briefly touch on encoder fundamentals and then explore the pros and cons of each technology, ending with how to choose the right encoder technology for a given application. Attendees will learn how to analyze an application and be able to generate a specification list for an encoder when their application requires one. Since there is no 'one size fits all' approach, you’ll discover how to use a comparison of different encoder technologies to select the right one for your application.
3:00 pm to 3:45 pm Integrating Vision and Motion
Nate Holmes, National Instruments

Integrating vision and motion in a design can provide many benefits, but it comes with its fair share of challenges. This session will explore the intersection of two very vertical technologies where domain specific expertise is the norm, and where technology trends are leading to some interesting possibilities.
3:45 pm to 4:30 pm Motor Slot Fill and Design for Manufacturability
Blaine Alderks, Windings

In this session you’ll learn the different methods for calculating slot fill and the designs that can affect the manufacturability of the stator. Attendees will have the opportunity to experience directly the challenges associated with high slot fill and how small design changes can dramatically affect the ability to achieve the desired fill.
3:45 pm to 4:30 pm Maximizing Performance of Precision Motion Stages in Industrial Applications
Drew Hines, ACS Motion Control

Precision motion stages are used in industrial high tech applications such as Semiconductor Equipment, Laser Micromachining/Microprocessing Equipment, Biomedical Analysis Equipment, and more. Issues such as resonances, inertial mismatch, backlash, friction, motor cogging, misalignment, sensor noise, and more can degrade the achievable resolution and throughput of the machine. This session will explain how advanced motion controllers can minimize or eliminate these effects, improve motion stage performance, and ultimately increase machine throughput and accuracy.
3:45 pm to 4:30 pm What's a Robot Digital Twin? + Why It Matters?
Julian Weinstock, Robotiq

Collaborative robots make automation simple and affordable for an ever-increasing number of manufacturing tasks. And they measurably boost productivity, but how do you effectively measure and optimize your cobots’ performance? Emerging technologies make this simple and affordable. In this session you’ll learn about the Digital Twin - the computerized companions of physical assets. They use data from sensors installed on physical objects to continuously collect performance data and apply advanced analytics to determine patterns, trend lines, and anomalies. Today, the digital twin is the enabling technology that allows manufacturers to monitor, analyze, and optimize performance in real-time and with just a few clicks. Digital twins are used to improve quality and yield, remove time wasted and increase efficiency, reduce cycle time, quickly diagnose and eliminate failures, improve planning, reduce operational costs, increase quality and boost productivity. In the near future, digital twins hold the promise to change the game entirely and make robot/automation operations predictive or even prescriptive.


WEDNESDAY, OCTOBER 18, 2017

8:00 am to 8:45 am Automation Market Outlook - 2018 and Beyond
Alex Shikany, MCMA/A3

This presentation will use statistical trends to paint a picture for the years to come in the global automation market. Motion control, motors, vision, imaging, and robotics will all be explored in detail, and several examples of technological trends will be discussed including smart factories, vision guided robots, machine learning, and more. Regional trends in both developed and emerging economies will also be covered.
9:15 am to 10:00 am The Big Chill: Magnetic Refrigeration Comes of Age
Steve Constantinides, Magnetics & Materials LLC

Households around the world are currently using 1.4 billion refrigerators, fridge/freezers and freezers which consume between 20 and 30% of household electricity. The common household refrigerator is little more than a hundred years old. The technology that is positioned to replace conventional refrigerators is based on a principle that is at least as old: the magnetocaloric effect (MCE). MCE devices, with a claimed efficiency improvement of 20 to 35%, have the potential to revolutionize cooling needs such as home refrigeration, refrigerated transport, refrigerated display cases in stores, freezers and refrigerators in restaurants, air conditioners in housing, industry and automobiles, and cooling devices in scientific equipment. In this session you’ll learn what MCE is, how it works, and when it will it happen.
9:15 am to 10:00 am Encoder Interfaces for More Compact and Cost-Efficient Drive Systems
Christian Fell, POSITAL-FRABA INC.

One cable technology is the next step to further reduce size and costs of drive systems. The combination of power and feedback transmission using one cable, drives development and integration of new motor-feedback interfaces. Open standards make is easier to combine components to meet cost/performance needs of the motion control system. In this session you’ll learn the advantages of one cable technology drive systems, the available motor-feedback interfaces, and how to integrate BiSS Line 2- and 4-wire communication into encoder kits.
9:15 am to 10:00 am IIoT and the Connected Factory Path to TSN for Connected Motion
Siddharth Ravikumar, Kalycito

With motion control applications becoming more distributed and very sensitive to time critical communications requirements in areas such as multi-axes robots and electric drive systems, it is important to be prepared for the interoperability demands that will continue to rise in future, as well as to leverage the economies of scale in using a standard solution that will drive down cost and further drive adoption of products for connected motion. In this session you’ll learn how multiple proprietary industrial communications technologies are converging towards the OPC-UA over TSN standard for integration of Operational Technologies (OT) with Internet Technologies (IT) to enable IIOT and the Connected Factory.
10:00 am to 10:45 am Extreme Temperature Permanent Magnet Motor Design Considerations 300C and Above
Brad Frustaglio, Yeadon Energy Systems, Inc.

This session will examine extreme temperature motor design techniques and comparing differences to standard temperature design practice. Demonstration of machine sizing and envelope performance analysis. Attendees will learn extreme temperature PM material selection, stator conductor material selection, and insulation techniques and dielectric limitations.
10:00 am to 10:45 am Control of Custom Mechanisms using General Purpose Motion Controllers
Nishant Unnikrishnan, Yaskawa America, Inc.

Motion controllers have traditionally been used for single axis control of servos actuators. Robot controllers have been used to control a group of servos to run a kinematic mechanism. There is demand in industry to consolidate the control programming of robots and motion components because the underlying control techniques that actuate motion are the same. Basic mechanisms like gantries, three axis scara mechanisms, delta mechanisms, etc. are now supported on general purpose motion controllers. Additionally, rather than choosing a standard off-the-shelf robotic mechanism from a robot vendor, machine builders see an advantage in designing unique mechanisms that give their processes an edge in parameters like speed and productivity. Once the mechanical design is complete, it is the control engineers’ task to design the motion control algorithm for this unique mechanism. A robot controller will not be able to help and so it falls on the motion controller to be able to control the custom mechanism. In this session you’ll learn methods that can be used to control custom mechanisms with existing tools commonly available in motion controllers. This will also provide motion control designers insight into features on the motion controller that can help make programming easier.
10:00 am to 10:45 am Transverse Flux Machine with Ferrite Magnets
Zhao Wan, North Carolina State University

Transverse Flux Permanent Magnet Machines (TFM) show great potential in applications such as electric vehicle traction motor, wind generator and robotics actuator. This presentation will give an overview of the advantages of TFM in torque density and efficiency, and the drawbacks of TFM in power factor and construction. To address the issues, a new type of Flux Switching TFM, utilizing ferrite magnets and soft magnetic composite material is proposed. The TFM prototype will be introduced in the presentation, together with benefits and impacts for its application. The presenter will focus discussion on potential low cost, highly automated mass production of such a motor.
11:15 am to 12:00 pm

PLCopen Motion Control creating Worldwide Efficiency in Application Development
Bill Lydon, PLCopen North America
In the past, development of application software with motion control incorporated required unique programs to be created for each application even though the functions are the same. The PLCopen motion standard provides standard application libraries that are reusable for multiple hardware platforms. This lowers development, maintenance, and support costs while eliminating confusion. In addition, engineering becomes easier, training costs decrease, and the software is reusable across platforms. This standardization is done by defining libraries of reusable components. The programming is less hardware dependent and is scalable across different control solutions on different architectures, ranging from centralized to distributed or integrated to networked control. It is supported by over 30 companies worldwide, giving the user the option to buy the best-of-breed. This presentation will show how this is done, including application examples.
 


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