Precision manufacturing upgrade is imminent, and traditional control technology encounters bottlenecks
As the semiconductor process breaks through the 3nm and below nodes, the LCD panel cutting accuracy is required to reach ±1μm, and the aircraft engine blade processing error needs to be controlled within 0.1μm. The traditional servo motor + reducer transmission control mode can no longer meet the needs. Problems such as positioning error caused by reducer gear clearance, precision attenuation caused by mechanical wear, and response delay caused by complex transmission chains are becoming increasingly prominent in high-end manufacturing scenarios. For example, when a semiconductor wafer inspection device uses a traditional servo system, the positioning error of the probe station reaches ±3μm due to the lag of the transmission chain, which directly affects the accuracy of nano-scale circuit detection; when a photovoltaic thin film deposition device is running at high speed, the dynamic response delay of the traditional control solution exceeds 50ms, causing the film thickness uniformity deviation to exceed 10%.
Three major technological breakthroughs, reshaping the precision control technology system
Direct drive control architecture: a leap from "mechanical transmission" to "electromagnetic direct drive"
Dual-core heterogeneous computing: nanosecond real-time control and edge intelligence integration
The controller is equipped with an ARM Cortex-A55+FPGA dual-core heterogeneous processor. The ARM core is responsible for complex algorithm operations and system management, and the FPGA implements nanosecond real-time control logic processing. This architecture enables the controller to simultaneously perform multi-axis interpolation operations (supporting up to 32 axes of collaboration), real-time status monitoring, predictive maintenance and other tasks, with a data processing speed of 2000MIPS, which is 4 times higher than the previous generation of products. After adopting this controller, the five-axis linkage processing efficiency of a certain aircraft engine blade processing center increased by 30%, and the processing time of complex curved surfaces was shortened from 4 hours to 2.5 hours. At the same time, the surface roughness Ra value was reduced from 1.6μm to 0.8μm.
Full-stack communication protocol: Building a seamless industrial 4.0 ecosystem
The controller supports 12 industrial communication protocols such as EtherCAT, PROFINET, and OPC UA. Through the built-in edge computing gateway, it can directly connect to the MES and ERP systems to achieve real-time upload and cloud analysis of production data. In the transformation of a semiconductor packaging and testing plant's smart workshop, the SR1015C02-2SN/97S1121 DD controller is seamlessly integrated with Yokogawa's CENTUM VP distributed control system, which increases the OEE (overall equipment efficiency) of packaging equipment from 68% to 89%, and the fault warning accuracy rate reaches 92%, predicting potential faults such as servo motor bearing wear 72 hours in advance.
Benchmark applications in multiple industries: from laboratory technology to industrialization
Semiconductor manufacturing: breaking through the limits of nano-level process controlPhotovoltaic thin film deposition: efficiency and reliability are both improved
After a TOPCon battery manufacturer used this controller to transform PECVD equipment, the uniformity of thin film deposition increased from ±5% to ±1.5%, and the hourly production capacity increased from 120 pieces to 160 pieces. The controller's built-in intelligent energy management system reduces the device's standby power consumption by 35%, saving about 120,000 kWh of electricity annually. More importantly, the direct-drive architecture eliminates the need for reducer maintenance, reducing the device's annual maintenance cost by 60% and unplanned downtime by 80%.
Technology leads the future: from precision control to industrial ecological reconstruction
The launch of Yokogawa's SR1015C02-2SN/97S1121 DD controller is not only a product upgrade, but also a reconstruction of the precision control technology system. Through open API interfaces and SDK development kits, the controller has attracted more than 50 upstream and downstream companies to join the ecological cooperation, covering sensors, actuators, industrial software and other fields. A relevant person in charge of Yokogawa Electric said: "We are building a full-chain precision manufacturing ecosystem of 'control + perception + decision-making'. In the future, we will use AI models and digital twin technology to achieve a leap from single-device control to full-line optimization."
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