THE MAGAZINE WITH DRIVEROBOTICS

THE NEXT EVOLUTION
IN THE OPERATING ROOM

02.2019

motionCONTENT

NEW

04 Expand your possibilities

New FAULHABER GPT gearhead series

06

ANNOUNCEMENT

04

06 MICROMO is now

FAULHABER MICROMOThe FAULHABER GROUP is restructuring its
North American Operations Center

08

INDUSTRIAL TOOLS & EQUIPMENT

08 Filigree powerhouse

FAULHABER drive technology ensuresdelicate handling of high-quality movements
MEDICAL ROBOTICS

12 The next evolution in theoperating room

16

After taking over industry, robots are now
conquering the medical sciences
FA C T O RY A U T O M AT I O N

16 From a grain of sandto a smartphone

12

From the processing of the silicon crystal to theassembly of PCBs, FAULHABER motors play animportant role

20

INDUSTRIAL TOOLS & EQUIPMENT

20 Delicate glaze firmly in grip

Viscosity tests with the help of abrushless DC-servomotor from FAULHABERSPONSORING

24

0202.2019

24 Automatic charging of EVs

FAULHABER motors move innovative
charging robot

EDITORIAL

IMPRINT

Issue 02.2019

Dear readers,
Christmas will soon be upon us and sweet treats are appearing in the shops. In
order for delicacies to melt in your mouth, a great deal needs to be observed during
production. The perfect viscosity is an important quality feature here and is decisive

Publisher / Editor:
DR. FRITZ FAULHABER
GMBH & CO. KG
Schönaich · Germany
Phone: +49 (0)70 31/638-0
Fax:+49 (0)70 31/638-100
Email: info@faulhaber.de
www.faulhaber.com

for the workability in the production process. To measure the viscosity, Brabenderhas realised a new rotational viscometer with the ViscoQuick, which uses a brushless
DC-servomotor from FAULHABER.

Layout:Werbeagentur Regelmann
Pforzheim · Germany
www.regelmann.de

I am proud that FAULHABER was awarded first place in the ranking of Germany’s
most innovative medium-sized enterprises. For this purpose, Munich Strategy
examined 3,500 companies on behalf of WirtschaftsWoche, a German weekly business
news magazine. “Not only is FAULHABER able to manage an incredibly complex
product portfolio in order to produce according to customer requirements, thecompany also sets new standards in the area of innovation culture”, says Dr. Sebastian
Theopold, founder of Munich Strategy.

Picture credits & copyright:
All rights reserved. The rights forthe graphics and pictures used as well asbrand names mentioned are held by therespective owner. The copyright for thearticles is held by the editor. Reproduction
or electronic processing of content, evensections thereof, is only permitted with theexplicit written consent of the editor.

In July of this year, MicroMo Electronics Inc. (Clearwater, Florida) was integrated
as FAULHABER MICROMO LLC, and thereby became part of the FAULHABER Drive
Systems division within the FAULHABER GROUP. We are happy to have successfullycompleted this integration. FAULHABER MICROMO remains under family ownership

Publication frequency & subscription:
FAULHABER motion is published twice ayear and is delivered to customers, interested parties and employees of FAULHABER
free of charge.

as wholly-owned subsidiary of Dr. Fritz Faulhaber GmbH & Co. KG. Through the
integration, our position on the North American market as a leading provider ofhigh-precision miniature drive systems will be further strengthened.

FAULHABER motion is also available as
an app.

Learn more about these and other exciting topics in this issue of FAULHABER
motion – the magazine with drive.

www.faulhaber.com/motion

I wish you a stimulating read!
Sincerely

Gert Frech-Walter
FAULHABER GROUP Management

FAULHABER motion

03

NEWS

EXPAND YOUR POSSIBILITIESFAULHABER GPT PRECISION GEARHEADSWith the new FAULHABER GPT series of gearheads, you move up a gear where others downshift. The pure metal gearheads achieve performancevalues that are comparable to those of significantly
more expensive technologies available on the market, such as those that use ceramic components. The
gearheads are available with diameters of 22, 32 and42 millimetres. They achieve top values for torqueas well as for speed. Compared to the predecessor
models, the input speed was more than doubled toover 10,000 rpm. During intermittent operation, it
can reach up to 20,000 rpm.
The gearheads of the FAULHABER GPT series aredesigned to be extremely robust and tolerate both
continuous as well as very abrupt and sudden loadchanges. They can be equipped with up to four reduction stages. Each stage was individually optimised
for high performance with respect to torque andspeed. One special feature of the product family is
the high number of available gear ratios and theirvery uniform distribution. As a result, the motor
power can be utilised optimally. At the same time,they are significantly shorter than other models withthe same diameter. Thanks to their minimal play,they are especially well suited for tasks with precise
positioning.

faulhaber.com/GPT/en

PRECISION GEARHEADSFAULHABER GPT SERIES

04

02.2019

SENSOR-FREE VERSIONMORE THAN 1,500 AUTOCLAVECYCLES POSSIBLE

STERILISABLE
BRUSHLESS DC-SERVOMOTORS
2057 … BA
FAULHABER developed the new sterilisable
2057…BA family of motors especially for medical
applications. The motors are fitted in a moistureresistant, stainless steel housing. During the development process, they were thoroughly tested forresistance to the loads experienced during autoclaving. Based on these tests, it is ensured that the standard motor can withstand undamaged at least 1,000
cycles in the autoclave. For the sensor-free variant,this value is 1,500 cycles. The drives are optimised
for high speeds of up to 65,000 rpm. Furthermore– like all motors from FAULHABER – they are characterised by high power values in relation to theirvolume. They are therefore very well suited for tightinstallation situations. Their low weight makes thempredestined for use in the handpieces with which
doctors and dentists perform delicate tasks, often
over several hours.

DOUBLE PREMIERETWO NEW ENCODERSPRESENTEDT he BX T family of motor s wa s ex pan d ed with the diameter- compliant IEF3 - 4 09 6
magnetic encoder. The combination of the BXT
motors with the IEF3-4096 encoder is the ideal solution if it is necessary to precisely position
in a constrained space and high torques are also
required. In this flat design, the IEF3-4096 offers
three channels with index function and a highresolution of up to 4,096 lines per revolution. Furthermore, a variant with line driver is available
with the IEF3-4096 L.
To eliminate interferences during signal transmission, the new magnetic, single-turn AES4096 L absolute encoder was equipped with aline driver. Thus, the motor/encoder unit canbe positioned up to five metres away from thecontroller. The encoder can be combined withbrushless DC-motors of the B, BX4 and BP4 series.
It transfers signals using the BiSS-C protocol.
The BiSS protocol is designed for industrial applications in which high transmission speed, flexibility
and minimal implementation effort are required.

faulhaber.com/news

faulhaber.com/news

MOTOR WITH
INTEGRATED ENCODER
2232 … BX4 AES-4096 L SERIESMOTOR WITH
INTEGRATED ENCODER
3216 … BXT IEF3-4096 SERIESFAULHABER motion

05

ANNOUNCEMENT

MICROMO IS NOWFAULHABER MICROMOThe FAULHABER GROUP is restructuring its North American Operations
Center to accelerate future growth.


In July 2019, MicroMo Electronics Inc. (MICROMO)­
was officially integrated as FAULHABER MICROMO
LLC, and thus becomes part of the FAULHABER
Drive Systems division of the FAULHABER GROUP.
The integration represents the realization of the long-­
term vision of the late owner of the company, Dr. Fritz
Faulhaber Jr. FAULHABER MICROMO’s position on the
North American market as a leading provider of highprecision miniature drive systems should thereby befurther strengthened and expanded. Dr. Faulhaber’s
objective of a family-owned single corporate unit
was carried through by his widow Ping Faulhaber.
The previous managing director of ­MICROMO, Ping
Faulhaber, explains: “This inte­gration ensures that
FAULHABER MICROMO can grow over the course ofgenerations and create added value for our high-tech
customers under a single name and with a shared vision as a company, managed by the Faulhaber family.”
FAULHABER MICROMO remains under family ownership, including Ping Faulhaber, as wholly-owned
subsidiary of Dr. Fritz Faulhaber GmbH & Co. KG
with headquarters in Schönaich, near Stuttgart,
Germany.

06

02.2019

Karl Faulhaber, CEO of
FAULHABER MICROMO LLC“THE NAME FAULHABERMICROMO IS A GOOD
CHOICE FOR THE FAMILYCOMPANY,because it honours important elementsof both­ of the founders’ legacies” says the
new CEO of FAULHABER MICROMO LLC, KarlFaulhaber. He is the grandson of the founders ofMicroMo Electronics Inc. and Dr. Fritz FaulhaberGmbH & Co. KG.

FAULHABER MICROMO LLC
located in FL/USA© FAULHABER

FAULHABER MICROMO plans to further
intensify service and product support onsite for the North American market. As theglobal market leader for high-precision
drive systems, FAULHABER’s extensivecompetencies in the areas of engineering,
design and project management should
contribute greatly in achieving this.
This organizational transformation will
be accompanied by a transition from theexisting MICROMO company brand to the
FAULHABER brand which bears the nameof the founding family and has become
known around the world as a recognised
symbol of high quality and innovation in
the area of drive technology.

FAULHABER MICROMO TEAM

faulhaber.com/news

FAULHABER motion

07

INDUSTRIAL TOOLS & EQUIPMENTFILIGREE

POWERHOUSE
High-quality mechanical watches are pieces of fine jewellery with a complex inner life. To produce
these marvels of craftsmanship, countless individual steps must work together in a refined way.
Today, watches are often put together at assembly stations, which support the highly qualified
watchmakers with semi-automated processes. During transport of the valuable watch movements,
motors from FAULHABER ensure delicate and smooth handling sequences.


Mechanical watches are actually an anachronism,
as they are no longer really needed for measuring
time. Nevertheless, demand remains high. Many
purchasers are looking not only for a prestigious
piece of arm jewellery but also feel a deep appreciation for the extraordinary refinement of the precision
mechanics of their timepieces. They are based on thehighly developed craftsmanship that has been passed
on over the centuries from generation to generation,
primarily in Switzerland. Most of the industry’s bigname manufacturers are located there.

Cluster for cutting-edge technology
Today, these manufacturers produce their products
in quantities that a pure craft workshop – a watchmaker builds the entire watch from A to Z – could nothandle. Although the most important work steps arestill performed largely by hand, the work is sharedand broken down into various processes. The skilled workers are supported in many of the steps bymachines, which automate the process to a certain
degree.
One such machine is the assembly station (French:
poste d’assemblage) from Precitrame Machines. The
Swiss company is based at approximately 900 m above
sea level in Tramelan, a small town in the Bernese
Jura, in the immediate vicinity of some of the mostrenowned watch manufacturers in the world. The

08

02.2019

region is also a typical cluster of hidden champions
for precision mechanics, mechatronics and machine
construction. Dozens of companies that are associated with watchmaking, arose from it or, among otherthings, serve as suppliers to the industry, are all based
there in a small area. They are characterised by thesame attributes as the well-known watch names:
products of the highest quality and technology that isamong the best in the world in the respective fields.

Optical and acoustic measuring instruments areused to, e.g., measure the rate and amplitude of theregulating element or to check the completeness ofthe components.

World leader in technology.
Precitrame produces machines for rotary-indexing
transfer and finishing for precision mechanicalproduction of every type as well as the aforementioned assembly station for watchmaking. When the
housing of this machine is closed, one sees a work
surface that contains a small, round opening at thefront centre. There, the watchmaker receives the
movement to perform the next assembly step. Oncecompleted, the watchmaker returns it to the same
location. The workpiece is now transported onwards
under the cover while the next one arrives forprocessing.

Mini-factory under the housing
Located under the cover is something that has
the appearance of a miniature version of an assembly plant. Numerous conveyor belts run next to one
another there. These move the workpieces back andforth, pass through a series of switches and can thereby direct them on different paths depending on whatwork step is currently being performed on the batch.
All movements, however, enter a loading device(French: chargeur) in the rear part of the station that
lifts them from the conveyor belt and directs themto an automated process. This may involve, e.g., applying a microscopically fine drop of oil to a specificlocation. This unit is, however, primarily responsiblefor quality assurance. Sophisticated systems remeasure
here to ensure that the assembly processes were
performed with the desired precision.

Miniature version of an assembly plant© Precitrame

FAULHABER motion

09

The measurement data is recorded automatically and transferred using the CANopen bus system. A
small QR code on the workpiece carrier allows it to be
associated with a specific watch. It is thereby possible
to fully document all assembly steps performed at
this station for each individual movement.

Gentle acceleration
Lift up from the conveyor belt and guide to
a process step – that sounds easy. But this processposes a number of technical challenges. The delicate
movements lie loose in their flat carriers. A sudden
movement could cause them to fall out, be damaged
and disrupt the process flow. At the same time, thedistances that are travelled here are, with respect tothe small dimensions, considerable. The vertical strokeof the loader, for example, is over 20 centimetres.
Its work should, of course, not delay the cycle timeof the entire machine. It is not enough to performthe individual processes slowly and, thus, in the safe
range.
Furthermore, three processes must be precisely
synchronised: the transport pallet with the workpiececarrier is moved to the gripper on a horizontal axis.
This grips the carrier and moves vertically upwards.
Once there, the gripper moves horizontally to the

The Gripper hand moves on three axes. © Precitrame

10

02.2019

INDUSTRIAL TOOLS & EQUIPMENT

measurement station, where the intended routine is
performed. An exactly coordinated profile is required
for each of these movements: start up slowly, accelerate gently, brake cautiously and again end the process at slow speed. FAULHABER developed a custom
solution to drive the three axes.
At its heart is a brushless DC-servomotor with
4-pole technology of the 2250 BX4 series. An integrated encoder with Hall sensor sends a precise position
signal to the control, thereby providing the basis forreproducible processes. The motor for the vertical axis
is also equipped with a brake for precisely regulating
the deceleration following the acceleration. In theevent of a process malfunction, e.g., a power failure,
the brake also holds the specified position and prevents the gripper from falling down.

Three million test cycles
A lead screw with especially steep pitch developed
specifically for this application by FAULHABER subsidiary MPS transfers the force of the motor over theentire length. The optimum material for the nut thatmoves back and forth on the lead screw was determined through complex endurance tests: the highly
stable PEEK plastic, which is also used as material for
medical implants, was found to be most suitable overthe course of three million cycles.
The profile generator is responsible for performing the individual movements using software that is
integrated in the servo drive of the motors. The parameters were optimized by the FAULHABER experts
directly in Tramelan for this special application. The
2250 BX4 servomotor is the smallest on the market
capable of performing this complex task. It also satisfies the other requirements that the assembly station
places on the technology. It is actuated by an MCBL
3002 S CO – an extremely compact servo controller
for brushless DC-motors.
Due to its compact design, another MCDC 3002 S CO
is used as an additional CANopen sensor node.
Motor 2232 BX4 COD was used for the horizontal
axes. Here, the entire servo electronics with CANopeninterface are already integrated with the same diameter – a special feature in the 22 millimetre class.
The entire machine corresponds to the dimensions
with which work is performed in this industry andis appropriately compact and filigree in design. Because up to three loaders must be integrated, spaceis even tighter. The gripper unit, which moves on thethree axes, weighs over 600 grammes, however. The
drive must therefore deliver peak performance inthe smallest of volumes. Precitrame and its end customer are pleased with the good cooperation with thedrive supplier: “The experts from FAULHABER worked"THE FAULHABER EXPERTSCONTRIBUTED IN MAKINGOUR ASSEMBLY STATION
A MODEL OF SUCCESS."

with great commitment on the development of thissolution. In addition to the outstanding product, we
also received optimum technical support. They contributed in making our assembly station a model ofsuccess.”

precitrame.com
faulhaber.com

FAULHABER motion

11

MEDICAL ROBOTICSROBOTICS

THE NEXT EVOLUTION
IN THE OPERATING ROOM
After taking over industry, robots are now conquering the medical sciences. The advantages are
obvious: absence of fatigue, maximum precisionand speed, optimum ergonomics. Experts see theiruse as the next evolution in the treatment of patients. Already today, robot systems are used in a
number of surgical applications, such as in orthopaedics, in neurology or in cardiothoracic and ENT
surgery. In addition to established manufacturers,
innovative start-ups are entering the market.

12

02.2019


Medical technology relies on FAULHABER not
only in robot-supported procedures. For example,
drive systems are used in implantable heart pumps,
surgical hand tools, in ophthalmology, in cosmetics and in medical imaging and image processing.
An air of quiet concentration prevails in the operating room. The team prepares the patient for theoperation. But the first incision is performed not but
a doctor, but by a robot. The surgeon sits focused in
front of his surgical console and uses the joysticks
to control the robot arms that are used for the procedure performed at the operating room table. Even
after a 24-hour shift, the robot cuts absolutely precisely
and smoothly. The camera, which is important above
all for minimally invasive operations, provides optimally prepared images absolutely free of vibrations.
On the 3D monitor, the doctor can see exactly what
is happening in the patient's abdomen. Instead of

the conventional 2D view, which is often very limited,he can see every detail on the 3D monitor. In addition, the slim, high-tech arms offer considerably more
freedom of movement when cutting, repairing or
suturing compared to standard procedures. Because
the body of the patient is precisely measured prior to
every operation, the computer can create a 3D imageof the surgical area. By converting the entries madeby the surgeon on the PC, incisions in the range ofa tenth of a millimetre are possible, something that
simply cannot be achieved purely by hand. With thehelp of a computer, the robot is able to check at all
times whether the doctor is operating where it isnecessary. In case of doubt, the system can stop thedoctor and thereby prevent potential medical errors.

13

Various systems
There is nearly no medical procedure in which a
robot-supported operation would not be possible.
Already today, more than 70 companies offer systems for a wide range of procedures. For example,
procedures on the spinal column, the knee, the hips,
in the abdomen, in neurosurgery, in the ear, nose andthroat area, during biopsies, in gynaecology and urology or even in operations on the heart or in the eye.
The technology is even used in hair transplants. The
devices used in the operating room have different
designs depending on their purpose. The bandwidth
ranges from very voluminous, multi-armed systems
to systems that are no larger than a beverage can.
While the former is used for complex procedures, thelatter system is used simply to accurately hold the
instruments at the desired position.

Medical technology with drive
The patient is aware of nothing that happensin the operating room. The anaesthesia works. An
anaesthetist closely monitors the vital functions. She
can rely on FAULHABER for the artificial ventilation.
Operating in the turbine unit of the ventilator thatis integrated in the anaesthesia system is a brushless,high-speed DC-micromotor with a diameter of just 24
mm. Not only is the motor extremely fast and quiet
over the entire speed range but also extremely dynamic. This enables very natural ventilation. Adults,
children and newborns can all thereby be ventilated
adequately and as naturally as possible throughout
the entire anaesthesia. In addition, the turbine-based
ventilation allows the patients to breathe freely(spontaneous breathing) at all times.
Because robot-supported operations are being
performed in an increasing number of disciplines,
the need for drive systems is growing as well, suchas for the positioning of robot arms. Highly dynamic systems that deliver the full speed in the shortest
possible time are needed here. Thanks to theirironless winding technology and flat speed-torquecurves, FAULHABER Drive Systems have all the necessary properties, such as exact positioning and speed
control. High-performance motor families such as
the FAULHABER BX4 or BP4 and the new BXT series,

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02.2019

MEDICAL ROBOTICSHIGHLY DYNAMIC
SYSTEMSFEWER
ERRORS IN TREATMENT
1

1/10 MMINCISIONS2

24/7
JITTER-FREE
AND PRECISE

3

SIGNIFICANTLY MORE
FREEDOM OF MOVEMENT

complemented by the extensive range of gearheads,
optical, magnetic or absolute encoders as well as Speedand Motion Controllers, are ideally suited for demanding robotics applications not only in medicine but inmany other areas as well.

Daily routine
Robot-supported operations are not just a futuristic vision but are daily routine in many operatingrooms around the world today. Even though a telemedical operation has already been performed –where the doctor sat at a monitor in the USA andoperated on a patient in France – in practice, it generally looks like this: robot and computer serve as assistants to the people on-site in the operating room.
Years of medical experience cannot simply be converted into a programming language. But surgeries can bemade safer through the use of robots. And FAULHABER
will play an important role. As well as outside as inside
the patient.

1

BRUSHLESS FLAT
DC-MICROMOTORS WITH
INTEGRATED ENCODER
3216 … BXT IEF3-4096 SERIES2STERILISABLE
BRUSHLESS DC-SERVOMOTORS
2057 … BA SERIES

3

DC-MICROMOTORS
1024 ... SR SERIES

faulhaber.com/en/markets/medical-laboratory-equipment

FAULHABER motion

15

FA C T O RY A U T O M AT I O NFROM A GRAIN OF SAND
TO A SMARTPHONE
The central technical element of our modern world is the microchip. From the coffee machine to communication satellites, there
is practically nothing that would function without it. Thus, themanufacture of microelectronic components is a key technology
par excellence. Motors from FAULHABER play a role in allimportant steps here – from the processing of the silicon crystal
to the assembly of PCBs.


Wafers of sand
The raw material for chip manufacture could
hardly be simpler: sand, quartz sand to be precise.
The sand is first melted, and other constituent parts
are separated from the main component, silicon. A
so-called seed crystal from the same material initiates crystal growth in the liquid mass. Cylindrical rods
with homogeneous structure are created. Discs about
two millimetres thick are cut off from these: the raw
wafers. After some smoothing and polishing, theblanks are coated with a photosensitive lacquer. The
conductor paths, the thickness of which in modern
chips is in the nanometre range, are created with aphotolithographic process and subsequent etchingof the material.

16

02.2019

The complex structures, which connect millions oftransistors on a chip to form an integrated circuit,are thereby created. Each unit is exposed up to thirty
times with different photomasks. The many dozens
of units on the wafer must be exactly aligned withthose from the previously performed exposure. In thismulti-stage process, the chip structures then appear
on the round disc, which is similar in appearance toa wafer and the source of its name.
Robots move the wafers during all steps and guidethem to the various process steps. The blanks arehighly sensitive and must not bump into anything
anywhere in spite of what are usually constrained
spaces in the systems. In order for error-free structures to be created, their alignment must be extremely precise. The same holds for the optical componentsof the lasers in the photolithographic systems. Ensuring the precise movement of the components withreliable reproducibility in the robots and in the lasers
are drives from FAULHABER, such as DC, stepper or
piezo motors.

Wire and synthetic resin
Opticalfinal inspectionof a typicalsilicon wafer

After the structures in the crystalline silicon havereached their final form, the individual chip blanks
are cut from the wafers. These now receive theirelectrical connections (pins) in the form of fine wires
made of aluminium or gold. They are unwound fromrolls, a process that is, of course, also fully automatic.
A special machine is responsible for this production
step, the so-called wire bonding. It guides the wireend to the desired location, unwinds and cuts therequired quantity and performs the soldering.
The chips are then enclosed by a protective shell,usually made from black synthetic resin. The process
is similar to plastic injection moulding only that here
very high precision is again required. The quantityof synthetic resin must be precisely dosed in order
to effectively protect the circuit yet also ensure that
nothing protrudes that could inhibit installation orfunction. Dosing is therefore performed by a motorised unit: the usually black synthetic resin passes
through a spindle, the forward motion of which transports it toward the injection mould. After travellingan exactly measured path – in the millimetre range –the motor switches to reverse so that a precisely
defined quantity of resin can be released and enter
the mould. Once this process has been completed,the circuits have their characteristic appearance: thechip is now finished and is tested in the so-called test
handler.

FAULHABER motion17

In this machine, a pick-and-place robot is responsible fortransporting and placing the chips in the testing devices.
Since parts are processed here that are no more than a few
square centimetres in size, the dimensions of the systemparts are also correspondingly delicate. The motors for their
movement must be extremely compact but also be able
to deliver very high acceleration values. The same applies
for the wire bonding mentioned above. In both cases, themotors must perform their work with the utmost precision. Because the requirements are so high, motors from
FAULHABER, such as the BX4 series with integrated
Motion Controller or the portfolio of linear DC-servomotors,
are used in many machines in this process area.

Packaging of tested parts in carrier tape

Rapid assembly and needle test
The tested chips are usually packed in plastic belts
and are then transported to the next stage in microelectronic manufacturing: to the assembly of the
PCBs. You are no doubt familiar with these usuallygreen plastic boards with chips, various other electronic components, copper conductive pathways
and shiny, silver-coloured solder points – after all,we encounter them literally everywhere. Together
with the components that hold and connect them,
they form the small or large computer units that are
responsible for flawless function not only in computers and smartphones but also in every car, in every
household appliance, in every machine and in countless other products. Mass production prevails here
as well: countless components are mounted on PCBs
every day.
This work is performed by automatic placement
machines. The belts with the components are fed tothe mounting stations on rollers. Small pockets inthe belt hold the components, a perforation at theedge of the belt enables precise transport. The belt
is unrolled so that the placement head can always
pick up one component. This last step is generally
performed under negative pressure: the component
is drawn in and held in the same manner. The headthen moves to the location on the PCB at which theappropriate openings for the connections of the chipor other component are located. It places the chips
on the openings; later they are soldered to the board.

Automatic PCB assembly using the pick & place method18

02.2019

FA C T O RY A U T O M AT I O NExample of chip inspection using adapter needles

It is easy to imagine how sensitive the hair-thinconnections are. Any misplacement, even a factionof a millimetre, would bend and, thus, destroy them.
Here, too: precision has top priority. At the sametime, a large throughput is required for the massive
quantities. Some machines manage over 100,000
components per hour. The bare eye sees only the
shadow of the tremendously rapid movement here.
The demands on the motors that move the conveyor
units and the mounting heads are similar to those in
the other areas of microelectronic production.

OVER 100,000
COMPONENTS
PER HOUR
The subsequent quality inspection must also be
extremely fast, as each individual PCB is thoroughly
tested. The electrical conductivity of the connections
provides information about the proper function of
the circuits. To measure it, extremely small needles
are guided to individual – two or more at a time –connections and placed under voltage. This is repeated for each part until all conductive pathways havebeen checked over. This process cannot be envisioned
as a leisurely testing operation, however: the boards
are often produced by the million. The fully automatic testing machines must therefore be able to handle
a large throughput. The movement of the needles,for example, is so fast that it can only be followed insuper slow motion.

faulhaber.com

FAULHABER motion

19

INDUSTRIAL TOOLS & EQUIPMENT20

02.2019

Delicate glaze
firmly in grip
Quickly determine viscosity

From smooth and creamy
to light and fluffy to thick andsticky – with foods, our mouthfeel
provides reliable information about
consistency. Spit out or swallow?
We make this decision in justa fraction of a second. In industry,
one would gladly have decisions
that could be made as quickly
and easily. In many sectors,
viscosity tests are necessaryduring production in orderto define and maintain optimum
process parameters. That isexactly what the new rotational
viscometer does, which Brabender
realised with the help of abrushless DC-servomotor
from FAULHABER.

FAULHABER motion

21With many products, viscosity is an importantquality feature or is decisive for their workability inthe production process. Viscosity measurements are
therefore useful in many areas, in goods receiving aswell as in quality control, during the optimisation ofrecipes or even between individual production steps.
To ensure that these analyses take as little time as
possible and can be completed with only small sample quantities, Brabender developed a new rotational
viscometer, the ViscoQuick. Depending on the sample
material, the device is able to complete a measurement in approximately 10 minutes. And can do sowith just 5 to 15 grammes of sample material (plusapproximately 100 to 110 g of solvent).

The measurement system is controlled via the
MetaBridge software; the measurements can bedirectly evaluated and graphically depicted. The
software is web-based and networks not only the
Brabender devices and their measurement results
but also their users. Multiple users can log in simultaneously and conveniently exchange their data – on
PC/Mac, tablet or smartphone.

The viscosity characteristics of a wide range ofmaterials are measured as a function of temperature
as well as gelatinisation properties – such as of starch.
The integrated heating/cooling function controls ­thetemperatures for various applications. The reusable
stainless-steel measuring pot is suitable for both acids
and bases.

paddle”, says Oleg Krawez, system architect at“Located underneath the measuring pot containing the sample is a motor which drives theBrabender, as he describes the principle functionof the new rotational viscometer. “If the viscosityof the sample changes, the torque of the drive
also changes while maintaining the same speed.
If, for example, starch gelatinises and, thus, thepaddle encounters more resistance, the torqueincreases as well.”

Linear speed/torque ratio
To determine the changes, the torque is measured
at the second shaft end of the motor. As a result, themotor becomes a virtual sensor, since viscosity canbe determined from the torque. The speed-torquecurve of the motor must therefore be as linear as
possible for use in the ViscoQuick, particularly at low
speeds. Depending on the analysis task, the speeds
are between 0 and 500 revolutions per minute.
It was therefore necessary to find the right drive.

Fast universal measurement device:
the ViscoQuick determines the gelatinisation propertiesof starch, the alpha-amylase activity in flour as well as
the absolute viscosity of Newtonian liquids.
(Copyright: Brabender)

22

02.2019

INDUSTRIAL TOOLS & EQUIPMENT

“After extensive tests, we decided

Long-lasting and compact

on the brushless DC-servomotor from

Other important requirements on the drive werelongevity and compact dimensions. After all, themotor needs to function reliably over the entire lifetime of the device as well as be easy to integrate.
The brushless servomotor convinced in both regards.
Due to the electronic commutation, its service life
depends mainly on that of the motor bearings. Here,highly precise pre-loaded ball bearings are usedwhich have proven their reliability in a wide range
of application areas.
At the same time, the very compact dimensions of
the 282 watt motor – measuring just 44 mm in diameter and 90 mm in length – were a perfect fit in the
ViscoQuick’s limited installation space, as the measuring device itself is designed to be very space-saving.
“We were, therefore, very happy that F­ AULHABER
also has a suitable, space-saving controller in theirproduct line with the MCBL 3006”, says a pleased­Krawez. With its dimensions of 58 mm by 65 mm, thefootprint of the controller, which is perfectly ­matchedto the motor, is the size of a credit card; in termsof height, it measures only 27 mm. It communicateswith the higher-level control system of the viscometervia an RS232 interface; actuation is also possible via
CANopen.
The combination of brushless DC-servomotor andmatched controller has proven effective in the ViscoQuick. Brabender also uses the same solution in othermeasuring instruments, such as in the Amylograph-E,
which supplies a reliable and reproducible picture of
enzyme activity (alpha-amylase) in flours and grains.
Here, too, changes in torque are measured and areautomatically recorded in an amylogram.

the FAULHABER line”, Krawez continues.
“The motor of the 4490 … BS seriessatisfies our requirements in every regard;
furthermore, we have already had goodexperiences with the drive specialists
from Schönaich.”

Motor
The 2-pole servomotor is a three-phase external
rotor motor with wide speed and torque range. The
integrated linear Hall sensors enable the required low
speeds. Thanks to its ironless design, the motor operates ­cogging-free, with an absolutely linear relationship between load and speed, current and torque aswell as voltage and speed and offers a highly sensitive
current/torque behaviour. These motor characteristics
are reflected in the measurement results. Viscosities­
can be determined with an accuracy of up to 0.5 cmg ina measurement range from 0 to 2,500 cmg.

brabender.com
faulhaber.com

FAULHABER motion

23

SPONSORING

24

02.2019

EVS

AUTOMATIC CHARGING OF

While electric mobility is becoming ever more popular, there is stillroom for developing functional standard technologies in someareas. One such example is the way cars are charged: nobody
wants to see streets littered with charging stations. And while
inductive charging is largely hidden from view, it comes with somesignificant dis­advantages. Volterio offers an efficient alternativethat makes sense. The proto­
type of the charging robot moves
using FAULHABER motors.

FAULHABER motion25


Charging stations can be an eyesore in innercities, and the bulky cables and plugs can also be
an in­convenience in people's garages. Contactless
inductive charging with coils embedded in the garage
floor or the road surface has none of these visual ormechanical annoyances. But unfortunately it comesat a heavy price, and in more than one way: making
the coils disappear means the ground has to be opened ­­­up and refinished; the maximum output is currently three kilowatts in most cases, which can result inlong charging times; and with this type of charging,a significant portion of the power is lost comparedto plug-in cables. This loss is even higher if the car is
not parked right over a coil.

Connector finds connection
The technology from Volterio offers an elegant
solution to all of these problems. When inactive,
the charger is an inconspicuous, only 6 centimeterhigh structure on the floor. The car is then parked
over it for charg­ing. Next, a robot arm extends
telescopically. At the end of this arm is a connector
which seeks its counterpart on the car's underbody.

The two components have previously exchanged
information with each other via encrypted wirelesscommunication. And since the conical-round current
carrier is not a connect­or in the traditional sense, it
is still able to make full contact even if the car is notparked in the optimal position. An ultrasonic system
is used to make sure that the arm accurately finds
its target. The connection is established in less than
15 seconds.
The connector must simply be within a range of
50 by 50 centimeter, and the car can even be parked
at an angle. It is also possible to embed the entire unit
in the floor for new constructions of garages or park­ing spots. The charging capacity of a charger withhome connection is 22 kilowatts, which means thateven the largest car batteries can be fully charged in
4-5 hours. The technology itself is designed to handle
up 100 kilowatts DC, which lowers the charging timeto an hour.
The idea behind Volterio stems from a masterthesis that Christian Flechl wrote in 2014 at the Graz
University of Technology (Austria). Today, he is theManaging Director of VOLTERIO GmbH, and his product is about to go into series production. An important aspect in the development of the prototype was
the three motors that move the robot arm along thethree axes: “We wanted to build a device that was asflat as possible, so there was very little space available
from the beginning”, the young graduate engineer
recounts. “At the same time, we need to moveconsider­able weight. So the motors – in conjunction
with the appropriate gearhead – have to offer hightorque, high speed and be small in size.”

Christian Flechl—
Managing Director
VOLTERIO GmbH26

02.2019

SPONSORINGPowerful, fast, reliable
A search on the Internet quickly led him to
FAULHABER, as not many companies are able tomeet these types of specifications. “In talks withother experts I was reassured that ­FAULHABER
was the way to go, and that became even moreevident when we started working t­ogether.
­FAULHABER sponsored the entire project withextensive technical advice, s­ elect­ing the rightmotors, and by offer­ing the motors themselves.”
DC-micromotors with planet­a ry ­g earheads anda suitable motion controller were installed in
the prototypes. In addition to that, FAULHABER
selected and provided other drives for testing
purposes.
The high motor performance of the CR series isbased on a very stable graphite commutation withlow wear, powerful neodymium magnets, and a­particularly high ratio of copper in the winding. T­ hecharging station is designed for about 20,000 cycles.

This means only about 1% of the service life of thedrives is used. Their robustness is also very important,because the Volterio units must work reliably evenafter long standstills and in harsh weather conditions.
The prototype performed very well in extensive
testing. In pivotal aspects, the technology is far super­ior
to competing concepts. Several manufacturers ofpremium cars agree. They are already preparing tohave the chargers go into series production. Volterio
is now working on new challenges: “Automatedcharg­ing processes can be used in many different
ways”, Christian Flechl explains. “This is true forthe entire field of logistics as well as for all driverless vehicles. Solutions for electric trucks are underdevelop­ment as well. We are developing suitablecharging robots, and we continue to rely on thevaluable support of FAULHABER.”

volterio.com
faulhaber.com

FAULHABER motion

27

PREVIEWCYBATHLON 2020
HSR TEAM POWERED BY FAULHABERAt the Cybathlon 2020 competition,
electrically driven assistance systems
for people with disabilities will be put
through rigorous practical tests. The
team from HSR University of Applied
Sciences Rapperswil (HSR Enhanced)
is participating with a robotic wheelchair and is being supported in theendeavour by FAULHABER, as ourcompact and powerful motors arepredestined for this application. In thenext edition of motion, read how
FAULHABER drive systems are helping
people both with and without disabilities overcome everyday challenges
with applications like this and throughother areas of human augmentationor prosthetics.

*000.9122.19*
Ident-Nr. 000.9222.19

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