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Baldor demonstrates the Ethernet motion revolution: 12 interpolated axes on one RJ45 cable

* ultimate industrial networking is being added to successful global drive family

At Machine Builder 2005, Baldor is demonstrating the potential of the Ethernet Powerlink protocol for machinery builders with a 12-axis system performing interpolated real-time motion control. At the heart of the demonstration is an Ethernet Powerlink equipped variant of the successful MicroFlex single-axis drive, Baldor's lean-and-smart drive concept that is now installed in hundreds of systems around the globe.

Available from April 2005, the new Ethernet-equipped MicroFlex servo drive has a lean hardware core that minimises costs for the networked control environment. It provides a dual-port Ethernet hub interface to support easy daisy chaining of drives. There is also a CANopen interface to provide a low-cost means of adding remote I/O or other components to the machine control system; this is supported by the decision of the Ethernet Powerlink group to use CANopen device profiles. The initial release of MicroFlex with Ethernet will offer a choice of single-phase drives capable of delivering continuous output currents of 3, 6 or 9A.

Baldor's demonstration shows 12 axes of Ethernet drives performing real-time interpolated motion; however the Ethernet Powerlink scheme has sufficient real-time speed to control up to 16 interpolated axes and many more loosely-coupled axes. Ethernet Powerlink will support up to 240 devices such as drives, I/O devices, absolute encoders, gateways, etc. Users have the option of controlling any loosely-coordinated axes using the CiA DS402 positioning drive profile, which is fully supported by Baldor's MicroFlex drive. This provides system builders with an elegant means of offloading the host motion controller, allowing simple commands to activate remote functions such as absolute or incremental moves, changing target positions on the fly, and performing homing sequences.

The new approach delivers major integration and system building benefits for motion and machine control. For a similar hardware bill-of-materials to today's technology, it delivers simpler system building and commissioning - through reduced wiring and improved operational efficiency and machine performance.

Discussions with machine builders have highlighted simpler wiring as a major benefit. "You only need a single Cat5e shielded cable for each node, replacing numerous digital and analogue signals and fieldbus communications to each device," says David Greensmith of Baldor. "Machine builders that we are talking to have picked on this attribute as a major saving, telling us it will remove as much as 100 Euros per axis in terms of reduced cabling costs, along with the associated savings in design of wiring diagrams and assembly labour."

After realising these benefits, further savings are possible thanks to the simplicity and flexibility offered by all-digital control. This is a key aspect of Baldor's approach to Ethernet Powerlink, and the vendor will enhance the power of the standard with a powerful new extension to its Mint motion control language.

"Mint software will make control and coordination of numerous axes much simpler than it is with traditional PLC languages, providing an object-based approach to axis referencing, and simple networking configuration using wizards," adds Greensmith. "Combined with the incredible richness of motion control functions available in Mint compared with ‘open’ industry software, I believe the combination of Ethernet and Mint gives engineers a real edge in machine automation development."

MicroFlex is a family of low-cost digital servo drives that provides users with a means of increasing the speed and smoothness of existing automation through the application of advanced digital control technology. The drives are specifically designed to address the need for a high performance yet low cost drive, and feature a very lean hardware core plus a designed-for-manufacture system that uses a special moulded casing and simple assembly techniques that keeps costs to a minimum.

Advanced space vector modulation (SVM) techniques are used to control the IGBT (insulated gate bipolar transistor) power devices in the drive’s output stage, resulting in significantly reduced switching losses and harmonics. Compared to conventional drives with a pulse width modulated (PWM) output stage, MicroFlex units enable servomotors to run more smoothly and up to 15% faster – equating to greater control flexibility, improved accuracy and increased machine throughput. The drive’s DSP core enables users to optimise system performance via software-configurable anti-resonance filters. Instead of employing ‘soft’ servo loop gains to eliminate noise and vibration by de-tuning the system – which is a compromise often faced when retrofitting a drive to an existing installation – users can set up the filters to optimise dynamic performance and minimise settling times.

To complement the Ethernet servo drive, Baldor is showing a motion controller with a high-performance core that will control large numbers of Ethernet Powerlink connected drives, as well as traditional analogue-controlled axes and stepper drives for maximum system design flexibility. Baldor will launch a complete family of Ethernet Powerlink options in April.

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