ACOPOS 6D-new mode of assembly production
ACOPOS 6D is a new member of the ACOPOS motion control family in Baccalais.It is designed for a new adaptive manufacturing scenario.Why is ACOPOS 6D launched?What is its technical basis?How does it work?This article will analyze its panorama.
What is ACOPOS 6D?
For common motors,including permanent magnet synchronous motors and linear motors,their motion is mainly rotation or a linear motion.Therefore,it can be understood as one-dimensional motion control.For example,the ACOPOStrak of Bacalay,its mover can move in two-dimensional space(X,Y).ACOPOS 6D provides six dimensions of motion control.
As shown in Figure 2,that is,the coil laid on the mechanical plane(equivalent to the stator of the rotating motor)provides magnetic field control through the ACOPOS power supply unit to drive the movement of the permanent magnet moving sub-slider(equivalent to the rotor of the synchronous rotating motor),which can achieve multi-dimensional movement.That is,the reciprocating motion on the X,Y and Z axes and the rotating motion along the X,Y and Z axes constitute the spatial motion of six degrees of freedom.With its internal controller,software and communication system,it forms the whole plane magnetic levitation motion control system.
Why design products like ACOPOS 6D?
Obviously,personalized production is ubiquitous in every field.With the intensification of competition,each manufacturer not only needs to rely on different specifications of products to adapt to different consumer groups and scenarios to design,but also needs to use personalized labels to highlight the value proposition of consumers.However,the manufacturing system composed of traditional machines,conveying systems,tooling fixtures,etc.,is often adapted to large-scale standardized production,and has reached the peak of quality cost.However,due to the frequent change of packaging and process changes required by personalization,the delivery capacity(output per unit time)is reduced,and the waste caused by startup waste is smaller than that caused by batch,and the rate of defective products is increased instantaneously,resulting in higher cost.
The digital printing technology,flexible electric drive technology and communication technology designed by the manufacturing industry are all to solve the problem of how to realize personalized production reorganization in the whole production.Bacardi has launched ACOPOStrak flexible electric drive transmission system before,and the ACOPOS 6D launched in 2021 is to further expand the dimensions of its motion control products,and expand four dimensions to reach new degrees of freedom.
Let’s look at a scenario of flexible manufacturing.The traditional filling system is usually aimed at a single variety.However,its production capacity is very strong,and can reach the production rate of 108000 bottles/hour.However,it is a standard product.However,if 10 different drinks are to be packaged as a box,do we need 10 production lines for production?However,the batch size is often very small,which makes it difficult for the traditional production line to make such orders.However,in the ACOPOStrak production line of Baccalais and KRONES,the production of small batch and multiple varieties can be realized.10 white bottles(not labeled)flow to 10 different filling heads,and then queue up to enter 2 different bottle caps,and then flow to the required labeling stations to affix 10 different labels.In this production process,it can be seen that it can switch the process without stopping and make the production products available quickly.This is the characteristic of today’s e-commerce consumption era.In order to reduce inventory,businesses require fast delivery,and the product demand of many businesses will change,which will cause peak production demand in some holidays.All of this makes the traditional manufacturing capacity must be replaced by the new production organization model,ACOPOS 6D,by changing the production organization form,makes the product free from the mechanical shackles of the traditional production line and achieve a higher degree of freedom,thus realizing large-scale customized production.
How does ACOPOS 6D form a production line?
When ACOPOS 6D works,the plane required for its movement can be spliced by 240*240mm plane stator modules as required,as shown in Figure 5.Each stator module is connected to the controller through real-time Ethernet POWERLINK.ACOPOS 6D can be arranged according to the layout of the production line,and then cooperate with robots,tooling fixtures,and workstations to design the production process.
ACOPOS 6D can be laid out by a block of stator modules according to the production needs,and the mover can choose to pass through each station and move in any form according to the needs,for example,it can be transported to station 1 for processing,it can also form a curve for processing,and it can also provide a processing slope with X and Y as an angle,which includes a variety of processing relationships such as transportation,coordination and coordination,positioning and synchronization,and curve,Then form the required product manufacturing process.
Virtual and mechanical connection mode of slider
The plane stator modules can be spliced into different layouts like the floor tiles,and then the processing positions are set beside and above them.The processed objects are loaded and operated by the sliders,and the sliders can move in groups,including the virtual connection(configured by software),which can realize synchronous control,or the synchronous operation of group loading,or the association relationship can be realized through mechanical connection.
How does ACOPOS 6D form a production system?
The X20 and APC of Bacardi can be connected to the 6D control box through POWERLINK.It mainly solves the control of the magnetic field direction and feedback positioning of the movement.The ACOPOSmulti power supply provides power for it.The stator module can form a production layout through the power supply and communication connection.The whole production system,including the plane magnetic levitation motor control of ACOPOS 6D,and other motor control and robot control of ACOPOS,constitutes the logic and operation process of the whole production unit.As shown in Figure 7,it is an ACOPOS 6D production control system architecture.
What performance can ACOPOS 6D achieve?
Each moving sub-module can achieve a running speed of 2m/s,acceleration of 2g,and repeated positioning accuracy of 1μm.The movement in the Z axis direction is 0.5-4mm,the rotation of X and Y axes is<20mrad,and the rotation of Z axis is<20°.
Digital twin system
Like SuperTrak and ACOPOStrak,the development of ACOPOS 6D production application can be early verified by digital software such as IndustrialPhysics.Because Automation Studio can establish a connection with these software,it can integrate with ABB robots through its planned production line,and carry out early verification of its production rhythm and space collision to ensure that it meets the design operation ability and feasibility
What are its advantages and application scenarios?
1.Six degrees of freedom motion control,in addition to the usual X,Y axis motion,also adds the Z axis and X,Y,Z rotation axis motion,ACOPOS 6D will move the motion control from the plane constraint to a broader space,which makes the freedom of production break through the shackles of traditional machinery and reach a new height.
2.Non-friction and wear motion control.Due to the use of pure magnetic levitation technology,the stator and rotor have no contact and mechanical wear,which makes the maintenance and precision reduction caused by the wear of traditional mechanical transmission eliminated and ensures the high consistency of its quality.
3.Be competent for clean environment.Because the stator plane and the rotor are designed with new materials,ACOPOS 6D can provide product transportation and processing coordination for the sanitary grade.
4.High precision machining:due to its repeated positioning accuracy,it can reach+/-1μm.It makes it competent for high-precision positioning scenarios,high-quality processing and assembly links,such as electronic semiconductor,lithium battery cell production and other links.The assembly process of electronic semiconductor products requires high positioning accuracy and angle flexibility,including responsiveness.These are places where ACOPOS 6D can play its role.
5.Scalable conveying system:For ACOPOS 6D,it can be expanded at will.A control unit can manage up to 80 flat stators and hundreds of actuators,which makes it possible to form a reusable and scalable conveying system.
6.Maintenance-free,for manufacturing enterprises,it is very attractive because stable and reliable production is the source of profit.High quality rate and high OEE ensure that enterprises can provide high-quality products with good efficiency and low cost.