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MCMA Technical Conference

MCMA Technical Conference Sessions with Detailed Descriptions


OPTIONAL Pre-Conference Training Workshop (additional 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. It is well-suited for people with a technical background, with little or no previous experience with permanent magnets. Covered topics include magnetic theory, electromagnetism, ferromagnetism, permanent magnet processing, thermal effects, magnetizing and magnetic measurements.

1:00 pm to 5:00 pm Fundamentals of Brushless DC Motor Design - Part One
Brad Frustaglio, Yeadon Energy Systems

This is a comprehensive design course that covers: basic concepts; configurations of BLDC motors; magnetic modeling; steel selection; magnet characteristics and selection; electrical and mechanical considerations; brushless motor operation; magnetic elements and their performances; sizing and shaping the motor; stator winding design; motor drive schemes; performance characteristics; motor commutation patterns; thermal considerations; and design methodology and approach.


OPTIONAL Certified Motion Control Professional Training (additional fee applies)

10:00 am to 11:00 am CMCP Course 1 - Basic Machine Design and the Physics of Motion
Marissa Tucker, Parker Hannifin

Introduction to basic machine design concepts and physics behind electro-mechanical motion control. Learn more about the Certification program here.
11:00 am to 12:00 pm CMCP Course 2 - Mechanical Motion Control Components and Subsystems
Keith Knight, AMETEK

Introduction to what a typical motion control system consists of and the typical mechanical components and subsystems it contains. Learn more about the Certification program here.
1:00 pm to 2:00 pm CMCP Course 3 - Understanding Inertia and Reflected Inertia
Keith Knight, AMETEK

The importance of inertia in electro-mechanical motion control systems and how the inertia of the components in a motion control system effect its performance. Learn more about the Certification program here.
2:30 pm to 3:30 pm CMCP Course 4 - Introduction to Magnetism and Motor Basics
Mark Holcomb, Celera Motion

Basics of magnetics and the types of magnets found in motors. Overview of the basic function and styles of electric motors commonly used in industrial automation, including the operating difference between brushed, brushless, step, AC induction, and direct drive motors. Learn more about the Certification program here.
3:30 pm to 5:00 pm CMCP Course 5 - Positioner Selection and Motor Sizing
Jim Wiley, Parker Hannifin

How to select an appropriate single axis positioner for specific application requirements based on loading, environment, motion profile, and positioning performance. Overview on determining the required torque, speed and inertia of the motor/drive system that is needed for your application. Learn more about the Certification program here.


OPTIONAL Pre-Conference Training Workshop (additional fee applies)

8:00 am to 12:00 pm Fundamentals of Brushless DC Motor Design - Part Two
Brad Frustaglio, Yeadon Energy Systems

This is a comprehensive design course that covers: basic concepts; configurations of BLDC motors; magnetic modeling; steel selection; magnet characteristics and selection; electrical and mechanical considerations; brushless motor operation; magnetic elements and their performances; sizing and shaping the motor; stator winding design; motor drive schemes; performance characteristics; motor commutation patterns; thermal considerations; and design methodology and approach.
1:00 pm to 5:00 pm Fundamentals of Brushless Motor Control
Dal Ohm, Drivetech, Inc.

This course provides fundamental concepts and knowledge necessary to design and apply brush and brushless DC motor drives. Magnetic and mechanical structure of the various motor types will be briefly covered in order to understand torque production mechanisms and to derive a circuit model. The content will cover 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.


OPTIONAL Certified Motion Control Professional Training (additional fee applies)

9:00 am to 10:00 am CMCP Course 6 - Digital Servo Amplifier Basics
Micah Stuedemann, Yaskawa America, Inc.

Basic operation of a digital servo amplifier, including servo control loops, tuning a servo system, defining system bandwidth and how to select the proper amplifier for applications. Basics of the major networks/field busses and advantages/disadvantages of each. Learn more about the Certification program here.
10:15 am to 11:45 pm CMCP Course 7 - Motion Controllers, Programming and System Design Basics
Marissa Tucker, Parker Hannifin

Overview of the software and hardware elements necessary to build a motion system, and how to integrate motion with other systems when designing a machine. Basic motion control software and programming languages. Learn more about the Certification program here.


8:15 am to 9:00 am KEYNOTE
Artificial Intelligence/Machine Learning
Rashmi Misra, Microsoft

Adding algorithm intelligence to machines and systems.
9:00 am to 9:45 am KEYNOTE
2030 – the Future of Robotics and Emerging Technologies
Jon Battles

What 2030 will look like with the rapid emersion of technology and disruption
10:15 am to 11:00 am Specialty Electromagnetic Components for Unusual Requirements
Dan Vasile, Moog, Inc.

Dual commutator brush-type DC motors are still a viable component that will be used in applications for many years to come. In this session we’ll compare brush DC motors with equivalent BLDC motors to show the key differences and where it is most advantageous to use them. As the price of NdFeB magnets has come down, the size of BLDC motors with permanent magnets has gone up. Today it is common to talk about 5000 HP motors, but it is not as common to find large bore resolvers that can be used to commutate these large motors. While there are technical advantages to using high-precision, environmentally robust resolvers for these large systems, there are also design and manufacturing challenges in producing these large devices. We’ll explore design solutions successfully using large bore resolvers across several applications.
10:15 am to 11:00 am Fundamentals of Linear Actuator Technologies
Michael Giunta, Macron Dynamics

Learn about the various types of linear actuators that currently exist in the market today, including linear motors, belt actuators, hydraulics, pneumatics, rod style actuators (which include acme, ball screw and rollerscrew technology). Application examples will be used to explore the pros and cons for each technology to help you choose the right type for your projects.
10:15 am to 11:00 am Making Sense of IIoT in 2018
Jeremy Drury, IoT Diagnostics

The biggest challenge to IIoT deployment is simply figuring out where to start. Projects are successful when we can start small, and scale fast. This session strips away the glitz and hype of IIoT and gets practical. You’ll learn how to set up the best internal team, how to look for the right physical and digital environment to connect, and how to properly evaluate third party platforms and sensor companies. As most of us aren't trained data scientists, we’ll explore what to do with the data we're seeing and discover how a single, numerical data point can actually ripple out and affect multiple layers of your business. We’ll showcase best (and worst) practices to successful IIoT projects.
11:00 am to 11:45 am Overcoming Segmented Stator Challenges with Automation Processes
Kumar Rajasekhara, Marsilli America

There are multiple segmented stator designs (single-pole, multiple-pole, and chain-pole) which pose significant challenges to the production of higher performance/increased efficiency motors. In this session we’ll explore various winding methodologies, high product mix solutions, high-volume production challenges, stator roll-up methodologies, stator closing methodologies and maintaining tight roundness tolerances. Real-world examples will be used to show various methodologies and applications of automation that can be used to overcome challenges while maintaining the quality and traceability of each motor.
11:00 am to 11:45 am Functional Safety Principles
George Schuster, Rockwell Automation

“Is this machinery safe?” Functional Safety standards and principals provide concise methods to answer this question, and also the means to demonstrate that functional safety has been achieved. But functional safety compliance can also provide significant improvements to the bottom line by streamlining machinery access, reducing Mean Time To Repair (MTTR) and by removing incentives to bypass safety procedures or technologies. Functional Safety principals provide tools to improve both safety and productivity, and this is fundamentally changing the way manufacturers are applying safety systems today.
11:00 am to 11:45 am Flawless Machine Design with Virtual Commissioning & the Digital Twin
Marcel Voigt, B&R Industrial Automation

In our current digital age, we can do many things from the palm of our hands. Are we applying the same principals when building new machines? What about virtualizing our machine so we are able to test to a level of complexity like never before? It may start with a drawing on a napkin, but before assembling this new machine on the shop floor, we can eliminate a big portion of physical commissioning by doing virtual commissioning in parallel. Virtual commissioning helps you make sure your mechanical machine design is going to work together flawlessly, and also ensures that new software interacts flawlessly too. You’ll learn what a digital twin is, and how it can be used to streamline the design and deployment of new machines, while improving long-term reliability. Explore how virtual commissioning can be used for faster product changeover on existing machinery. Discover other ways the initial investment can pay off, to help you determine if and when to deploy this new technology.
2:45 pm to 3:30 pm Effects of Temperature and Saturation on PMBLDC Motor Torque Constant
Brad Frustaglio, Yeadon Energy Systems

Evaluating torque constant (Kt) on Permanent Magnet Brushless Motor (PMBLDC) machines is typically considered as a static problem. In this session, we will investigate temperature and saturation effects on Kt and implications on high performance machines.
2:45 pm to 3:30 pm PLC Object Oriented Programming
Bob Trask, Beckhoff Automation

While Object Oriented Programming (OOP) is widely used in software development in many segments, adoption of this programming method in industrial automation is not as common. Some reasons for this slow adoption may be due to limitations of the industrial platforms being used, perceived complexity of OOP, or the skill level of the personnel involved in the overall life cycle management of industrial applications. However, as product development cycles are being shortened and the demand for custom features continue to grow, industrial automation software developers are turning to OOP to meet these demands. Some advantages of this approach include: easy re-use of code; the ability to extend functionality of existing software functions; reduced software development time; and easier maintenance of software (i.e., life cycle management). To meet the increased demand for OOP, manufacturers of automation platforms are providing software environments and tools that allow developers to use OOP methods in an "industrial friendly" way, where application engineers, technicians and service engineers can work with it. In this session you will see an example of the basic concepts of OOP, how it can be applied to industrial applications, and how the perceived complexity of OOP is overcome.
2:45 pm to 3:30 pm Harmonics in Power Systems: Causes, Effects and Mitigation Technics
Nikunj Shah, Siemens Industry, Inc.

Static power converters utilize power semiconductor devices for power conversion and constitute the largest nonlinear loads connected to the electric power systems. These converters are used for various purposes, such as adjustable speed (or variable frequency) drives, uninterruptable power supplies, switch-mode power supplies, etc. These static power converters draw non-linear (non-sinusoidal) currents and the supply voltage waveform gets distorted at the point of common coupling (PCC), producing harmonic components. These harmonic components do not produce any active or useful power. Instead, they create many unwanted issues and phenomenon in the power systems, such as excessive heating of the equipment, resonance condition, system instability and oscillations. This session will provide general awareness of the power system harmonics, their causes, effects and techniques to mitigate them, especially with adjustable speed (or variable frequency) drives. You’ll also gain technical insight into the method of harmonic measurement and evaluating compliance according to voltage and current distortion limits set forth by IEEE 519.
3:30 pm to 4:15 pm Linear Transport Technology: Driving change, adding flexibility, and IIoT compatibility to new machine design
Peter Swift, B&R Industrial Automation

In this session you’ll learn about a disruptive technology called Linear Transport Technology. Discover the various options available in the market and their capabilities. We’ll tie the advantages of the technology in general, to a shift in machine designs using the technology and cover future uses of track-based systems. Lastly, we will discuss how this technology fills a crucial gap in the current customer order to product delivery cycle that can unlock customized mass production without driving up unit costs.
3:30 pm to 4:15 pm High-Tech Applications of Motion Control
William Catalano, ORMEC Systems Corp.
This session will describe the turnkey servo control system developed for NASA’s Winch Electromechanical Drive System (WES). The WES has a horizontal pull configuration that will be used at sea for recovery of the Orion Multi-Purpose Crew Vehicle (MPCV) into a US Navy Amphibious Transport Ship. Key components include two 200NM servo motors used together in the power-head as well as additional servo motors for take-up reel and level-winder. Included will be the general architecture of the motion control system, as well as the addition of several features developed in the motion engine specifically for this application.
3:30 pm to 4:15 pm Advanced Electrical Drive with Python Analytic
Giulio Corradi, Xilinx

This session describes a new, innovative open-source Python based productivity framework and infrastructure that effectively binds motor and motion control systems with programmable SoC hardware around Python. This simplifies the addition of a high-performance hardware off-loader for faster control in the programmable logic. Diagnostics, control, and predictive maintenance can be executed within fast, real-time controls. The primary goal of the open source framework is to make it easier, which rapidly enables designers of embedded systems to exploit the unique benefits of programmable SoCs in IIoT/Industry 4.0 and other applications.
4:15 pm to 4:45 pm New Automation Technologies - Minimizing Gear Noise with an Orbitless Primary Stage
Leo Stocco, Orbitless Drives Inc.

Miniature, high-torque actuators are used in applications such as wearable medical devices, automotive cabins, and appliances. These reside in close proximity to humans, so silent operation is highly sought after. In this session you’ll learn how noise in a miniature actuator is dominated by the primary stage gear noise. Discover how noise is minimized without sacrificing performance by using an Orbitless primary stage. This session will include practical results of a prototype unit.
4:15 pm to 4:45 pm Improved Modeling of Surface Degraded Permanent Magnets
Kevin Kurtz, Quadrant Solutions

This session will discuss the development of more accurate magnetic models for sintered NdFeB magnets with SA/V ratios greater than 1.9/mm. You’ll explore the many variables in the manufacturing process to better understand what impacts the final magnet (and then can easily be incorporated into the model). Surface damage from manufacturing is suspected in causing large gaps between real-world and simulated properties in magnets with a SA/V value of great than 1.9/mm. The degraded properties will be looked at with the goal of noting the least destructive manufacturing process and creating more accurate simulation models for NdFeB permanent magnets.
4:15 pm to 4:45 pm Replacing Optical Encoders with Magnetic Encoders – The Journey to the Highest Magnetic Accuracy
Dr. Torsten Becker, BOGEN Electronics GmbH

The times when magnetic measuring technology could be brushed off as too inaccurate for industrial measurements are finally over! In recent years, great progress has been made in system accuracy of magnetic measurement solutions. Today, magnetic systems can compete with many optical systems which are used in motion control applications. In this session you will learn about the system accuracies of optical and magnetic measuring systems, you’ll see a comparison that includes key drivers. Interfaces and application examples are shown and a discussion on which system accuracies are actually needed in industrial applications for motion control will take place.


8:00 am to 8:45 am KEYNOTE
How 5G Connectivity will Drive Smart Manufacturing
Dr. Yongbin Wei, Qualcomm Technologies, Inc.

9:15 am to 10:00 am Practical Advanced Tuning Approaches for Motion Control Systems
Atef Massoud, Omron

The performance of a motion control system fundamentally depends on tuning the servo. There are many different challenges for different mechanics and applications, but also there are many advancements. In this session you’ll learn: the outline characterization of industrial servo challenges and demands; current models, algorithms and approaches; and the practical advanced industrial tools, deployment and application.
9:15 am to 10:00 am Motor Drives for Electric Aircraft and Solar Electric Race Cars
Damien Lawhorn, University of Kentucky, Department of Electrical Engineering

This presentation covers three main topics: The solar car at the University of Kentucky, a study on conventional vs axial flux coreless PMSMs, and three-port DC/DC converter applications in electric vehicles. The Gato del Sol V is fifth in a series of vehicles created by the University of Kentucky’s solar car team. The team designed their first solar race car in 1999 and entered their first race in 2003. Since then Gato del Sol has competed in the Formula Sun Grand Prix, as well as the American Solar Challenge. The solar car team at UK is continually searching for ways to improve performance of their vehicle. Studies into electric motors and power electronics help discover new ways in which these solar vehicles can improve their performance.

Solar vehicles commonly implement axial flux permanent magnet (AFPM) motors. A comparison of two types of AFPM motors is explored. The first machine in this comparison is a conventional AFPM with a single rotor and single stator. The second machine is a coreless AFPM machine with multiple stator and rotor discs.

A solar vehicle has three main power sources: the solar panels, battery, and electric machine. The battery and motor can also act as a load, consuming power. The power flow is controlled by the power electronics implemented at the DC interface of the drivetrain system. A three-port full-bridge DC/DC converter is considered for its suitability for this application. Not only does the three-port full-bridge converter provide bi-directional power flow between the three ports, but also allows for constant power operation of coreless AFPMs at a wide range of speeds. This is done through an approach called “current weakening”, which involves raising the DC bus voltage of the motor side inverter at speeds exceeding the rating. In implementing the devices for current weakening operation, the voltage rating must be increased.

This study examines the cost difference for increasing voltage ratings of the motor side inverter switches between traditional and wide-bandgap semiconductors. The operation of this converter is discussed, as well as the operation during current weakening. The two studies discussed in this presentation deal with their applications in solar racing vehicles. These electric motor and power electronic concepts also have uses in other instances. The potential for benefits in other applications will also be discussed.

9:15 am to 10:00 am Practical Considerations for Networked Drives
Mark Lewis, DART Controls

While network connectivity of drives is a hot topic (IIoT), careful consideration prior to implementation is important. What protocol(s) do we offer? What will be the answer to that same question in five years? Is Ethernet the obvious choice? This session will offer practical experience gained from actual applications to highlight key considerations when implementing networked drives in support of an IIoT strategy. Topics addressed include: Customer requirements (OEM vs. plant); Network topologies (OEM vs. plant); Considerations for which protocol(s) to support; How IoT impacts drive design; Is Ethernet at the drive level warranted?; Safety and security considerations; Early adopter applications; and The possibilities of Bluetooth/WiFi and smartphones/tablets.
10:00 am to 10:45 am Innovations in Absolute Linear Encoders
Chris Heberlein, Balluff

Although the concept of direct load monitoring is not new, recently several market requirements have arisen regarding improvements in machine performance, including shorter integration and start-up time, and an overall strong thirst for more data. This session will explore direct load monitoring and the many benefits when utilizing this feedback technique. You’ll learn the many applications best-suited to adding the benefit of absolute position with quadrature interface. Discover how to tap into encoders to gain the benefits of connectivity at this level. Also covered are the challenges that exist and how IO-Link encoder solutions solve those challenges. Intelligent sensors make it possible to implement intelligent production systems, and the data which they provide enables intelligent control of these systems. In interaction with all intelligent components, this enables more efficient utilization of all the machines in a plant and ensures better use of the existing resources. The demand for intelligent sensors as data providers will continue to grow. In the future, intelligent sensors will be a permanent and necessary component of modern and self-regulating systems, and will therefore have a firm place in every sensor portfolio.
10:00 am to 10:45 am Key Figures of Merit for Soft and Permanent Magnetic Materials
Steve Constantinides, Magnetics & Materials, LLC

What is the difference between magnetic flux density and magnetic induction? The difference between magnetizing force and magnetic field strength? What kinds of permeability are there and which ones matter, and when? How about the difference between isotropic and unoriented? At the heart of soft and permanent material selection is a clear understanding of magnetic terminology and the test methods used for establishing values of the key parameters. This session will build a clear understanding of hysteresis fundamentals along with legacy and currently preferred terminology.
10:00 am to 10:45 am Achieving Interoperability with OPC-UA TSN - Time Sensitive Networks
Thomas Burke, President and Executive Director, OPC Foundation

Integration of all communication from the ERP level to the field level is an essential requirement for today's most advanced production systems. To penetrate the barriers between IT and automation, equipment owners are increasingly turning to the open OPC UA standard. When it comes to complex processes with real-time requirements, however, OPC UA has its limitations. That will soon change, thanks to Time Sensitive Networking (TSN). Adding Pub/Sub capability to OPC UA coupled with TSN yields new capabilities. It can be 18 times faster than what is in the market, and with far better configuration capabilities. In this session you’ll learn some of the history of fieldbuses and why an interoperable protocol between IT and operation technology is needed. Discover the concepts behind OPC-UA TSN and how you can deploy it.
11:15 am to 12:00 pm KEYNOTE
The Impact of US Steel Tariffs on Industry
Michael Sonsogno, Cogent Power Inc.

Over the past 12 to 18 months, the threat of tariffs on steel has been unclear at best. The reality today is that there are several tariffs and counter-tariffs that our industry is struggling to navigate through. How do we better understand these changes and how are they going to impact businesses today and in the future? The continued threat of what the future of tariffs holds, and how to plan for these moving forward, is an important aspect of future business growth. This session will give a high level overview of what the tariffs are, especially as they relate to electrical steels, and how to navigate the evolution of these tariffs moving forward.

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