If the classical approach based on general automation does not achieve the performance goals for a given task because the design becomes too heavy, too big or too complex, then modern mechatronics may bring the solution.
We develop highly integrated mechatronic systems with superior power density for your application, where highly dynamic motion benefits from radically minimizing the moving mass. This enables us to design servo grippers with integrated sensors and actuators. We have even developed and built a complete light-weight robot arm, which outperforms any ordinary robot system in many ways.
We develop, design and simulate multidisciplinary using up-to-date CAx technologies that allow easy data exchange between the various departments such as mechanics, electronics and computer science. Out specialists understand technology challenges even beyond the scope of their own fields of expertise and work closely together across all engineering disciples.
We develop custom PCBs for the integration in mechanical systems, e.g. for direct control of actuators, sensors or servo systems. Standard components are 8-/32-bit microcontroller by Atmel and ST, also FPGAs and CPLDs by Xilinx and fieldbus systems such as Profibus, DeviceNet, AS-interface and EtherCAT. Our preferred electronics design tool is Altium Designer 15 featuring integrated circuit simulation for analog and digital signals at frequencies of up to 5 GHz on multilayer boards. Altium also generates complete mechanical and thermal models of the PCB, which we can use in further simulations.
We use ANSYS for multi-physics FEA simulations in order to validate of the desired functionality of mechatronic systems from an early stage. This allows the development of suitable structural components satisfying all requirements, identifying and avoiding potential stress points in the process. For example, to ensure the reliability of an electrical subsystem installed at critical a location, where it is exposed to high levels of mechanical and/or thermal stress, detailed models are verified using the CAD system and heat flow simulations in ANSYS, avoiding thermo-mechanical stress and component failure.
For demanding applications we develop highly integrated powerful modules, even complete servo systems with integrated precision gears or direct drives. Maximum power density is achieved by integrating motor, brake, dual encoders and servo amplifier into a very small unit, which can then be controlled from a real time servo network with minimal wiring. Likewise, we interface dozens of sensors and other I/O signals to a custom PCB at the robot tool and connect it to an AS-i or EtherCAT fieldbus to reduce overall weight and wiring and increase system reliability. Integrating a vision camera and a powerful lighting module with a sophisticated thermal design is a further example of application specific integrative engineering.