MOTION CONTROL FEATURE
A CORNERSTONE OF MOTION ENGINEERING
objects are stored, retrieved and positioned with speed and accuracy. Such systems often pair vertical motion with
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robotic arms or actuators to deliver payloads exactly where they need to go, seamlessly integrating into storage, retrieval and manufacturing workflows. Indexers bring precision and reliability to even the most demanding environments.
MOVEMENT MECHANISMS Most systems rely on one of three core mechanisms for vertical movement: • Lead-screw systems: This mechanism uses a rotary motor to drive a threaded shaft, converting rotational motion into smooth linear movement. Widely used for their reliability, simplicity and suitability for moderate-speed applications, lead-screw systems are particularly advantageous in settings requiring precise control over shorter distances, such as laboratory equipment or compact industrial devices.
• Belt and pulley systems: For faster speeds and lighter loads, belts and pulleys translate rotary motion into linear motion with efficiency and flexibility. These systems are commonly found in automated storage and retrieval applications, where speed and efficiency take precedence over heavy-duty load handling. Their lightweight design and low
rom semiconductor production and laboratory blood analysers to automated warehouse robots, indexers ensure
Indexer control systems are the backbone of many high-performance motion applications.
Gerard Bush, sales application engineer, INMOCO, examines the technology and its applications
maintenance requirements make them a cost-effective choice for many industries.
• Direct-drive linear motors: These brushless DC motors deliver excellent precision and speed, making them ideal for applications that demand extreme accuracy, minimal wear, and long lifespans. By eliminating mechanical linkages, direct-drive systems reduce complexity and provide smoother motion, making them perfect for high-precision environments such as semiconductor manufacturing and medical device automation. Occasionally, rack-and-pinion setups are used in heavy-duty industrial applications where ruggedness and durability are key requirements. These systems provide the strength and stability needed for demanding tasks like lifting heavy loads in warehouse robotics or industrial assembly lines.
TECHNIQUES Though indexing does not appear to be a particularly complex form of motion at a glance, there are several advanced techniques that make all the difference in delivering precise, efficient movement. S-curve profiling, for example, smooths out acceleration and deceleration, reducing vibrations
NEW SERVOMOTOR WITH BUILT-IN ETHERNET
Available with application support from Mclennan, the MAC1004 integrated servomotor from JVL A/S is said to offer a new level of performance, efficiency and flexibility for precision motion control in industrial automation. As part of a new generation MACmotor range, the compact MAC1004
features a new software and hardware design; and delivers 1kW of continuous servo power and a 3kW peak rating. With increased efficiency and a 100% duty cycle rating, its six built-in Industrial Ethernet options and faster processor combines with a new absolute multi-turn encoder to make this suitable for almost any application, the company states. This is directly powered from 115 or 230 VAC (optional 320 VDC) and, as a standalone integrated servo motor, allows machine builders the benefit of reduced machine wiring in addition to fewer or smaller control cabinets in a typical setup. Further controller design improvements have led to higher motor efficiency; and a faster, more advanced, processor enables precise and smooth motion control for superior production throughput. With
its 100% duty cycle operation, the MAC1004 is well suited to use in high-demand automation applications. Furthermore, a new battery-free, self-powered, state-of-the-art absolute encoder is available for long-life and zero-maintenance operation. The MAC1004 can also be supplied with an STO connector and equipped for SoE Safety over Ethernet, internal brake, IP67 protection, and M12 or M16 connectors for harsh environments.
Mclennan T: 01252 531444
www.mclennan.co.uk
and ensuring faster settling times. Compared to conventional trapezoidal profiles, S-curves inject less energy into the mechanism, creating smoother, more efficient movements. Another crucial feature is gravity
compensation, which is achieved by using DC torque offsets. This method balances the force of gravity on the load, reducing strain on the servo system and improving overall efficiency. Acceleration feedforward techniques further optimise motion, especially during high-speed tasks. The final advanced technique is motion error
detection. This monitors position accuracy in real time, and if it exceeds acceptable limits the system halts motion automatically, protecting both the mechanism and its payload from damage caused by obstructions or excessive friction.
APPLICATIONS Indexer control systems are used across a range of industries. Semiconductor manufacturing relies on them for wafer handling and SMIF-pod loading, while laboratories use them in blood analysers and DNA sequencers. In industrial settings, they power automated storage and retrieval systems, machine tool management, and tape or cartridge handling. They are integral to automated warehouses,
where they ensure speed and precision in retrieving and storing materials; and in sample preparation systems in research labs where their accurate, repeatable positioning capabilities, enhance efficiency and reduce errors. In data storage facilities, indexers handle tapes and cartridges with unmatched reliability. Indexers also support medical diagnostics,
assisting in the precise positioning of biological samples during testing processes; robotics systems in manufacturing where they coordinate the movement of parts along production lines; and in aerospace and defence where they play a critical role in the handling of delicate components and materials.
SMARTER MOTION SOLUTIONS Indexer control delivers the motion precision and reliability manufacturers need to stay ahead in automation. By leveraging advances in technology, engineers can design systems that meet the most demanding requirements while maintaining cost-effectiveness.
INMOCO
T: 01327 307600
www.inmoco.co.uk
MAY 2025 DESIGN SOLUTIONS 39
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