Control movement precisely

"Our approach is to supply individual components for the automation process as well as complete positioning and automation systems as it applies to the quality assurance environment," emphasises Simon Smith, European Director Aerotech. But what good are high-precision positioning and automation solutions without high-performancemotion control? With the new Automation1 release, Aerotech has once again broken through boundaries in motion control. "Our highlight of the show is the feature enhancements to the Automation1 motion control platform in release 2.4," said Simon Smith. "With Python API support, all of our control’s Python help files are now available. If you have any questions about the Python interface, you can always refer back to it."

The machine setup, data visualisation and the ‚Homing Setup helper‘ module have also been significantly improved. In addition, the Aerotech programmers have further simplified the uploading and downloading of MCD files and Automation1 now supports the Gantry-mode for XI4 and iXI4 Servo controllers with absolute encoder support.,The device catalogue and machine setup for linear gantries now guides you through the task of setting up gantry parameters for custom gantry configurations. 3-axis PSO with the GL4 module with IFOV (Infinite Field of View) and BiSS absolute encoders are now supported, which is important for the integration of galvo scanners and other lasers to synchronise moving servo axes with precise laser firing control, delivering better part quality. . This also increases throughput, further improves positioning accuracy and eliminates stitching errors. In the machine apps, users can now drag and drop several machine app modules into the Module container, a separate area of a MachineApp to allow more configuration flexibility. To increase usability, notifications and animations can be executed directly in the MachineApp using indicators.

Precise measurement of surfaces

One focus of the Control trade fair is the area of surface measurement technology. Especially the production of optical components used in laser material processing, biotechnology, medical and semiconductor manufacturing requires high-precision surface measurements including non-destructive quality assurance. With the SMP multi-axis motion system, Aerotech addresses the needs of metrology equipment manufacturers supporting these markets. "Optical components are used everywhere, for example in medical technology for prevention, diagnostics and therapy or for laser processing of materials in additive manufacturing," Simon Smith knows from practical experience. High-precision optics, however, require high-precision measurements of spherical, aspherical and cylindrical shapes in the nanometre range. A prerequisite for this, he says, is therefore flexible 2D and 3D contouring. "We were able to show in field tests as well as in practice that the processing time for surface measurements can be reduced by up to 40 per cent due to the excellent positioning properties, and the elimination of the traditional step and scan approach over larger parts with XY axes" says Simon Smith. And the SMP requires up to 60 per cent less floor space than Cartesian measuring systems due to its construction.

Planar linear tables – precise over the entire length

The PlanarDL series of linear stages offers excellent geometric and dynamic performance, according to manufacturer Aerotech. The integrated low-profile XY stage is driven by a linear motor, features precision cross roller bearings with anti cage migration, and is available in nine model variations depending on travel and accuracy. The number of motors per Servo axes, air/vacuum lines for vacuum clamping devices or other process pneumatic components are available as standard options. Many different travel and performance options make planar linear stages ideal for a range of applications, from surface profiling to LED wafer scribing.

The XY design with its planar geometric performance shows its strengths especially in applications where straightness and flatness are important – straightness up to ±0.4 µm; flatness up to ±1 µm. The components of the linear stage are optimised from the point of view of high dynamics and rigidity to meet the most demanding dynamic applications. The linear stage allows speeds of 1 m/s and accelerations of 1.5 g, ensuring high throughput and maximum accuracy.

Aerotech Hexapods

The Hexapods from Aerotech provide true 6 degree of freedom positioning with outstanding load-bearing capacity. The HEX150 and the larger, HEX300, can be positioned with Automation1, trade visitors can see for themselves at stand 5425. Simon Smith knows the outstanding features of the hexapod: "With the comparison of the two hexapods, we want to demonstrate the significantly better minimal incremental motion on a small and large hexapod positioning system, together with larger travel range than similar sized competitor products, all in a compact yet rigid platform." In addition the six degrees of freedom (DOF) enable precise translation in the X, Y and Z directions, as well as rotation around each of these axes. Which hexapod a user chooses for their positioning tasks depends on the load to be moved, travel range and the space available. "Our miniature hexapod is ideal for space-constrained applications with multiple DOFs that require fine positioning resolution." Here, Aerotech particularly recommends applications such as alignment, assembly and interconnection of photonics components, optics inspection and alignment, optical wafer probing, aerospace and satellite sensor testing, and sample alignment in synchrotron and beamline applications. The wide range of motion as well as the simple control and programming with virtual pivot point adjustment simplify integration into complex applications and complete systems. Fast settling times ensure high throughput with repeatabilities of less than 2 μm at high payloads of up to 7.5 kg and a holding force of up to 100 N when deenergised.  The small step sizes also allow for a wide range of applications for the HEX150.

The Automation1 control platform has its own "HexGen Hexapod" simulation software integrated. This enables easy programming and control of the Hexapods in any user-defined coordinate system. For collision considerations, the user can visualise and simulate the available working space. Preconfigured models from a stored library of standard designs are also available.