This makes hexapod applications easier to configure and the coordination of moves with other axes of motion using the same controller easy.

“With the new drives, hexapods can be controlled like any other axis in the Automation1 network,” emphasises Brian Fink, Product Manager at Aerotech. “This allows users to significantly reduce development time, cabling effort and integration costs without compromising control precision.”

The Automation1 motion control platform is Aerotech’s central control system. It combines software, controllers, drives, and the HyperWire fibre optic communication bus into a unified environment for high-precision motion and automation tasks.

Functional architecture

The HXA4 and iHXA4 drives are designed for the second generation of the Aerotech hexapod family, which includes the HEX150-125HL model. They combine precise position control with integrated safety and diagnostic functions. Position-synchronised outputs (PSO) allow measurement or trigger events to be precisely linked to feedback position. The Safe Torque Off (STO) function ensures safe operating conditions during service or setup procedures. Analogue and digital inputs and outputs are available for direct connection of sensors, cameras, or external actuators.

Compact design, reduced complexity

The HXA4 and iHXA4 drives have only two main cables per hexapod. This significantly reduces the amount of cabling required. The compact housing facilitates installation in existing control cabinets or directly on the machine. Combining the controller and drive in a single device not only reduces space requirements but also the susceptibility to errors. Users receive a scalable solution that integrates seamlessly into existing automation structures.

The hexapod drives are suitable for a wide range of precision applications. According to Aerotech product manager Brian Fink, typical areas of application include: optical alignment, adjustment, and bonding processes; manipulation and packaging of photonic components; wafer and lens inspection; test setups in aerospace engineering; characterisation of electro-optical systems; and sample positioning in synchrotron and beamline experiments.

“The combination of Automation1 software, HyperWire communication and the HXA4 and iHXA4 models creates a consistent, scalable control concept,” explains Brian Fink. “This allows hexapods to be integrated directly into automated processes. The coordination of complex movements becomes simpler, more reliable and more economically efficient.”

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The HEX150-125HL was developed for maximum precision in positioning. Its sophisticated design with simplified cabling and improved kinematics enables outstanding dynamics and accuracy. With a maximum payload of 12 kg and movement ranges of up to 30 mm linear or 30 degree rotary per axis, the miniature hexapod is suitable for demanding industrial and scientific applications.

Thanks to its robust, rigid parallel kinematic design, it is particularly robust and ideal for automation solutions. Users from industries such as electronics, photonics, automotive, mechanical engineering and medical technology benefit from its high precision and dynamics – especially in quality assurance and metrology.

Simon Smith, European Director at Aerotech, emphasises: “The HEX150-125HL has been developed to enable more precise, faster and more flexible movements in confined spaces. With its combination of compact design, powerful control and easy integration, it offers an outstanding solution for a wide range of high-tech applications.”

Flexible integration into existing systems

Its compact design with a simplified two-cable solution makes integration into research and production environments much easier. An optional mounting plate allows easy attachment to optical tables or breadboards. The 35 mm openings in the platform and base improve access to the workpiece and provide space for additional cables and hoses.

Powerful controls and intuitive software

The precise Aerotech motion controllers, which have won many awards for their performance, ensure maximum precision and user-friendliness. They support programming in multiple coordinate systems and offer an intuitive user interface. Real-time visualisation and simulation tools facilitate the optimisation of motion sequences. The HexGen software also simplifies the simulation of the working area and possible motion sequences.

Efficient motion control with drive technology

The HEX150-125HL can be operated with the new XA4-DC-AX2 and AX4 servo drives from Aerotech. These compact single and multi-axis drives are suitable for control cabinet installation and are part of the user-friendly Automation1 platform. The platform enables precise system configuration and control via a software-based motion controller.

The XA drives support various feedback systems and have an on-board memory for high-speed data acquisition and process control. With the Automation1 controller, up to twelve HyperWire motion axes can be controlled and up to nine user tasks can be executed simultaneously. The HEX150-125HL can be flexibly mounted in a 19-inch rack, under a machine base or on another panel.

In addition to use in laboratory environments, the HEX150-125HL also offers great potential for automated production. With speeds of up to 30 mm/s and 30deg/s, it optimises throughput times in industrial processes. Its robust design ensures reliable performance – even during years of continuous operation.

Highest precision for modern applications

Aerotech presents the HEX150-125HL, a powerful and versatile miniature hexapod that is characterised by precision, compactness and simple integration. “Our customers benefit from simple implementation, maximum repeatability and flexible integration options,” summarises Simon Smith.

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In addition, the Hexapod 150-125HL has undergone design improvements which, according to the manufacturer, lead to significant increases in performance.

The new Hexapod from Aerotech offers a versatile solution for users who need to position workpieces with high dynamics and precision. Thanks to its special design, the parallel kinematic hexapod is extremely robust and rigid. It is therefore particularly suitable for use in automation solutions and is ideal for measuring and testing technology in quality assurance, for example. Aerotech also sees a wide range of applications for the HEX150-125HL in the fields of electronics, photonics, automotive, mechanical engineering and medical technology.

Robust, compact and yet flexible

Compared to its predecessor, the HEX150-140HL, the new HEX150-125HL features a number of enhancements: a reduced height of 125 mm and a base diameter of 150 mm with medium Z travel, a cable reduction to a total of just two cables, one cable for motor power and one cable for feedback, a simplified strut design and a larger, more robust joint construction.

“The joints are incorporated directly into the base and moving platform, which increases the rigidity and load capacity of the miniature positioning system,” explains Simon Smith, European Director at Aerotech. “What’s more, our users get more performance for less money: our new HEX150-125HL will cost 30 per cent less than its predecessor.”

More performance for less money

The unmistakable advantages over other positioning systems lie in the flexible six degrees of freedom, which enable precise translation in the X, Y and Z directions as well as rotation around each of these axes, while at the same time ensuring exact positioning.

With a movable working platform of 130 mm diameter, the HEX150 can handle loads of up to 12 kg vertically and 5 kg horizontally with travel ranges in X of 42 mm, in Y of 44 mm and Z of 17 mm. It also offers a central opening with a diameter of 35 mm.

The new Hexapod also increases the number of available positioning paths with a minimum incremental movement of 15 nm. It offers improved repeatability, higher speeds in the X and Y directions of 30 mm/s and in the Z direction of 8 mm/s compared to its predecessor, as well as improved load capacity, which, according to the manufacturer, leads to significant increases in performance in the application.

Efficient movement control with XA drive technology

The HEX150-125HL can be moved using the new XA4-DC-AX2 and AX4 drives from Aerotech. These compact single and multi-axis servo drives are designed for installation into a control cabinet. The XA drive series is an integral part of Aerotech’s user-friendly Automation1 motion control platform, which allows systems to be precisely configured and controlled. The platform has its own software-based motion controller, which makes it easy to control the servomotor drives.

The XA drives support multiple feedback device types and have on-board memory for high-speed data acquisition and process control. With the integrated Automation1 controller, up to twelve HyperWire motion axes can be controlled and up to nine user tasks can be executed simultaneously. The HEX150-125HL can be mounted in a standard 19-inch rack, under a machine base or on another panel.

Simon Smith concludes: “With the new HEX150-125HL, we are once again setting new standards in precision and flexibility. In combination with the XA drive technology and the Automation1 motion control platform, we offer our customers a powerful and cost-effective overall solution that opens up a wide range of possible applications. Our most important design goal was to improve the motion performance while further increasing the efficiency and user-friendliness of our products.”

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Aerotech CEO Mark Botos (left) and president Bob Novotnak (right)

Celebrating over 50 years as a leader in motion control, well known for its hexapods, and most recently having introduced a delta robot system, Aerotech has grown from a three-man start-up to a high-tech company with over 500 employees. We speak to Aerotech CEO Mark Botos and president Bob Novotnak about the company’s development.

Aerotech’s history dates back to 1970, when Stephen Botos and two fellow engineers started prototyping a positioning system for industrial use in a garage. The first positioning system manufactured was a simple two-axis electromechanical application.

What were some of the key milestones in Aerotech’s history that brought the company to the leading motion control solutions provider that it is today?

BN: Decisive milestones were certainly the development of coordinated multi-axis control in the 1980s and our own servo motor production in the mid-1990s. This enabled us to ensure that our positioning solutions positioned with high precision down to the nanometre range. We have also been able to open up new markets with innovative and low-maintenance air-bearing rotary axes.

One example of this is our new ABRX series for surface measurements in the nanometre range. With large air bearing surfaces, we achieve significantly better running accuracy than mechanical or other air-bearing rotary stages available on the market, which benefits not least applications that require exceptional flatness of movement. In terms of angular accuracy, load capacity and off-axis error movements, ABRX also outperforms all other rotary stages on the market to date.

MB: For me, an important milestone was the introduction of customised solutions into our portfolio. This enabled us to convince numerous new customers in all industries of our positioning know-how and win them over. In addition, we have established and successively expanded our global presence. Today, we are represented in all important key markets, partly with our own subsidiaries. Another important step in 2017 was the implementation of an integrated ERP system to control our manufacturing processes. This paved the way to transform our previously predominant single-item production into an effective small-series production.

What were the biggest challenges in Aerotech’s history that the company was able to overcome?

BN: Basically, these were mainly economic crises that we had to deal with. One was the collapse of the US machine tool industry in the early 1980s and then around the turn of the year 2000 the big telecom crash, ie the dotcom bubble.

MB: We were able to come through these crises relatively unscathed because we had made a good name for ourselves in the market for positioning systems from the very beginning and had gained a foothold in all industries, so that we were and are not dependent on just one industry.

How has the growth and increasing customer demand worldwide affected your business?

BN: It continues to drive us to develop new products and business initiatives. Even though this permanently brings challenges, our products and services are in demand. We help our customers solve some of their toughest automation challenges.

MB: The biggest problems were caused more by the uneven demand. The global aspect has been less of a problem. So it is not always easy to react to the rapid ups and downs of the high-tech industry. But we continue to drive progress by using our core competencies in technology.

What have you done to build capacity to keep up with the increased demand for your products and services?

MB: We have been working on building a diverse supply chain to expand our existing production capacity. The focus has been on expanding our production capacity by doubling our clean room space. However, some things we do cannot be outsourced. Therefore, we have developed internal training and sustainable recruitment programmes to build, attract and retain the talent we need.

Can you explain how technology is driving your business forward – both for your internal operations and for your products and services?

MB: The constant change in technologies creates new opportunities. As many devices, such as smartphones, become smaller and more ubiquitous, the demand for manufacturing these products is constantly increasing. At the same time, these developments also influence our manufacturing processes, with lasers and additive processes being the best examples. To put it in a nutshell, the smaller applications and devices become, the more precise the positioning has to be in manufacturing.

BN: I would add that our customers are increasingly automating their products because of the higher precision, smaller size and lack of available labour. This is where we see ourselves as a reliable partner for micro-production in the future as well.

What are the key features that make Aerotech unique both as an employer and as a provider of precision automation systems?

MB: Respect for our employees and their families creates an environment where people like to stay because they know they share in the company’s success through profit sharing and an employee share ownership programme. And our customers can rely on us for both product performance and our global service. Our products perform as stated, backed by data, and are supported by us for as long as possible.

BN: Aerotech is unique in the industry in that we have the expertise in-house on many of the core technologies needed for our business. This gives us the opportunity to permanently adapt these technologies to the current and future needs of our customers. A good example of this is our new Automation1 control platform, which is developed based on customer requirements and is constantly being expanded functionally to meet customer needs.

Where do you want to take Aerotech in the future?

MB: We naturally want to continue our growth story so that we can enable our employees and customers to achieve their own life goals. Our current starting position as well as the market opportunities are optimal to sustainably drive future growth. We have hired around 100 new employees in the last six months alone.

BN: Of course we want to keep growing, but in a smart way. We see a bright future for precision automation systems. And so we will continue to do what we do best: build the best precision motion control and automation equipment for our customers. One of the latest examples is the further development of our popular ANT nanopositioning stages. Building on the proven predecessor model, the 2nd generation ANT95 and ANT130 high-precision nanopositioners are designed to support users even better in terms of dynamics and precision.

We see a wide range of possible applications for this, for example in assembly and inspection in photonics, in fibre alignment and optimisation, in the manufacture, testing and inspection of optics, in sensor testing and qualification, but also in semiconductor manufacture and inspection as well as in research and laboratory applications.

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The positioning accuracy can be controlled via three parameters: the drive, the guides and the motion control used. “When it comes to positioning down to nanometres, drives and guides can be as precise as you like, but it’s the control software that makes the difference,” says Simon Smith, European director of Aerotech. “We can certainly achieve quite a lot with an extremely high constructive and costly effort, but ultimately the software must be able to precisely control and position the system.”

Automation1 is a motion control platform that can also integrate the entire periphery. It is intended to replace the previous Aerotech control platforms A3200, Ensemble and Soloist. “We only deliver new positioning systems with Automation1 as the control platform,” emphasises Smith. “The easy-to-learn and easy-to-use architecture alone makes it much easier for users with Automation1.”

While the latest release builds on previous versions, it includes a number of new features. For example, the previous CNC user interface is replaced by the new Machine Apps HMI development tool. With this fully customisable tool, Aerotech says it is setting new standards in user interfaces for drive systems.

Seamless integration of PLC-based systems is also provided with EtherCAT compatibility. With this, Aerotech has extended the options for high-precision motion processes to PLC systems when they are embedded in a conventional system with lower precision.

“With the new release 2.2 of Automation1, it now functions as a complete machine control system with all components and thus offers much more than a mere ‘motion control’,” concludes Smith.

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“The HEX150-140HL offers not only significantly better minimum incremental motion, but also greater linear travel than any of its competitors – all in a compact yet rigid platform,” said Simon Smith, European director at Aerotech. “The combination of small size, high precision and excellent load capacity also allows for a much higher degree of flexibility. Users can rely on consistent, reliable six-DOF movement in every application.”

The HEX150-140HL is said to be ideal for space-constrained applications with multiple DOFs that require fine positioning resolution, such as alignment, assembly and interconnection of photonic components, optical inspection and alignment, optical wafer probing, aerospace and satellite sensor testing, and sample alignment in synchrotron and beamline applications.

Other important features are the high load capacity of up to 7.5 kg with the ability to resist backdriving with force up to 100 N, the large range of motion for easy integration into complex applications, and the simple control and programming with virtual pivot point adjustment.

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The HEX RC features 6-axes of drives capable of controlling any combination of brush, brushless, or stepper motors. It digitally performs both current loop and servo loop closures to ensure the highest level of positioning accuracy and performance. The HEX RC connects and controls up to 26 additional axes of servo, stepper, or piezo-driven stages using the A3200 distributed control architecture.

The HEX RC is designed with an ASCII command interface over TCP/IP for control in applications such as beamlines. Alternatively, it can act as a master controller to control other A3200 external drives via the FireWire interface.

The HEX RC accepts amplified-sine or digital encoders. Optional integrated encoder multipliers, up to X4096, ensure high-resolution positioning. An optional 6-axis jog pendant permits easy, manual control of the positioning system. In safety critical applications, an emergency stop option with redundant safety relays can be added.

Aerotech’s A3200 focuses on ease of use for the programmer, shortens development time compared with other tools, and provides the flexibility to use the tools or controller most familiar to programmers. A complete Integrated Development Environment and a comprehensive .NET motion library provide classes for motion, I/O, status, and diagnostic information. You can program in Visual Studio and use the .NET library, or use the Motion Composer (IDE) to develop code with AeroBasic commands or G code. A LabVIEW VI library is available for NI users, while a complete C library is available for those using Visual Basic, C++, or C.

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The HEX300-230HL is actuated with six high-accuracy struts built with precision preloaded bearings, ball screws, and drive components. Unlike competitive hexapods driven by DC brush servomotors, the HEX300-230HL is driven by Aerotech’s AC brushless, slotless servomotors that maximize its performance and longevity. Directly coupling the AC brushless servomotors to the ball screw results in increased drive stiffness, higher positioning accuracy, and better minimum incremental motion (20nm in XYZ and 0.2μrad for θxθyθz), compared to competitive designs using belts, gearheads, or compliant couplings.

Specially-engineered strut pivot-joints provide low friction and high stiffness, enhancing the hexapod´s overall performance. The HEX300-230HL´s superior structural design offers the user a generous load capacity of up to 45kg.

The HEX300-230HL´s platform and base can be easily modified with user-specific features or mounting patterns. It features a 100mm diameter clear aperture in the platform, while a 60mm diameter clear aperture in the base allows workpiece access from the bottom. The base mounting holes adapt directly to English and metric optical tables.

Aerotech hexapods can be vacuum-prepared for demanding applications such as synchrotron sample or optics manipulation, semiconductor manufacturing and inspection, or satellite sensor testing.

Driving the HEX300-230HL is Aerotech’s award-winning A3200 motion control software. Built on years of experience with difficult kinematics applications, the A3200 controller allows easy programming and control of the hexapod in any user-defined coordinate system.

Aerotechs HexSim software gives users the ability to easily visualize and simulate the available workspace. Tight integration between HexSim and the A3200 motion controller provides real-time motion visualisation in any user-defined coordinate system. An intuitive graphical interface permits selection of the active coordinate system for easy virtual pivot-point programming and motion.

You can find more information on Aerotech’s HexGen hexapods here.

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With its high-load capacity, large travels, high speeds, and sub-micrometer precision, the HEX500-350HL means no compromising on application specifications. Aerotech claims the HEX500-350HL is the only hexapod on the market today that provides guaranteed positioning accuracy specifications.

The HEX500-350HL is actuated with six high-accuracy struts that are built with precision preloaded bearings, ball screws, and drive components. Instead of the more typical DC brushed servomotors, the HEX500-350HL is driven by AC brushless, slotless servomotors that maximise device lifetime and performance. The servomotors are directly coupled to the actuator ball-screw enabling increased drive stiffness, higher positioning accuracy, and better minimum incremental motion (20nm in XYZ and 0.2μrad for θxθyθz) when compared to competitive designs that use belts or compliant couplings. The strut pivot-joints are engineered to provide low friction and high stiffness enhancing overall hexapod performance.

The HEX500-350HL is designed with flexibility and customisation in mind. The platform and base can be easily modified with user-specific features or mounting patterns. The HEX500-350HL is designed with a 150mm diameter clear aperture in both the platform and base to allow for workpiece access from the bottom. The base is designed with mounting holes to adapt directly to English or metric optical tables. The hexapod can also be vacuum prepared for demanding applications in synchrotron sample or optics adjustment, semiconductor manufacturing and inspection, or satellite sensor testing.

Driving the HEX500-350HL is Aerotech’s award-winning A3200 motion control software. Built on years of experience in difficult kinematics applications, the A3200 controller allows easy programming and control of the hexapod in any user-defined coordinate system. Aerotech’s HexGen software gives the user the ability to easily visualise and simulate the available workspace.

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Extensive use of carbon fibre and light-weight aluminum on the RCP-DELTA results in a robot that is capable of sustaining 200 pick-and-place operations per minute with peak acceleration on the order of 15g. With absolute encoders on each motor the RCP-DELTA robot never has to be referenced, even after a loss of power.

The RCP-DELTA control system is based on Aerotech’s A3200 Machine Controller. The A3200′s networked, distributed architecture provides a scalable platform upon which additional RCP-DELTA robots, I/O, and positioning devices can be integrated easily. Multiple programming interfaces provide deployment flexibility on the RCP-DELTA by allowing developers to work in the environment that matches their skill sets or application requirements.

External sensors are supported on the RCP-DELTA with industry standard fieldbuses (EtherCAT, Modbus TCP, Ethernet/IP, and others) or applications operating in the RCP-DELTA controller’s real-time enabled Windows operating system.

Multiple robot configurations

IP65 protection is standard on the RCP-DELTA (sealed against dust and low-pressure water jets) and IP69K (sealed against dust and close-range high pressure and high temperature spray) is available on the RCP-DELTA for applications where periodic cleaning with high-pressure water and/or steam is required.

The RCP-DELTA supports all standard A3200 programming and control capabilities such as multi-block look-ahead, corner rounding, and command shaping. Additional Delta robot specific functions are included on the RCP-DELTA controller for common robotic operations such as target queues, tracking moving material, and teaching tool/part locations.

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