There was a time not so long ago when engineers had to design automation systems completely from the “ground up” using basic unguided actuators. Shock absorbers, hard stops, sensor and pneumatic plumbing solutions, bearing rails and other guides had to be custom-fitted for an individual system. Today, there are many companies offering high-quality standard engineered components, from robotic grippers to guided linear and rotational components that are pneumatically and electrically actuated. Building on this progress, modular guided actuators are now available to further simplify and improve the machine design process. Here is how:
Eliminate time and cost associated with designing adapter plates–Especially with systems involving several functions (i.e. gripping, rotating, multi-axis linear movements), using modular components can save thousands of dollars over producing and designing custom adapters. The savings in engineering time alone allow engineers to focus valuable attention on other areas of the machine development. In addition, mistakes can be avoided in manufacturing incorrect adapters that could set back machine installation for weeks. Pre-engineered gussets and other supporting elements take additional burden off the mechanical design engineer.
Reliable Components Sizing–When sizing a subsystem of actuators, careful attention must be given to ensure that every actuator is capable of handling its foreseeable load at worst-case speed. In some situations, base actuators must support the mass of several others projecting the center of gravity of the overall payload to an unfavorable position. Checking dynamic moment loading of an application against technical specifications in an actuator product catalog can often be confusing and time consuming. With modular components, subsystem design is pre-engineered and can be checked using computer software allowing for fast calculations, even with a wide range of input variables. Once a subsystem is properly sized, mechanical interference between components can sometimes occur making it difficult to physically use them together. The engineer is then forced to either reevaluate their selection, or undertake a difficult design. The result can lead to costly adapters that are time consuming to assemble and disassemble by maintenance engineers working for the end customer. Modular system design ensures a simple and trouble-free fit between components.
Making Changes–It is very common for last-minute changes to be required in a machine design process. A truly modular system incorporates standardized mounting and location features on its components, allowing for changes with minimal drawing revisions. Standard solutions for mounting multi-actuator subsystems to a machine provide further flexibility by allowing for height and rotational adjustments. Having uniform stroke and sensor adjustments throughout a system benefits operators and maintenance people learning to work with the machine.
Adding Complexity–Many applications require actuators to have three or more positions. While certainly achievable using electric servomotor drives, electric systems are often more expensive and harder to implement than pneumatic systems. Modular component systems can provide multiple linear positions via stopper cylinders mounted along the uniform bolt pattern surfaces of a linear slide. Also, retractable stops can be incorporated at the end of slides. Rotary units can achieve mid positions while still remaining compact and lightweight. For demanding applications involving many positions, modular linear modules are available with electric linear motor drives.
For many engineered consumer products on the market today, new models are the result of incremental improvements over layers of prior development. From computers to automobiles, product engineers cannot afford to “reinvent the wheel” on every component being used in a new product. Likewise, custom machine design engineers no longer have to design their own grippers and guided cylinders, nor do they have to design their own subassemblies of guided actuators. Modular components simplify the machine design process, improve reliability, reduce the chances for mistakes, and contribute to faster development times from concepts to completed machines producing products on a factory floor.
Tom Reek
Regional Sales Manager–AutomationSCHUNK Inc.
