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Dedicated to the Science of Motion

AUTOMATION SOLUTIONS FOR

Laser Processing

Medical Device Manufacturing

Life Sciences

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2 www.aerotech.com WORLD HEADQUARTERS, Aerotech, Inc., Pittsburgh, PAPhone: 412-963-7470 Email: [email protected]

Aerotech, Ltd., United Kingdom • Phone: +44-118-9409400 • Email: [email protected] GmbH, Germany • Phone: +49-911-9679370 • Email: [email protected] KK, Japan • Phone: +81-47-489-1741 • Email: [email protected]

CONTENTS

3 Aerotech Success in Laser Processing

4 Cylindrical Material Processing

6 3D Laser Cutting & Welding

7 2D Laser Cutting & Welding

8 Advanced Laser Control

10 Laser Ablation

12 Laser Marking

14 Laser Drilling Applications

15 Aerotech Success in the Medical Industry

16 Stent Manufacturing

18 Guidewire, Catheter, Cannulae, Hypotube, and

Endoscope Manufacturing

19 Hermetic Seam Welding

20 Intraocular and Contact Lens Manufacturing

21 DNA, Drug Discovery, and Proteomics

22 Device Assembly

23 Medical Device Manufacturing

24 Aerotech Success in Advanced Motion Controls

25 Soloist™: Stand-Alone, Single-Axis Controller

26 A3200: Digital Automation Platform

28 A3200: Intelligent Networked Drives

30 Ensemble™: Stand-Alone, Multi-Axis Controller

31 Engineered Systems

32 Aerotech Online

33 Worldwide Training and Support

34 Aerotech at a Glance

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3www.aerotech.com WORLD HEADQUARTERS, Aerotech, Inc., Pittsburgh, PAPhone: 412-963-7470 Email: [email protected]


LASER PROCESSINGAEROTECH SUCCESS IN

For over 35 years, Aerotech has been dedicated to developingsolutions for the laser processing industry. We continuallyenhance our existing product line and invest in new developmentsto address the most stringent customer requirements. This resultsin products that offer the highest accuracy, highest throughput,and highest reliability, ultimately leading to the lowest costof ownership for our customers.

Aerotech’s broad range of motion control products means we canprovide the optimal solution for your application. Our expertiseincludes systems for shop floor, R&D, vacuum, and cleanroomenvironments. Our ability to provide custom-engineered productsand systems to end users, integrators, and high volume OEMs isunmatched, and our products deliver quality, performance,flexibility, and the highest return on investment.

Aerotech’s focused development has led to our state-of-the-artAutomation 3200 motion controller capable of synchronizing32 axes of motion, with advanced features such as PositionSynchronized Output (PSO) for precise laser control, coordinatedmotion between servomotors and galvos, seamless integrationof PLCs, and sophisticated plotting and diagnostic utilities thatenable rapid debugging of process and motion parameters.

Coupling these advanced control features with mechanicsthat are designed for long life and low maintenance in harshenvironments provides laser machine manufacturers the means to build the best overall systems in the industry.

Laser P rocessesSer ved :

• Cutting

• Welding

• Marking and engraving

• Drilling

• Ablation

• Micromachining

• Cladding

• Peening

Laser s i nManufac tu r ing ofMedica l Dev ices :

• Stents

• Hypotubes

• Guidewires

• Hermetic sealing of pacemakers and otherCRM devices

• Device assembly

• Orthopaedic braces

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CYLINDRICAL MATERIAL PROCESSINGSOLUTIONS FOR

Many laser cutting and welding processesrequire the handling of cylindrical or bar-stock-type materials. Aerotech’s extensive line ofproducts includes component-level solutions aswell as optimized, combination linear/rotarymotion systems designed to automate thehandling of these materials. Direct-drivetechnology coupled with a frictionless rotaryunion for collet actuation enable speeds inexcess of 2000 rpm for high throughputapplications. ER collets are available forprecision cylindrical gripping applications anda 3-jaw concentric gripper is available forI.D./O.D. and odd form profiles.

Fea tur ing/Recommendat ions :

• A3200 controller

• Integrated mechanical packages(LaserTurn™ 1, LaserTurn™ 2, LaserTurn™ 5)

• Direct drive, high-torque rotary axis withintegral pneumatic collet adapter or 3-jawgripper (ACS, ACS-LP)

LaserTur n™ 1The LaserTurn 1 cylindrical laserprocessing platform supports the smallesttube holding capability (100 microns) ofthe LaserTurn family. A highly repeatablecollet assembly allows precision indexingof material to produce continuous patternsin long tubing stock without operatorintervention to align the laser cut betweensuccessive part feeds. With throughputcomparable to the VascuLathe™ and amaximum tube diameter of 8 mm (drycut), the LaserTurn 1 is ideally suited forhigh throughput, small diameter tubeprocessing applications.

Precis ion Components, Mount ing,and Gr ipping OptionsThe high performance, direct-drive rotary stagesused in the LaserTurn product family are availablein component form. Multiple precision mountingsurfaces ease integration while a large selection ofgripping options is available to support a widerange of material profiles.

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LaserTur n™ 5The LaserTurn 5 cylindrical processing platform isavailable with a 3-jaw concentric gripper for I.D.and O.D. gripping or ER collet chuck for highprecision applications. With custom jaws thegripper can hold materials with square orhexagonal profiles. A 12 mm clear aperturesupports bar-feeder-type applications forautomated material loading. Accelerations up to3 g enable the quickest direction reversals forcomplex motion profiles.

LaserTur n™ 2The LaserTurn 2 cylindrical processing platformsupports tube diameters up to 10 mm in dry cuttingor 5 mm in wet cutting with an ER16collet-closer assembly. The rotary axisis capable of speeds up to 2000 rpmfor high-throughput applications.

Opt iona l Too l ing P la t fo rmsThe LaserTurn series is available with front- and rear-mounted tooling platforms withoptional features such as automated materialadvance and alignment assemblies.

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3D LASER CUTTING & WELDINGSOLUTIONS FOR

3D laser cutting and welding applicationsrequire a combination of both linear androtary axis motion to ensure that laser beamdelivery is perpendicular to the part at anypoint during processing. As a complete motionsystem provider, Aerotech can supplya precision-aligned, multi-axis, articulatedsystem with micron-level rotary axis ofintersection and arc-second orthogonalitybetween axes. Systems can be based on splitbridge (separate X and Y axes), gantry,remote Z, or any combination in between. Allstages are sealed against environmentalcontamination for use in 24/7 cutting andwelding applications.

Gant r y fo r Of f se t Weld ingThis long travel, sealed gantry system features alarge offset in the A/B rotary axis assembly tosupport offset welding applications. The verticalaxis can dynamically adjust the focal distanceduring processing for consistent weld quality.

Mul t i - Ax i s L inear/Ro tar yCombina t ionX/Y linear stage configuration with low profile,direct-drive rotary axes. The direct-drive rotarystage at the workpiece (ADRS series) features high-speed rotation (up to 600 rpm) with highresolution (7,000,000 counts/rev after interpolation)for the highest possible performance.

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2D LASER CUTTING & WELDINGSOLUTIONS FOR

Aerotech has a broad range of solutionsavailable for 2D and 2.5D laser cutting andwelding applications. Systems can beconfigured with traditional stacked XYorientations, split axes with the X on the baseand Y on a bridge, or full gantry systems withflying optics or fiber-based beam delivery.

Ceramic P rocess ingThe ALS5000 coupled with the wide-bodyALS5000WB base provides increased roll stiffness for multi-head ceramic processing applications. Low angular errors allow the accurate placement ofpart features over large areas while thehigh dynamic stiffness holds tighttolerances on small part features.

F la t Shee t P rocess ingAerotech’s latest generation gantry system hasbeen optimized for high-speed laser cutting andwelding applications. The low CG of the bridgecoupled with dual linear motors/encoders and stiffmounting interfaces have demonstrated micron-level dynamic accuracies on high-speed cuttingapplications. A large radius cable managementsystem allows integration of fiber-based beamdelivery systems while mounting surfaces on thebridge structure enable the attachment of optics forfree space laser-beam delivery.



• Sealed linear motor stages(ALS5000, ALS25000, ALS1000)

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ADVANCED LASER CONTROLSOLUTIONS FOR

Laser processing involves precise coordinationof several subsystems to produce high-qualityparts. While some of this coordination can beaccomplished by careful timing of variouscomponents, utilizing the advanced features ofAerotech’s Automation 3200 motion controllerto manage this coordination reducesdevelopment time while producing the highest-quality parts.

Pos i t ion Sync hron izedOutpu t (PSO)Hermetic welding, micromachining, and ablationrequire precise control and spacing of laser pulseson the material being processed to provideconsistent quality. When using a fixed frequencylaser, this is complicated by the need for constantvelocity, severely limiting processing speeds whenfaced with complicated geometries. By utilizingAerotech’s unique Position Synchronized Output(PSO) capability, the laser is fired according toreal-time position feedback in 3 dimensions,removing the need for velocity regulation andeliminating the effects of external disturbances,thus increasing both process throughput andquality. When multi-axis PSO is required, thefeedback positions are vector processed to exactly synchronize 2D or 3D contours.

PSO functionality includes several easilyprogrammed operation modes, each fullyconfigurable to interface with lasers equipped with externally synchronized control, includingCO22, YAG, and excimer lasers. Modes ofoperation include:

• Fixed distance firing

• Windowing

• Array-based firing

F ixed D i s tance F i r i ngThis mode provides single- or multiple-pulse outputas a function of one to three axes' positionfeedback for a fixed distance. This minimizes theheat affected zone (HAZ) from over-processing amaterial. Applications include cutting, welding,and hole drilling where complex contours requirereal-time interaction with the laser pulses fordependable consistency. Typical processesinclude stent manufacturing, hermetic welding, anddrilling holes in turbine blades.

WindowingIn windowing mode, output pulses are restrainedinside a user-defined window with the first pulserelative to the edge of the window. Windowing iscommonly used when the processing of a partrequires the axes to move beyond the part forsettling or direction reversal in applications such asflat panel manufacturing or fuel injector drilling.

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Remote Laser Weld ingWelding applications often involve componentswith intricate patterns that require high throughputprocessing. Remote laser welding involvesscanning a fixed, focused laser beam over aworkpiece from a distance. Since minimal setuptime is required to position the laser, and the beammay be quickly scanned over a large area withminimal motion, cycle time is significantly reduced.

Utilizing transformation functions in the A3200controller to transform rotational motion into X/YCartesian space allows for simplified programmingin linear dimensions or importing from CADdrawings.

Ar ray -Based F i r ingArray-based firing provides single- or multiple-pulseoutput based on process parameters stored in an arraybased on position. Applications include gray-scalemarking of materials where each pixel has differingfrequency and power characteristics, and processing ofdifferent materials in the same set of motion commands.

Addi t iona l Opera t iona l Modes• Pulse on command

• Single- or multiple-pulse output based on commandfrom a program

• Pulse generator

• Pulse output based on a defined fixed frequency

• Velocity-based analog ramping

• Scaling an analog output as a function of one- to three-axis vector velocity based on auser defined “zero-speed” output voltage andtarget-speed output voltage

Appl i ca t ion Versa t i l i t yIn addition to laser control, PSO can be used totrigger any data collection event in applicationssuch as triggering probes or cameras during NDTs(Non-Destructive Tests) and force or flow controlsystems. The ability to capture data correlating toknown pulse spacing along complex contours isideal for inspection systems such as ultrasonicpulse/echo and through-transmission, eddy currentmeasurements, and X-ray.

Benef i t s of Direct -Dr ive Gimbalsfor Remote Laser Welding

• High-accuracy angular position and ratecapability

• High axis stiffness for precise pointing

• Direct drive, brushless servomotors result in zero backlash and arc-second accuracy

• Cog-free design for outstanding velocity stability

• Continuous 360° rotation of azimuth and elevation including built-in slip ring



• Direct-drive gimbals(AMG and AMG-LP series)

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LASER ABLATIONSOLUTIONS FOR

Ultra-fast lasers and excimer lasers aretraditionally used in applications wherematerial ablation is required. Ablation is anathermal process where the photon energy ofthe light is sufficient to break the chemicalbonds at the atomic level, converting thematerial directly from a solid into a plasma.The time duration of the pulse for ultra-fastlasers is shorter than the heat diffusion time inthe material, which results in no thermaldamage, recasting, or heat-affected zone. Theshort pulse duration also produces materialremoval rates that are quite low (nanometersper pulse) when compared to microsecond-regime IR lasers. This small depth of ablationper pulse can be used to create 3D structureson a nanometer scale.

Excimer lasers also work through an ablationprocess. However, the beam profile is squareor rectangular as opposed to the circularpattern typical of ultra-fast lasers. The excimerbeam is passed through a mask that clips the

beam energy into a pattern defined by thegeometry of the mask. This masking techniquemakes it easy to ablate complex patterns.Feature sizes projected onto the materialthrough the mask can be adjusted bydefocusing the laser, and it is possible to buildcomplex three-dimensional patterns inmaterials using multiple masks and thedefocusing technique.



• High-performance, linear-motor, open-framestages (ALS3600)

• Direct drive, open aperture rotary axis (ADRT)

• Direct drive, low-profile rotary axis (ADRS)

Mask A l ignmen t P la t fo r mHigh precision excimer applications that use amasking technique to clip the homogenized beamprofile can require precise mask alignment of XYZand rotary axes. Aerotech’s MaskAlign platformutilizes high resolution direct-drive linear androtary axes for precise, repeatable positioning.Beam projection through the stage set isprovided by a 120 mm clear aperture.

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Cus tom Large -P ro f i l e Z - L i f t S tageExcimer applications can use a defocusingtechnique to change the aspect ratio of the maskpattern projected onto the part. Different sizefeatures can be projected onto the part with asingle mask profile. Repetitive firing in position,while changing the focal position, can be used tocreate sloped 3D surfaces in the material. Basedon the application requirements, Aerotech cansupply standard and custom solutions for focalheight positioning.

3D Ul t ra -Fas t Laser P rocess ingThe ablation process occurs at a specific energythreshold for a given material. It is possible to havean ablation spot size smaller than the actual laserspot size by manipulating the beam intensity profileand divergence. The system shown uses aprecision vertical lift stage to control the focalposition with up to 4.5 nm resolution, while the air-bearing XY stage provides extremely flatmotion to maintain focus over full travel whileproviding extremely small step sizes (10 nm) for the accurate placementof sub-micron part features.

Vertical lift stage

XY air-bearingstage

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LASER MARKINGSOLUTIONS FOR

Scanheads are excellent devices for quicklymarking vectors or graphics, but are limited bythe relatively small field of view in which theycan process. By coordinating scanner motionwith traditional servo axes, the field of viewcan be significantly expanded while maintainingthe quality and throughput expected of scannertechnology.

Nmar k™ SSaMThe Nmark SSaM is a galvo scanner controller,supporting the industry standard XY2-100 interface,that is capable of synchronizing the galvo motionwith servomotors. Residing on Aerotech’s advancedAutomation 3200 software-based motioncontroller’s FireWire® network, the Nmark SSaMcan be connected with any other A3200components including linear and PWM servoamplifiers, drive racks, and stepper motor controllers.Combining this flexibility with the vision, PLC,robotics, and I/O control capabilities of theAutomation 3200 allows for ultimate controlarchitecture customization.

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Nmar k SSaM Fea tures :

• Multi-vendor scanner support with industrystandard XY2-100 interface, with support forup to three axes of clock and directionstepper motors, two galvo mirrors, anda third axis for dynamic focus control.Additional features include first pulsesuppression, first pulse delay, on-the-flymarking, image transformation, and a fullcomplement of opto-isolated digital andanalog I/O.

• Scanner and servo motion is programmed inindustry standard RS-274 G-code languagealong with AeroBASIC™ command extensionsfor laser and IO control. With all majorCAD/CAM vendors supporting RS-274output, users have a direct conversion pathfrom CAD data to galvo and scanner motion.

BroadMar k Graph icMany applications require raster-type scanning ofthe laser for bar codes, bitmaps, and scribing.When the object being processed is larger thanthe scanhead’s field of view, it is common to stitchseveral exposures together. This can result indiscontinuities in the image due to angular errors inaligning each exposure, reducing image qualityand the range of applications suitable for thistechnology. With the Nmark SSaM’s BroadMarkfunctionality, linear and rotary servo motion can becoordinated with the galvo mirrors so that theentire raster scan is completed in one continuouspass, eliminating these angular errors.

S t re t c hed Vec torScanners are commonly used in vector-type lasercutting, welding, marking, sealing, and ablationapplications that require the process to be completedin a single pass of the laser. Coordinating vectormovement with servo motion vastly expands thisworking field and effective vector length, allowingfor a wider range of products to be processed,fully utilizing the advantages of scanner technology.

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LASER DRILLING APPLICATIONSSOLUTIONS FOR

Nd:Yag and Q-Switched lasers are typicallyused in laser drilling applications. Laserdrilling is usually accomplished by one of twomethods: either with percussion laser drillingor trepanning the beam. While percussiondrilling is often a faster process, trepanning thebeam results in a lower heat affected zoneand allows for complex hole geometries. Inboth cases, precise contouring of the motionaxes is required to maintain tolerances.

5/6 - Ax i s Laser Dr i l l i ngFive- and six-axis motion assemblies composed of high resolution direct-drive axesallow accurate drilling of deep aspect-ratioholes in components such as fuel injectors,which require precise positioning of partsin three-dimensional space. Highperformance, wide body, linear-motorstages ensure cantilever load effects aremitigated while maintaining micron-levelaccuracy. Two axis, direct-drive rotaryassemblies position to arc seconds ofaccuracy, allowing for precise contouringof the part.



• High-performance linear motor stages(ALS5000/ALS5000WB)

• Direct drive, high-torque rotary tilt axis(ADRT)

• Direct drive, low-profile rotary axis (ADRS)

ALS5000WBwide body, linearmotor stage

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MEDICAL INDUSTRYAEROTECH SUCCESS IN THE

Advancements in core technologies such as electronics,software, and imaging have continued to drive the developmentof new medical devices and diagnostic procedures. The growingcomplexity of these devices and stringent FDA validationprocedures require precision automation components andsystems to ensure consistent, repeatable results. Likewise, thecosts associated with supporting the infrastructure andintegration of these systems into specialized cleanroommanufacturing environments require solutions with the highestpossible output per square foot of production space whilelimiting maintenance and downtime.

Aerotech is uniquely positioned to meet the stringent requirementsof this industry. Our standard motion products can be configuredto meet most automation requirements with proven reliabilitydemonstrated by over 35 years of sales into the medical field.Application specific optimized solutions, such as our stentcutting and hermetic sealing solutions, are available that candemonstrate up to a 5x improvement in throughput overconventional approaches, providing a lower total cost ofownership and maximizing your return on investment.

Appl i ca t ionsser ved :

• Stent cutting

• Cardiac pacemaker,defibrillator, and neuro-stimulation seam welding systems

• Guidewire, catheter, and hypotubemanufacturing

• DNA sequencing

• CAT scanners

• Proteomics

• Haptic mills

• Blood sequencing

• Patient and X-raysource positioning

• Magnetic resonancescanners

• Oncology

• Surgical staples

• Intraocular and contact lens manufacturing

• Retinal inspection

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STENT MANUFACTURINGSOLUTIONS FOR

VascuLathe® represents a revolutionaryapproach to satisfying the demandingrequirements of stent manufacturingapplications. The fully integrated motionsystem couples automated material handlingfunctionality with high performance direct-drivelinear and rotary motion capability. Theintegral linear-rotary design increasesthroughput by 2 to 5 times when compared totraditional screw-based or other manufacturingapproaches, while still maintaining submicrontolerances on tight part geometries.

The increased throughput gives much neededflexibility in the extremely competitive stent-manufacturing environment. The higherthroughput of the VascuLathe implies that fewermachines are required to produce anequivalent number of stents when compared totraditional manufacturing approaches,resulting in lower total labor costs and reducedfloor space requirements. Alternatively, theVascuLathe can be used to meet increased andvaried product demand within the existingmanufacturing space, saving the costsassociated with facility expansion.

Integral frictionless rotaryunion optimized for stentmanufacture provides alifetime of maintenance-freeoperation.

Stainless rollcovers protectbearings andfeedback fromcontamination.

Optional wetcutting withcoolant return.

Sophisticated machinestructure facilitates easyalignment, maintenance,and operation.

Simplified, reliable cablemanagement systemensures trouble-freeoperation.

U.S. Patent 7,038,334U.S. Patent 7,105,956

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The VascuLathe features Aerotech’s Automation3200 controller (A3200), a 100% digitalautomation platform. The A3200’s advancedcontrol architecture has special path planningfunctionality that automatically adjusts the cuttingspeed to minimize path errors in tight stentgeometry, maintaining form quality throughout thepart. Sophisticated laser control functionsautomatically adjust the laser power and rep rateto minimize the heat-affected zone of the materialas a function of the cutting speed. Specializeddrive electronics are optimized for the frequentdirection reversals encountered in a typical stentprofile and help to further minimize following error.Advanced plotting and diagnostic tools displayaxis performance in real time and processmonitoring functions report peak position error,path cut length, and stent cut time at the completionof each part, providing an instantaneous measure ofpart quality on a piece-by-piece basis.

Precision ER16, ER25, or ER40 colletsupports 0.5 mm to 30 mm O.D.tubing, enabling the VascuLathe tosupport the manufacture of a widearray of peripheral, cardiovascular,and neurovascular stents.

Lower materialcenterline reducesmachine height andfixture sizes giving alower profile, more rigidsystem.

Threaded tooling areas located atthe front and back of theVascuLathe ease integration ofcustom material handling features.

Manual alignment fixture withprecision reference surface andlocating pins for rapidreplacement of bushingmaterial.

Parallel jaw gripper forautomated advance of tubingmaterial.

Highly advanced drive technology resultsin superior surface finish.

Future-proof software-onlycontrol and networkarchitecture (FireWire®).

Special softwareprograms to assist inproduct changeover.

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GUIDEWIRES, CATHETERS, CANNULAE,HYPOTUBES, AND ENDOSCOPES

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SOLUTIONS FOR

Many medical devices and diagnostic toolsare fabricated from tubular materials that canhave multiple features integrated along theirlength. For example, a hypotube may have askive or slot on the distal end to facilitate theplacement of components such as ballooncatheters, and will have a spiral or interlacedpattern cut along the length for flexibility anddirectional control when inserted into thebody. Endoscopes have intersecting, welded,cylindrical features for camera and controlports and irrigation features for clear viewingthrough the device. All of these productsrequire precise angular positioning andvelocity control during the manufacturingprocess to ensure consistent, repeatableperformance of the finished component.


• A3200 or Ensemble motion controller

• Rotary axes with integral pneumatic colletadapters and 3-jaw grippers (ACS, ACS-LP)

Low Pro f i l e , D i rec t -Dr i ve Ro tar yS tages Fea tu re ER Col le t sAerotech manufactures direct-drive rotary stageswith automated material handling features for easeof integration into new and existing systems. Air-activated ER collets can grip tube diameters from0.2 mm to 30 mm and can be used to positionhypotubes, cannulae, and other medical devicesfor laser and mechanical forming processes.

3- Jaw Gr ippersA 3-jaw parallel gripper for I.D. or O.D. grippingis offered, and includes a clear aperture forproduct feed-through. Optional jaw travel rangesare available to suit different material sizes andpeak gripping force requirements. Custom jawprofiles can be created to grip hexagonal andother non-round profiles, or to set the materialdepth of grip.

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HERMETIC SEAM WELDINGSOLUTIONS FOR

The ever-shrinking geometries of electroniccomponents, coupled with advances in batterytechnology, have led to the development of alarge array of implantable medical devices forheart rhythm management (pacemakers,defibrillators) and chronic pain relief (neuro-stimulation). These products share a commonpackaging technique that consists of a titaniumhalf-shell enclosure joined together with ahermetic seam weld. The integrity of the weldis crucial to ensure the long-term reliability ofthe device and to protect the patient fromcontamination. Traditional approaches to thewelding process have utilized standard rotaryand linear motion devices coupled with

complicated post-processing software to createthe weld path. Aerotech’s HermeSys is aholistic design that optimizes all aspects of thehermetic seam-welding process. Specializedmechanics are used to accurately position thedevice during the welding process. Onboardkinematics allows the programming of weldgeometry in part space for rapid optimizationof process parameters on the machine (nopost-processing required). And, finally, areference design is available for an automatedmaterial handling system to ensure that thepart load/unload cycle can keep pace withthe optimized welding process.

Her meSys™ Her me t i c SeamWeld ing Sys temThe HermeSys features a purpose-designedmechanical structure that is substantially stiffer thancomponent-level solutions. The increased stiffnessallows high acceleration with minimal followingerror, a critical requirement for holding toleranceduring the multiple direction changes and rapidstart/stop of the linear and rotary axes during thewelding process.

Rea l - T ime K inemat i c sReal-time kinematics removes the needfor complex post-processing tools tocreate multi-axis laser weld paths. Theweld profile is programmed inlinear/arc segments or points on acubic spline interpolated path. Partgeometry and welding speeds can beoptimized on the machine without re-posting the weld profile.

INTRAOCULAR ANDCONTACT LENS MANUFACTURING

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SOLUTIONS FOR

Intraocular and contact lens manufacturingrequire precise speed control, high radial andaxial stiffness, and minimum runout of thetooling for precise manufacturing of lenses.Aerotech’s LENSGEN® system was designed toproduce superior quality IOLs, contact lenses,and molds with minimal setup, offering ahighly reliable, completely sealed design.

LENSGEN ® Two - Ax i sOp t i ca l La t heThe LENSGEN® two-axis latheproduces aspherical and sphericalIOLs and contact lenses faster and withunsurpassed surface finish andaccuracy. The high performanceair-bearing spindle that is rigidlymounted to the Z-axis stage requiresno water cooling and offers infinitelyvariable speed control. An LVDT probesystem verifies lens blank placementbefore lathing, preventing any mishapdue to incorrect arbor insertion or other factors.Linear axes are available with either high precisioncrossed-roller bearings or air bearings for smooth,stiff, and accurate operation. Brushless linearservomotors drive the stages, avoiding accuracylimiting effects such as backlash and hysteresisassociated with lead or ball-screw-driven stages.Both the linear and rotary stages are completelysealed to protect the bearings, increasing stagelife and reducing maintenance costs. The naturalgranite machine base provides both high rigidityand excellent thermal stability. Passive vibrationisolation elements isolate the base from itsfabricated steel frame.


• A3200 or Ensemble multi-axismotion controller

• High performance linear motor stage (ALS5000)

• High performance, direct drive, air-bearing rotary stage

DNA, DRUG DISCOVERY, AND PROTEOMICS

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SOLUTIONS FOR

Historically, DNA and other reactive-agent-based analysis procedures have used low-endpositioning devices such as stepper motors andbelt drives to distribute solutions into low-densitywell plates. As the industry has progressed tohigher density plates with smaller sample sizes,more sophisticated motion control technologyhas been required to increase the efficiencyand reduce the costs of the test procedure.Likewise, newer luminance analysis tools withextremely sensitive detector technology haveplaced more stringent requirements on themotion platform in terms of positioningaccuracy, velocity stability, and flatness oftravel. As a single-source manufacturer of high-end motion control equipment, Aerotech isuniquely positioned to provide solutions for thelatest generation of lab automation tools.

ABL1000 and ALS130L inear S tages Aerotech’s ABL1000 air-bearing stages andALS130 series crossed-roller mechanical-bearingstages are well-suited for applications requiringexcellent velocity control, positioning accuracy,and in-position stability. Micron-level flatness of travel also makes these stages ideal forapplications that are sensitive to depth of focus.



• Linear motor gantries (AGS1000)

• Low-profile, linear motor, mechanical andair-bearing stages (ABL1000, ALS130)

L inear Motor Gan t r ie sAerotech’s AGS series gantries have the throughputand accuracy to handle high throughput, highdensity well-plate screening applications. Linearmotor technology and direct-drive motors ensure a long, maintenance-free operational lifetime.

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DEVICE ASSEMBLYSOLUTIONS FOR

Aerotech has manufactured gantries for avariety of applications, including pick-and-place machines, automated assembly, visioninspection, dispensing stations, andpackaging. These solutions can be fullycustomized to meet unique demands andprocess variations. Dual brushless servomotorsand dual noncontact linear encoders on thelower axis provide the highest accuracy andhighest throughput solutions.

AGS10000 L inear Motor Gan t r yWith velocities up to 3 m/s and accelerations upto 3 g, the AGS10000 is designed for speed. The optimized cable management system withprovisions for customer cables was designed forlong life, while the robust mechanical structure wasdesigned for high servo bandwidth, with optionalrisers and an integral controller and drive chassis.The Z and theta axes are customizable for yourapplication. The fully flexible configuration optionsallow for wide variations in part size andorientation, providing a highly versatile gantrysolution.

Com ponen t Car tes ian Gan t r yComponent gantry assembly solutions are optimizedfor aligning components or for rapid pick andplace assembly. With travels up to 600 mm by600 mm and an optional vertical axis, thesegantries are fully scalable to meet your applicationrequirements. Built with precision ball screws andbrushless rotary servomotors, maintenance-freeoperation is assured, resulting in the lowest cost ofownership to assemble your products.



• High performance, linear motor gantry(AGS10000)

• Linear ball-screw focusing axis (ATS1000)

Many complex medical devices require avariety of motors and other motioncomponents for an array of tasks. Reliabilityand ease of integration are key to effectively

building the highest quality machines asrequired in the medical industry. Aerotechoffers a wide range of standard motors thatcan be selected to best fit your application.

S lo t le s s , B r ush les s Ro tar y Motors• Standard NEMA sizes for easy integration

and retrofitting• Advanced slotless design yields superior

velocity and position control• Brushless technology provides

maintenance-free use and delivers higher accelerations than brush motors

Br ush les s Ro tar y Motors• Standard NEMA sizes for easy integration

and retrofitting• Wide range of torques cover a variety of

applications (0.7 - 95 N-m)• Advanced 8-pole design matched with skewed

stator minimizes torque ripple and cogging forsmoother velocity control

• Rugged construction ideal for 24/7 productionapplications

• Optional IP65 through IP67 constructionallows use in harsh environments

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MEDICAL DEVICE MANUFACTURINGCOMPONENT SOLUTIONS FOR

Frameless Torque Motors• Five frame sizes to fit most applications• Frameless design for easy integration into

OEM machines• Slotless stator and high-pole-count rotor provide

zero cogging for exceptional velocity andposition control

• Up to 116 N-m of peak torque and29 N-m of continuous torque

Br ush les s L inear Motors • Advanced design yields 49% greater continuous

output than comparative models• Zero-cogging allows smooth velocity and

position control• Symmetrical mounting pattern allows tracks to

be mounted end-to-end for unlimited travel• Optional air cooling for greater rms force• Up to 3820 N of peak force and 955 N of

continuous force

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ADVANCED MOTION CONTROLSAEROTECH SUCCESS IN

Motion Control at its FinestAround the globe and 24 hours a day, Aerotech’s state-of-the-artsingle- and multi-axis motion controllers are used in a variety ofapplications, from research and development, to calibration andtesting, to 24/7 production manufacturing and more. These servoand stepper controllers solve simple and complex motion taskswith easy-to-use, highly flexible interfaces. By combining ourcontrols expertise with outstanding positioning mechanics,Aerotech delivers the finest system solutions available with theleast amount of customer risk. We offer several differentinnovative digital control architectures, from PC-based FireWire®

controllers to stand-alone systems with Ethernet, USB, or GPIBinterfaces, so our customers can get synchronized motionsolutions that match their needs.

I nnova t ionIn addition to a standard suite of features, our controls includeimportant interfaces for: high-speed, 3D vector-based positionsynchronized outputs (PSO) for highly accurate position-basedevent triggering; rapid position latching for precise event-basedposition capture; and unique handling of motion relating to laserprocessing, including acceleration limiting, cutter compensation,and 3D error correction.

S im p l i c i t yOur control software provides a library of easy-to-use commandsfor initializing the system, commanding incremental or absoluteposition motion, velocity motion, fault trapping, error handling,and synchronized and asynchronous I/O. These functions can bemultitasking or a single process thread. Motion commands cansimultaneously command many axes to move together orindependently. Concurrent with the motion application, ourcontrollers process numerous fault and error checking routines sothe customer remains focused on the motion process and not thesystem housekeeping tasks. Our software is compatible with RS-274 G-code, C++, .NET, or LabVIEW®. Numerous cannedfunctions and programming examples for scanning, tracking, andpoint-to-point motion can be immediately integrated by customersfor rapid program development.

F lex ib i l i t yAerotech controllers feature interfaces for brush and brushless servomotors including sinusoidal commutation, as well as steppermotors. Standard encoder interfaces include TTL quadrature inputs, analog sinusoidal encoder inputs, and resolver andinductosyn inputs for magnetic encoding where optical encoders are impractical. We have many onboard I/O channelscontrolled from single or multiple I/O commands. These I/O are easily combined with Opto 22™ modules for a large varietyof DC, AC, and switch closure capabilities. Opto-coupling I/O protects the controls from over-voltage or over-current damage.I/O can be expanded by additional controllers or with Ethernet I/O modules. Aerotech designed and manufactured linear andPWM amplifiers feature high power outputs with low electrical noise, and minimum crossover distortion and dead time. Theyprovide fast reaction motion capability while minimizing electrical noise. We manufacture our own linear and rotary motors tocomplement our amplifiers, eliminating problems of component compatibility and wiring.

Our expertise in all facets of the motion system – controls, drives, motors, and mechanics – allows us to understand andoptimize the total system solution better than any other manufacturer. Call us today to assist you with your application.

Automation 3200

Soloist™

Ensemble™

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STAND-ALONE, SINGLE-AXIS CONTROLLERAerotech’s Soloist™ single-axis digital servocontroller combines advanced softwarearchitecture (.NET) with a power supply, anamplifier, and a position controller in a singlepackage. The flexibility and scalability of the

Soloist™ make it the ideal controller for bothsmall and large applications on the productionfloor and in laboratory applications.

Soloist™ CPSoloist™ MP Soloist™ CL

LAN/WAN/Internet

Sca lab le des ignsu i tab le fo r la rge ax i s - coun t webapp l i ca t ions or s tand -a lone opera t ion

• Digital drive in models up to 30Apk

• Six programmable inputs (two high speed); fourprogrammable outputs

• ESTOP input

• Dual encoder inputs formaster/slave applications ordual-loop control

• Optional AUX power, encodermultiplier, single-axis PSO,integral or external shunt

• Expansion board with16 digital inputs, 16 digitaloutputs, one analog input, oneanalog output, and brake relay

Advanced so f twarearc h i t ec tu re reducesdeve lopment t ime andeases ma in tenance

• Development environment for.NET (C#) or Windows® (C++)

• Virtual instruments for theLabVIEW® environment

• Positioning modes includeindexing, homing, velocityprofiling, freerun, andCAM tables

• Autotuning makes servo tuningfast and simple

• File storage folder forparameters, programs,maintenance data, etc.

• Multitasking operating system

• Advanced data loggingcapabilities

Industry standard interfaces(Ethernet/USB/RS-232)make connect iv i ty quickand cos t - e f f ec t i ve

• Multi-axis configuration throughEthernet up to 1024 axes

• MODBUS over Ethernetmaster/slave capabilities

• Status, development, andcommands can be performed viaEthernet or locally through USB

• General purpose RS-232serial port

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DIGITAL AUTOMATION PLATFORMThe Intelligent 32-Axis Motion, Vision, PLC, Robotics, & I/O Platform

EXTENSIVE I/OC APABIL IT YAll Automation 3200drives and drive racks areavailable with anintegrated 10/100 Base-TEthernet interface,permitting interaction withthird-party I/O boardsand PLCs.

EASILY INS TALLEDDIGITAL DRIVES FROM10 A to 150 AFrom highly compact, cost-optimizeddesigns to self-contained, plug andplay models, Aerotech has the drivefor any application.

Ethernet I/O Expansion

Analog and Discrete I/O

Dis t r ibu ted Mot ion Con t ro lMotion control is performed atthe drive level.

F i reWire ® ( IEEE -1394) INDUS TRYS TANDARD, HIGH-PERFORMANCECOMMUNIC ATION NET WORK

DIGITAL DRIVE f ea tu res• PWM or linear

• Integrated 10/100 Base-T Ethernet

• Onboard x65536 encoder multiplication

• Resolver or inductosyn feedback

• 20 kHz position, velocity, and current-loop sample rate

• Integral power supply

• Sinusoidal commutation

• Local I/O ports

• Higher throughput due to highperformance control, network,and high-power drives

• Higher quality output (accuracyand precision) due to fullydigital drive and advancedservo algorithms

• Faster startup and changeoverresults from fully integratedmotion platform, easy-to-usesetup tools, and extensivediagnostics

• Lower startup and lifecycle costdue to lower component countand reduced engineering time

• Higher reliability due to fewercomponents

• Simplified integration as allmajor automation componentsare bundled into one platform

• User interface flexibility due tolocal or remote processing

• “Future Proof” architecture builton commercially available PCsrunning Windows® 2000/XPoperating systems

A3200 ADVANTAGES

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• Point-to-point motion

• Interpolated motion

• Velocity profiling

• Look-ahead

• Electronically gearedmotion

• Cutter compensation

• CNC functionality

• Electronic CAMprofiling

• Position synchronizedoutput

• Fast position capture

• High-speed registration

• Gantry mode

• Motor control

• Dual loop control

• Axis calibration

• Orthogonalitycorrection

• 3D error mapping

• Helical interpolation

• Autotuning

• Coordinatetransformations

• Normalcy, partsrotation, mirroring,and retrace

• Cubic spline fitting

• Kinematics

Motion generation and synchronization are centralized at the PC. Motionexecution is decentralized at the drives. A3200 operates on any standard desktopor industrial PC. Servo loops are closed on the drive.

RETROFIT TOEXIS T INGMOTORS &DRIVESUse as an integratedsystem or interface toexisting motors anddrives in a cost-effective retrofit.

Mot ion Con t ro l le r

Nservo Nstep

Robotics

Vision

Any ServoAmplifier

Any StepperDrive

Any Stepper Motor

Any Brush or Brushless Servomotor

Npaq® 6-AxisDrive Rack

ROBUST, HIGH-PERFORMANCE MOTION ENGINE CAPABILITIES

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INTELLIGENT NETWORKED DRIVESAerotech Ndrive® series digital servoamplifiers, Automation 3200 controller, andlinear and rotary servomotors are perfectlymatched to provide the ideal solution for yourmotion control application. Available modelsinclude the Ndrive HP, Ndrive HL, Ndrive CP,Ndrive MP, and Npaq®. Additional solutionsare the integrated Nsys console, Nservo, andNstep interfaces.

• Easy networking via industry standardFireWire® interface

• Digital current, velocity, and position loops forimproved motion stability

• Drive brushless and DC brush-typeservomotors, as well as stepping motors

• Input voltage range from10-320 VDC or 7-240 VAC

• Bus voltage from 10-320 VDC

• Output current 10-150 A peak (5-75 A continuous)

Available features and options (all options not necessarily available on all models):

Ndrive MP“Micro-sized” drive savesspace and reduces cost

Ndrive CPCompact drive minimizesintegration time

Ndrive HPHigh performance drive for demanding applications

Ndrive HLHigh powered linear drive for ultimate performance

• 20 kHz PWM or linear output

• Dedicated ESTOP input and optional brake

• Up to 3 axes of Position Synchronized Output

• Up to 16 in/16 out expansion board withanalog in/out (optional Ethernet for additionalI/O)

• Integrated hardware or software multiplier

• CE compliant

®

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• Extend the life of your capital investment byretrofitting your existing amplifiers and drivesto interface with the A3200 controller

• Retrofit older Aerotech or third-party servo,analog, or stepper drives

• Nservo and Nstep each support up to 4 axes of control

• FireWire® enabled for easy networking

Cos t -E f f ec t i ve Mac h ine Re t ro f i t sw i t h Nser vo and Ns tep :

NstepInterface older stepperdrives to the A3200 controller

NservoInterface older servo or analogamplifiers to the A3200 controller

NsysIntegrated console containing computer, controller,I/O, and customer supplied product

Npaq®

Highly integrated six-axisdrive chassis

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MULTI-AXIS MOTION CONTROLLER

™

The Ensemble™ is Aerotech’s next-generationmulti-axis controller for moderate- to high-performance applications with high-speedcommunication through 10/100 Base TEthernet or USB interfaces. It offers easy-to-use, affordable multi-axis motion programmingfor laboratory experimentation, productiontesting, or advanced OEM automatedmanufacturing systems.

Ensemble™ Epaq and Dr ives• Up to 10 axes of coordinated motion

• Multiple 10-axis systems can be controlled bya single PC via Ethernet or USB

• Controller architecture capable ofcoordinating motion of up to five independenttasks

• Capable of driving and controlling linear orrotary brushless, DC brush servo, andmicrostepping motors

• Complete motion capabilities include:point-to-point, linear and circular interpolation,electronic gearing, velocity profiling

• Program in AeroBASIC™ with the IDE, Microsoft .NET including C#, VB.NET®,Managed C++, or LabVIEW® over Ethernet orUSB from Windows® 2000 or Windows® XP

• Remote ASCII interface provided forWindows® or non-Windows® programs(including Linux) to command the Epaqthrough standard Ethernet, RS-232 port, andoptional IEEE-488

• Advanced Windows®-based remotediagnostics, tuning, and programminginterface software

• Axis jogging/control with optional joystick

• Epaq is available in rackmount or desktopversions

Ensemble™ Family (left to right): MP, CP, CL, Epaq

Engineered

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ENGINEERED SYSTEMS

Ion Beam Profiling in Vacuum

Advanced Laser Machining Discrete Part Milling Machine

Liquid-Cooled, Vacuum-Prepped System

Precision Optical Production High-Precision Air Bearings

Rapid Prototyping Advanced Pick-Place-Inspect Station

Patterned Media Inspection

High Volume Production Inspection Station

4-Axis Coordinate Measuring Machine

Optical Lens FabricatingPrinthead Inspection Station High-Accuracy Laser Machining

Electronic Inspection High-Speed Optical Indexer

Aerotech engineers and manufacturesspecialty high-performance subsystems. Ourhighly-trained staff of experienced softwareand hardware engineers enables ourcustomers to get to production readiness faster.Aerotech provides real-time collaborativesupport — either at your facility, at our facility,or on the web.

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AEROTECH ONLINEAerotech’s website at www.aerotech.comis your comprehensive resource for allAerotech information worldwide. Our productinformation is very thorough and better thanhaving a catalog. Each product section comeswith all the information available in print andincludes downloadable 2D and 3D models.Register for our e-newsletter In Motion toreceive news on all of the current activities atAerotech.

Produc tNav iga t ionEasy-to-use productnavigation intuitivelyand quickly guides youthrough our broadproduct range.

Cur ren t P roduc t andCom pany NewsThe most current product andcompany news is featuredprominently on our home page.

Wor ldwide Sa lesOf f i ce Loca torUse our worldwide sales officelocator to quickly find an Aerotechoffice near you.

Cus tomer Ser v i ceOur customer service centerprovides contact information forAerotech customer serviceworldwide. Also included aredetails on our training programs,software and product manualdownloads, and an FAQ section.

Se lec t yourMar ke tOur “select a market”feature details market-specific automationsolutions from Aerotech.

I n s ta l la t ion and S tar t up (Commiss ion ing)Aerotech offers startup and commissioning services to minimize startup times, reduce cost, and acceleratetime-to-production. By combining our product knowledge with your process and application expertise, newsystems and applications can be completed faster and at a reduced overall cost.

Eng ineer ing Suppor tAerotech provides complete engineering support for our products, including onsite support andmaintenance, and remote support via phone, fax, website, and/or WebEx® software. As a manufacturerstaffed by engineers, we understand the unacceptability of downtime.

Tra in ingAerotech training classes are designed to help our customers realize the full potential of our products. Bydemonstrating all of a product’s features and how to use them, customers have been able to reduce startuptime and quickly optimize their applications. Aerotech’s classes have been developed, and continuallyupgraded, using feedback from our customers.

Aerotech has over 35 years of expertise in designing motion control and positioning systems andcomponents with an unsurpassed track record of reliability. When you make the choice to purchase fromAerotech, we urge you to learn how to get the most from your new Aerotech products. Aerotech providesboth onsite (your facility) and/or in-house (our facility) training for our customers’ convenience.

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WORLDWIDE TRAINING & SUPPORTAerotech offers comprehensive worldwidetraining and customer service either at customerfacilities or at one of our Aerotech trainingcenters.

Our Tra in ing P rog ram Fea tures :

• Standard and customized courses

• Hands-on training with Aerotech positioning systems

• Interactive training with experienced instructors

• Comfortable, spacious facilities

Aerotech Inc (U.S.A.) Aerotech GmbH (Germany)

Aerotech Ltd (United Kingdom)

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AEROTECH AT A GLANCE

Cor pora te Headquar te r s • P i t t sburgh , PA • USA

Aero tec h UK

High Volume Manufacturing

Worldwidestartup serviceand on-sitetraining

Fully equipped on-site training facilities

Over 100,000 axesinstalled worldwide

Aero tec h Ger many Aero tec h Japan

Worldwide Service and Support

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ADRT rotary stages

Technically Superior Components High Performance Sub-Assemblies

Bes t - i n -C las s Sub -Sys tems Comprehens ive Tec hn ica lSuppor t Ser v ices

Custom softwareapplication support

Advanced analyticaltechniques foroptimization of systemgeometry

3D models to facilitatefaster and more accurate

system layout

ALS1000 linearmotor stage

Highestperformancebrushless linearand rotary motors

Award-winning Automation 32001-32 axis motion, vision, PLC, robotics, and I/O platform

Highly integrated motion sub-systems with machine frame,display, and packaged electronics

Custom-engineered,vacuum, and cleanroom

compatible systems

Production-proven, largeformat air-bearing systems forflat panel and semiconductorapplications

Ndrive®A3200 Npaq®

Award-winning FiberMax®

6-axis nanopositioner

LaserTurn™ 5 high-speedcylindrical laser cutting system

Highest throughput linear motorCartesian gantry systems

Aero tec h ’s Wor ldwide Sa les and Ser v i ce Loca t ions

- Aerotech Headquarters - Direct Field Sales Office - Aerotech Subsidiary - Representative

Dedicated to the Science of Motion

www.aero tec h .comCA0208B

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