Mechatronics have woven their way into the mental toolboxes of components suppliers and OEMs alike. The concept's existence is not new, with most OEMs having been using these techniques for years. Mechatronic applications, however, continue to evolve. And there isn't perfect agreement in the industry as to what it entails.
“Mechatronics is a better way of building machines,” says Brian Ormanic, senior robotic and integration engineer, ARPAC, LLC, Schiller Park, Ill.
“It’s a buzz word; nobody really seems to understand what it means,” says Colin Warnes, director, sales engineering and project management for ADCO Manufacturing, Inc., Sanger, Calif., fueling the belief that nailing down a universal definition of mechatronics is difficult. But OEMs know it when they see it. Schneider Packaging Equipment and Omega Design shared two recent examples.
An early adopter
Schneider Packaging Equipment’s use of mechatronics might actually predate the creation of the buzz word.
“For us, it’s common sense that well-designed machines require mechatronic engineering,” says Schneider controls engineer Bryan Buyck. “Some [of our machines] may appear more heavily mechanical and some more focused on controls engineering, but our design process is always multidisciplinary. It’s been standard practice at Schneider Packaging for 45 years, and we have had minimal implementation issues. This is key to ensuring our machines have the lowest possible total cost of ownership.”
The Brewerton, N.Y. based-OEM began using mechatronic principles as a way to meet its internal standard of high-quality machines. The collaboration of mechanical, electrical and programming engineers further supports Schneider’s mission of lowering its customers’ costs.
“Powerful and efficient technology and cross-discipline engineering add quality and cost-savings passed on to our customers,” says Buyck. “Our products utilize solid mechanical engineering practice and components combined with the latest control technologies in PLCs, sensors, and servo control.”
Obviously after more than 40 years, new technologies have emerged to ease the design and integration of mechatronics, especially in the software field.
Schneider uses Motion Analyzer software from Rockwell Automation to helped streamline the servo motion application design process.
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Image 1: A motion profile built by a user in Motion Analyzer software.
The program allows engineers to create motion profiles inside the software, and input load and mechanical parameters. They can also choose the best servo/reducer/drive combination for the application by comparing cost, inertia ratio, peak speed and torque, motor winding temperature and power consumption.
“Software is a powerful mechatronic tool,” says Buyck. “Through the process of building an axis profile, we clearly define what is mechanically, electrically and programmatically required for the application.
Image 2: Screenshot of the Motion Analyzer software shows a list of acceptable solutions. Users then choose one solution based on their priorities, such as cost against a lower inertia ratio.
Dampening the tamping
Omega Design, Exton, Pa., used a mechatronic solution to improve a pucking conveyor, eliminating an annoying noise. As CEO Glenn Siegele explains it, the machine served its function perfectly fine —unscrambling bottles with a pneumatic tamper — but was louder than he felt was necessary.
“It was inside a guard package, so the noise was somewhat mitigated but still resonated a ton of noise. Just bang, bang, bang, almost like a hammer” he says.
The tamper had a mechanical ratchet handle with a scale. The operator would use this to adjust the cylinder body to match the preset recipe selection for the bottle being run. However, regardless of bottle size the tamper would move three inches up and down, bottoming out at both ends. Omega used cushions and shock absorbers on the cylinder to quell the noise, but it still clocked in at about 90 decibels.
“Since we were just using an old cylinder with a valve, it always had to run the full stroke, even if the small bottles only needed a half inch or one inch stroke,” he says, noting that the full strokes also added unnecessary wear and tear on the component.
He videotaped the tamper in motion and sent it to Numatics, a supplier he had worked with in the past. Numatics National Packaging Manager Dana Greenly had a couple of ideas that “probably would have worked” in Siegele’s opinion, but Greenly felt there was a better way to dampen the noise. He knew that Enfield Technologies offered a very precise balancing valve that would do the trick and had no problem directing Siegele to a direct competitor.
Enfield offered a solution in the form of an external Balluff transducer on a cylinder.
“It'll raise up to just clearing whatever bottle you're running, depending on how you have programmed it,” Siegele says. “It’s only going to go as far as it has to go to seat that bottle, never bottoming out. Since it's always hitting an air cushion, you don't get any of the noise anymore. It's virtually silent.”
The new solution reduced the parts involved from 49 pieces to 28, cut labor time in half and didn’t significantly alter the price. From the customer perspective, Omega now has a quieter, more user-friendly device that lasts longer, can be reconditioned in 15-45 minutes, has recipe-controlled product set points and is a much cleaner design.
The project benefits to Siegele were much more than just the end results for the customer however as it offered real-world messages beyond dollars and cents.
One of the lessons is you don't always think you have to invent everything yourself. “Engineers are prideful and engineers are smart and clever, but you know what?” Siegele says. “If you're using a cylinder application, talk to a cylinder expert. They have seen a hundred of these things in the last two weeks, not three. They might just possibly know something.”
He also couldn’t speak highly enough of Numatics effort to provide him with the best solution for his company, truly representing a partnership rather than a simple customer and supplier relationship.
“Instead of pushing me into his product line, which again would have been dramatically better than the one I had, Numatics recognized that solution might have been a triple instead of a home run,” he says. “I really respect that and will continue to do business with them in the future because of it.”
Mechatronics in action
PMMI, in conjunction with its Education and Workforce Development Committee defines mechatronics as the combination or overlap of electrical, mechanical and controls engineering to create technologies for manufacturing. Employers today need multi-skilled workers to operate, maintain, and troubleshoot equipment on the plant floor.
To achieve this, workers require mechatronics skills. PMMI’s online Mechatronics Certificate Tests benefit both employers and the workforce.
For example, employers can assess the capabilities of current workers and then provide them a pathway to learn and become more valuable to an organization. Workers can confirm their technical knowledge and better pinpoint areas for further training.
Components suppliers and OEMs are investing in the future of their companies and the industry by helping with the development of PMMI’s Mechatronics Certification tests.
“The reason these test matter to OEMs and their business is standardized testing allows OEMs to evaluate candidates and make sure they are qualified and have the requisite skills,” says Tom Jensen, Lenze Americas, Uxbridge, Mass.
Based on industry-developed standards PMMI’s tests are recognized by the U.S. Department of Labor and the Manufacturing Institute’s Skills Certification System.
Lisa Hansen from the Kraft Heinz Company became aware of PMMI’s certification tests at a recent PACK EXPO. A packaging technician at the multinational’s Mason City, Iowa operations, she initially took the mechatronic pilot tests and has taken each new offering.
“I am a firm believer that if you do not go after your own training than it is your fault if you do not learn,” says Hansen. “You cannot expect everything handed to you, you must learn new things all the time or you will fall back, not go forward.
“As I took each test I learned more things from taking the tests that made me look at things that I fix from a different perspective. The tests have given me the confidence to perform my job with less stress and better understanding.”
Bayer CropScience’s, North Muskegon, Mich., Bryan Crozier also took part in the early testing stages to see how his own knowledge stacked up against a standardized test.
“I think a certification program like this can be very beneficial for anyone looking to gain knowledge of industrial automation,” says Crozier. “Younger folks can study material outside of a college setting. This is very important as college is not meant not everyone. An accredited program is great for proving that you have knowledge worthy of hiring.”
Beckhoff North America, Minneapolis, Minn., Senior Systems Architect Bob Trask immersed himself in the creation of PMMI’s Mechatronics Certification for several reasons.
“The benefits for Beckhoff are many,” says Trask. “It offers the opportunity to modernize the material to reflect current trends in automation while I also get to see first hand the issues and concerns from three distinct viewpoints - Academia, OEM's, and vendors.”
He also relishes the opportunity to be involved in not only the creation of a standardized test but also the creation of a measuring stick to use in the hiring process.
“With the high costs involved in training employees, having experience in this field is important,” he says. “Much of the test is not something you can easily find on an Internet search or from a textbook. You have to have lived it.”
Hansen agrees with Trask's sentiments on the necessity of real world experience regarding the tests.
“The knowledge is vast and gives you an understanding that cannot always be obtained without day to day working,” she says. “It will give you confidence and knowledge you would not receive from any other classes. It is broad based so no matter what company you work for you will gain the knowledge to perform your job better.”
Morrison Container Handling Solutions, Glenwood, Ill., President Nick Wilson views his company’s support of mechatronics certification and education as more than just a desire to improve his bottom line.
“Supporting the development of Mechatronics education and testing serves two important goals for our company and the industry: one, a dynamic, innovative Morrison workforce, and two, the broad but critical goal of keeping manufacturing jobs in the U.S.,” says Wilson. “At Morrison, we believe we can help achieve this by bridging the gap between education and practical application, and supporting education and workforce initiatives wherever we can. It is one of the guiding forces for Morrison now and into the future.”
For more information on PMMI’s Mechatronics programs visit pmmi.org/mechatronics or contact Stephan Girard, PMMI director of workforce development at [email protected] or 571.612.3196.
“Supporting the development of Mechatronics education and testing serves two important goals for our company and the industry: one, a dynamic, innovative Morrison workforce, and two, the broad but critical goal of keeping manufacturing jobs in the U.S.,” says Wilson. “At Morrison, we believe we can help achieve this by bridging the gap between education and practical application, and supporting education and workforce initiatives wherever we can. It is one of the guiding forces for Morrison now and into the future.”
For more information on PMMI’s Mechatronics programs visit pmmi.org/mechatronics or contact Stephan Girard, PMMI director of workforce development at [email protected] or 571.612.3196.
