Viewpoint Mechatronics @ Work: Key Principles for Successful Solutions By Joel Galliher Director Mechatronic Systems Bosch Rexroth Corporation The popularity of mechatronics has grown rapidly as OEMs and end-user manufacturers strive to develop more efficient and integrated production systems, ones that are versatile and make the most intelligent use of today’s automation technologies. Generally speaking, mechatronics is the intelligent selection and integration of mechanical and electrical components into machines and production lines to accomplish complex automated manufacturing applications. Just as importantly, it is also the engineering discipline guiding the design and creation of mechatronics systems. Successful mechatronics systems are not only measured by how well they operate – their value is also assessed by the ease (or difficulty) associated with their design, construction and commissioning. Rexroth engineers and product developers have unique insight into these challenges. We have engineered our technology and developed our applications expertise to help you maximize intelligent system design and component selection to achieve the smartest, most cost-effective and productive mechatronics solution. In doing so, we have identified six key principles which need to be considered as you engineer a mechatronics solution – no matter what industry or application your machine is designed for: Intelligent integration – Select components designed to fit together, including built-in connectivity for mechanical and electrical interfaces; technologies like Rexroth linear modules, including the Omega Module OBB, CKL Linear Module and VKK Feed Module, each with specific capabilities and load characteristics, but all with standardized mechatronic interfaces. Energy efficiency – strict control of energy consumption is a standing requirement for virtually all automation systems – so selecting mechatronics components requires a “just right” balance: just enough energy to accomplish a task, move a load or complete a motion cycle. For example, Rexroth has pneumatics monitoring devices to help optimize pneumatic airflow, helping you control flow and detect leaks. Modularity – Constantly changing markets require modular technology with components engineered to handle changes and updates easily and quickly; Rexroth designed our widely used VarioFlow Chain Conveyors for quicker design, installation and start-up, and with multiple mechanical interfaces and connectors to make reconfiguration easier. Optimized control – it is crucial to leverage the latest advances in electronics and fieldbus architectures to maximize both the flexibility and productivity of automation systems; this includes investigating and giving strong considerations to platforms such as Rexroth’s IndraControl MLC L45 PLC, which provides a high-performance, cost-effective controller platform with support for robotics and a wide range of interfaces including SERCOS III and Ethernet IP. Precision – today’s automation systems can’t sacrifice quality for throughput; ultra-tight motion and endpoint accuracy are essential. So the challenge for mechatronics engineers is to select components that enhance both precise motion and productivity. The Rexroth CKL Compact Module with ironless linear motor is one example: it combines the speed of a belt-driven module with the accuracy of a ball screw. Load – it’s useful to have an open mind when assessing the variety of options for moving loads - electric motors, pneumatics, or hydraulics all offer advantages. It’s important to consider weight, distance carried and the required speed of the duty cycle in this process. One rule of thumb: avoid automatically selecting familiar technologies that may be over-powered or under-powered for a particular machine task. To make sure that your next mechatronics project is successful, work with the Drive and Control experts at Bosch Rexroth who have engineered a complete solutions platform for mechatronics applications. Our EasyHandling platform is a comprehensive system with drive and control technologies, standardized interfaces and multiple software tools for selection, sizing, setup and commissioning of handling systems. To learn more, just visit www.easy-handling.com before you start your next mechatronics project.