Considerations for Building Complex Precision Mechatronics Solutions

Creating solutions which achieve single-digit micron accuracy (or better) is no easy task.

There are hundreds of factors which must be considered when creating an advanced solution like the ones created here at Aerotech & each project must be considered on it's own merits. No two systems are identical.

As a Field Sales Engineer that interacts with our customers on a daily basis, I wanted to write about some of the common questions, issues and themes that arise for the Engineers and Scientists that we work with. Below I have condensed these thoughts into some simple points in the hope that it gives anyone reading this a starting point when considering a precision motion control solution.

1) Total Cost of Ownership is paramount

It can be tempting to think in the short-term when designing a motion solution. The allure of cheaper components and smaller up front costs can appear irresistible. However - this a false economy. It is important to factor in the total lifetime of the system. Costs can mount up extremely quickly when you end up replacing components, dealing with production down time and re-designing systems that are not fit-for-purpose. System builders should remember that...

2) A solution is only as good as it's weakest link.

With any complex motion system, errors can compound and multiply. You may think that you have chosen two (or more) mechanical stages which are up to the task. However when the stages are combined, mounted and aligned, the errors at the Point of Interest / Work-point sum up to give you undesirable results. This is why for truly accurate solutions it is important to select high quality components throughout the system.

With that being said, even choosing high quality components may not be enough to ensure proper performance. This is because...

3) There can be performance losses between different manufacturer's products

For example: You have selected what you consider to be a leading manufacturer's mechanical stage. You have paired it with a leading manufacturer's drive/control hardware. You can expect perfect performance, right?

Wrong. Handshakes between different manufacturers products can produce errors in unexpected places. "Too many cooks spoil the broth" is a common phrase here in the UK. It can also be applicable to precision motion control solutions.

The solution to this is a single-source motion control platform, like Aerotech's Automation1. Using a single control infrastructure that communicates using Hyperwire, a 100KHz Network Rate with a 2gbps communication rate, as well as advanced features like Position Synchronised Output it is possible to achieve unparalleled motion co-ordination, triggering events in the 10s of nanoseconds and revolutionising what's possible with high-speed lasers and other process applications.

4) There is no substitute for Experience

Motion control is an extremely complex discipline, with so many factors to consider. The wealth of talent and knowledge that has been accrued in over 50 years of solving complex motion challenges at Aerotech can not be overstated. Over the decades Aerotech has worked closely with global leaders to solve the most complex motion challenges, and every single day I learn something new from the talented engineers here.

If you are thinking about designing a motion control or automation system, please reach out to us. We will work in partnership with you and your team to ensure that your motion or automation system performs to the highest level for years to come, giving you the best total cost of ownership and industry-leading performance. Whatever the industry, Aerotech can help. Find out more here: Aerotech