automation solutions for the automotive, machine tool ...jinhoe/notes/skmv4792 automotive...

Dedicated to the Science of Motionwww.AEROTECH.com

MACHINE TOOLS

Gun Drilling

Precision Surface Grinding

Customer Machine Controllers

EDM Applications

Milling, Boring, and TurningApplications

ASSEMBLY AND PACKAGING

PCB Assembly

Vision Assisted Pick-and-Place

Bobbin Winding

Unwind, rewind, and tension control

Rotary knife and flying cutoff

AUTOMOTIVE

Automation Solutions for the Automotive, Machine Tool, Assembly, and Packaging Industries

AEROTECH

Laser Cutting andWelding of Panels

and Parts

Auto-body CoordinateMeasuring Machine

Fuel InjectorManufacturing

WindshieldGlass Cutting

ShockAbsorberTesting

CamshaftGrinding

SteeringWheelTesting

TIG Welding

Auto-bodyPainting

Air BagTesting

WORLD HEADQUARTERS, Aerotech, Inc., 101 Zeta Drive, Pittsburgh, PA 15238 • 412-963-7470 • Fax: 412-963-7459 Aerotech, Ltd., Jupiter House, Calleva Park, Aldermaston, Berkshire RG7 8NN, UK • +44-118-9409400 • Fax: +44-118-9409401 Aerotech GmbH, Süd-West-Park 90, D-90449 Nürnberg, Germany • +49-911-9679370 • Fax: +49-911-96793720

www.aerotech.com

Table of Contents

Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies.

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6 9

10 12

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1 Automation Control System Markets

2 Aerotech at a Glance

4 Automotive Applications

6 Machine Tool Applications

9 Assembly Applications

10 Packaging Applications

12 Distributed Control Architecture

14 Simplified Integration...Reduced Cost

15 High Performance, Cost-Effective Retrofits

16 Software Motion Controller Functionality

20 Intelligent Networked Drives

22 Programmable Logic Controller

23 Vision Systems

24 Servomotors

26 PC Based Hardware Controllers

30 Superior Mechanics from Aerotech

31 Engineered Systems

34 Aerotech Online

36 Aerotech: A History Dedicated to the Scienceof Motion

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Automation Control Systems Markets

Aerotech has a long history of serving the Automotive,Machine Tool, Assembly, and Packaging industries. We havesupplied key high-performance subsystems and components(controls and mechanics) for many applications both inproduction and in R&D.

Aerotech products feature innovative designs that advance thestate-of-the-art in motion, vision, PLC, robotics, motors, andmechanics, while addressing industry-specific needs notadequately met by other products. For over 30 years, customerrequirements have driven our product designs, resulting in thehighest throughput, best accuracy, and highest return oninvestment available today.

Aerotech provides the industry's broadest variety of motioncontrol products to suit your application. We manufacture alarge selection of high-performance linear and rotary brushlessservomotors and drives, linear and rotary mechanical- and air-bearing stages, nanopositioners, and much more. Ourexpertise includes systems for shop floor, R&D, vacuum, andcleanroom applications. Our abilityto provide custom-engineeredproducts and systems to both endusers and high-volume OEMswith fast turnaround isunmatched in theindustry. Aerotechdelivers quality,performance, flexibility, and thehighest return on investment(ROI).

MARKETS AND APPLICATIONS

AUTOMOTIVE

Fuel injectors, cam shafts, and windshields

Tire tread testing, shock absorbers, air bagaccelerometers, and fuel metering systems

Car-body painting, TIG welding for transmissions, weldingfor catalytic converters, and CMM for the auto body

CUSTOM MACHINE TOOL

Milling, drilling, grinding, boring, and turning

Laser processes, routing, water jet cutting, knife cutting,and EDM (Electrical Discharge Machining)

PACKAGING

Unwind, rewind, and tension applications

Printing, coating, laminating, perforating

Rotary knife, flying cutoff, and slitting operations

ASSEMBLY

Pick-and-place

DIGITAL AUTOMATION PLATFORM FEATURESDistributed software-based controller with 32-axes ofsynchronized motion.

Multiple high- and low-power configurations of drives andmotors for every application.

One unified programming environment for motion, vision, PLC,robotics, and I/O.

Pre-packaged application specific functions such as multi-blocklook ahead for higher accuracy parts while maintaining highthroughput, velocity profiling, CAM tables, cutter compensation,electronic line shaft gearing, and many more.

Uses standard RS-274 (G and M codes).

WORLD HEADQUARTERS, Aerotech, Inc., 101 Zeta Drive, Pittsburgh, PA 15238 • 412-963-7470 • Fax: 412-963-7459 Aerotech, Ltd., Jupiter House, Calleva Park, Aldermaston, Berkshire RG7 8NN, UK • +44-118-9409400 • Fax: +44-118-9409401

Aerotech GmbH, Süd-West-Park 90, D-90449 Nürnberg, Germany • +49-911-9679370 • Fax: +49-911-96793720

www.aerotech.com

New machines or retrofit existing machines with substantiallyless startup time, reduced changeover time, and higherthroughput.

Distributed control system using industry standard, high per-formance FireWire® (IEEE-1394) network minimizes wiring.

Completely digital controller results in lower maintenance andhigher performance.

Scalable — no degradation in performance as the axis countincreases.

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Highest Throughput Best Accuracy Lowest Cost of Ownership Highest ROI

Technically Superior Components Create...

High Volume Manufa

Corporate HeadquartersPittsburgh, PA, USA

High Performance Su

Aerotech at a Glance

Comprehensive Technical Support Services

Award-Winning FiberMax®

6-Axis Nano-positioner

Highest Throughput Linear MotorCartesian Gantry Systems

Highest Performance BrushlessLinear and Rotary Motors

Ndrive® A3200

Npaq®

Award-Winning Automation 3200 1-32 Axis Motion, Vision, PLC, Robotics,

and I/O Platform

ALS1000 SeriesLinear MotorStages

ADRTRotary StageSystem

Custom softwareapplication support

3D models to facilitate faster and moreaccurate system layout

Advanced analytical techniquesfor optimization of systemgeometry

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acturing World Wide Service and Support

Aerotech Germany Aerotech UKNew Facility ExpansionPittsburgh, PA, USA

ub-Assemblies... and Best-in-Class Sub-Systems.

High-Speed CylindricalLaser Cutting Systems

Production-Proven, Large Format Air-Bearing Systemsfor Flat Panel and Semiconductor Applications

Custom-Engineered,Vacuum andCleanroomCompatibleSystems

Highly Integrated Motion Sub-Systems with Machine Frame,Display and Packaged Electronics

WorldwideStartup Serviceand On-SiteTraining

Fully EquippedOn-Site TrainingFacilities

Over 100,000 Axes InstalledWorldwide

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Automotive Applications

AEROTECH ADVANTAGES IN THE AUTOMOTIVE INDUSTRYWe have a full line of high-power drives and motors forproduction environment.

All-digital drives eliminate drift over time, providing superiorrepeatability without recalibration.

FireWire® used for communications decreases cabling by 38% overtraditional systems. Using fewer cables and components not onlydecreases changeover time, it also increases reliability.

High performance, deterministic network (FireWire®) provides fordistributed motion generation and synchronization while all-digital drives support high bandwidth local control for each axis,increasing performance.

Synchronization of up to 32-axes of real-time motion in one PCeliminates integration of multiple controllers for high axis-countsystems, increasing reliability.

The Automation 3200 integral PLC and robot motion controldecrease changeover times, or ease integration with existingsystems to leverage your investment.

FireWire® supports live insertion/hot pluggable, makingmaintenance and reconfiguration time faster.

Extensive diagnostics make debugging new applications orsystem failures quick and easy, decreasing changeover andmaintenance times.

Use of virtual mode and motion control tools provide for dry runsat desktop or on floor without actual machining operations,saving time and eliminating costly mistakes.

Bottom Line: HIGHEST THROUGHPUT


Aerotech GmbH, Süd-West-Park 90, D-90449 Nürnberg, Germany • +49-911-9679370 • Fax: +49-911-96793720 5

www.aerotech.com

Automotive ApplicationsAerotech has been satisfying the production and R&D motion needs of automotivemanufacturers and parts suppliers for decades. A few of the applications usingAerotech products are:

FUEL INJECTORSTo achieve higher performance engines with lower emissions requires precisionmanufacturing of the fuel injection system, specifically the repeatable, precisionmachining of the fuel injector. Aerotech has long been involved in the developmentand manufacturing of high performance, multi-axis systems to manufacture fuelinjectors and other automotive parts.

WELDINGTo achieve high-quality welding in a flexible manufacturing process, such as smallbatches of multiple parts on the same machine, Aerotech has been installingcontrollers since 1970 at major automotive suppliers for TIG welding of transmissionsand welding of catalytic converters.

SENSOR TESTINGAs the demand for reliable and high-performance onboard sensors increases, so do thetesting requirements of the sensors. For over 30 years Aerotech has built many testingsubsystems for air-bag sensors, fuel-metering systems, wheel testing systems, andCMM for auto-body measurement with touch probes.

PAINTINGAuto-body painting requires the coordination of high axis-counts with complextrajectories while maintaining smooth, high-speed motions on the assembly line.Aerotech has supplied automotive painting subsystems that coordinate high-axiscounts to meet these challenges. You can store multiple body styles in memory,facilitating body style switching on the fly for scalability and performance. Our high-speed motion and trajectory synchronization capability provides for precisionmovement over the profile and contour of the auto body while moving on aconveyor.

CAM GRINDINGCam grinding has been a core application of CNC machines for decades. ElectronicCam Profiling is a standard, built-in function that defines motion in CAM tables.Multiple cam part profiles (with large tables) can be stored in a single A3200 forfast changeover time. Mirror quality surface finish results from our real-time cubiccurve-fitting function that interpolates position between points. Preprogrammedindividual lobe profiles can be ground to exact tolerances in one operation.

HIGH-SPEED WINDSHIELD GLASS EDGE GRINDERHigh-speed glass edge grinding machine applications will take part data in X, Ycoordinates and transform them into an R, θ format and store this directly in the axisservo-processor memory.

SHOCK ABSORBER TESTINGAerotech high force (over 4500 N peak) linear motors have been used for testingshock absorbers to understand their response to road conditions.

High-Speed Glass Edge Grinder

8 Lobe Camshaft Grinding

Bottom Line: FASTEST CHANGEOVER

10-Axis Automotive Painting System

ShockAbsorberTesting

Grinding Head,Slaved to MainSpindle, PreciselyFollows Cam Profile

Main Spindle

R Axis

Typical R, θ Profile

R

0 90 180 270 360 θ

θ Axis

Cut Pattern

Glass Sheet

X

Y

Path

Conveyor


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Bottom Line:

The motion control tool kit includes autotuning, 2D and 3D plotting utilities, andsophisticated cursor and zoom tools that provide detailed system information tominimize integration efforts.

Advanced diagnostics include program line identifier for a given position, pathmeasurement tools, and peak position error reporting.

Decrease development and setup times.

Sealed stages protect against debris and dust.

Direct-drive slotless motors are available for applications requiring high position andvelocity accuracy. Motors can be sealed to meet IP67 specification.

Ball-screw-driven stages produce high continuous force outputcapability and are well suited for vertical or continuous forceapplications.

Engineered cable management systems ensure problem-freeoperation for the life of the system.

PSO (Position Synchronized Output) provides the position ofmultiple axes within 50 nanoseconds of the actual motorposition. Even at high speeds this means events such as firing alaser are accurate to within 0.15 microns.

Interpolated motion provides higher fidelity motion commandsto each axis, minimizing position error during movement.

Sample rates of 20 kHz provide the basis for high bandwidthcontrol loops, increasing throughput at the specified measuringtolerances.

FireWire® provides plug-and-play scalability and peer-to-peercommunications, greatly simplifying wiring and thus loweringintegration costs and time.

Software-based motion controller removes dependencies on PCbus. Therefore, as PCs increase in speed, the block processingtime decreases, resulting in higher throughput. Commercialavailability decreases lifecycle cost.

AEROTECH ADVANTAGES IN MACHINE TOOLS

Bottom Line: HIGHEST RELIABILITY

Machine Tool Applications

High PerformanceRotary Stages



www.aerotech.com

The A3200 is an automation platform that coordinates motion control, vision, robotics, and I/O in a single system. The pre-packaged integration of the modules software and hardware eliminates large system integration costs.

The A3200 and associated hardware modules (Ndrive® and Nservo) can be used to retrofit aging machines. Existing motors and/ordrives can be used with this new high-tech controller to improve production rates, shorten setup, and decrease lifecycle cost. Thisis a low-cost life extension that adds flexibility to your manufacturing capabilities.

Multi-Block Look Ahead interpolated motion automatically adjusts the trajectory generation to minimize position error during asmall radius cut.

Built-in 2D and 3D Normalcy eliminates complex trajectory programming.

Helical, Circular, and Linear Interpolation eliminates application programming.

Multiple independent CNC programs can be run on a single controller. They can be setup functional (one program for motion, onefor I/O, one for fault diagnostics), they can be used to coordinate multiple machines and processes, or run multiple independentmachines.

Built in Jog, Offset, and Return operation provides coordinated multi-axis motion that can be halted at any time. The axes cancontinue motion from the offset tool path or return to the interrupted motion point and continue along the original path.

Multiple part profiles can be stored in a single A3200 for fast changeover time.

Dry runs can be done virtually on the desktop, eliminating unnecessary dry runs on the production floor, and minimizing bothsetup and changeover times.

Cutter radius compensation eliminates application programming for every tool. It can be used to accommodate different tools orto compensate for tool wear over multiple uses.

A3200 uses standard EAI-274D or G-codes for standard CNC operations, enabling the use of existing CNC programs.

By making use of the A3200 Ncontrol® SDK, machine builders can customize the user interface from the ground up to be machinespecific.

Bottom Line: LOWEST SYSTEM INTEGRATION COST

Machine Tool Applications

Machine Tool ApplicationsMILLINGAerotech controllers are used by major machine-tool builders for contoured milling applications to achieve high quality millingin flexible manufacturing processes such as running small batches of multiple parts on the same machine.

DRILLINGDrilling requires high-speed point-to-point moves that are easily provided by the Aerotech controllers.

EDMAs the demand for higher precision parts increases, so do the requirements of EDM. Aerotech has constantly met therequirements for contoured higher-precision part tolerances while increasing system throughput.

GRINDINGGrinding has been a core application of Aerotech's CNC controllers and mechanics for decades.

Aerotech supplies precision mechanics and controllers for other typical metal-cutting machines such as turning, boringmachines, broaching machines, gear cutting machines, tapping/threading machines, lathes, turning centers,machining centers, and station-type machines. Aerotech products can also accomplish other multidimensionalprocesses such as routing, water jet cutting, knife cutting, and ECM (Electrochemical Machining).

A3200 Controller and Intelligent Drives

Sealed, High-Performance Linear Stages HMI


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Bottom Line: HIGHEST RELIABILITY



www.aerotech.com

Assembly ApplicationsSMALL ELECTRONIC PARTSASSEMBLYCombining Aerotech controlswith our advanced mechanics,including air bearing,mechanical bearing, linearmotor and ball-screw-drivenstages, affords the appropriaterepeatability and accuracyduring the assembly processfor small parts.

PICK-AND-PLACE Aerotech has long providedpick-and-place gantries formany assembly lines,including PCBs and cellphones.

Bottom Line: HIGHEST PRECISION MANUFACTURING

AEROTECH ADVANTAGES IN ASSEMBLY

Axis calibration compensates for repeatable mechanical errors to improve position andvelocity accuracy.

Multidimensional error mapping provides calibration tables to compensate for repeatable multi-axis (e.g., X-Y plane) misalignments in mechanics.

Gantry Mode seamlessly controls mechanically-linked axis to ensure position and velocityaccuracy.

Dual-carriage linear motor stage with cross axis increases throughput and reduces system cost.

All-digital drives eliminate drift over time, providing superior repeatability withoutrecalibrating, and less maintenance.

Lower component count compared to traditional systems increases reliability anddecreases lifecycle cost due to lower spare counts, less down time, and smaller maintenance windows.

User provides Position-Velocity-Time trajectory in real-time to Aerotech controller on a per axis basis and the A3200 will generate thetrajectory command to all axes using a cubic spline algorithm.

Interpolated motion provides higher fidelity motion commands to each axis, minimizing position error during movement.

FireWire® is not subject to noise and offset of analog systems. This better signal-to-noise ratioprovides for higher data rates and, therefore, higher throughput.

Advanced diagnostics minimize downtime.

FireWire® noise immunity results in higher fidelity position commands, thus higher precision.

Camera control synchronization for part recognition, position determination, and motion adjustments.

Specialized coordinate transforms reduce programming complexity.

Ndrives® fordistributed

control

Dual gantrymode for higher

precision

High-forcelinear motor

A3200 fortrajectorygeneration

Integrated cablemanagement


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Packaging Applications

AEROTECH ADVANTAGES IN PACKAGINGReal-time target modification provides for in-transit trajectoryalteration that permits accommodation of external events. Forexample, a vision system can be integrated to correct forinaccuracies in part placement, part position, etc., withoutrequiring the system to finish the current move. This increasestesting throughput.

Software-based motion controller removes dependencies on thePC and PC bus. Newer PCs can be used with the same software.Protection from constant changes to PC hardware technologies,especially ISA and PCI bus, increases standard life. Our software-based motion controller eliminates the necessity to change thecontroller as PCs evolve and increase in speed. This reduceslifecycle cost and learning curves.

Aerotech provides forapplication-specific needsthat improve accuracy andprecision, such as Multi-BlockLook Ahead, and help inapplications with small radii.

Position Synchronized Output (PSO) provides the position of multipleaxes within 50 nanoseconds of the actual motor position. At highspeeds, events such as laser firing are accurate to within 0.15 microns.

Programmable Output Pulseallows the user to generate andcontrol the window/region(defined by two positions inspace) during which the on andoff time of the firing/trackingsignal is generated to anothersub-system. This output signalcan be set by frequency and dutycycle or by setting the pulse-width based on an event.

Third-party I/O support provides flexibility in the type of systembeing controlled or monitored. It provides a mechanism tointerface to existing equipment and/or non-Aerotech equipment.The ability to work with existing equipment lowers integrationcost while improving scalability and throughput of the cell.

Up to 32-axes of motion can be coordinated in real-time with nosystem performance degradation for maximum scalability.

Bottom Line: LOWEST LIFE-CYCLE COST

Rack-Mount Drives

SlotlessServomotors

Sealed Linear-Motor-Driven Stages

Custom UserInterfaces



www.aerotech.com

Packaging ApplicationsPacking operations require the controller to facilitate fast andfrequent line changeover while being scalable and reliable.

LOAD AND UNLOADPacking operations require coordinated motion with the conveyorfor the loading and unloading operation, with fast changeover fornew products. The Automation 3200 can either control all of themotion or interface with existing motors and amplifiers.

MARKING AND PRINTINGMarking and printing applications that require real-timesynchronization with the PLC can benefit from the A3200.

LABELINGAccurate label placement requires a motion controller that canrespond to changes in line speed and quickly initiate an overlaymotion. Typically, product travels through the label machine ona conveyor. However, the conveyor can change speeds. Thisrequires the labeling mechanism to remain synchronous with theproduct conveyor, and the A3200 provides this synchronization.

SCRIBING Ceramic scribing requiring high-speed coordinated motion hasbeen done with Aerotech controls.

HIGH-SPEED REGISTRATION High-speed registration is used in the precise control of printing,rotary knife, flying cutoff, die cutting, and feed-to-mark applications.

ELECTRONIC GEARING Electronic line shaft master/slave control with programmableratio and phase. Synchronize control of unwind, rewind,tension, and registration in applications involving printing,coating, laminating, perforating, and slitting.

Bottom Line: SHORTEST SETUP TIME

Typical labeling

application with synchronization of

motor, sensor, and conveyor.

Electronically synchronizeup to 32 axes of motion with the A3200.

Typicalpackagingapplication

The A3200 can beaccessed remotely for convenient control ofmultiple operations.

POWERFUL SOFTWAREExtensive suite of development tools:

• Nmotion® SMC — Software Motion Controller

• Ncontrol® SDK — Software Development Kit

• Nview® HMI — Human-Machine Interface

• Nlogic PLC — Programmable Logic Controller

• Nvision® VCM — Vision Control Module

Modular software architecture permits mixing andmatching of applications to suit the automation processrequirements.

Programmers can create their own applications withNcontrol® SDK, a collection of Active X-basedcomponents.

Easy to use out of the box.

A3200 ADVANTAGES• Higher throughput due to high-performance control,

network, and high-power drives• Higher quality output (accuracy and precision) due to fully

digital drive and advanced servo algorithms• Faster startup and changeover results from fully integrated

motion platform, easy to use setup tools, and extensivediagnostics

• Lower startup and lifecycle cost due to lower componentcount and reduced engineering time

• Higher reliability due to fewer components• Simplified integration as all major automation components

are bundled into one platform• User interface flexibility due to local or remote processing• “Future Proof” architecture built on commercially available

PCs running Windows® 2000/XP operating systems

THE INTELLIGENT 32-AXIS MOTION, VISION,PLC, ROBOTICS, & I/O PLATFORM

EXTENSIVE I/O CAPABILITYAll Automation 3200 drives and drive Paqsare available with an integrated 10/100Base T Ethernet interface. This permitsAutomation 3200 systems to interact withthird-party I/O boards and PLCs!

EASILY INSTALLED DIGITAL DRIVESFROM 10A-100AAll drives are self-contained with aninternal bus supply. Plug them in,make the network connection, andthe unit is ready to go!

PLCEthernet I/O Expansion

Analog and Discrete I/O

Distributed Motion ControlMotion control is performed atthe drive level.

IEEE-1394 (FireWire®) INDUSTRY STANDARD, SUPER-HIGH-PERFORMANCE COMMUNICATION NETWORK

DIGITAL DRIVE FEATURES• PWM or linear • Integrated 10/100 Base T

Ethernet• Onboard x65536 encoder

multiplication• 20 kHz position, velocity,

and current loopsample rate

• Integral powersupply

• Sinusoidalcommutation

• Local I/O ports

Soft PLC


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IEEE-1394/FIREWIRE®

ADVANTAGES• Deterministic architecture maintains consistent

performance updates across all 32 axes• 30 to 1000 times faster than competitive motion

networks • 3.2 Gbps over fiber • No system degradation as number of axes increases• Versatile high-speed, low-cost communication

system • “Future Proof”• Commercially available• Nonproprietary architecture• OHCI compliant• International standard• IEEE-1394 standard on PCs

ROBUST, HIGH-PERFORMANCEMOTION ENGINE CAPABILITIES• Point-to-point motion• Interpolated motion• Velocity profiling• Multi-block look-ahead• Electronically geared motion• Cutter compensation• CNC functionality• Electronic CAM profiling• Position synchronized output• Fast position capture• High-speed registration

• Gantry mode• Motor control• Dual loop control• Axis calibration• Orthogonality correction• 3D error mapping• Helical interpolation• Autotuning• Coordinate transformations• Normalcy, parts rotation,

mirroring, and retrace• Cubic spline fitting• Kinematics

Motion generation and synchronization are centralized at the PC.Motion execution is decentralized at the drives where the servoloops are closed. A3200 operates on any standard desktop orindustrial PC.

RETROFIT TO EXISTINGMOTORS & DRIVESUse as an integrated systemor interface to existingmotors and drives in acost-effective retrofit.

Motion Controller

Robotics

Vision

Any ServoAmplifier

Any StepperDrive

Any Stepper MotorAny Brush or Brushless Servomotor

Npaq®

6-Axis Drive Rack

Distributed Control from Aerotech



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Nservo Nstep


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NSERVO FOR RETROFIT APPLICATIONSNservo is a FireWire® based four-axis interface module with digital rateand position loops that provides three phase output (+/-10 volt) forcommutated motors and accepts resolver, encoder, or tachometer feed-back for loop closure. With Nservo, the Automation 3200 system caninterface with drives and motors that do not support FireWire®, such asspindle drives, induction motors, and other specialized motors.

NSTEP FOR STEPPER MOTOR APPLICATIONSWith Nstep, the Automation 3200 system can interface to steppermotors and galvanometers not supported by FireWire® for open loopcontrol. This provides a simple and inexpensive mechanism to controlsynchronized motion with servo and stepper motors from a singlecontroller. Nstep provides two axes of control with two clock anddirection outputs per axis.

Compared with traditional PCI card solutions which contain many “breakout” modules and excessive wiring, thedistributed architecture of the Automation 3200 reduces integration time by replacing unnecessary cabling andelectronics with a simple plug-and-play FireWire® cable. In addition, many commonly used devices such as encodermultipliers and I/O modules can be integrated into the Ndrive®, further reducing the amount of cabling and panel spacerequired. The elimination of the components and cables means faster integration, lower support costs, and fewer spareparts to manage — all designed to make your integration smoother and improve the bottom line.

TRADITIONAL 6-AXIS SOLUTION AUTOMATION 3200 SOLUTIONIndustrial PC with multiple open PCI slots

8-axis control card withencoder expansion

Interfacemodules

Encoder multipliers

Drives

Motors

I/O module

Any P3-800 class computer running Windows®

2000, XP with FireWire® port

Ndrives® with integrated encodermultipliers and I/O connections

Plug-and-play FireWire® cable

Significant Integration and Support Savings

- 38% less wiring

- 65% fewer components

- Plug-and-play drive interface cabling (FireWire®)

- Simplified troubleshooting

- Increased design flexibility

BENEFITS

Motors

Simplified Integration...Reduced Cost



The Automation 3200 and associated hardware (Ndrive®, Nservo, and Nstep) are ideal for retrofitting existing machines.Existing motors and/or drives can be used with our digital automation platform to improve production rates, shorten setup,and decrease lifecycle cost. This low cost, low-risk life extension improves performance and extends capital equipment life.

Existing Motors Are Retained

Up to 32 axes of control

Ndrives®AerotechMotorsNdrives®

Third partymotors

Third party amplifiers and motors

ServoDrives

Servomotors

StepperDrives

StepperMotors

Save the disassembly and rework of drive and/or motor mounting and wiring.Save the cost of new motors and amps. Increase performance.

BENEFITS

Complete Aerotech SolutionExisting Motors and AmplifiersAre Retained

Up to 32 axes of controlUp to 32 axes of control

Automation 3200Control

Nservo

and/or

Nstep



Complete upgrade of integratedmotion control platform provides formaximum performance increase.

BENEFITS

Servomotors

StepperMotors

High Performance, Cost-Effective Machine Retrofits


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Basic motions such as independent axispositioning and jogging are simple toimplement. Users can program in eitherabsolute or incremental mode, or jog atconstant speed with programmable accel,decel, and feedrate. Accel and decel canbe linear or sinusoidal.

Linear and circular interpolated motionsare supported. Users can program inAeroBASICTM English-style commands,G-codes, or C/C++/VB. The Nmotion® SMCalso can run CAD generated programs.

A special feature of velocity profiling is theability to anticipate sharp corners or smallradius arcs. The Nmotion® SMC continu-ously monitors multiple blocks and willautomatically decelerate as needed for theseconditions. The number of blocks it canlook ahead is limited only by availableprocessor time.

ELECTRONICALLY-GEARED MOTIONS

Mechanical line shaft motioncan be replaced with electronicgearing. Gear ratios areprogrammable and can beelectronically engaged anddisengaged for flexible,software-based machinecontrol.

Also known as tool radius compensation,this feature automatically adjusts the pathto allow for the radius of a cutting tool.

Nmotion® SMC supports CNC stylemotion. In addition to cutter compensationand look-ahead, advanced functionsinclude coordinate transformation,parts rotation, normalcy, mirroring,and retrace.

CAM profiling is a special version ofelectronic gearing where complex slavemotion is generated as a function ofanother axis, a master encoder, or a virtu-al axis. CAM motion is defined in CAMtables. Cubic spline interpolation ensuressmooth profiles. The Nmotion® SMC’slarge memory cache allows it to storemany large tables.

POINT-TO-POINT MOTION

INTERPOLATED MOTION

CUTTER COMPENSATION

CNC FUNCTIONALITY

The Nmotion® SMC offers the broadestarray of programming interfaces and coremotion capabilities of any automationsystem available today. All motion com-mands can be accessed in C, C++, orVisual BASIC® for custom OEM applica-tions or in AeroBASICTM, a rapid proto-typing development language based onan RS-274 G-code style programminginterface. The Nmotion® SMC has theprogramming flexibility and capability tomeet the requirements of the mostdemanding motion applications forOEMs and end-users alike.

ANALOG POWER CONTROL

The Nmotion® SMC can adjust the setting ofan analog output in relationship to the vectorspeed of two axes. This function permits theautomatic regulation of laser power or mate-rial dispensing processes as the axes changevelocity. Combining analog power controlwith look-ahead acceleration limitingreduces program complexity and increasesmachine throughput by specifying a peakmachine speed and analog power setting andhaving the control automatically adjust thesevalues as a function of the programmed toolpath.

ACCELERATIONLIMITING

ELECTRONICCAM PROFILING

Software Motion Controller



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This function is used to precisely set digi-tal outputs as a function of motor posi-tions in one or two dimensions. Ratherthan operate as a background task in theNmotion® SMC, this function is off-loaded to separate hardware on theNdrive® for fastest execution and maxi-mized accuracy.

GANTRY MODE

Nmotion® SMC has built-in gantry con-trol algorithms. Complex gantry controlis reduced to a few simple commands.Single feedback/dual motor or dual feed-back/dual motor configurations are easilycontrolled.

ARBITRARY PATH GENERATION

Nmotion® SMC supports arbitrary pathgeneration where the user specifies theposition, velocity, and time. The controllercan then perform a linear or spline interpo-lation between the points to provide anultra-smooth contiguous path. Multipleaxes’ motioncan be coordi-nated to createan arbitrarypath in multidi-mensionalspace.

For packaging and label printing applica-tions, Nmotion® SMC supports high-speed registration operations where anaxis can move a predefined distancebased on the transition of a digital input.The registration move can be superim-posed over motion in progress to supportrotary-knife-style applications. The regis-tration “distance” can also be monitoredand modified to adjust for variations inmaterial length.

Axis calibration is a way to compensatefor repeatable mechanical errors in amechanism such as a ball screw. Alookup table onboard the Nmotion® SMCis used to make corrections based onmeasured data. Backlash correction val-ues can also be entered to minimizereversal errors.

Aerotech’s advanced 3D error mappingallows accurate positioning in an XYplane with an XYZ positioning system. Alookup table contains error data for threeaxes as a function of two of the axes.

FAST POSITION CAPTURE

The Automation 3200 system has thecapability to store motor positions basedon the transition of a digital input. Thishigh-speed position capture capability,with a latency on the order of 50 nanosec-onds, is useful for applications where theaxis positions must be closely correlatedto an external event such as a touch probein a coordinate measuring machine or atransducer reading in an ultrasonic inspec-tion system.

3D ERROR MAPPING

AXIS CALIBRATIONPOSITION SYNCHRONIZED OUTPUT

HIGH-SPEED REGISTRATION

KINEMATICS

The Nmotion® SMC can execute complexinverse kinematics equations within theflow of the trajectory generation.Application programs can be created inX/Y/Z part space and seamlessly trans-formed into joint coordinates. For maxi-mum flexibility, transformations are writ-ten in the C or AeroBASICTM program-ming language and are executed withinthe real-time operating system. Thisarchitecture permits the integration ofspecialized application specific transfor-mations to meet the requirements ofalmost any robotic-type actuator.

The Nmotion® SMC trajectory generationsoftware supports modification of movetargets on the fly. These modificationscan be given at any time during themotion profile and as often as required bythe application.

ON THE FLY END-POINT MODIFICATION

JOG & OFFSET, JOG & RETURN

Multi-axis coordinated motion can behalted at any time and the axes can bejogged off of the machine path. The axescan continue motion from the offset toolpath or return to the interrupted motionpoint and continue along the original pro-gram path.

High-speed sensor todetect mark edge

100

80

60

40

20

0 100 200 300 400 500 600

OriginalEndpoint

Final Endpoint

Samples

Velo

city


Dual-loop control is used to eliminate theeffects of backlash and other sources oferror.

SINUSOIDAL COMMUTATION

Brushless motors must be sinusoidallycommutated to obtain the smoothestmotion. By having the motion controllerperform the commutation, multipletransducers and cables are not needed.The A3200 has direct dual analog outputsto support commutation.

Velocity profiling is amode of motion whereconstant vector velocityis maintained along theprogrammed path.

Accuracy in an XY configuration can bedramatically improved using a lookuptable. The table contains error data forone axis as a function of the other axis’position, thereby reducing positioningerrors caused by misalignment of theaxes.

DUAL-LOOP CONTROL ORTHOGONALITY CORRECTION

PARTS ROTATIONThis feature is usefulin cases where a two-dimensional partmust be repeated indifferent orientations.The user programs apivot point and rota-tion angle. This eliminates the need totranslate the part program many timesover.

MOTOR CONTROL VELOCITY PROFILING

The A3200 can be used to control brush,brushless, or stepper motors in anycombination.


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The Ncontrol® SDK is a collection ofActive-X programming objects and aC++ class library that greatly reducesthe programming effort required tobuild custom Automation 3200applications. The Active-X componentspermit “drag and drop” programming invisual programming environmentswhile the class library provides anobject-level programming interface forC++ programmers. The SDK simplifiesI/O handling, event management, faulthandling, data collection, and programmanagement through an intuitive, high-level programming interface.

EXAMPLE FUNCTIONALITY

Program management and display

Data collection

Event manager for fault handling

Monitor I/O, axes’ positions, programvariables

Axis configuration

Parameter display and editing

Motion and task status display

Remote HMI capability

APPLICATION (VB/C/C++)OCX

CLASSLIBRARY

AERSYS.DLLDEVICE DRIVER

A3200 SOFTWARE ARCHITECTURE

Ncontrol® Application Programming Interface

Software Development Kit



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MANUAL MODE SCREEN

The Nview® HMI software offers arobust joystick (jog) and MDI commandline interface. The joystick mode offerstwo configurable virtual joysticks fordistance and freerun jogging. The MDIcommand line allows the manual entryand execution of immediate commands.

CUSTOMIZABLE INTERFACE

The HMI buttons on the Run and Manualscreens can be customized by the user toperform a variety of functions including:program execution, setting output, andlaunching external programs. CNCprograms can be automatically run atstartup, and axes can be renamed.

DIAGNOSTICS

Organized by tabs, the diagnostics utilityallows the status of the machine and systemto be determined with the click of a mouse.

SYSTEM ANALYSIS AND AXIS TUNING

Years of experience and research haveled to the development of a completeanalysis tool, including an Autotuneroutine. Using this tool, systemcharacteristics such as torque, positionerror, and velocity can be quicklydetermined quickly.

PLOTTING UTILITIES

Displaying the realtime tool tip path in 2-or 3- dimensional space allows for thevisual verification of axis position.

ONLINE HELP

Not only a quick reference guide, the onlinehelp also serves as a comprehensive onlinemanual. With over 1,500 searchable topics,the help file can be the only manual that youever need.

PARAMETER EDITOR

Logically divided into categories of axis,task, and machine automation, the editorgives real-time access to parameters.Using clear text descriptions, the purposeof each parameter is easily understoodand does not have to be cross-referencedwith a manual.

INPUT/OUTPUT

The I/O display screen enables the quick viewing and manipulation of virtual, drive, andEthernet based I/O. The state of digital outputs can be changed through a single mouseclick. Edit boxes are provided for reading and writing register-based data.

Human-Machine Interface

PSO/Absolute Encoder Interface (J301)

2 Channels SSINet for buffered RS-422 (mul-tiplied) encoder IN/OUT (J302, J303)

LED indicators

2 (18 bit) Analog Outputs and Brake Relay(TB301)

2 (16 bit) Analog Inputs (TB302)

User Power (TB303)

8 Opto-Isolated Outputs Common Sink orCommon Source (User-Defined) (TB304)

8 Opto-Isolated Inputs Common Sink orCommon Source (User-Defined) (TB305)

IEEE-1394 (FireWire®) J201, J202, J203Ethernet J204

Optional PowerSupply

1-3 Phase 28-240 VAC50/60 Hz

3 Phase 40-340 VDC Motor Output 50 - 100 Apk

External Shunt

Power LED

Motor Feedback Connector (J207)Emergency StopSense Input (TB201)

AuxiliaryI/O (J205)

RS-232(J206)


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Drawing upon 30 years of advanceddrive R & D, Aerotech has developed aline of intelligent digital drives for theAutomation 3200 network. Connectedvia the IEEE-1394 (FireWire®)communication bus, these drives providedeterministic behavior, auto-identification, and easy software setup from the Nmotion®

software controller. Featuring an 80 MHz DSP, the driveshave fully digital current and servo loops providingselectable 1-20 kHz loop sample rate, 32 MHz encoder datarate, and an Ethernet port for access to third-partynetworked I/O solutions. Designed for the discriminatingmotion control user, they also feature onboard brake relaysand options such as programmable resolution multiplication(x65536) and two-axis position synchronized outputs. Inaddition to these features, the use of the commerciallystandard FireWire® communication link makes integrationto the Automation 3200 network as easy as illustrated:

Wide output power range from 10 A peak to 100 Apeak at 320 VDC

No transformer required; direct connection to AC line

PWM and linear power stages available

Digital current, velocity, and position loops forimproved motion stability reliability

Optional integrated encoder multiplier for higherthroughput and reduced wiring

Flexible design provides ability to drive brushlessand DC brush-type servomotors as well as steppingmotors

UL, CE, and CSA approved

Intelligent, Networked Drives

Model shown below is a 100 amp Ndrive®.Additional intelligent digital drive modelsshown on next page.



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Recognizing that not everyone wants to panel-mount their amplifiers, Aerotechalso supplies the Npaq®, a 3U high, 19” rackmount chassis capable of poweringsix axes of motion while providing unparalleled ease of integration. Foregoingthe complicated wiring and assembly schemes offered by other vendors,Aerotech has designed the Npaq® to accept simple plug-in digital amplifiers aswell as one-step connections to the Automation 3200 network (via FireWire®)and third-party Ethernet I/O networks. Already containing 16 opto-isolateddigital I/O, four 16-bit analog inputs, and four 16-bit analog outputs, theaddition of an Ethernet port allows the user to control machines with thenetworked I/O of choice. Combine that with the ability to accept linear andPWM drives of varying power, support onboard encoder multiplication acrossall axes, and connect to additional Ndrives® and Npaqs®, and you have apowerful solution for all of your automation needs.

Compatible with all linear androtary feedback devices:Resolver, encoder (incremental,absolute), inductosyn, laserinterferometer

20 kHz sample rate for currentloop and 8 kHz for servo loops

High bandwidth server tominimize position and rate errors

Low costsolution

(NCdrive)

Base unit

(Ndrive®)

Expanded I/O capability

(Ndrive®)

Linear amplifiersfor low-noiseapplications

(NLdrive)

High power up to100 A peak(Ndrive®)

Intelligent, Networked Drives

Additional intelligent digital drive models

6 axes of amplifiers

INTEGRATED PLC AND MOTIONVendors of motion automation solutionsoften overlook I/O programming inter-faces. With Aerotech’s Automation 3200system, support for sophisticated PLC pro-gramming capabilities is available with theNlogic soft PLC programming environ-ment. Nlogic is based on an IEC61131-3compliant PLC kernel that has been field-tested in thousands of installations world-wide. Programming interfaces for all IEClanguages are supported.

ETHERNET I/OThe I/O capacity of the Automation3200 system Ndrive® and Npaq® compo-nents can be expanded easily throughonboard 10/100 BASE-T Ethernet ports.Each drive can be directly connected toan Ethernet I/O expansion module with acrossover cable. This eliminates the needfor hubs or switches and provides a ded-icated high-speed, collision-free commu-nication channel. Ethernet I/O units thatcommunicate with the ModBus/TCPprotocol are supported, includingdevices from WAGO, Opto22, Sixnet,and Schneider.

SEAMLESS INTEGRATIONEthernet-based I/O can be mapped intothe virtual I/O through an easy-to-useconfiguration utility. Virtual I/O can beused as a programming resource forinter-task communication, transferringdata between PLC and motion tasks, ortemporary holding registers.

HARD PLCWhile being integrated with a soft PLC,the A3200 can also be used with a sepa-rate hard PLC.

Virtual I/O Map

128 Floating Point Outputs

128 Floating Point Inputs

128 Register Outputs

128 Register Inputs

4096 Binary Outputs

4096 Binary Inputs

Flow Chart Program

Function Block Diagram

Instruction List Program

Ladder Diagram

Structured Text Program

Integrated PLC and motion

Industry standard IEC61131 language support

Machine and process sequence control through supervisory PLC program

PLC as master and motion controller as slave or motion controller as master and PLC as slave


22

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Soft Programmable Logic Controller

Aerotech's new vision and motion toolkit is designed for rapid prototyping with end users, system integrators, and OEMs in mind.Experienced vision and motion engineers, as well as first-time users, can begin rapid prototyping immediately with Nvision®.

Our complete product offering will address the unique requirements associated with integrating vision into automation productionprocesses.

Program in VB/C/C++ or use AeroBASIC to rapidly debug, prototype, and deploy vision-assisted applications.

Nvision® can be easily applied to any combined vision and motion application such as pick-and-place, part identification,measurements, etc. Nvision® builds on the Matrox Imaging Library (MIL®).

Standard and non-standard cameras can be interfaced with various hardware options.

Standard vision tools such as blob analysis, centroid calculations, edge detection, and geometrical feature analysis are integratedwith the A3200.

USER ADVANTAGES

Using Nvision® you can quickly set up,test, and save inspection objects with noprogramming necessary.

Our user-friendly pull down and pop-up vision controls let customers testinspection objects for robustperformance.

Load inspectionsSet ROIsRun inspectionsReturn results

Nview® HMI

VB Ncontrol® SDK



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Vision Control Module

VISION ASSISTED MOTIONCONTROL and RAPIDPROTOTYPE INSPECTION

Users can easily call inspection objects from Nview® HMI, Ncontrol® SDK, VB, orC++. Users can also make custom multiple-inspection objects or use results to adjustmotion profile.

Servomotors: Direct-Drive Linear and Rotary SolutionsLinear Motors BLMUC, -C, BLM, -H, -X, -FI, -FS Series

Advanced design yields 49% greater continuous output force than competitivemodels

Zero-cogging design allows super-smooth velocity and position control

Special magnet options available for increased force output

Utilizing a symmetrical mounting pattern, the modular tracks mount end-to-endfor unlimited travel

Optional cooling for higher rms force

Multiple forcer models provide a wide output selection

Drawing less current than competitive models (for a given output), ourlinear motors run significantly cooler — a critical benefit for high-precisionapplications

Vacuum versions available

Up to 4740 N of peak force and 1200 N of continuous force Advanced magnetic field synthesis andanalysis yields highest motor outputpower per unit volume.

Frameless RotaryMotors

S-Series

Three frame sizes

Frameless design for easy integration into OEMmachines

Slotless stator and high-pole-count rotor provide zerocogging for exceptional velocity control

Large torque range

Up to 146 Nm of peak torque and 36.5 Nm continuoustorque

ADRT Rotary System

ADRT Series

Three frame sizes

High torque output, low system inertia, high systemacceleration

Outstanding velocity stability, wobble, and runout

Large aperture, optional slip ring, rotary joint, brakeassembly, and tabletop

Applications range from indexing to high-speed lasermachining to precision wafer inspection


24

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ServomotorsBM Series

Standard sizes (NEMA) for easy integration and retrofitting

Wide range of torques cover most applications (0.5 - 75 Nm)

Advanced 8-pole design matched with skewed stator minimizes torque ripple and coggingfor smoother velocity control

Rugged construction ideal for 24/7 production applications

Excellent power density rating results in maximum torque in a compact package

Optional IP65 through IP67 construction allows use in harsh environments

Vacuum, food processing ready and explosion proof construction are standard configurations

BMS Series

The ultimate replacement for brush-type motors

Standard NEMA sizes for easy integration and retrofitting

Advanced slotless design yields superior velocity control

Brushless technology provides maintenance-free use and delivers higheracceleration than brush counterparts

Ultra-high resolution (8 M cts/rev) available when combined with Aerotech MXH encoder multiplier

Vacuum versions available

Custom BM Motor

Extremely rugged design for demanding environments such as automotive and machine toolindustries

IP67 (Immersible) and IP68 (Submersible) sealing available

1.4 - 50 Nm continuous torque range

Custom Motor

Designed exclusively for the food and baking industries. Capable of withstanding repeatedhigh pressure washdowns. Smooth housing and special connectors minimize potentialentrapment areas.

“Finless” extruded aluminum housing

FDA-approved epoxy coating

Stainless-steel shaft available

Optional terminal box

1.4 - 50 Nm continuous torque range


26

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PC-Based Hardware ControllersUNIDEX® 500/550 8-Axis Motion Controller

PCI bus format

Program in native G-code or AeroBASICTM commandset, C, C++, Visual BASIC® or LabVIEW®

Common software libraries, utilities, and HMI software

Complement with packaged drives or modular amplifiersand motors

CE compliant

UNIDEX® 511 4-Axis Motion Controller

Enhanced four-axis,DSP-based PIDFVFA

motion engine

On-board autotuning

Advanced multi-processor design

Integral linear,brushless servo, DC servo, and microstepping drives

Complete motion capabilities include: point-to-point;linear, circular, and helical interpolation; electronicgearing; velocity profiling

Program in native G-code or AeroBASICTM command set,C, C++, Visual BASIC® or LabVIEW®

Front panel displays and keypad for convenient menu-assisted programming

Remote interface via two standard RS-232 ports andoptional IEEE-488

Advanced Windows®-based remote diagnostic software

UNIDEX® 100 Single Axis Motion Controller

Complete package includes controller, driver,and power supply

Brushless, DC servo, and micro-steppingdriver models

Advanced motion control for master-slave,cam profile, and registration-basedapplications, plus output-on-the-fly

Autotuning feature minimizes set-up time

Multi-tasking operating system enables background PLCfunction or operator interface

Stand-alone operation: store user programs in 32 KBnonvolatile memory

RS-232 interface standard; RS-422 and IEEE-488 optional

16 opto-isolated digital I/O points; 2 position latch inputs;dedicated home, limit, and analog inputs

Compatible with LabVIEW® for Windows®

BA Intellidrive Single Axis Motion Controller

Provides positioning of brushless orDC brush-type servomotors

Available in models up to 100 A peak

Capable of point-to-point motion froma program, or initiated from an input

User defined acceleration and velocityparameters

Autotuning

Step/Direction input to drive servomotors

Programs and parameters stored in nonvolatile FLASHPROM for easy upgrade

Host-mode operation allows customer’s PC to sendcommands via RS-232 for immediate execution

Positioning modes include Indexing and Teach

UL and CE approval on low-power models

Stand Alone U511



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Servo AmplifiersBA 10, 20, 30, 50, 75, 100 PWM Amplifiers

Wide output power range from 10 A peak to 100 A peak at 320 VDC

No transformer required; direct connection to AC line

Capable of running brushless or single-phase DC brush motors

Velocity, torque, and dual-phase mode input command

Accepts both encoder or tachometer feedback for velocity control

Can be externally commutated

UL, CE, and CSA approval on low-power models

BAL Linear Amplifier

Non-switching, high-performance linear operation for ultra-smooth control of brushless motors

Totally modular design accepts 110 VAC or 220 VAC input power

Ideal for air-bearing systems and noise-sensitive applications

DR 300, DR 500, DR 600 Drive Racks

Low profile

Plug-in drives

Brush, brushless, or stepper

Variety of amplifier power

Integral power supply

Rack-mount design

Optional brake control circuitry

Uses BA series amplifiers

Optional E-Stop circuitry

BAS HMI setup with online help

Custom build your own interface

Easy to use out of the box

RS-274B (G and M code)

AeroBASICTM for custom motion

LMA Series

Travel lengths to 1 mVariety of motor sizes available

Compact, space-saving design

Integral E-chain for easy integration

Intelligent design protects motor and encoder from contamination or damage

Continuous force outputs from 73 N to 276 N are available

AGS10000 and 20000 Series

Velocities to 5 m/s

Accelerations to 5 g

Customizable Z and theta axes

Noncontact linear encoders

Rugged design for 24/7/365 day use

Lower cost-of-ownership due tononcontacting, non-wearing linearmotor and encoder

Optional machine base and risers

Optimized cable managementsystem

Optional coatings for enhanced ESDprotection

Available with high-performancemotion controllers and amplifiers fora complete, turnkey solution

Cartesian Robots

Actuators

T configuration Vertical or Z-axis operationTwo single-axis actuators

1 m x 1 m travel1.3 m x 1.5 m travel

1 m x 1 m travel gantry configuration


28

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Options and Accessories

Terminal Blocks

Interconnect Options

Position SynchronizedOutput Card for synchronouslaser firing to 3-dimensionalmachine motions

PC controller expansioncard for additional I/O

I/O Options Joystick

Multipliers Handwheel

Manual Mode Screen Program Execution

Program CompilerParameter Editor Diagnostics

System Analysis andAxis Tuning

Plotting Utilities

CustomizableInterface

Cables

Industrial computer

Software Interfaces

TeachPendant


30

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Superior Mechanics from AerotechOur hard cover design provides protection from sparkingand other debris introduced in the machining process. Therobust aluminum cover is protected with a TeflonTM

impregnated coating that provides a Rockwell 62 hardnessmaking it impervious to scratching. For applications notrequiring a hard cover, a bellows cover can be used.

HALAR (High Accuracy Linear Accuracy andRepeatability) and HALSF (High Accuracy LinearStraightness and Flatness) are available options.

Side seals keep dirt and particulates out of the stage,protecting bearing surfaces and linear encoders fromcontamination. The vertical orientation of the sealingsurface deflects debris away from the stage. Competitortop-seal designs can collect this debris, requiring periodicmaintenance and resulting in the eventual failure andreplacement of the sealing mechanism. Stages can be air-purged for additional environmental protection.

Direct-drive linear motors provide the highest accelerationand velocity with the lowest maintenance and total cost-of-ownership of any competing drive technology. Directdrive technology has superior velocity control to ensuregood edge quality on laser cutting and marking processes,while linear encoder feedback greatly improves overallsystem accuracy and repeatability.

Stages and motors can be made vacuum compliant to 10-7

torr.

Aerotech’s advanced mechanics include direct-drive rotarystages. These stages come in many configurations to meet theprice/performance goals of most manufacturing applications.Rotary stages use slotless, brushless motors for cog-freeoperation. Clear apertures up to 100 mm provide clearancefor beam delivery or feed-through of pneumatic or electricalcontrol signals. All rotary motors have low inertia rotors.

For medium-to-high accuracy systems, ball screw andworm drive systems are available.

Air-bearing stages provide maximum velocity,smoothness, flatness, accuracy, and repeatability.



APPLICATION SUPPORT AND DEVELOPMENTAerotech has engineered and manufactured specialty high-performance subsystems that meet customer needs for avariety of applications. Contact us with your application requirements and we will work with you to design a superiorsolution for your specific needs. By utilizing our highly trained staff of experienced software and hardware engineers,customers can get to production readiness faster. Not only is our staff available, the years of sample code that we havewritten will be drawn upon. Aerotech provides real-time collaborative support - either on site at your facility, on site atour facility, or through the web.

Engineered Systems

Ion Beam Profiling in Vacuum

Advanced Laser Machining Discrete Part Milling Machine

Liquid-Cooled, Vacuum-PreppedSystem

Precision Optical Production High-Precision Air Bearings

Rapid Prototyping Advanced Pick-Place-Inspect Station

www.aerotech.com

Patterned Media Inspection

High Volume Production InspectionStation

4-Axis Coordinate MeasuringMachine

Optical Lens FabricatingPrinthead Inspection Station High-Accuracy Laser Machining

Electronic Inspection High-Speed Optical Indexer


32

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Aerotech offers comprehensive worldwidetraining and customer service either atcustomer facilities or at one of our Aerotechtraining centers.

Our Training Program Features:

Standard and customized courses

Hands-on training with Aerotechpositioning systems

Interactive training with experiencedinstructors

Comfortable, spacious facilities

Worldwide Training and Support

Aerotech North America Aerotech GmbH Aerotech Ltd

CLASSES OFFERED

Automation 3200 Installation, Programming& Operation

UNIDEX® 100 and 500 Programming andOperation

Mechanical Maintenance & Troubleshooting

Customized Training for your AerotechSystem

EXPERTS IN MOTION

Ron Rekowski,M.S.E.E., Director ofProduct MarketingAdvanced AutomationDivision, is the chiefarchitect of theAutomation 3200.

Dr. Robert Novotnakhas over 9 years ofservice at Aerotech,and is instrumental innew product R&D.Bob is head ofAerotech’s AdvancedAutomation Division.

Dr. Joseph Profeta hasmore than 15 years ofexperience in technolo-gy and is responsible forthe automotive, machinetool, assembly, andpackaging markets atAerotech.

INSTALLATION AND START UP (COMMISSIONING)Aerotech offers startup and commissioning services to minimize startup times, reduce cost and accelerate time-to-pro-duction. By combining our product knowledge with your process and application expertise, new systems and applica-tions can be completed faster at a reduced overall cost. By working with Aerotech during the commissioning, you canlearn more about Aerotech products and their capabilities.

ENGINEERING SUPPORTAerotech provides complete engineering support for our products, including onsite support and maintenance, andremote support via phone, fax, website, and/or WebEx® software. As a manufacturer staffed by engineers, we under-stand the unacceptability of downtime.

TRAININGAerotech training classes are designed to help our customers unleash the full potential of our products. Bydemonstrating all of a product's features and how to use them, customers have been able to reduce startup time andquickly optimize their applications. Aerotech’s classes have been developed, and continue to be upgraded, usingfeedback we receive from our customers who have participated in the classes. This feedback is used to ensure the courseis optimized and that every feature is covered thoroughly.

Aerotech has over 30 years of expertise in designing motion control and positioning systems and components with anunsurpassed track record of reliability. When you make the choice to purchase from Aerotech, we urge you to learn howto get the most from your new Aerotech products. Aerotech provides both onsite (your facility) and/or in-house (ourfacility) training for our customers’ convenience.



www.aerotech.com

Award Winning AerotechAerotech’s strong commitment to research and development has resulted in many patents and a number of awards for ourinnovative products. We look forward to the future and our part in advancing the capabilities of our customers for manyyears to come.

Machine DesignSlides/Ways

Lightwave OFC 2001Attendees’ Choice AwardFiberAlign® 130

PD & D Top 50Product 2002Automation 3200

Aandrijftechniek 2002“Most Innovative Product”FiberMax®

Lightwave NFOEC2002 Attendees’Choice AwardFiberMax®

Design News 2002Best Product of theYear finalistAutomation 3200

Aerotech: An ISO 9001 Registered CompanySince 1995, Aerotech’s quality system has been certified tothe ISO 9001 standard. The ISO 9001 standard encompassesthe Aerotech organization through manufacturing.

As part of our commitment to the ISO standard, weformally survey our customers on a monthly basis whichprovides valuable feedback as to how to continuallyimprove our products and processes.


34

www.aerotech.com

Aerotech Online

Product NavigationEasy to use productnavigationintuitively andquickly guides youthrough our broadproduct range.

Current Product and Company NewsThe most current product and companynews is featured prominently on ourhome page.

Worldwide Sales Office LocatorUse our worldwide sales officelocator to quickly find an Aerotechoffice near you.

Customer ServiceOur customer service centerprovides contact information forAerotech customer serviceworldwide. Also included aredetails on our training programs,software and product manualdownloads, and a FAQ section.

Aerotech’s website at www.aerotech.com is your comprehensive resource for all Aerotech information worldwide. Ourproduct information is very thorough and better than having a catalog! Each product section comes with all theinformation available in print and includes downloadable 2D and 3D models. Register for our e-newsletter In Motion toreceive bi-monthly news on all of the current activities at Aerotech.

Select your MarketOur new “select amarket” feature detailsmarket-specificAutomation Solutionsfrom Aerotech.



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Sign up to receive our e-newsletterAerotech’s bi-weekly e-newslettersbring you timely news, productinformation, technology tips, servicebulletins and more!

Visit www.aerotech.com to subscribe!

Aerotech OnlineDownloadable 2D and 3D ImagesComprehensive product informationincluding descriptions, specifications, 2Dand 3D models for all of our productsprovides an unparalleled resource for ourcurrent and future customers.

36

1970s: Introduced first ball-screw-based positioning systemswith advanced linear servo drives. This represented a revolu-tionary advancement in system throughput — five times bet-ter than lead screw and stepper motor technology. Adaptedand widely deployed by IBM, DuPont, and Westinghouse.Patent on coarse and fine adjustment positioning mechanism(U.S. Patent #3,727,471). Established subsidiary inGermany.

1980s: Introduced UNIDEX® series microprocessor-basedmotion controllers. Developed brushless amplifier and rotarymotors which increased throughput, reliability, anddecreased maintenance. Patents on a switching amplifierwith MOSFET driver circuit (U.S. Patent #4,554,512), amilling machine tool changer (U.S. Patent #4,426,763), amicrostepping translator controller (U.S. Patent #4,652,806),and for closed-loop torque angle control of a synchronousmotor (U.S. Patent #4,884,016). Established subsidiary inthe United Kingdom.

1970 1980 1990 1991 1992 1993 1994 1995

1990: Introduced the U500 ISA PC-bus-based motion con-troller and the UNIDEX® 511 stand-alone, multi-axis motioncontroller.

1991: Patent on successive fringe detection position interfer-ometry (U.S. Patent #5,018,862). Introduced AOM seriesAZ/EL optical mounts.

1992: Patent on quadrature error correction (U.S. Patent#5,134,404). Introduced the BLM series linear brushlessmotors.

1993: Introduced the BM series brushless rotary motors.

1994: Introduced the ABL8000 air-bearing stage and BAseries amplifiers.

1995: Introduced the ALS2000 linear motor stages series.Developed the ABL9000 H-bridge air-bearing stage.

Aerotech: A History Dedicated to the Science of MotionAerotech innovation means:

• Highest Throughput

• Best Accuracy

• Lowest Cost of Ownership

• Best Return on Investment

37

2002: FiberMax® wins NFOEC 2002 Attendees’ ChoiceAward. Automation 3200 named Design News 2002 BestProduct of the Year finalist and PD & D EngineeringAwards 2002 Top 50 Product. Patents on a calibratedencoder multiplier (U.S. Patent #6,356,219 and #6,501,403),on a direct-drive tilt and goniometer stage (U.S. Patent#6,442,851), and on a small footprint vertical lift and rota-tion stage (U.S. Patent #6,486,574).

2003: Aerotech developments include the ADRT andADR160 series rotary stages; the AVL113/125 vertical liftstages; the ASR2000 high-speed spindle; the ATS1000,ATS1100-H, and ALS1000 series linear stages; theABL1000 air-bearing stage; the BL linear amplifier; andcontinuous improvements to the Automation 3200. Aerotechexpands headquarters. U.S. Patent #6,588,081 for small foot-print direct-drive mechanical positioning stage.

1996 1997 1998 1999 2000 2001 2002 2003

1996: Introduced the AGS10000 linear-motor-driven gantry.

1997: Introduced the BA Intellidrive.

1998: Patent on linear-motor-driven vertical lift stage (U.S.Patent #5,731,641). Won the Machine Design AchievementAward for slides and ways. Introduced the BLMF series flatlinear motors and BAL linear amplifier.

1999: Introduced the ABL2000 linear air-bearing stage andthe U500PCI PC-bus-based motion controller.

2000: Won the Machine Design Achievement Award forslides and ways.

2001: Aerotech develops the first software-based, 32-axisintelligent motion, vision, PLC, robotics, and I/O platform— the Automation 3200. The Automation 3200 is voted oneof the year’s 50 most innovative products by the readers ofDesign News. FiberAlign® 130 wins OFC 2001 Attendees’Choice Award.

- Aerotech Headquarters - Direct Field Sales Office - Aerotech Subsidiary - Representative

Aerotech’s Worldwide Sales and Service Locations

CA1103A

Dedicated to the Science of Motion


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