Modular systems allow the creating of thousands of motion design variants. Increasingly, free software can show which modules can be combines with each other, and which adapter plates, centering, and standard parts are required for assembly - plus calculate guide loading, cycle times, and (for pneumatic modules) the degree of utilization of end positions.

Modular systems are based on standardized individual components that can be combined in different ways to form moving machinery, while reducing the amount of planning, design, and commissioning by system integrators, plant designers, and users. Interchangeable motion components also boost stability, while concurrently allowing modifications and expansions for reconfiguration when a design's purpose changes.

Consider one typical system — the Deprag Compact Assembly Module (DCAM), manufactured by Deprag Inc., with U.S. headquarters in Lewisville, Texas. The DCAM's first iteration assembled mobile phones, abolishing expensive and time-consuming hand assembly: One Swedish cell-phone manufacturer commissioned the first DCAM Weasel assembly platform — and the first 100 were put to use on cell-phone assembly.

At MOTEK 2011 in Stuttgart, engineers presented a new iteration. Jürgen Hierold of Deprag explains, “Until now, every DCAM has been custom, so they took a long time to produce — from initial consultation, through design engineering, to the manufacturing stage — and that degraded delivery times.” In contrast, new modular DCAMs can be deployed in a variety of assembly and production tasks, while a height-adjustable base plate ensures production and operator safety. Production parts are either manually loaded (using a sliding part nest or rotary index table) or automatically by means of a linear transfer mechanism. X and Y axes have tooth-ring drives and (if needed) are augmented with a ballscrew-driven Z-axis. Axes are ultimately driven either by three-phase stepper or servomotors.

DCAM Version A reaches 400 mm in the X axis, and 250 in the Y axis. In version B, both the X and Y axes travel up to 600 mm. The optional Z axis has an effective working range of 150 mm — useful for applications in which several processing points (or paths) must be completed quickly — for assembly, pliable and hard-plate labeling, monitoring the presence or position of components, and dispensing, joining, and marking.

Up to 80% of applications can be covered with standard solutions, preconfigured from modules to complete assembly groups: only challenging applications require special systems. Show here are Schunk subcomponents (eletrical, pneumatic, and structural) that puzzle together to quickly form performance motion systems.

Engineers at Schunk Inc., Morrisville, N.C., are also pursuing modularity. Via adapter plates, many of their gripping modules connect for thousands of application variants. For linear motion and gantry setups, a pneumatically driven line gantry (for payloads of 5 kg), two electrically driven line gantries, and two electrically driven room gantries (for up to 20 kg) sport stroke lengths tailored to particular applications.

For support structures of flexible design, pillar profiles abound. In both electrically driven and pneumatically driven gantries, the servo drives, energy supply, mechanic connections, and sensors are all integrated.

No matter the supplier, Schunk engineers recommend asking the following questions when modularity is a major design goal.

• How big is the selection of modules for a given family of motion components? Which sizes, weights, and movement ranges are covered? Which drive types does the program comprise? What kind of performance do the modules allow? Is it easy to choose the right module? Does the program also include connecting and add-on elements?

• Do the modules have uniform interfaces?

• How are the modules controlled? How difficult is the integration into machines and plants?

• Does the manufacturer offer CAD data for every module? For assembly groups, does the manufacturer preconfigure components?

• How much energy do modules consume?