Electromechanical Group

The automotive vehicle industry has experienced introductions of several new technologies and upgrades. One significant example is the rising amount of electrical content per vehicle. Testing for vehicle and engine performance is essential in the wake of additions and conversions from each of the new technologies. 

Concurrently, OEM manufacturers are facing a number of cost pressures that are fueling the dynamometer market, from both regulatory and the consumer base, leading to higher investments in R&D and testing. 

The major drivers for dynamometers use for in-plant automotive facilities are test stands with enhanced accuracy, increasing demand for vehicle quality standards and increasing awareness toward quality in new markets. The challenge faced is how to get the price down on vehicles when all other costs are increasing.
 

Increasing electric and hybrid vehicle production will require more specialized testing stands:

• Automotive plants are looking at purchasing new test stands to support the production of electric and hybrid vehicles.

• Drive/control equipment on existing test stands may go obsolete, so parts and service will be hard to come by.

• Production costs will rise with energy prices if existing equipment is not replaced with a more energy efficient solution.
   

Automotive or truck manufacturers or makers of components or sub-systems that go into a new vehicle already have test stands and dynamometer equipment that may be outdated and in need of drive/control retrofit. These customers who already have older test stands suffer from down time, trouble obtaining parts and excessive energy consumption. 

OEMs looking to purchase test stands may want specialized features in the drive/control system and not every supplier can offer that. Or, they may be looking to purchase a new test stand or dynamometer and may want to specify certain equipment in addition. Our engineers will work with the test stand manufacturer on a special design as needed. 

A dynamometer is a necessity in automotive vehicle testing equipment used by OEMs, component suppliers and automotive testing service providers for recording several parameters such as force, torque, power and speed of the vehicle.

The use of this testing equipment is essential throughout the production cycle of an automobile, making it a necessary component of all vehicle assembly lines. This testing equipment is also used in vehicle engine manufacturing factories and dynamometer laboratories or the automotive testing service facilities to evaluate vehicle and engine performance.

Test stands and dynamometers cover a wide range of applications, but are most commonly used to test manufactured items for adherence to specification while simulating real-world operating conditions. While “test stand” is a more general term defining a machine that could test nearly any item including pumps, automotive components or electrical components, a “dynamometer” is used to measure torque or power and is more closely associated with motor or motor vehicle testing.

A drive system is used in these applications to either provide motive force or absorb it, depending upon the type of test stand:

1. A pump test stand requiring a motor to spin the pump and a drive/control system to regulate the speed and torque delivered to said pump.

2. A dynamometer used to test an electric motor would require a second motor that would effectively act as a braking device to load the motor under test.The drive and control system would be required to absorb this energy while regulating the speed and torque during the test.

A third example would be a test stand designed to test rechargeable batteries. Here, no motive force is involved, but the test gear would charge and discharge the batteries in a controlled manner, allowing the batteries’ functionality to be evaluated.

Many test cell designs are energy wasters. Older technologies like water brakes, fan brakes or eddy current devices, for example, convert kinetic energy from the testing process to heat. Replacing these methods with a regenerative drive system can allow this wasted energy to be recaptured and returned to the power grid. In addition to reducing your carbon footprint, a solid-state drive system will quickly pay for itself in power bill savings. Energy saving features exist even within the drive system, like smart ventilation in the AC890PX series that senses internal temperature and adjusts fan speed to save energy when the unit is lightly loaded, or in cooler ambient temperatures.

Parker regenerative drives can harvest energy from the testing process and return it to the power grid, providing a substantial net reduction in a plant’s electric use. Older dynamometers that are widely in use simply burn off the excess power and dissipate it as heat, which is wasteful of resources. In the grand scheme of things, our engineering expertise in special equipment for electric and hybrid vehicle manufacturers contributes to these vehicles being efficiently manufactured and sold, resulting in less polluting gas and diesel-powered vehicles on the road.  
 

Parker can provide a drive/control retrofit that will allow you to keep your existing mechanical equipment and enjoy more efficient operation. And, in many cases, better performance, and have the knowledge that the drive/control system is up to date and serviceable.  

For example, if you have an existing test cell using DC motors as prime movers or absorbers, and do not wish to upgrade to AC technology, the DC590+ digital DC series is a flexible and economical solution for test rigs through 2000 HP. Replace your obsolete SCR units with the latest in digital DC to eliminate costly repairs and downtime, with the added benefit of IoT capabilities.

For OEMs of vehicle test stands who are looking to expand into new markets of electric and hybrid vehicle manufacturing, Parker can provide custom or specialized drive and control systems that meet the unique testing needs of these vehicles. For those competing in the more traditional markets, Parker draws from over 30 years of experience in drives and controls to provide systems that are compact, easy to maintain, and energy efficient. 

Have a dynamometer application or just want to learn more? Download our Test Stands and Dynamometers Solutions brochure.

Article provided by Lou Lambruschi, marketing services manager for Parker's Electromechanical and Drives Division.

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When it comes to linear actuators, selecting the right drive technology can be a precise balancing act as there is no ‘one size fits all’ solution.

Due to the breadth of applications – from automated packaging lines and pick-and-place operations to complex machines such as 3D printers – making the correct choice is less about concentrating on a single aspect than finding the optimum balance of performance from a variety of different factors.

Most electromechanical linear actuators rely on one of five common drive train types: ball screws, lead screws, timing belts, rack and pinion tracks and linear motors.

Ball screws are ideal for high duty cycle applications and where high force density, precision and repeatability are required. The rolling ball bearings reduce friction and deliver high mechanical efficiency, even in continuous use. Ball screws can achieve moderate speed.

Lead screws are suitable for low duty cycle applications, or those requiring small adjustments. They typically only offer about half the efficiency of ball screws, so require twice the torque to achieve the same thrust output. However, lead screws provide cost-efficient and compact solutions for high-force applications.

Timing belts are simple, robust mechanisms for high-speed applications requiring long life and minimal maintenance, where precision greater than 100 microns is sufficient. They are efficient and easy to operate and can run at 100 percent duty cycle. Timing belts are available in longer lengths than screw drives.

Rack and pinion systems are useful for very long travels requiring high speed but are not known for their precision. They offer high force density but require regular system lubrication. In addition, removing system backlash from this type of drive train is not always possible, and they can be quite noisy in operation.

Linear motors offer high speed, acceleration and precision. Cost is the principal drawback, while force density is also less than other drive systems. The absence of a mechanical connection between the moving and static components of linear motors makes their use difficult in vertical applications.

The selection options for a linear drive can be grouped into the following categories: precision, expected life, throughput and special considerations (PETS).

For precision, always start with an understanding of needs relative to resolution. The other considerations are repeatability and velocity control. Linear motors and ball screws are typically best in terms of precision characteristics.

With lifespan, mechanical efficiency is the primary consideration, unless the requirement is for a dirty or harsh operating environment. High drive train efficiency is synonymous with long life and reduced energy consumption. Factors such as wear resistance, dirt resistance and maintenance requirements are also important. Due to their high efficiency and limited maintenance needs, timing belts are the go-to option in this category.

Throughput can be considered by first scrutinising the speed and acceleration or deceleration characteristics of each technology – depending on the length of linear travel required. If the need is for longer travel where more of the cycle time is spent at top velocity, speed is the most important. If shorter moves are required, acceleration and deceleration characteristics will take precedence. Linear motors are unparalleled when it comes to throughput.

Some other considerations to take into account when looking at each technology include material and implementation costs, while force density is a further increasingly important factor to bear in mind as machine designs continue to miniaturise, particularly when specifying end effectors or tooling mounted to an axis.

For more information about the four key performance characteristics to consider when choosing a linear drive train from our white paper click here to download.

Article contributed by Olaf Zeiss, product manager, Actuators Electromechanical & Drives Division Europe.

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In a world of constant technological advances, the photonics industry is seeing rapid growth with no signs of a slow-down. Photonics is the branch of technology concerned with the properties and transmission of photons. Photons are applications involving a laser. Lasers often conjure up images of an evil scientist plotting to destroy an unsuspecting city with a “laser death ray.” To the contrary, laser applications are commonly used in many markets to improve the quality of life – think healthcare or autonomous cars.  

 

Precise motion requirements

Applications in the photonics industry usually require a precise motion control system to function properly. In addition to these sub-micron specifications, many applications require high speeds and long lengths of travel. To meet these requirements, a linear motor stage is usually the best option. Parker offers a range of linear motor stages to satisfy these application needs. From miniature linear stages such as the miniature square rail, mSR, to completely custom designs, we can provide the linear stage that provides speed and precision.

 

Parker’s product and expertise in this area were on display at SPIE/Photonics West Exhibition, the world’s largest photonics technologies event in January in San Francisco. Parker displayed XY custom systems made of linear motor stages to simulate performance in laser based applications including laser scribing/cutting and cellular scanning. Customer feedback reiterated the need and desire for these products out in the field. Products need to be fast and accurate while maintaining their Abbe errors (stiffness, smoothness and flatness). Parker has designed products specifically to provide Abbe specs above the industry standard along with the drives and controllers to complete the motion system, Learn more about Parker’s linear motor stages. 

Other types of electromechanics also apply. Many applications still use a screw-driven stage on the Z-axis. Designers will choose this route since they usually do not require the precision or speed provided by a linear motor stage for this axis. The other advantage is that a magnetic counterbalance is not needed when the unit is not in use. Parker’s MX80S and MX45 series are ideal for these applications as they provide the needed precision at a reasonable price.

As the photonics industry evolves and requires better motion control, Parker will adapt as well to continue learning and providing the best solutions possible to customers. We are excited for the future of photonics. For more information on products from Parker’s that support the photonics industry, visit our website. 

Article contributed by Patrick Lehr, product manager for precision mechanics, Electromechanical and Drives Division North America, Parker Hannifin Corporation. 

Linear actuators are typically grouped into two principal types: fluid power actuators that operate on differential pressure, and electromechanical actuators driven by an electric motor. Increasingly, electromechanical solutions are providing an attractive alternative to hydraulics in a wide and diverse array of automation systems.

Electromechanical systems offer: 

• Simpler and smaller installation
• Greater flexibility
• Quieter positioning and torque control
• Lower energy costs
• Less maintenance
• Potential to provide more ATEX-rated solutions for use in explosive environments

In complex applications, electromechanical solutions can be particularly advantageous as they provide control over the entire motion profile. Moreover, integral encoders accurately control speed and position, while some solutions can also control and monitor torque. Programmability means that motion and force profiles can be changed using software without having to shut down and reconfigure the machine.

In terms of energy consumption, unlike hydraulics, electromechanical solutions use power only when they are performing work, thus contributing to significant savings. Also, due to their minimal impact on the environment, solutions of this type are strongly preferred in applications where clean operation is important or desired.

An example case for electromechanical solutions is put by Industrie Cometto SpA, an Italy-based designer/manufacturer of trailers, semi-trailers and self-propelled vehicles, which wanted to replace hydraulic systems on its EMT (Electric Modular Transporter) to achieve greater flexibility in terms of speed and control, and make it suitable for use in ATEX classified atmospheres.

Replacing hydraulics

The traction and steering systems on the EMT are now equipped with Parker electromechanical products. Each transporter can have from four to 16 wheels, all of which have to follow a perfect trajectory to ensure coordinated motion. With this in mind, the drive system has to guarantee precision in terms of speed, position and torque control. An AC, three-phase, 2.3kW electric motor is fitted to the traction system on the EMT.

With regard to the steering system, the position of each wheel axle is controlled electronically using an encoder. Here, each suspension unit is linked to the load platform by a rotation system driven by a 1kw electric motor. The motor is controlled by an absolute encoder and managed by Cometto’s central processing unit.

Parker supplies the complete motor and drive packages for both of Cometto’s non-ATEX and ATEX EMT vehicles. For the latter, Parker provides its EX (explosion-proof) servo-motors with AC890 variable speed drives.

The EX series is a range of permanent magnet explosion-proof brushless servo motors characterised by excellent motion quality, dynamic acceleration/deceleration capabilities and high torque output over a wide speed range. Parker’s AC890 is a compact, modular system variable speed AC drive engineered to control speed and position of open-loop and closed-loop, single- or multi-motor AC induction or PMAC motor applications. The AC890 variable speed drive is compatible with any AC motor and many speed/position feedback options.

Ultimately, electromechanical solutions offer engineers a number of potential benefits over hydraulics that are proving difficult to ignore when it comes to new system designs. These can include one or many of quality, reliability, maintenance, performance, cost, ease-of-use, noise levels and operational response.

EX-Series Explosion Proof (ATEX) Brushless Servo Motors

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Article contributed by Edi Gherbezza, electromechanical, motion & drives
application manager & business development manager  for Motion Systems Italy

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With its high power density and flexible mounting capabilities, permanent magnet direct drive servo motors like the Parker PM-DD series have a proven track record in many manufacturing applications. Let's take a look at five successes spanning various industries.

As the world's communications infrastructure continues to grow and evolve, the demand for fiber optic cable has been increasing. With Parker distributor Cross Automation in Charlotte NC, we were able to provide PM-DD motors for a vertical lathe, used to dispense glass for fiber optic wiring. The combination of smooth low-speed operation, compactness, and the ability to mount directly to the rotating shaft made the PM-DD a winner over standard servo motors. 

Machine tools demand accuracy, and in the second case study, the task at hand was to repeatedly index a table that was three feet in diameter. With displacement occurring 1.5 feet (457 mm) away from the motor centerline, its high resolution (20 bit) absolute encoder was critical to the application. Thanks to the PM-DD's high load carry bearings, (1500 N in this case) where previously a conventional servo motor and worm gear solution was used, the PM-DD proved to do the job while eliminating the worm gear. The drive train was simplified and ongoing maintenance associated with the mechanical gearing was eliminated. This solution was sold by Faber Associates, Parker distributor based in Clifton NJ.

Automotive assembly is a rigorous application with hundreds of interdependent operations, all of which must function reliably, at the risk of costly downtime. A rotary table was used in the operation of adjusting vehicle headlights. Simplicity and high positioning resolution were the main factors leading to the adoption of the PM-DD in an application solved by Parker distributor Reco-Wesco from Indianapolis. Being able to mount the motor directly to the table eliminated the need for multiple mechanical components that would have required maintenance and been a potential failure mode.

Automotive industry testing applications often duplicate real-life scenarios that the finished vehicles will be exposed to, but must take into account the worst-case situations. In this case, the PM-DD motor was used for an electronics test bench. Part of a multi-axis assembly, the test bench would simulate the rough vehicle road conditions, including a rollover, that the electronics might be subjected to. PM-DD was preferred over a standard servo motor due to its smooth, slow speed, operation, good bearing support and high torque.  This solution was sold by Parker distributor  RSA of Fond du Lac WI.

The fifth and final application was in the life sciences field. A PM-DD motor was used for an indexing table that carried five stations to support the assembly of medical devices. The first station was to load the part, second applied adhesive, third was for UV curing of the adhesive, fourth was inspection and fifth was where the part was unloaded. In this case, the PM-DD replaced a pneumatic indexing table. Key to its success was a smooth start and stop operation versus the previous pneumatic solution. Also, the PM-DD with Parker P-Series Drive allowed for a variety of indexing locations to be programmed providing more flexibility than a more traditional rotary indexing table. This solution was provided by Automation Incorporated, a Parker distributor out of Minneapolis MN. 

Learn more about the PM-DD by visiting our Precision Direct Drive Rotary Servo Motor Series Product webpage to buy or download a Parker P series
Direct Drive Rotary Motors​ catalog. 

Article contributed by Jeff Nazzaro, gearhead and motor product manager, Electromechanical & Drives Division, Parker Hannifin Corporation.

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