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Linear Motor Technology
Motor & Drive Systems Conference 2008
Jrgen Khnle
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A small linear motor history
Who discovered the basics of the linear motor technology?
When was the first linear motor designed?
When was the first patent applied for?
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c ae ara ayBuilds the first experimentalelectrical motor
1831 Michael Faraday (UK)Explain the electrical induction
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or tz . von aco ermanyFirst usable electrical motor
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ames er axweTheory of electrodynamicsand their mathematical
formulas.
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arce eprez ranceElectric hammer with linearmotor
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We discussing about a very old technology
First linear motor application 1882125 ears a o
First patent 1885
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Linear Motor Technology
Linear motor technologies (application view)
SWOT analysis of these linear motor technologies
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Linear Motor Technologies (Application View)
Customers are interested in the solution of their application and not the specific linear motorec no ogy. e ma n cr er a or e se ec on o near mo ors are:
Dynamics for short positioning times
Or Accuracy
Customers are looking mainly on the difficulties in the application. The technology based maindisadvantages are:
e magne s genera e a s rong magne c e w g a rac on orce o ron par s.
Due the used materials (iron, copper, steal) are the linear motors very heavy.
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Linear Motor Flat Bed
Every rotary motor Theoretical the rotary And formed to a flatpr nc p e can e use
to build linear motorsmotor can be cut bed linear motor
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Flat Bed Linear Motor Technologies (Application View)
Linear motors with permanent magnets Linear motors without permanent magnets
Bed with permanent magnets
Main advantage
High power density
Bed with sheeted metal
Main advantage
No magnetic fields
Main disadvantage
Permanent magnets attract iron parts withhigh force.
Main disadvantage
Power density is poor.
bed. A good linear guide system is necessary.
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Tubular Linear Motor
Flat bed linear motor
the side
To get a tubular linear
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Tubular Linear Motor Technologies (Application View)
Short Coil System Long Coil System
Main advantage High power density
system Main advantage
No external ma netic fields
Permanent magnets attract iron parts withhigh force.
Main disadvantage
Reduced power density
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SWOT Analysis Linear Motors with Permanent Magnets
Strength Weakness High power density
High load capacity
High attraction force between slider and bed
Heavy duty linear guide system necessary
Difficult assembly due high attraction force
Magnets get more and more expensive
Opportunity
Highest load carrying capacity
Threats
Permanent magnets can loose Machining centers c arac er s cs, magne empera ure
exceeds 8090C
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SWOT Analysis Linear Motors without Permanent Magnets
Strength Weakness No external magnetic field
High load capacity
Air bearing easy possible
Poor power density
Machining of the bed is very expensive
With air bearing smooth operation possible
Opportunity
Due the smooth operation ideal for
Threats
Very heavymeasur ng mac nes an g accuracy
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SWOT Analysis Linear Motors Short Coil System
Strength Weakness High power density
Simple production
High attraction force between slider andmagnetic rod
Difficult assembly due high attraction force
Magnets get more an more expensive
Opportunity
Compact design
Threats
Permanent magnets can loose Handling c arac er s cs, magne empera ure
exceeds 8090C
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SWOT Analysis Linear Motors without Permanent Magnets
Strength Weakness No external magnetic field
High load capacity
Drive similar to pneumatic cylinders
Poor power density
Opportunity
Change of pneumatic cylinder designs to
Threats
Very heavynear mo ors
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Comparison Between the Different Linear Motor Technologies
Drive Flat bed with Flat bed Short coil Long coiltechnology permanent
magnets
without
magnets
system system
Load 200 kg 200 kg 200 kg .200 kg
Stroke 10 m 10 m 3 m 0.5 m
Velocity 10 m/s 4 m/s 10 m/s 3 m/s
Acceleration 250 m/s 80 m/s >250 m/s >250 m/s
rec s on . .
Externalmagnetic
Yes No Yes No
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Guide system Circulating balllinear guide
Air bearing;Linear guides
Slider bearing;Linear guides
Slider bearing;Linear guides
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Hybrid Linear Motor Technology
Combination of linear motor and pneumatic in one axis
SWOT analysis of the hybrid linear motor technology
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Comparison Servo-Pneumatic Drive with Linear Direct Drive
Servo-Pneumatic Drive Linear Direct Drive
High speed (3 m/s)
Medium acceleration (30 m/s)
Slow force generation (30 ms)
High speed (>3 m/s)
High acceleration (150 m/s)
Quick force generation (1 ms) Medium accuracy (0,1 mm)
Complex control loop
High power density
High accuracy (1 m)
Simple control loop
Low power density
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Cost efficient
No heat generation
High purchasing costs
Strong heat generation
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Comparison Dynamic Force Generation: Linear Direct Drives
Linear Direct Drive
peak force
Quick force generation
force reduction 1
controller amplifier: overheat
- .
Force must be reduced. Reasons:
Force reduction 2
linear motor: overheat
-
after 1 s: overheating of thecontroller amplifier
Depends on the cooling
after 110 min: overheating ofthe linear motor
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me1 ms 1 - 10 min1 s
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Comparison Dynamic Force Generation: Pneumatic Cylinder
pneumatic cylinder
peak force = continuous force
Slow force generation
No temperature depending force
(depending on the
iston osition
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me10 ms 100 ms
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Comparison Dynamic Force Generation: Hybrid Axis
peak force linear motor + pneumatic Ideal force generation
No force reduction necessary
1,5 times peak force
2 5 times continuous force
1 ms 1 min1 s time
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Force distribution in the frequency domain
High frequency components of the reference force are the inputs of the current controller
Low frequency components of the reference force are the inputs of the pressure controller
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n s way: au oma c compensa on o s a c orce e grav y
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Measurement data of a positioning experiment
Total Force
ec r ca orce
Pneumatic Force
Forc
[N]
Mass load 5 kg
Positioning time 0.35 sec
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Time[sec]
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System ConceptFCT Software
Hybrid Axis + Internal Interface
motor +
temperature ext. Controller
ition
ramming
internal
wiring
switch
measuring
system
48Vfirmware
for interface
pressuresensors
Posi
pro
pneumatic
controlsignal
firmware
for controller
connections
Platform:
HME + HMP cylinder
+ pressure sensors
compressed airmax. 500 mm
servo valve
6 bar
220V
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power supply
supply
(volume / filter)
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Technical Data HME-P
Project Hybrid Axis: Linear direct drive with pneumatic support
Mechanical dimension HME
More dynamic than the single linear motor
Linear direct drive
By redundant system higher security
Both drive systems work active controlled and parallel
Plug & Work
Guide
Low self-heating
Higher duty cycle
Size 16 2 Internal
Stroke [mm] 100, 200, 320 100, 200, 320,400
Thrustforce
Continuous [N] 140 260
Pneumatic cylinder
n er ace
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Pea N 240 375
Repeatability [mm] 0.03 0.03
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Comparison: Servo-Pneumatic, Linear Direct Drive and Hybrid Drive
ervo- neuma c near rec r ve y r r ve
Peak force 120 N 200 N 250 N
Absolute accuracy 0.2 mm 0.03 mm(temparture extenstion)
0.01 mm
Max. speed 3 m/s 3 m/s 3 m/s
Cycles/sec cont.
operation
1 1.2 2.0
Max. payload vertical 5 kg 2 kg 7 kg
Duty cycle at Fmax 100 % 5 % 50 %
Costs complete system 70 % 100 % 120 %
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SWOT Analysis Hybrid Linear Motor Axis
Strength
Weakness g acce era on
High accuracy Double continuous force Three times eak force
g ynam cs on y w re a ve y smaloads
Expensive technology Stiff mountin surface necessar
Very compact design Low heat generation of the drive Higher security (redundant system)
Play in the assembly must be small Compressed air necessary Failure rate higher (more components)
unc on o a o ng ra e n egra e With same performance cheaper than a
comparable linear motor
ore cu ns a a on
Opportunity Offers highest possible dynamics Combination of dynamics and accuracy
Threats Belt driven systems can reach similar
dynamics, but the not the accuracy
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Costs saving of 2535% of a linear motor
with similar performance
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Why are linear motors necessary?
Where is the place of linear motors in the drive technologies?
SWOT analysis of the drive technologies and selection support
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Elements Pneumatic Axis
Fixin holesfor load
Piston
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General Technical Data Standard Pneumatic Load 100 kg
Symbol
Acceleration 30 m/s
Precision 100 m
Stiffness medium Stroke 10 m
*
Flexibility not programmable
Power Density high
a n enance ma n enance- ree
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Applications Standard Pneumatic 1 axis application (example)
Assembly by force fitting
Load Medium 30 kg 100 kg 200 kg
Dynamics Medium 0,5 m/s 3 m/s >5 m/s
2 axis application (example)Assembly of bulb socket
Stroke Medium 2 m 5 m 10 m
Accuracy Low 100 m 50 m
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SWOT Analysis Standard Pneumatic
Strength Weakness Low costs
High power density
Simple technology
Expensive energy
No low speeds possible
Constants speed difficult
overload possible
Long time holding force without additionalenergy
Noisy
leakage
Opportunity
Simple applications with 2 positions
Threats
Large number of competitors
(Servopneumatic)
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SWOT Analysis Servo Pneumatic
Strength Weakness Low costs
High power density
Simple technology
Expensive energy
No low speeds possible
Constants speed difficult
overload possible
Long time holding force without additionalenergy
Noisy
Leakage
Strokes 202000 mm
Opportunity
Unique selling position of Festo (no
Threats
Technology unknowncompe or
Future: hybrid technology (combination ofpneumatics and electrical drives)
Energy costs
Price reduction of electrical drives
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Belt Driven Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Picture shows DGEL-_-ZR
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Elements Belt Driven Axis
Fixing holese er or oa
Axis)
Pulley (inside
Axis)
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Motor adaptor
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General Technical Data Belt Driven Axis Load up to 200 kg
Symbol
Acceleration 100 m/s
Precision 100 m
230VAC
Stiffness medium Stroke up to 10 m
*
Flexibility high
Power Density medium
a n enance ma n enance- reeBelt axis
with
motor
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Applications Belt Driven Axis 1 axis application (example)
Transport of parts in a machine
2 axis application (example)
Unloading parts from a machineLoad High 30 kg 100 kg 200 kg
Dynamics Medium 0,5 m/s 3 m/s >5 m/s
Stroke Short 2 m 5 m 10 m
Accuracy Low 100 m 50 m
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SWOT Analysis Belt Driven Axis
Strength Weakness Cost optimized electrical axis
Long strokes
Light weight
Medium stiffness
Belt sensitive against lubricants and solvents
Wear
X-lengths possible
Belt is exchangeable (cheap spare part)
High dynamics
Tension at long strokes
Damages due mechanical block possible
Opportunity
Dynamic applications
Threats
Large number of competitors
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Lead Screw Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Picture shows DGEL-_-SP-KF
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Elements Lead Screw Axis
Motor
Bearing
Adaptor
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Bearing Spindle Nut
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Applications Lead Screw Axis 1 axis application (example)
Adjustment of positions (rare movements)
Load Medium 30 kg 100 kg 200 kg
Dynamics Low 0,5 m/s 3 m/s >5 m/s
Stroke Short 2 m 5 m 10 m
Accuracy Medium 100 m 50 m
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SWOT Analysis Lead Screw Axis
Strength Weakness High forces
Medium accuracy
Interesting costs
Low speed
Medium acceleration
Lubrication very important
Self locking Friction (low efficiency)
Opportunity
Cost sensitive applications
Threats
Lifetime of the screw
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Ball Screw Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Picture shows DGEL-_-SP-KF
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Elements Ball Screw Axis
Motor
Bearing
Adaptor
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Bearing Spindle Nut
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General Technical Data Ball Screw AxisLoad up to 200 kg
Symbol
Acceleration 50 m/s
Precision 20 m
230VAC
Stiffness highStroke up to 2 m
*
Flexibility high
Power Density medium
a n enance u r ca onScrew Axis
with
motor
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Applications Ball Screw Axis 1 axis application (example)
Loading of machines (adjustable)
Load High 30 kg 100 kg 200 kg
Dynamics Medium 0,5 m/s 3 m/s >5 m/s
2 axis application (example)Testing of printed circuit boards (PCB)
Stroke Short 2 m 5 m 10 mAccuracy High 100 m 50 m
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SWOT Analysis Ball Screw Axis
Strength Weakness High forces
High accuracy
Medium speed
Medium acceleration
Limited strokes
Not repairable
Only standard strokes For longer strokes only limited speed
Opportunity
High loads with higher dynamics and
Threats
Costs for linear motors will fall
accuracy Belt systems can move similar loads, but notwith the accuracy
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Linear Motor Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
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Elements Linear Motor Axis
Slider with coils
Linear guide
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Measuring system
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General Technical Data Linear Motor Axis
Load up to 30 kg
Symbol
Velocity 510 m/s
Acceleration 150 m/s
Precision 3 m230VAC
Noise level low
Stiffness high (depends on motorcontroller) Motorcontroller
Stroke up to 10 m
Costs 4 * pneumatics
Flexibility high (free programmable)
Power Density low
Maintenance lubrication of guides
M
3 ~Linear Motor
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Applications Linear Motor Axis 1 axis application (example)
Loading of machines (precise) 2 axis application (example)
Positioning for optical quality test
3 axis application (example)
Load Low 30 kg 100 kg 200 kg
Dynamics High 0,5 m/s 3 m/s >5 m/s
Filling of micro arraysStroke Long 2 m 5 m 10 m
Accuracy High 100 m 50 m
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SWOT Analysis Linear Motor Axis
Strength Weakness
High acceleration
High speeds
High accuracy
High dynamics only with relatively smallloads
Expensive technology
Long strokes Often specialist nowle ge necessary
Stiff mounting surface necessary Play in the assembly must be small
Opportunity
Offers highest possible dynamics
Threats
Belt driven systems can reach similar
Combination of dynamics and accuracy ynam cs, u e no e accuracy
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Comparisons Electrical Axis
Content
Comparison Between the Different Axis Technologies (Technical Data)
Comparison Between the Different Axis Technologies (Recommendation)
Selection of Axis Technologies Based on the Needs of the Application
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Comparison Between the Different Axis Technologies (Technical Data)
Drive Standard Belt Driven Screw Driven Ball Screw Linear Motortechnology Pneumatics Axis Axis Driven Axis Axis
Load Up to 100 kg Up to 200 kg Up to 100 kg Up to 200 kg Up to 30 kg
Stroke Up to 8.5 m Up to 10 m Up to 2 m Up to 2 m Up to 10 m
3 m s 510 m s 0 5 m s 35 m s 510 m s
Acceleration 30 m/s 100 m/s 30 m/s 50 m/s 150 m/s
Precision 100 m 100 m 50 m 20 m 3 m
Noise Very noisy Noisy Low Medium Low
Stiffness Medium Medium Very high High High
Costs 1 2*pneumatics 2,5*pneumatics 3*pneumatics 4*pneumatics
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Flexibility Not
programmable
Programmable Programmable Programmable Programmable
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Comparison Between the Different Axis Technologies (Recommendation)
Drive Standard Belt Driven Screw Driven Ball Screw Linear Motortechnology Pneumatics Axis Axis Driven Axis Axis
Load ++ +++ ++ +++ +
Stroke +++ +++ ++ ++ +++
++ +++ + ++ +++
Acceleration + +++ + ++ +++
Precision ++ ++ ++ +++ +++
Noise + ++ ++ +++ +++
Stiffness ++ ++ +++ +++ +++
Costs +++ ++ ++ + +
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Flexibility + +++ +++ +++ +++
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Selection of Axis Technologies Based on the Needs of the Application
Drive Standard Belt Driven Screw Driven Ball Screw Linear Motortechnology Pneumatics Axis Axis Driven Axis Axis
High Load + +
Long Stroke + + +
High Velocity + +
High Accel. + +
High Precision + +
High Stiffness + + +
Low Costs + +
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High Flexibility + + + +
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Future Outlook
What are the main future trends in the field of linear motors and other direct drives.
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Reasons for Automatization
High level of process standardization
Environmental conditions
High quantities
Unburden employees
Process capability
ReproducibilityControl of large
number of variants in
a production
Productivity
Labor cost reduction
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0% 10% 20% 30% 40% 50% 60% 70%
User's View Manufacturer's ViewSource: WZL, RWTH Aachen and Institute Production Technology of Fraunhofer Institute
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Control of Large Number of Variants in a Production
ort o o o pneumat c cy n ers atFesto in 1954:
50 catalo ue roducts
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Control of Large Number of Variants in a Production
ort o o o pneumat c cy n ers atFesto today
>25000 catalo ue roducts
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Control of Large Number of Variants in a Production
ro uct on mac nes nee
several variants / products onone machine
Leads to the use of free
programmable electrical axis
Higher througput to improvethe return on investment
Higher needs on accuracy to
Leads to the use of high dynamic
linear motors
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mprove e repro uc y
67
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Reasons for Automatization
High level of process standardization
Environmental conditions
High quantities
Unburden employees
Process capability
Reproducibility
Productivity
Labor cost reduction
Control of the cost
factor production
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0% 10% 20% 30% 40% 50% 60% 70%
User's View Manufacturer's ViewSource: WZL, RWTH Aachen and Institute Production Technology of Fraunhofer Institute
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Control of the cost factor production
ro uct on mac nes nee
the labor costs
Leads to the use of high dynamic
Higher needs on accuracy toimprove the reproducibility
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Labor Costs in Selected Countries
Annual crowin rate
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Indonesia China India Russia Poland Tsch. R. Korea Japan USA Germany
Source: BCG
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Price Trends Machines and Components for Machines
increases for quantities than for turnoverforecasted.
The average price for most machines will ustomers
decrease in the next years by 35%.
A quantity rise of 24% is forecasted. Our
Festo
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Source: European Machinery Production Yearbook 2007, IMS Research
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Technology Trends
Markets requests less products in themedium technology area and go more to lowand high technology areas.
High Tech
For low technology area
costs factor is the leading reason
Medium TechMarket Market
or g ec no ogy eve
increase of productivity is the leadingreason
ow ec
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