Keys To: "Mechatronics Made Easy"

M ech a tro n i c s
BY: Mark Huebner Market Development Manager PBC Linear & 3DP Unlimited
5 keys to
mechatronics made easy

Bringing together mechanical, electrical, programming, and control engineering is
not effortless. But integrating technology advances, and focusing on these five
areas, can simplify the process and ensure that mechatronics is made easy.
Todays fast paced product development cycles and rapid advances in technology have pushed
the need for greater cross-disciplined engineering. Where once the mechanical engineer could solely
concentrate on the hardware, the electrical engineer on the wiring and circuit boards, and the control
engineer on the software and algorithmic programming, the field of Mechatronics brings these areas
together creating a focus for a complete motion solution. Advances in, and the integration of all three
fields together, streamline mechatronics design.

It is this simplification that is driving advances in robotics and multi-axis Cartesian systems for
industrial uses and manufacturing, automation for consumer markets in kiosks and delivery systems,
1
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DESIGN WORLD
along with the rapid acceptance of 3D printers into mainstream culture.

Here are five key factors that, when put together, result in easier mechatronics design.
Integrated linear guides and structure

In machine design, bearing and linear guide assemblies have been around so long, that often the mechanics of a motion system is treated as an afterthought. Advances in materials, design, features, and
manufacturing methods, however, make it worthwhile to consider new options.
For example, pre-engineered alignment built into parallel rails during the manufacturing process
means less cost because of fewer components, greater precision, and fewer variables in play over the
length of a rail. Such parallel rails also improve installation because multiple fasteners and manual
alignment are eliminated.
September 2014
Newer parallel rails feature pre-engineered alignment, which reduces the overall cost
and improves movement precision. Newer linear guide systems integrate support structures
into the linear rail itself. The shift from individual component design to engineered onepiece designs or integrated sub-assemblies reduces the number of components, which also
cuts cost and labor.
In the past it was almost a guarantee that whatever linear guide

system an engineer selected, they would also have to consider
mounting plates, support rails, or other structures for the needed
rigidity. Newer components integrate support structures into the
linear rail itself. This shift from individual component design to
engineered one-piece designs or integrated sub-assemblies reduces
the number of components, while also cutting cost and labor.
Higher Speeds
Longer Travels
Lower Thrust Carrying Loads
Belt
Rack & Pinion

Lower Precision
Lower Cost
Higher Precision
Higher Cost
Lead Screw
Power Transmission Components
Selecting the right drive mechanism or power
transmission components is also a factor. The
selection process, which involves balancing
the right speed, torque, and precision performance with the motor and electronics, begins
with understanding what results each type of
drive can produce.
Much like the transmission in a car operating in fourth gear, belt drives suit applications where top speeds over extended length
strokes are required. On the opposite end of
the performance spectrum are ball and lead
screws that are more like a car with a powerful responsive first and second gear. They
offer good torque while excelling at quick
starts, stops, and change of direction. The
chart shows the differences between

the speed of belts and the torque of
screws.
Similar to linear rail advances,
pre-engineered alignment is another
area where lead screw design has advanced to deliver greater repeatability
in dynamic applications. When using a
coupler, pay attention to the motor and
screw alignment to eliminate wobbling that reduces precision and life.
In some cases, the coupler can be eliminated completely and the screw affixed
directly to the motor, merging directly
the mechanical and electrical, eliminating components, increasing rigidity and
precision, while cutting cost.
www.designworldonline.com
Ball Screw
Lower Speeds
Shorter Travels
Higher Thrust Pushing Loads
Selecting drive mechanisms or

power transmission components
involves balancing the right speed,
torque, and precision performance
with the motor and electronics.
This chart gives a rough idea of
the capabilities of various motion
control components.
September 2014
DESIGN WORLD
59
M e ch a t ro n i c s
The chart shows the differences between the

speed of belts and the torque of screws
Screw (1 mm lead)
Repeatibility
5-10 micron
Typical Max. Velocity
<1 m/sec
Belt
50 micron
3-10 m/sec
Example Application
(continued from page 59)
Max Speed
Thrust*
0.98 in./sec
68 Lbf
78.5 in./sec
3 Lbf
*NEMA23 motor at 24V using 1 mm lead on screw motor torque is 24 ozf-in. at 1500 rpm
Other considerations
Limited by Critical
speed, screw whip
and end fixity
May require
gearbox for dynamic
performance or
inertia matching
Lead screw design can deliver high repeatability in dynamic

applications, but attention should be paid to the motor and screw
alignment. In some cases, you can eliminate a coupler and affix the
screw directly to the motor, eliminating components, increasing
rigidity and precision, while cutting cost.
Before
3
After
Electronics and Wiring

Conventional configurations for the electronics in motion control
applications include complicated wiring arrangements, along with
the cabinets and mounting hardware to assemble and house all of the
components. The result is often a system that is not optimized along
with being difficult to adjust and maintain.
Emerging technologies offer system advantages by placing the
driver, controller, and amplifier directly onto a smart motor. Not
only is the space needed to house the additional components eliminated, but overall component count is trimmed and the number of
connectors and wiring are simplified, reducing potential for error
while saving cost and labor.
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DESIGN WORLD
September 2014
Smart motors simplify and eliminate a lot of wiring.
Moving the controller and the drive

onboard the motor simplifies any troubleshooting that may be needed. Access to the
motor and electronics is uncluttered and
straight forward.
Designed for Manufacturing (DFM)

Bracketization
Along with easier rail assembly of integrated designs, experience and emerging technologies such as 3D printing increase your
ability to create prototype mechatronic and
robotic assemblies to DFM standards. For
example, custom connector brackets for
motion systems have often been costly and
time consuming to process through a tool
room or fabrication shop. Today, 3D printing lets you create a CAD model, send it to
the 3D printer, and have a useable model
part in a fraction of the time and at a fraction of the cost.
3D printers can help deliver custom connector

brackets for motion systems at a fraction of the
time and cost of sending designs out for tooling.
Connectorization
Another area of DFM that has already been

covered is the use of smart motors that
put the electronics directly on the motor,
making assembly easier. In addition to this,
newer technologies that integrate connectors, cabling, and cable management into
one package, simplify assembly and eliminate the need for traditional, heavy, plastic
chain type cable carriers.
Long Term Maintainability

Newer technologies and advances
in design not only affect the
up-front manufacturability, but
can also influence the ongoing
maintainability of a system. For
example, moving the controller
and the drive onboard the motor
simplifies any troubleshooting that
may be needed. Access to the motor
and electronics is uncluttered and
straightforward. Additionally, many
systems can now be networked
allowing for access from virtually
any location to perform remote
diagnostics. DW
PBC Linear
www.pbclinear.com
http://dwo.me/1plm6G1
Mobi l e Integra ti on Powered By
Newer technologies integrate connectors, cabling, and cable management into one package, which eliminates
the need for traditional, heavy, plastic chain type cable carriers. Photo courtesy of Cicoil
September 2014
DESIGN WORLD
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M ech a tro n i c s

mechatronics made easy

along with the rapid acceptance of 3D printers into mainstream culture.

Integrated linear guides and structure

In the past it was almost a guarantee that whatever linear guide

Rack & Pinion

chart shows the differences between

Selecting drive mechanisms or

The chart shows the differences between the

(continued from page 59)

Lead screw design can deliver high repeatability in dynamic

Electronics and Wiring

Smart motors simplify and eliminate a lot of wiring.

Moving the controller and the drive

Designed for Manufacturing (DFM)

3D printers can help deliver custom connector

Another area of DFM that has already been

Long Term Maintainability

Mobi l e Integra ti on Powered By

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