For applications such as robotics that require the coordination of multiple axes of DC or brushless DC motors, a master controller is required. These controllers are freely programmable and can typically achieve multi-axis coordination as a kinematics group or can programme and control axes individually.

To achieve this control, application designers might be tempted by the familiarity of a PLC or a standard microcontroller. However, a microcontroller dedicated to providing motion coordination of multiple axes can create a higher performing, more reliable control system.

To optimise multi-axis control for applications that require up to six DC, BLDC, or stepper motors, maxon’s MACs range includes the MiniMACS6, which is ready to control and power slave devices, and the MicroMACS6, a more compact controller that requires a power stage.

Real-time capability

One of the standout features of the MACS controllers is their real-time capability. Unlike typical microcontrollers such as the Raspberry Pi, which may struggle with real-time processing, the MACS range excels in handling time-critical tasks. This makes them ideal for applications requiring precise timing and synchronisation.

The MiniMACS6 model comes with integrated power amplifiers, a feature not commonly found in standard PLCs or microcontrollers. This integration allows for a more compact machine design, capable of driving brushed DC, brushless DC (BLDC), and stepper motors directly. This reduces the need for additional external components, simplifying the overall system architecture – as well as reducing cost.

maxon provides a free software development kit (SDK) with numerous functions and examples, making it easier for developers to get started. This SDK is tailored to leverage the full capabilities of the MACS controllers, offering a more streamlined development process compared to generic and less specialised SDKs typically available for standard PLCs and microcontrollers.

Integrated kinematics libraries

For applications involving complex motion control, such as delta and SCARA robots, the MACS controllers come with integrated kinematics libraries. These libraries simplify the implementation of sophisticated motion profiles, reducing development time and improving system performance.

maxon offers hardware modifications on request, providing a level of customisation that is typically not available with off-the-shelf PLCs and microcontrollers. This flexibility allows the MACS controllers to be tailored to specific application requirements, enhancing their versatility.

BLE service option

The MicroMACS6 model includes a BLE (Bluetooth Low Energy) service option, enabling wireless communication and control. This feature is particularly useful for applications where wired connections are impractical or where remote monitoring and control are desired.

Offloading higher-level controllers

By handling all motion control tasks within the MACS controllers, the workload on higher-level controllers is significantly reduced. This offloading allows the main controller to focus on other critical tasks, improving the overall system efficiency.

The MACS controllers feature integrated functions such as jerk-limited profiles, which ensure smooth operation of motors. This capability is crucial for applications requiring precise and gentle motion, reducing wear and tear on mechanical components and enhancing the longevity of the system.

In summary, the maxon MiniMACS6 and MicroMACS6 controllers offer several advantages over standard PLCs and microcontrollers. Their real-time capability, integrated power amplifiers, comprehensive SDK, kinematics libraries, customisable hardware, BLE service option, and ability to offload higher-level controllers make them a superior choice for many automation and control applications. These features collectively contribute to more efficient, compact, and reliable systems, setting the MACS range apart in the competitive landscape of control solutions.

The MicroMACS6 motion controller is designed for embedded integration in kinematic applications, such as Delta, SCARA and lightweight robots. Compact size and weight make the motion controller advantageous for mobile robots, including AGVs (automated guided vehicles). Multi-axis motion control means that MicroMACS6 can also enhance productivity and efficiency for machines and systems such as pick and place applications.

The MicroMACS6 master motion controller achieves multi-axis coordination as a kinematics group, or it can programme and control axes individually. MicroMACS6 can control up to six motor controllers, including a combination of maxon EPOS4 position controllers and maxon ESCON speed controllers. The controller features a range of motion functions, such as path generator with sinusoidal/trapezoidal profiles, position and velocity control feed forward, as well as position marker/touch probe.

The motion controller enables versatile device integration thanks to its I/O array, including six digital inputs with free programmable functionality. In addition, MicroMACS6 features two, free programable analogue inputs with a 12-bit resolution, operating within a range of 0 to +10V and at a frequency of 1kHz, providing precise signal control. Hosting four digital outputs with free programmable functionality, MicroMACS6 also includes a 25kHz PWM capability. The controller also includes a DIP switch to configure Node ID, as well as CAN Bus Termination settings, ensuring seamless communications connections.

Providing flexible network integration, as well as connectivity to a range of peripheral devices, MicroMACS6 supports various communications options, including a full speed USB interface. MicroMACS6 supports the CANopen protocol, functioning as both a master and slave, and complies with CiA 301 CANopen application layer and CiA 402 motion control profiles. The motion controller also offers compatibility with EtherCAT via Ethernet.

Highly compact dimensions enhance ease of design integration, while the motion controller’s minimal weight optimises performance and efficiency for applications that require low mass. MicroMACS6 weighs just 26g and measures 21mm high, 40mm wide, and 55mm long. Fast installation is achieved via two, M2.5 screw mounting points.

OEMs can achieve fast and straightforward programming via universal languages including MS Visual C# and MS Visual C++, as well as maxon’s simple to use ApossC_SDK language. For commissioning and management, maxon’s intuitive ApossIDE installation software enables rapid set-up and use. MicroMACS6 is compatible with Windows 10 and 7 operating systems, and provides access to Windows DLL for PC in 32-bit and 64-bit versions.

The controller has also been developed for use in demanding environments, and durable design ensures reliable operation in temperatures ranging from -30°C to 55°C, as well as humidity as high as 90%.

The controller operates with a logic supply voltage minimum 8V and maximum 28V.

The new multi-axis motion controller can be combined with a maxon compact drive, achieving a complete motion control system. The company’s engineers also provide bespoke compact drive system design, specific to application requirements.

Technology plays an increasingly important role in rehabilitation services and healthcare. Therefore, clinicians, engineers and companies recognise that they need to accelerate the development of technological solutions to best meet the needs of patients. This is the main goal of the partnership between drive specialist Maxon and start-up Fourier Intelligence, which specialises in exoskeletons and robotic rehabilitation. The two companies are pooling their expertise to develop industry-leading technologically products and platforms for patient treatment. To seal the partnership, a memorandum of understanding was signed in December 2020.

“The partnership between Maxon and Fourier is a powerful combination,” said Eugen Elmiger, CEO of Maxon Group. “Fourier’s understanding of the interplay between modern rehabilitation robotics and technological products perfectly complements Maxon’s philosophy of making the world a little better with our precision drive systems. Together, we will be able to generate industry-leading technology products and platforms.”

Fourier already uses BLDC motors from Maxon in its ExoMotus X2 exoskeleton. In addition, Maxon will become part of the Exoskeleton and Robotics Open Platform System (EXOPS), an open platform for research and development of exoskeleton and robotics systems. Maxon will provide a variety of customised drive solutions with motors, gearheads, encoders and controllers to aspiring engineers who want to develop robotics solutions for rehabilitation services.

“Partnering with Maxon will allow us to provide the best technology portfolio on which to conceive, design and build the next generation of transformative technological products and platforms,” said Zen KOH, co-founder and deputy CEO of Fourier Intelligence. “Together, as one team, we will unlock the full potential of technological rehabilitation and put patients on the best path to recovery.”

Visit the Maxon Motor website for more information

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With the EC-i 30, drive specialist Maxon Motor is introducing a new brushless DC motor (BLDC). It has a diameter of 30mm and is therefore smaller than the EC-i 40 currently available. Like its predecessors, this motor stands out for its high dynamics, low cogging torque, and high torque. It is available in two lengths, each in a Standard and a High Torque version, with a maximum nominal torque of up to 110mNm at 75W.

Despite their impressive performance, EC-i 30 DC motors are a cost-effective alternative to existing drives. Because of this and their compact design, they are especially suitable for applications in robotics.

In all versions, the new EC-i 30 motors can be expanded with encoders, gearheads, servo controllers, or positioning controllers from Maxon Motor – easily and conveniently in the Maxon online shop.

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Industrial graspers are built to pick up one thing, move it and put it down. If you have two different sets of objects, you currently need two different grippers to perform that task. Shadow’s Smart Grasping System has a library of different grasps, meaning you can use one hand to pick up many different types of object, which reduces the need for multiple machines in the factory.

To control the grasper, each SGS finger uses a Maxon brushed DCX 14mm motor and GPX 16mm gearhead combination. The DCX range was attractive to Shadow as it is configurable online and offers super-fast delivery – in fact it was ready within 10 days. The power to weight ratio was appealing and, together with the strong gearbox, gave additional torque on a smaller motor. The DCX range uses ironless rotor technology which gives smooth and precise control for the gripper.

Rich Walker, managing director at Shadow Robot explains: “Most industrial graspers don’t have torque sensors. Here at Shadow, we think that if you want the most flexible and safe robots, then that’s exactly what you need. We’re moving away from a time where robotics were strictly bits of metal clanking around, and moving towards smarter, intelligent technology that understands how it interacts with the world. Which is why we’ve designed the Smart Grasper with this in mind.”

Torque sensing provides your robot with precision, making accurate grasps with a better hold, increasing the success rate of the grasps, and therefore making for a safer work environment. The SGS has sensors that monitor the torque in the springs of the joints. If you want to apply a particular torque to a finger, you can do that as there are a series of elastic actuators which control it, plus you can physically back-drive it too, increasing human interaction safety. “No other commercial grippers have this quality,” says Walker.

The Smart Grasping System is a universal solution to many manufacturing needs. It means companies require fewer robots, fewer spare parts, less training for staff and less human cost, all resulting in a system that can be installed across multiple sites, with an extremely easy user interface and setup. Companies will save money and time, increase efficiency and bring their business in line with smart manufacturing concepts such as Industry 4.0.

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Key components of the anthropomorphic hand are miniature electric motors from Maxon Motor, and Walk also discusses the relationship between Shadow Robot and Maxon.

Visit the Maxon Motor website for more information.

But, for these refined feedback loops to breathe autonomy into the creation, they would need to be properly fed. The Robot Studio knew that, just like in the human body, the mechanical loads at play would need to be monitored with great sensitivity and quickness; they theorized this could be achieved by employing force sensor technology. But there were a couple caveats: these sensors would need to be designed to safely withstand incidental loads that exceeded the magnitude of forces they were designed to accurately monitor; and, to meet the spatial constrictions of this human form, their performance would need to be packaged into an impossibly small size.

Faced with a measurement challenge that fell somewhere between exotic and impossible, the Robot Studio reached out to FUTEK Advanced Sensor Technology. Since FUTEK had reputably pioneered sensor designs for applications ranging from deep sea to outer space, they expected the FUTEK engineering team would bring their own cutting-edge technologies to the table. They did not expect this futuristic sensor they sought would be in stock and ready for shipment: the LSB200 Super Miniature Load Sensor.

Out of the box, the overachieving performance specifications of the LSB200 more than fit the bill. An impressive 0.05% of scale nonlinearity comfortably can satisfy the most aggressive performance tolerances. A 1000% safe overload rating allows the LSB200 to survive forces up to ten times its calibrated range. And with all the precision and reliability of strain-based sensor technology packed into a geometric volume of roughly 2mL, the spatial displacement of the LSB200 seems more like a typographical error than reality. With the successful integration of the FUTEK LSB200 sensors, this groundbreaking prototype now serves as a platform for The Robot Studio’s next exploration: a biomimetic human torso.

In the ever-advancing field of robotics, the world can only guess what is next to come. And, we at FUTEK Advanced Sensor Technology await your call to help you get there.

Read more about the project on the FUTEK website.