Designing a Motion-Control System … Software in 2015 Makes It Easy will show how software is simplifying the work of motion-control designs. It will cover programming and software tools that help engineers pick component faster and with the physical layout of a motion system. Then the webinar will segue into an explanation of programming options to help designers author controller schemes faster ... sometimes within user-friendly environments. During this webinar, attendees will learn how to use software to calculate output requirements; how to pick from motion-control design software offerings that fit pieces together virtually; what options there are for automatic software generation of motion profiles and bills of materials; and ways to use one specific piece of software to pick an electromechanical actuator, motor, and drive for a single-axis motion system.

1. Designing a Motion-Control System ...
Software in 2015 Makes It Easy

2. q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

3. Designing a Motion-Control System ...
Software in 2015 Makes It Easy
Wednesday • June 23, 2015
Submit your questions!
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4. Designing a Motion-Control System ...
Software in 2015 Makes It Easy
Presenters:
Lisa (Elisabeth) Eitel
Senior Engineer Editor
Design World
Thomas Worsnopp
Product Manager
Servo Pneumatics and PLCs
Festo Corp.

5. Designing a Motion-Control System ...
Software in 2015 Makes It Easy
1. Enabling technology landscape in 2015: Better processors than ever (thank you,
Moore’s Law) and configurability of physical components play synergistic role with
software in eliminating busy work of motion design.
2. Design software: More interoperability is driving dynamic collaboration.
3. Selection software: An array of increasingly powerful tools make short work of virtual
prototyping.
4. Example from Festo: One engineer from Festo walks us through the use of advanced
sizing and selection software.
5. Programming software: The trend towards standardization on IEC 61131-3 continues
as more engineers recognize the benefits of open-source languages.

6. Once, machines were mostly mechanical …
So now there’s an industry migration to electronically controlled systems.
But with that type of motion designs no longer efficient enough,
industries have abandoned it …

7. Even in this department there’s been a design evolution …

8. … so today, motion-control systems use suites of
compatible tools, components, and modular subsystems:

9. Suites of compatible components + modular subsystems:

10. Mechatronics are the extension of this trend
Microwave sensor for pneumatic
actuators
Maker-grade Synthetos TinyG six-axis
CNC controller
Firgelli’s miniature actuators
in Youbionic hand

11. … and some direct-drive technologies
are mechatronic designs in motion:
NSK Megatorque Motors
for positioning
Schaeffler IDAM INA MDDS-002 X-Y
stage for optical scanning
Moog Animatics
SmartMotor for multi-axis
coordination
LinMot linear-rotary motors for
pick and place, stacking, or
aligning

12. Proprietary programs to setup, tune, and run motion hardware abound
Here you see software for parameterization, commissioning, design, and programming from Ace Controls, Aerotech,
Rockwell, Fanuc, National Instruments, Galil, AutomationDirect, TI, PMD, ABB-Baldor, Lenze, and Fanuc.

13. On physical level, motion builds are often from scratch
Tweet to #DWwebinar • @DW_LisaEitel

14. Separate mechanical-drive, gearing, and motor
design needs careful calculation to avoid oversizing

15. Sizing and selection software to the rescue
Go to motioncontroltips.com and search Motor Selectors

16. Sizing and selection software to the rescue
Tweet to #DWwebinar • @Festo_US • @DW_LisaEitel

17. Lets designers unify programming in
multi-controller automation
Side note: Libraries in programming software
• Rockwell’s RSLogix Architect lets hardware and tag
synchronize with RSLogix 5000 and EPLAN Electric P8
• Keeps controls and electric drawings updated
• EPLAN models for 26,000 of this particular manufacturers’
components, so engineers can drag and drop into designs

18. Even CAD software simplifies selection with part libraries …

19. Besides part libraries, there’s more interoperability in 2015:

20. One specific example from Festo

21. Result: List of working options, motion profile, single-axis drive bill of materials

22. Designing a Motion Control System...Easier How?
Tom Worsnopp
Product Management – Electric Automation / Advanced Handling / Servopneumatics

23. • Global automation company
• Supply components and systems solutions, including:
• Pneumatic actuators
• Valve manifolds
• Electromechanical actuators
• Motors and drives
• PLCs, motion controllers, and HMIs
• Handling systems
Festo Company Overview

24. 1. Sizing and selection of solutions
2. Ordering components and systems
3. Configuration of stepper/servo drives
4. Programming
Software automates the process
Designing a Motion Control System...Easier How?

25. 1. Engineer consults catalogs
2. Engineer manually
calculates viable solutions
3. Engineer weighs cost
versus performance
Sizing and Selection in the Past
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26. 1. Input application requirements
2. Software automatically determines solutions that works
Sizing and Selection Now
PositioningDrives for sizing a single axis
Handling Guide Online (HGO) for sizing
a multi-­‐‑axis gantry

27. 1. Input application details:
• Load mass
• Stroke length
• Location of center of gravity
• Detailed motion profile
• And so on…
PositioningDrives for Sizing and Selecting a Single Axis
Load mass
Stroke length

28. 2. List of solutions is generated
• Performance of each solution is available
• Listed from lowest price to highest price
PositioningDrives for Sizing and Selecting a Single Axis

29. 3. Automatically generate a bill of materials
4. Configure additional options
5. Export bill of materials to the online shop or save for later
PositioningDrives for Sizing and Selecting a Single Axis

30. Software tool on the Festo website to size gantries (1-axis, 2-axis, 3-axis)
1. Input application data
2. Select from suggested list of gantry solutions
3. Configure additional options
4. Download CAD models and documentation immediately
5. Order gantry in the online shop
Handling Guide Online (HGO) for Sizing and Selecting a Gantry

31. • Save Time
• Eliminate time spent comparing technical specifications in catalogs.
• Explore a broad range of products that you may not have otherwise considered.
• Focus on a narrow range of products that meet your application needs.
• Save Money
• Festo software tools are free to download and/or use.
• Properly size the components (actuators, motors, drives) for your application.
Oversized components cost more to purchase up front and to maintain in the long run.
• Increase Performance
• Find solutions that are guaranteed to work together with a long service life.
Benefits to Sizing and Selection with Festo Software Tools

32. Thank you, Tom! Put into context …
So, just to review:
• Motion technologies in 2015 include hardware that’s easier to configure
• New software for parameterization, commissioning, and design
• Programming options in a state of evolution … with proprietary offerings
incorporating more universal tools for interoperability

33. After selection of axis components, motor controller needs
configuration …

34. But what if the motion design needs more customization?
Programming software ……………….. Such as CoDeSys:
Tweet to #DWwebinar • @Festo_US • @DW_LisaEitel

35. Leading the charge in programming-software
simplification in 2015
IEC 61131 …
• Originates from the International Electrotechnical Commission (IEC)
• Took root thanks in part to increasing affordability of PLCs
• As a controller-languages standard, it specifies the syntax, semantics, and displays for
programming languages that include:
PLC Ladder Diagrams (LDs), Sequential Function Charts (SFCs), Function Block Diagrams
(FBDs), Structured Text (ST), and Instruction Lists (ILs)

36. Controller Development System supports all five
programming languages and C for easier setup
One tool for programming IEC 61131-3: CoDeSys
• Unlike other IEC 61131 offerings,
CoDeSys generates native machine
code for common processors … for
fast and reliable code

37. Analysis • Design • Construction • Testing •
Validation • Operation• Maintenance
IEC 61131-3 simplifies:
Improving maintenance yields high returns for end users
IEC 61131-3 controls also work independently on
distributed controllers … useful for even fairly complex
automation tasks
Data types are Real, Byte, Word, Boolean, Integer, Time
of Day, Date, and String data; user-defined also possible

38. IEC 61131-3 doesn’t directly define motion control
standards, but is framework for PLCopen
PLCopen
✓ PLCopen function-block libraries for single and
multi-axis motion
✓ PLCopen like IEC 61131-3 is hardware
independent so defines no block implementation
✗ Some PLCopen Motion Control software doesn’t
produce compatible programming
✗ A few features of advanced motion controllers
sometimes missing

39. Hardware connectivity complements software
Point-to-point connection at the
field level with IO-Link:
• Standardized IEC 61131-9 IO for
communicating with sensors and
actuators
• Based on familiar three-wire
sensor + actuator connection (not a
fieldbus or special cabling)
Example:

40. More interoperability at motion-system device level

41. More interoperability at higher levels

42. Software for design, integration, and
programming are leading time-savers today
Design software in 2015 has more interoperability for more collaboration
and tools and parts libraries to save engineers time.
Some programming software is moving towards standardization on IEC
61131-3’s open-source languages.
Selection software comes in increasingly powerful
tools make short work of virtual prototyping. Festo’s
PositioningDrives offering is one good example.

43. Designing a Motion-Control System ...
Software in 2015 Makes It Easy
Questions?
Lisa (Elisabeth) Eitel
Senior Engineer Editor
Design World
leitel@wtwhmedia.com
Thomas Worsnopp
Product Manager
Servo Pneumatics and PLCs
Festo Corp.
tom.worsnopp@us.festo.com

44. Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com

45. Designing a Motion-Control System ...
Software in 2015 Makes It Easy
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