Successful integration of a motion system involves more than just stacking positioning tables and driving them with controllers. As a manufacturer of automation systems, motion control specialist Aerotech offers its customers comprehensive support for high-precision and/or industry-specific automation processes. In this interview, Norbert Ludwig, Aerotech's Managing Director, and Brian O'Connor, Vice President of Marketing, explain the choice customers have between a pure component solution, a customized motion subsystem, and a fully integrated system.
Mr Ludwig, how long has Aerotech been active in the market?
NL : Since 1970, we have been supplying solutions for standard products such as motors, drives, controllers and positioning tables. Our custom-developed motion subsystems include positioning systems on granite structures with undercarriage and vibration isolation, as well as external measurement systems.
And what characterizes their integration solutions?
NL : Our integrated systems are near-turnkey machines designed with our customers to run an automated process. They include not only Aerotech's own precision motion control components, but also full automation integration for elements such as part handling, process instrumentation, safety devices and customized software.
How can a component manufacturer achieve such integration expertise?
NL: Over the In recent years, we have worked closely with customers from a wide range of industries, becoming increasingly involved in the field of process automation. As a manufacturer of automation systems, we help manufacturing companies to optimally automate their processes with the precision motion components we produce.
BC : Aerotech Inc. offers its customers a full range of integration options, from a low level of integration, i.e. motion components only, to a turnkey automation machine. This differentiates us from a supplier of standard motion components or a traditional integrator. Some customers want to build the machine themselves, while others are not entirely comfortable with this option. We are flexible in our approach and work closely with our customers to find the best solution for their needs.
When we develop a turnkey automation machine for a customer, we see it as a partnership. The customer knows the application and understands the production process for their part. We're experts at understanding the customer's process, and building a machine based on that process that executes it with the utmost precision and efficiency.
And which customers do you have in mind first?
NL : Our integration expertise is of particular interest to companies that are in the process of setting up, expanding or modernizing their production. Particularly in medical technology and precision manufacturing, many companies have neither the personnel nor the vertical manufacturing range to develop mechanical and control engineering in parallel. In addition, solutions are becoming smarter and more complex, so that a single company can no longer master all the implementation stages. As a result, supplier know-how is becoming increasingly important. And this is where our real work as an automation system manufacturer begins: We offer detailed integration advice, resulting in either the delivery of individual components, a subsystem that can be seamlessly integrated, or even a complete automation solution. Application training, courses and services round off our range of services.
Where do you see your greatest opportunities in the automation market?
NL : Aerotech has a high level of vertical integration, especially when it comes to drive components and control elements. We have grown with our customers over the years, acquiring application knowledge in many sectors.
BC : Our philosophy of vertical integration enables us to be extremely flexible, while ensuring quality and performance at every level of the machine. Because we manufacture the controllers, motors and positioning mechanisms ourselves, we know exactly how they interact with each other and within an automation system. This enables our team to customize and optimize a machine with the utmost efficiency.
NL : If it's a laser welding process, for example, where the laser beam needs to be deflected as quickly and precisely as possible, the experts know exactly which axes are suitable in combination with which galvo-scanner. We can then optimize accordingly, so that the customer only needs to couple and control his laser. He can also use our control platform, with which he can immediately control his laser welding system. In addition, customer-specific specifications that go far beyond the Aerotech component level can be integrated into the subsystem. For example, if the customer already uses a control cabinet, Aerotech control electronics can be flexibly integrated into it. Other elements, such as control or measurement, can also be integrated.
On the mechanical side, for example, we can also supply partially integrated systems that the customer wishes to complete. If, for example, a granite adjustment system is required for the machine, our experts will prepare it according to the customer's specific needs. Other functions, such as laser beam guidance or certain sensor technologies, can then be integrated by the user himself according to his needs. These are the tasks we are entrusted with every day. The aim is to offer the customer a freely scalable solution, ready for use as quickly as possible without too much effort, and which can be flexibly adapted to future process requirements.
How do you usually go about integrating a system?
NL : The first step towards actual integration always begins with a detailed consultation of the application. During this process, customers also learn that Aerotech control technology can be used to move much more than, say, the 6 axes of a hexapod positioning system. If, for example, the laser is to be triggered according to the position of the Hexapod and fired by pulse at a specific point, it is also possible to use the Automation1 control platform or the previous model. In this way, the entire process can be controlled from a single central command. Measurement processes can also be entrusted to the Automation1 platform, so that measured values are also processed and stored via analog inputs, for example, so that the entire result is stored in real time in a single control unit for perfect synchronization with movements.
Our entire business strategy is designed for close cooperation and to give our customers a long-term competitive edge in their respective market segments. That's why we insist on investigating what needs to be done. In this way, we get to the heart of the application and optimize it. Ideally, we can offer the customer a system where everything is already prepared, so that all he has to do is configure his machine.
And what does it actually look like?
NL : For example, a close collaboration has been established with a well-known Swiss manufacturer of ceramic dental implants. An Aerotech manufacturing system with integrated galvo-scanner is used to laser the micro grinding tips. The complete mechanical part with linear drive, axes and control software came from Aerotech, while the housing and the rest of the periphery were built by the implant manufacturer's own team. To process a part, the workpiece is loaded by a handling robot. Both the robot and the measuring system used can be connected via Aerotech's control software. In this particular case, the medical device manufacturer had no experience of laser technology and how it could be integrated into a manufacturing system. They also knew that there was no such thing as a ready-to-use system with an integrated laser; nevertheless, the company was looking for a supplier capable of covering as broad a spectrum as possible. Aerotech matched this profile and was able to realize the idea of the production system desired by the customer, mastering the CNC control, linear drives, axes, galvo scanner for the laser : Aerotech was able to supply and integrate all production system components.
Do you also supply complete subsystems?
NL : Yes, of course we do. We also offer medical technology manufacturers, in particular, a competitive edge in a highly competitive medical device manufacturing market, thanks to our medical device laser welding systems, stent cutting systems and other motion systems and components. By way of example, I'd like to mention our HermeSys and VascuLathe system solutions.
HermeSys is a motion subsystem for laser welding of implantable pacemakers, i.e. high-pressure gas welding. Thanks to its compact design, the HermeSys motion platform features high rigidity, which has been proven to improve the quality of laser welding joints. The compact design of the HermeSys, with few protruding superstructures, makes it easy to integrate handling systems for material infeed and outfeed. An automated loading and unloading system is also integrated into the system, so that pacemaker production can be operated fully automatically - with high productivity and consistent quality.
With the VascuLathe, we have developed an innovative, compact laser-cutting solution for stent production that has proven itself in practice. The fully integrated motion system combines automated handling functions with direct-drive linear and rotary movements. Thanks to the integrated linear-rotary design, throughput is increased by a factor of two to five compared with conventional ballscrews or other drive principles, and also enables sub-micron manufacturing tolerances.
Where will you be offering more integration solutions in the future?
NL : As a manufacturer of automation systems, we want to be a central point of contact for our customers. This is why we are also increasingly seeking strategic partnerships with other suppliers, for example in the field of surface metrology. We have dedicated a separate application group to the topic of integrating measurement systems into positioning systems. We are able to provide customer-specific solutions if, for example, the user needs to measure large samples that are beyond the scope of standard measuring equipment.
How far do you go with this?
NL : In the meantime, such forms of integration can be realized for complete test machines. However, we do not limit ourselves to Keyence, but can also seamlessly integrate measuring systems from other manufacturers at any time. The necessary components are either delivered directly to the customer, or all integration measures are already carried out in Fürth, so that the customer receives a turnkey measuring system.
BC : Aerotech uses the term "integrated automation systems" to designate systems whose core is precision motion control and automation, where the customer has little or no integration to do once he has received the equipment. In other words, the machine is virtually turnkey.
Where do you see yourself in the future, i.e. what system solutions do you want to offer your customers, Mr. O'Connor?
BC : We will continue to do what we do best, while adapting to the future needs of a modern, technological society. We will continue to offer high-precision drive and automation solutions, from components to complete turnkey automation solutions. However, we will achieve this by integrating macro-trends such as improved connectivity, smarter automation, predictive analytics and miniaturization into these designs.