CL04 - Introduction to iTRAK Independent Mover Systems

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Introduction to iTRAK Independent Mover Systems


Agenda

Application Success

Components and Parts of System

Value of iTRAK System

Evolution of Machinery


Current Technology vs. iTRAK®

3

Chains = Limitations Inflexible

High maintenance

Low performance

iTRAK Linear Magnetic Drive Flexible

Tool independence

Software control

Low maintenance

High performance

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 4

The Value of iTRAK to ManufacturersIncreased Throughput

Traditional Machines

Process options are limited

Continuous and intermittent motion cannot coexist

Mechanical drivetrains limit speed

iTRAK Based Machine

Faster machines because of new capabilities

Continuous and intermittent processes can be mixed for maximum productivity

Linear motors improve throughput


The Value of iTRAK to ManufacturersMinimized Change Over Time


Multiple tool sets

Labor intensive part changes

Many hours of lost production

Inflexible production scheduling

iTRAK Based Machine

Single tool set

Programmatic part changes

Maximized production time

Flexible production scheduling

OEE

50 g 100 g 250 g


The Value of iTRAK to ManufacturersReduced Machine Footprint


Extra mechanical drive trains

Space required so all processes are same time of motion

iTRAK Based Machines

Direct drive tooling minimizes footprint and mass

Mixing continuous and intermittent motion optimizes footprint

Track shape opens up new opportunities for optimizaiton

Traditional Machine

iTRAK Machine

10% - 50% Smaller!


The Value of iTRAK to ManufacturersImproved Production Flexibility

Traditional Machine

Long production runs required for profitability

Complex supply chain

Hard scheduling requirements

iTRAK Based Machine

Shorter production runs are possible, getting

closer to Just In Time manufacturing

Realize full potential of Connected Enterprise

Flexible production scheduling


The Value of iTRAK to ManufacturersReduced Maintenance

Traditional Machine

Complex, expensive mechanics

Frequent adjustments required for compliant systems

Regular inspections required to determine when maintenance is needed

iTRAK Based Machine

Predictable, infrequent maintenance

Reduced operator interaction with internal parts of machine

Robust direct-drive mechanical system


The Value of iTRAK to Machine BuildersMarket Leading Design

Traditional Machine

Precious time spent on mechanics without inherent value addition

Longer design cycles

iTRAK Based Machine

Innovation through programming

Flexible platform can be re-used for multiple machines

Focused on market differentiation in the end product

More customization and attention to customer needs


The Value of iTRAK

10

Increased production rates – 50% or more!

Reduced downtime for changeovers

Reduced machine footprint

Shorter runs can still be profitable

Reduced periodic maintenance

Increased flexibility with a single design

Greater focus on adding value

Differentiated machine design


Technology Basis

11

Magnets move over independently energized coils

Magnets and movers have no intelligence

Coils are stationary

No flexing cable wear or need for slip rings

Absolute positions are measured with closed loop servo control

Technology can be applied to straight or curved motors



iTRAK Solutions

Common Solution Requests

Track Plates: Top and

Bottom

Movers

Bearing

Rails

Machine

Frame

Power and Control

Module

Drives and

Motors

• Custom Mover Designs

• Custom Bearing Designs

• Power and Control Module Modifications

• Custom Firmware and Application Programming

• Mover and Segment Optimization

• Profile Development and Validation

• Bearing Life Specifications

• Top and Bottom Track Plate Modifications

• Machine Frame Modifications


iTRAK Linear Module

14

Communication

PowerMultiphase Drives

Multiphase Coils

Standard length of 400 mm

Stainless steel motor cover for durability

Wash-down IP65 to be part of the machine

Three coil lengths for the right amount of

force (50, 100, 150 mm)


iTRAK Curve Module

Power

Communication

Multiphase

Drives

Multiphase Coils

Standard arc length of 400 mm

Radius of 254 mm

Quarter-turn curves make layouts adjustable

Stainless steel motor cover for durability

Wash-down IP65 to be part of the machine

Three coil lengths for the right amount of

force (50, 100, 150 mm)

Dedicated catalog numbers for Left and

Right turns


iTRAK Configurations

16

Orientation

Horizontal

Vertical

Stand-Up 90o

Modular & Scalable

Oval

Rectangle Square

Linear / Straight


iTRAK Mover

17

Motor

Magnet

Position Magnet

Vee

Rollers

Bearing Track

Standard mover and bearing

designs are available

Suitable for most applications

Long life through lubrication

Uses high strength steel vee

wheels

Customers can design their own

Build to suit your application

Differentiate your machine


Power and Control Module

Power supply and shunting for motor and drive

segments

iTRAK Gateway for drive communication

Branch circuit protection and isolation

Integrated disconnect and Emergency Stop safety

circuitry

Power and communication distribution

Power and Control Module


iTRAK to Controller Interface

iTRAK

Gateway

Synchronizes with Kinetix drives,

motors and encoders

Uses standard motion instructions

Configuration and Programing in

Studio 5000

Compatible with CompactLogix

and ControlLogix


Programming with Logix Designer

20

Sample Code is available to speed up

development

Application examples have been created

Queuing, Grouping, Synchronizing

Solves complex math and sequencing

requirements

Familiar tools and instructions


Specifications and Capabilities

21

Wide range of forces and speeds, sized for your application

Speeds up to 5 m/s Capable of 7 m/s with reduced bearing life

Continuous: 46 N to 417 N

Peak: 88 N to 793 N

High acceleration

Up to 10 g

Tight mover-to-mover pitch

As close as 65 mm center to center

Smaller tooling and more varied product handling capabilities

Payloads can be into the hundreds of kg

Bearings designed for variety of loads and long life


Power Modules Mover Magnets Position

Magnets

Power/Control Cables

Multiple Sizes50mm,100mm,150mm

Straight, Left, Right

Multiple Sizes50mm,100mm,150mm

1 Stack, 2 Stack, 3 Stack

Feedback

MagnetsNorth and South Polarity

1 Power Rating Power and Control

9

Standard Part Numbers9

Standard Part Numbers

2Standard Part Numbers

1Standard Part Number

14Standard Part Numbers

iTRAK Products and Solutions

22

Bearing Design Machine Design Mover Design Application

Development

Post Sales

Support

Standard Bearings

Designs

Track Plates Design

and Fabrication

Standard Movers

Available

Standard RSLogix

Application Templates

Warranty Support

Custom Bearing

Design Consultation

Turn-key Machine

Delivery

Custom Mover

Design Consultation

RSLogix Programming

Custom Firmware

Billable Support

Services

https://www.google.com/url?q=http://www.hepcomotion.com/en/dualvee-single-edge-slide-system-pg-14-get-6&sa=U&ei=UEJIU8IDqJ7ZBcvxgagL&ved=0CDQQ9QEwAw&usg=AFQjCNFiZ2NC57NFX99uqpQst1Iqdv1rcg

https://www.google.com/url?q=http://www.hepcomotion.com/en/dualvee-single-edge-slide-system-pg-14-get-6&sa=U&ei=UEJIU8IDqJ7ZBcvxgagL&ved=0CDQQ9QEwAw&usg=AFQjCNFiZ2NC57NFX99uqpQst1Iqdv1rcg

https://www.google.com/url?q=http://apac.rockwellautomation.com/oem/en-in/midrange/technical.aspx&sa=U&ei=tUdIU-2OCcTj2wXCy4DAAg&ved=0CDQQ9QEwAw&usg=AFQjCNGNopIerVf6AZPWdau2gnHP09hAfQ

https://www.google.com/url?q=http://apac.rockwellautomation.com/oem/en-in/midrange/technical.aspx&sa=U&ei=tUdIU-2OCcTj2wXCy4DAAg&ved=0CDQQ9QEwAw&usg=AFQjCNGNopIerVf6AZPWdau2gnHP09hAfQ


Application Examples

23

• High Speed Collating Machine

• iTRAK transfers incoming product to a continuous motion end load

cartoner

• Accepts product with random spacing and syncs it

IndeCart® 2

“Enables new performance

levels and creative solutions to

packaging line needs.”

Customer Testimonial



24

• Simplex/Duplex Form, Fill and Seal Pouching Machine

• iTRAK makes it “pitch-less”

• Capable of handling large one-up pouches or small two-up pouches

• Machine footprint & changeover times drastically reduced with iTRAK

“This technology will

forever change the way

that pouching is done.”

Innopouch K400

Roger Calabrese, Competence

Center Manager, KHS

http://www.khs.com/en.html

http://www.khs.com/en.html



25

• High Speed Case Packing Machine

• iTRAK handles the cases using two carriers to carry each box

• This allows the machine to handle any size box without tool changes

• Machine footprint & changeover times drastically reduced with iTRAK

• Introduced at interpack 2014

CL 175

“This cartoning machine is the most popular system

among the ones proposed by Cama and it is now

showcased in a totally new version, which includes

the no-chains intelligent track system…”

Riccardo Panepinto, Operations Director

at Cama Group


Return on Investment

26

Factors to Consider

Throughput Increase

Product Change Time Decrease

Maintenance Cost Decrease

Floor Space Decrease

Why iTRAK Wins

Faster Production Speeds

Reduced Downtime for Maintenance and Changes

More Flexibility in Design

Smaller Footprint for Machine and Parts

Easy Programming

Typical

Payback Period:

6-24 months


Application Criteria

27

iTRAK is a good fit when:

Considering a next-generation design

Existing system is experiencing speed limitations

Process gains from mixing intermittent and continuous motion

There is a need for frequent changeovers

A “pitch-less” machine could add value to current processes

Current application uses chains or belts

Maintenance costs are out of control

Take the leap to a better machine!

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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Thank you!