See Aerotech at Productronica 2019

Aerotech develops high-precision motion control system, positioning tables and associated software. They can be used wherever high throughput is required, which also includes many production processes in the electronics industry. Norbert Ludwig, managing director of Aerotech GmbH/Germany says: "As a long-standing research and development partner for electronic manufacturing, we are happy to present an innovative range of solutions to trade visitors at Productronica, which they are able to use in sustainably optimising their manufacturing processes. Our new combination of an AGV galvo scanner with an IGM positioning system particularly deserves your attention: On the one hand, the system is very easy to program, on the other hand, it shows a significantly better performance both in scanning and positioning."

AGV-SPO galvo scanner

With the AGV-SPO galvo scanner, Aerotech sets new standards in regards to high-precision laser technology. By combining with the IGM positioning system, the laser scanner fully plays to its strengths. Norbert Ludwig explains: "Our IGM positioning tables have become much stiffer by combining granite with axes that were screwed on directly. The more flexible construction makes it even easier to customise the build based on the customer's wishes."

Higher stiffness also has an effect on laser positioning precision. By removing dynamics from the laser and transferring them to the axles of the IGM, the scanning clock rates and throughput improve significantly.

By using IGM, the specifications of the laser are also utilised better. By screwing the guide rails directly onto granite, IGM systems end up being smaller than conventional positioning systems, which may, for example, save some floor space in laboratory or clean room environments.

When using automation platform A3200, integrating an AGV scanner into the linear axis of an IGM is done as a plug and play expansion of the XR3 high-performance control and GL4 galvo control. The coordinates can be programmed easily afterwards. An advantage of this combination is that it can be programmed in XY and the control system then automatically synchronises with the laser scanner. That means the image traversed by the scanner is split into scanner and XY movement. This improves structural performance, errors are avoided and there is no traditional stitching. The IFOV (Infinite Field of View) function comes into play here, which helps synchronise linear or rotary axes with the laser scanner. At the moment, laser and positioning systems can also be controlled with the Automation1 platform, however.

Automation1: Making positioning system controls simple

Using an optimised control platform not only reduces valuable development time, but may also mean being able to deliver goods to your customers faster. With the Automation1 Precision Machine and Motion Control Platform, Aerotech ushers in a new era of precision motion and process tool control. It combines controlling positioning systems and its components in a single platform, which is equipped for the task with a new software-based motion controller.

The platform controls drives for servomotors, galvo scan heads, piezoelectric actuators and various other devices. Computer drives can be connected via the HyperWire motion bus connector, the highest performance communication bus connector in the motion control industry.

The hardware of Automation1 is equipped with integrated digital and analogue I/O, making it very simple to integrate complex motions and related controls of process tools. Norbert Ludwig says: "Automation1 is the future of motion control. It is the first development environment for motion control which puts user experience and precise motion at the forefront of product design at the same time. Even the servomotor and galvo scan head drives already outperform all previous driver hardware from Aerotech."

According to Aerotech, the new platform supports modern growing markets for precision machines and motion control while being particularly well-suited for automation systems, precision laser processes, testing and inspecting processes as well as other applications, with process controls being very closely coupled with motion controls. In turn, this new control and drive development enables better motion control optimisation with faster motion and setting times, higher position stability and improved contour performance.

Laser cutting displays

Moreover, Aerotech is demonstrating its comprehensive know-how on laser cutting by using the example of OLED displays. One of the biggest challenges in manufacturing them is cutting the individual displays from a much larger substrate. For this step in the process, laser cutting has emerged as the superior technology over the past few years. There are three main reasons for this: the growing size of displays (flexibility), the cutting speed (efficiency) and the quality of cutting edges (quality), which pose incredible challenges to the process parameters with this material specifically.

Considering that OLED display polymers are very sensitive to fluctuating laser parameters such as laser spot size and output density when laser cutting larger displays of more than 100mm, optimal synchronisation between scanner and servo table movement is highly important. Norbert Ludwig explains: "This is the only way to reach the throughput of a scanner-based system for larger working areas. For this purpose, a uniform control architecture is particularly relevant when using laser controls with combined motion systems."

The manufacturers of OLED displays mainly expand the working areas of their laser cutting systems by combining scanner motions with the simultaneous motion of a larger subsystem (e.g. an XY table moving the substrate). In this case, the motion controller takes on a very important task by controlling the synchronisation between scanner and servo table movement in one laser path. The resulting cascaded motion eliminates the dependency between field of view and laser spot size of the scanner. Norbert Ludwig notes: "As a result, the process engineer can choose the optimal optics for high-quality material processing regardless of part size."

Real-time error compensation

Another advantage of controlling the scanner and servo table with a united hardware and software platform is minimising the dynamic errors of servo steps. Executing cascading motions via a single integrated control algorithm allows the scanner to compensate for errors in tracking the servo table in real time. Consequently, manufacturers of OLED displays will suffer virtually no losses in accuracy compared with separately controlled scanner systems. This is very important for the process, as retaining accuracy during maximum speed processing is another challenge for cutting OLED displays with lasers.

The integrated feedback of the entire motion system (including the scanner) makes it possible to modify the pulse energy or the average laser output based on the tool-on-part speed of the laser spot. Modern laser control functionalities such as these give the user even more implicit control over the uniformity and output density of the cutting process. Norbert Ludwig explains: "The advantages provided by this laser control system are mostly based on a common control architecture, where any feedback can be reviewed and combined within the control system. We will gladly prove this to those who come and see us on our stand at Productronica."

Aerotech will be at Productronica in Munich, from November 12-15 2019, hall B2 stand 340. Go to www.aerotech.com for more information.