DESIGN WORLD NOVEMBER 2020

www.designworldonline.com

November 2020

inside: Motion Control: Round linear guides or profile linear guides?

p. 58

Internet of Things: Equipment-as-a-service— a look at three technologies

p. 66

Electronics: Basics of security in RFID readers

p. 70

Ultrasonic bearings

help smooth out flat glass applications

page 76

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What will events look like in 2021?

We’ve all heard, “necessity is the mother of invention.” The pandemic has certainly brought out some creative ideas regarding trade shows.

With all the digital versions of nearly everything — meetings, education, tradeshows — one wonders if these changes will be permanent?

A few months ago, I spent a morning at a trade show booth — my first time since walking the IFPE show in Las Vegas in March. But this was the new virtual trade show hall om igus, the German-based motion plastics manufacturer. I was invited to tag along as one of the company’s large customers was escorted around the booth.

Virtual tradeshows were touted as the next big thing back in the late 1990s and the publishing company I worked for then pushed a ridiculously expensive version of them. That vision involved awkward avatars moving around a virtual trade floor. And, unsurprisingly, it ended in disaster.

This, thankfully, was a more intelligent way for a manufacturer to proceed. The main screen shows a view of the company’s actual tradeshow booth, set up in its Cologne headquarters facility. You can move in any direction to different areas of the booth. Once at a technology area, click on any product that looks interesting. A video of a corporate expert appears, describing the item. Most are a few minutes in length, giving some basics of the product, including how it improves on earlier models or competitive products, and listing sample applications.

While I’m not hoping tradeshows go the way of the dinosaur, when will people get comfortable with business travel again? My guess is that the first half of 2021 will look a lot like 2020, and we’ll start seeing actual events in the second half. I’m already seeing some associations say they’ll push ahead with late Spring events. Some shows normally held in the first part of the year are already announcing new dates in late Summer or Fall of 2021.

A lot will likely depend on the availability of vaccine(s) and how effective they are. Fortunately, the longer we fight Covid-19, the more we learn about what measures can minimize our risks. And Zoom fatigue has become a thing already — imagine what it’ll be like in another six months!

So, fingers crossed that our paths will cross sometime in 2021 on a show floor in Chicago or Las Vegas or Orlando. In the meantime, stay safe! DW

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Teschler on Topic How to maximize results and ruin a business I once worked for a company whose business was a mix of publications and trade shows. The trade shows made a lot of money. The publications were profitable, but not nearly as much as the trade shows. That made those of us writing for the company’s magazines and websites a little like second-class citizens. We had no clout or resources, and the trade show folks o en treated us like we had IQs ten points lower than theirs.

I eventually le this sorry situation, but I kept tabs on my old employer.

The company was eventually sold to a firm whose overwhelming majority of revenues came om running industrial trade shows. This outfit couldn’t wait to dump the publications and websites that came with the acquisition. That le them even more heavily invested in the trade show business, which was their goal all along.

All this transpired just before Covid hit. If you are familiar with the current state of trade shows, you can probably guess what happened next. With few other business lines to cushion the fall, the company went om a first-half operating profit last year of $321 million to a first-half operating loss this year

of $957 million. Massive layoffs have ensued. The word bloodbath comes to mind.

These results probably wouldn’t surprise University of Toronto Professor Roger L. Martin. Martin is an outspoken proponent of the idea that the single-minded quest for growth--as practiced by the money-losing trade show company—is a pretty dumb idea. “Judging company performance solely on the basis of short-term shareholder value increase has caused executives to give short shri to longterm stewardship of their employees, communities, and the environment,” he says.

Martin also blames this lack of balance partly for the big divide between the working class and the well off. “Unconstrained pursuit of laborcost efficiency has le tens of millions of American workers earning less than a living wage while the top 1% achieve unprecedented wealth,” he says. He doesn’t see the situation getting better so long as “business, economics, and public-policy schools still teach the importance of a singular objective function...And it isn’t going to happen as long as reward systems are geared around achieving singular goals--like achieving this year’s budget, which is still the dominant goal in much of American public and private-sector life.”

Interestingly, basic engineering practice illustrates the downside of running a business according to the theories Prof. Martin rails against.

Suppose you set out to design a circuit or a suspension bridge. If you subscribed to the maximum optimization theory prevalent in business today, you’d build in no cushion whatsoever to handle loads even slightly larger than the design maximum. A er all, adding capacity above what’s necessary could be viewed as spending money on unused resources. Business schools teach that the presence of unused resources is a situation that good managers must avoid.

Of course, an engineer who allowed no safety margin in the interest of efficiency wouldn’t be designing products for long. But a manager running a business this way might wind up keynoting the consumer CES show— if the trade show business wasn’t in shambles. DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW_LeeTeschler

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DESIGN WORLD

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Technology Forward

And another way to make parts fast Many people tend to think of traditional manufacturing (machining and injection molding) as wellestablished industries. All the new ways to make parts were discovered long ago and now there is only incremental change, if any at all.

The additive industry, however, is still in the beginning stages of exploration and development. So, it should not be a surprise that innovative ways to make parts continue to emerge.

One of the newer innovations is Additive Molding developed by Ethan Escowitz, CEO and founder of Arris Composites.

Additive molding combines additive manufacturing and high-volume injection molding technologies to create composite materials made of continuous fiber-reinforced thermoplastics. The technology has broad benefits across many applications and markets, enabling smaller, thinner, lighter, and stronger products. Plus, it’s scalable and energy efficient with minimal scrap. Parts made om this process exhibit high quality, high dimensional accuracy, and good repeatability.

This process, which uses materials typically associated with the aerospace industry, aligns material fibers in a way that increases a part’s strength. A part’s strength can o en be higher than titanium yet light in weight.

Additive molding combines the two worlds of aligned fiber and continuous composites that developed in the aerospace industry.

That process primarily consisted of hand lay-ups such as that used in automotive and boat building.

Presently, it is used to develop embedded electronic products, such as those found in consumer electronics, antennas, and items for use in recreational equipment.

New ways to embed electronics into products is a growing field, and 3D printing is being examined as a way that might solve some design and production challenges.

With the Arris Composites method, putting glass fiber into carbon fiber composites can create an antenna in a window. The combined materials deliver one of the highest strengthto-weight ratios found in materials.

According to Escowitz, “The molding is key and the strength is delivered through a synergy of two steps. The first step is to form the continuous composite material that creates a near net shape composite part with aligned fibers running through the part to reinforce the part optimally. But the consolidation of that material under high temperature and pressure is what delivers the consolidation and the minimal void content that makes this process exciting.”

Even with all the exciting developments in additive technology,

Escowitz makes a good point about thinking in different ways.

“Whenever a new manufacturing technology comes along, it’s important to step back and look at the products and the product architecture in terms of the legacy that is tied to the limitations of how it had to be produced, and can you perhaps undo some of those assumptions. When composites first came to aerospace, there was a term called black aluminum where you would see a composite manufacturer, make a part with features that were designed for aluminum manufacturing and be produced at sometimes a greater cost in a composite manufacturing method just because they were recreating the legacy, even though it wasn’t what was practical for the new manufacturing method.”

New ways to make parts can shake up old thought patterns, which generally tends to benefit everyone. DW

Leslie Langnau llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

8

November 2020

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DESIGN WORLD

11/5/20 12:22 PM

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Green Engineering Paul J. Heney

• VP, Editorial Director

Connectivity, automation provides

20% improvement in vehicle fuel efficiency

Vehicle efficiency improvements are generally accomplished by incrementally modi ing components and control systems — o en at a cost of millions of dollars. But now, a team led by Southwest Research Institute has applied connectivity and automation to achieve a 20% improvement in efficiency on a 2017 Toyota Prius Prime.

Working with collaborators at the University of Michigan and Toyota Motor North America, the team is sponsored by the Advanced Research Projects Agency – Energy as part of its NextGeneration Energy Technologies for Connected and Automated On-Road Vehicles program.

The program to develop enabling technologies set forth an ambitious target: To reduce the energy consumption of the Prius Prime by 20% without making changes to the powertrain and without compromising emissions, safety or drivability.

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“We knew these tools had the potential for making a big impact on fuel efficiency,� said Sankar Rengarajan, manager of SwRI’s Powertrain Controls Section. “Vehicle connectivity and automation are already being used to effectively improve vehicle safety and driver convenience. For this program, we were able to tap into those existing data streams and put the information to use in a new way.�

Onboard sensing combined with data om vehicle-to-vehicle, vehicle-to-in astructure and vehicle-to-everything technologies DESIGN WORLD

11/4/20 9:04 AM

provided the information needed to predict driving environments and develop new technologies. The team achieved these benefits by developing the next generation in vehicle dynamic and powertrain control so ware, designed to proactively use “look-ahead� information to anticipate vehicle power demand.

The new tools developed to meet these efficiency goals include ecorouting, eco-driving and power-split optimization. “We like to call eco-routing Google Maps with energy,� Rengarajan said.

Using a mapping tool like Google Maps, drivers can set their destinations and see routes that may add a couple of minutes to their arrival, but that are more fuel efficient. While the technology is appealing to the eco-minded consumer, for delivery and service fleets, this 5–10% savings in fuel consumption can add up to millions of dollars in savings each year.

Eco-driving uses information om neighboring vehicles to minimize accelerations, while power-split optimization uses knowledge of routes and speeds to optimize battery and engine operations to more efficiently meet power demands.

SwRI engineers used internal funding to deploy the eco-driving technology in a mobile driver advisory application,

or “app,� that runs on regular smart phones or tablets. The driver advisory app connects with traffic lights and roadway in astructure to “see� up to half a kilometer ahead and alert drivers to drive more efficiently. For example, if a stoplight is red a few blocks ahead, the app will tell the driver to speed up or slow down by a few miles per hour to avoid stopping. For heavy-duty trucks, making a full stop at a red light and re-engaging the engine when the light turns green is a significant source of fuel consumption.

The team also built a unique connected and automated vehicle (CAV) chassis dynamometer, a system to measure force, torque and power, that interfaces with traffic simulation so ware to provide a controllable, repeatable environment for testing the new technologies. Calibrated using realworld data om Fort Worth, Texas, the simulator proved critical for evaluating control algorithms and accurately quanti ing energy consumption. “Not only can these tools be applied to any on-road vehicle,� said Scott Hotz, assistant director of SwRI’s Ann Arbor Technical Center, “but we also believe there are more improvements to be made. It’s quite a leap om making efficiency improvements by modi ing vehicles and engines directly.�

Following the program’s success, the SwRI team is collaborating with regulatory and commercial organizations to commercialize the new tools.

Separately, the U.S. Department of Energy has provided $3.2 million to investigate the benefits of using CAV technology with different types of vehicles, as well as evaluating the impact of smart in astructure solutions like intelligent intersections as part of the Energy Efficient Mobility Systems initiative. DW

Southwest Research Institute connectedpowertrain.swri.org

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Contents 11 • 2020

•

vol 15 no 11

•

designworldonline.com

Medical www.designworldonline.com

58

How

decontamination could solve the

54 _MOTION CONTROL

70 _ELECTRONICS

Retooling the online world

Basics of security in RFID readers

Manufacturers are upgrading and expanding their presence online with improvements to help designers with everything om online ordering to new design tools.

58 _LINEAR MOTION Round linear guide or profile linear guide?

Here we outline how to choose a linear guide for a given application and environment.

66 _INTERNET OF THINGS Equipment-as-a-service—a look at three technologies

These IIoT tools can help put the EaaS model to work in your machinery quickly and affordably.

Well-publicized hacks illustrate why contactless credentials demand sophisticated security measures that can evolve as fast as the cracking techniques used by bad actors.

November 2020

CONTENTS.11-20_Vs2.LL.indd 12

COVID-19 mask shortage problem

Medical Tips cover 11-20_V1.indd 87

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87-95

76 _MECHANICAL Ultrasonic bearings help smooth out flat glass applications

Construction glass, automotive glass, or other special glasses are the largest segments of the growing flat glass industry. Growth drivers such as technological innovation and energy consumption challenge the various glass product’s properties and production processes.

80 _INTERNET OF THINGS Can standard I/O systems simplify designs?

When OEMs can standardize their designs with one family of I/O products, it simplifies their efforts and gives them the flexibility to adapt controller platforms as needed.

12

A Supplement to Design World - November 2020

www.designworldonline.com

ON THE COVER With no surface contact or dynamic turbulence in the ambient gas, substrates are handled damage free. | ZS-Handling GmbH

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

ON THE COVER

DESIGN WORLD

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11.20

• contents departments 04

Insights

06

Teschler on Topic

08

Technology Forward

10

Green Engineering

16

Design For Industry

26

Design Notes

38

Internet of Things

42

CAE Solutions

96 Product World

THIN ENOUGH?

104 Ad Index

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November 2020

DESIGN WORLD

11/4/20 9:07 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney Senior Contributing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Executive Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora CREATIVE SERVICES

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

OPERATIONS

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick Front End Developer Melissa Annand mannand@wtwhmedia.com Software Engineer David Bozentka dbozentka@wtwhmedia.com

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VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

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Events Manager Jen Osborne jkolasky@wtwhmedia.com @wtwh_jen Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

WTWH Media, LLC 1111 Superior Ave., 26th Floor, Cleveland, OH 44114 Ph: 888.543.2447

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2014 Winner

Medical Design & OUTSOURCING DESIGN WORLD

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Design for Industry Aerospace

A 3D printed “mothership” used to launch multiple PocketQube satellites into space The original idea came om Professor Robert J. Twiggs om Morehead State University (MSU), who proposed the standard of “a satellite that fits in your pocket”. A PocketQube is a type of miniaturized satellite for space research that usually has a size of 5 cm cubed (one eighth the volume of a CubeSat), a mass of no more than 250 grams, and typically uses commercial off-theshelf components for its electronics.

Fully loaded 3D printed AlbaPod 2.0 for flight – rear cover removed for inspection.

Courtesy of Alba Orbital 3.Fully loaded 3D printed AlbaPod 2.0 for flight – Rear cover removed for inspection. | Courtesy of Alba Orbital

This type of satellite is quite young – started in 2009 – but its importance is increasing as a solution to the rising costs of CubeSat launches to low Earth orbit. Since then, interest for PocketQubes has arisen om the Space industry. The first PocketQube Standard was issued in June 2018, providing a shared platform to the PocketQubes community; one of the contributors (along with GAUSS Srl, TU Del ) is Alba Orbital, a fast-growing high-tech SME based in Glasgow, Scotland.

Alba Orbital provided a hub of support for the class of PocketQube satellites, by not only building its own platforms but providing parts and launch to companies, universities and space agencies around the world.

Recently, Alba Orbital needed to build an updated version of its PocketQube satellite deployer, AlbaPod 2.0. The goal was to improve on

previous designs in terms of weight, manufacturability, access and incorporate a number of safety features.

The company’s engineering team turned to CRP Technology for the manufacturing of the deployer. CRP Technology is an Italian-based 3D printing company that offers Windform composite materials.

3D printed AlbaPods 2.0 in Windform XT 2.0. Courtesy of Alba Orbital. 2.3D printed AlbaPods 2.0 in Windform XT 2.0. | Courtesy of Alba Orbital

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Most of these materials are suitable for space applications and have passed outgassing tests at NASA and ESA. As with any aerospace part, minimizing weight is a major design goal. Plus, it is essential that the material be approved for flight due to tight rules regarding degassing once in space. It was clear that using a material already approved by the major launch providers would ease the adoption of the launcher by all parties.

For CRP Technology’s 3D printing department, the work began with an accurate analysis of the 3D and 2D files. Selective Laser Sintering with Windform XT 2.0 Carbon composite material was chosen.

The team noted that the pod needed to withstand high vibrations, and in the worst scenario, contain any satellite that breaks ee internally. Windform XT 2.0’s toughness and strength make it a suitable candidate for this use case.

Windform XT 2.0 features improvements in mechanical properties including +8% increase in tensile strength, +22% in tensile modulus, and a +46% increase in elongation at break.

Once CRP received the final .STP file om Alba Orbital, it created the AlbaPod v2, a light weight flight proven 6P (Up to 6 satellites) 3D printed deployer for PocketQube compatible satellites, with a mass of <500g (60% less than AlbaPod v1).

Professional 3D printing, combined with Windform XT 2.0 Carbon-composite material, proved to be the best choice: the 3D printed deployer has successfully passed the control criteria.

3D printed AlbaPod 2.0 on vibration table going through preflight certification. Courtesy of Alba Orbital, 1.3D printed AlbaPod 2.0 on vibration table going through preflight certification. | Courtesy of Alba Orbital

DESIGN WORLD

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Design for Industry Aerospace

3D printed AlbaPod 2.0 vibration testing. Courtesy of Alba Orbital Orbital 5. 3D printed AlbaPod 2.0 vibration testing. | Courtesy of Alba Orbital

The material combined with the manufacturing technique allowed the design team to design parts that cannot be manufactured with traditional techniques, with thin sections and complex geometry’s, and these parts can be manufactured and delivered in a action of the time for a traditional supply chain.

“The most innovative aspect of the project,” said one engineer, “was the sheer number of components we switched over to Windform XT

Rod Ends and Spherical Bearings designed and manufactured to Aurora’s exacting standards for quality and durability.

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DESIGN WORLD

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POWER TRANSMISSION

RETAINING DEVICES & satellites inside, but must also contain the satellites in the event of catastrophic failure of a payload during the launch as anything breaking ee could fatally damage other payloads or the launch vehicle itself. This was tested thoroughly with ee masses on vibration tables at extremely high loading and the shell held up phenomenally.

Additionally, weight is a concern with anything going into space due to the costs associated, using Windform XT 2.0 reduced the mass of a number of major components.

The Alba Orbital team foresee and hope for an increasing use of professional 3D printing in the field, because, they say, â&#x20AC;&#x153;3D printing allows us to rapidly improve design and customise/create launchers for demanding payloads which may fall outside the PocketQube standards or require special considerations. It will also allow the fast integration of new release mechanisms to switch manufacturers quickly and easily if problems with supply chain arise.

The Alba Orbital team performed many tests on the 3D printed AlbaPod v2. On September 9th 2019 the first integration occurred. At the beginning of December 2019, the team launched 6 PocketQube satellites into orbit via the AlbaPod v2 (mission: Alba Cluster 2). Alba Cluster 2 has been on orbit for 100 days. New launch with 3D printed AlbaPod v2 (Alba Cluster 3) is expected for later 2020. DW

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Design for Industry Aerospace

Boom Supersonic rolls out XB-1 aircra with 3D printed flight hardware components

The Boom Supersonicâ&#x20AC;&#x2122;s XB-1 aircra includes 21 flight hardware components manufactured

by Velo3Dâ&#x20AC;&#x2122;s Sapphire 3D metal printer. Unveiled at Boomâ&#x20AC;&#x2122;s hangar in Centennial, Colorado, the XB-1 marks a turning point in commercial viability for supersonic travel and demonstrates the power of additive manufacturing (AM) to enable innovation while accelerating product development.

Boom Supersonic and Velo3D announced a partnership in 2019 to manufacture complex flight hardware to build XB-1, and ran a series of qualification trials on the Sapphire system. The printed Titanium parts are used for engine hardware, the environmental control system, and structural components.

Characteristics of the geometric designs include tall, thin walls with high aspect ratios, which are difficult to manufacture with traditional processes such as welding and casting, or even most existing 3Dprinting technologies.

Velo3Dâ&#x20AC;&#x2122;s SupportFree printing process enables design eedom and quality control, eliminating manufacturing constraints to innovation in aircra design.

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XB-1 is the worldâ&#x20AC;&#x2122;s first independently developed supersonic jet. It will be used to demonstrate critical technologies for Overture, Boomâ&#x20AC;&#x2122;s future commercial airliner, such as advanced carbon-fiber composite construction, computeroptimized high-efficiency aerodynamics, and an efficient supersonic propulsion system. XB-1 is the end-product of years of development effort, including multiple wind tunnel trials, dozens of structural tests, hundreds of simulation iterations, and tens of thousands of work hours. DW

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DESIGN WORLD

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Design for Industry Packaging

Conveyor clamping module controls product accumulation

There are several ways to control the accumulation of products as they head into a packaging configuration. The Clamping Module for the FlexMove conveyor system is one example. It gives users the ability to hold back or pace products for accumulating applications.

The Clamping Module suits totes, boxes, bottles and square, round and rectangular containers. As products pass through the Clamping Module, pre-programmed photo sensors trigger a pneumatic-clamping actuator that is mounted on both sides of the conveyor. The Clamping Module produces a gap of about one product length; product must be able to withstand some back pressure and squeezing force.

Features and technical specifications of the Clamping Module include: • Maximum single product weight: 2.3 kg (5 lb) • Maximum product accumulation weight: 13.6 kg (30 lb) • Fixed or adjustable width Clamping Module option • Maximum conveyor speed: 50 m/min (164 /min) • Mounting for photo sensor with 18-mm barrel • Available on FlexMove conveyors: • FS (65 mm) • FM (85 mm) • FC (105 mm) • FL (150 mm) • FU (180 mm) • FV (260 mm)

The FlexMove flexible chain conveyor is an aluminum- ame, flexible chain conveyor suitable when floor space is limited as they are designed to make tight 360° turns in and around machinery and equipment. FlexMove conveyors suit packaging, part handling, product transfers, assembly automation, machine conveyance and tight spaces.

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Dorner www.dornerconveyors.com.

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Precision Control for Your Operations

Integrated vision and drive system

simplify position detection A joint solution for easy integration of vision technology is available. Machine builders, systems integrators and end users can quickly realize inspection, validation, position detection and quality control applications built around SICK cameras and Mitsubishi Electric Devices.

The solution is for use across a number of industries, including automotive, food and beverage, life sciences, machine building and OEM design. It combines a SICK vision camera with ready-built and tested function blocks for the Mitsubishi Electric GX Works PLC programming environment. This makes it simple to set up vision applications on Mitsubishi Electric PLCs. Both companies believe that vision solutions provide essential information that can enhance a range of automation processes. But more than that, they are the eyes of Industry 4.0 and therefore a key element of the digital transformation of industry.

SICK and Mitsubishi Electric have worked together for a number of years. Now they are taking that collaboration to the next level, as SICK joins the e-F@ctory Alliance. This makes for users to embed vision technology into applications such as product manufacturing, handling and packaging. DW

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Design for Industry Safety

Communications in hazardous areas The intrinsically safe 4G/LTE Android smartphone Smart-Ex 02 offers a large 5-in. display, good ergonomics and an optimized accessory concept.

This Smart-Ex 02 is an advanced explosion-proof smartphone for Zone 1/21 and Div. 1. Equipped with the latest Android 9 operating system, it is fast and secure. It simplifies communication between employees, the control center and backend systems.

The Smart-Ex 02 supports 21 different LTE equency bands and is delivered simlock- ee. Global Ex and approval certifications enable worldwide use and global rollouts. Smart-Ex 02 is also AT&T approved and network ready.

Designed for an extended temperature range om -20 to +60°C, the Smart-Ex 02 can be operated under extreme conditions.

For maximum durability, its display is protected by shock- and scratch-resistant gorilla glass. Even in direct light, the user can easily read the display, forward data and share it in the corporate network. With a powerful replaceable battery (4400 mAh), longer shi s and 24-hour work coverage are possible.

Operating the SmartEx 02 is easy: push-totalk and alarm buttons, volume control and the camera release button are intuitive to handle due to their ergonomic design and handy arrangement – even while wearing

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gloves. Configurable Android keys are available for individual assignment, while dedicated keys for PTT and alarm functions ensure swi communication in case of emergency. A multi-functional mounting plate concept (belt clip, hand strap, charger, docking station) ensures easy carrying, mounting and charging.

Additionally, the Smart-Ex 02 can be supplemented by peripheral devices including the Cube 800 Ex-camera and the explosion-proof Smart-Ex Watch as well as headsets, microphones, scanners or Bluetooth beacons by ecom.

The Smart-Ex 02 is the first device certified for Zone 1/21 and Div. 1 to be approved for three important compatibilities:

• AT&T Network Ready • Compatible with T-Mobile BYOD • Google (AER) Validation Smart-Ex 02 has passed a battery of rigorous tests to be verified for carrier compatibility and to ensure a good customer experience. Likewise, being AT&T Network Ready and carrier compatible provides an extra sense of confidence that end users have come to expect om these global market leaders.

Additionally, Google AER guarantees timely patches and security updates.

Digital Products and Services product line enables staging, management and real-time monitoring of the Smart-Ex

DESIGN WORLD

11/4/20 2:05 PM

02 and other mobile devices om ecom. It combines automated staging in device manufacturing, mobile device management and device analytics. The solution can be used as a fully-fledged enterprise mobility management system, if desired. This ees IT departments om time consuming routine tasks and ensures more security during operation: mobile devices can not only be set up and managed easily, but also updated at any time (over-the-air). Security-relevant events can be made visible by the analysis of historical data.

Additional features:

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Optional integrated cameras (12 MP rear and 5 MP ont camera) with autofocus and LED flash Bluetooth 4.2 incl. BLE GPS / A-GPS / Glonass / Beidou / Galileo Up to 128 GB additional storage via microSD Wi-Fi 802.11 a/b/g/n/ac/e/e/e/k/r/h 2.5 + 5 GHz for real-time data acquisition Optional so ware features such as high-performance bar code scanners Magnetic USB port Dedicated keys: PTT key, alarm key, Android function key AT&T approved and network ready DW

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Design Notes

Reaching new levels of take-up

efficiency

Edited by Mike Santora • Associate Editor

The new RD10 rim drive shaftless take-up uses a roller drive system that fits in a smaller footprint while providing superior efficiency — Shown without guarding for clarity.

As demand for copper wire and other cable products grows, distributors continue to look for ways to improve efficiencies, reduce costs, and maximize space in their facilities.

In response to industry trends, Reel Power Industrial, a manufacturer of reel and coiling solutions, recently added a new rim drive sha less take-up to its RD line.

The units are typically used by wire and cable distribution facilities where large spools of copper wire are transferred down to smaller reels for contractor use.

RD10 reels are “rim driven,” allowing quick change out and loading of large wire and cable spools. The machine uses a geared motor to drive a roller, which rotates the cable reel as it coils. The geared motor’s output sha is coupled, via chain and sprocket, to the drive roller. A smaller motor/gearbox drives two threaded rods, which then move the ejection roller up and down the ame.

Maintaining a consistent winding torque through all speed ranges is critical to ensure proper spooling.

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“For over 30 years, the RD line has been periodically updated to take advantage of innovative technology as it became available,” said Joe Crosley, Sr. Electrical Engineer at Reel Power Industrial. “Initially, RD Series take-offs were offered with a 20 hp mechanical variable drive system that provided high-torque but was cumbersome and expensive to maintain.

Then, as VFD motors and controls became available, we upgraded but had to increase horsepower to maintain low-end torque.”

The goal was to design a new roller drive system that would fit in a smaller footprint while providing better efficiency. The only way to meet the reduced size requirement was to use a more power-dense, right-angle geared

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Design Notes

ONE COMPONENT, NON-DRIP

ADHESIVE for STRUCTURAL BONDING EPOXY SYSTEM TEMPERATURE RANGE Serviceable from -60°F to +500°F

RD10 reels are “rim driven” allowing for quick change-out and loading of large wire and cable spools.

ELECTRICAL INSULATION Volume resistivity, 75°F >1014 ohm-cm

STRENGTH PROFILE

motor versus the in-line drive used on previous versions of the machine.

A er testing geared motors om different manufacturers, Reel Power selected the Bauer BK Series geared motor with a permanent magnet synchronous motor (PMSM) for the main reel roller drivetrain. The PMSM technology maintains consistent torque om 0 to 120 Hz and does not overheat at lower power as some other competitor models.

The RD unit requires a variable speed control to allow the operators to control the rewind process. “Older RD models accomplished this via mechanical variable speed drives with adjustable pulleys. Newer models used VFD drive controls with inverter-duty induction motors,” Crosley said. “However, switching to permanent magnet (PM) motors is not always a simple adjustment. A er thoroughly testing many VFD controls, we found some drive manufacturers do not have adequate algorithms for PM motor control.”

Once a VFD and a Bauer BK unit were selected that met the initial performance criteria, the RD10 was loaded with a 10,000 lb. reel and run for several hours, including stops and starts, to veri that the new geared motor could handle the load. Bauer engineers worked A Bauer BK Series closely with the Reel Power geared motor drives a roller which rotates the large cable reel as it coils.

The output shaft of the geared motor is coupled, via chain and sprocket, to the drive roller.

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engineering team to fine-tune the motor to meet performance expectations.

The compact Model BK40 supplied features PMSM technology that reduces heat losses om the rotor by 100% and total losses by approximately 25% while increasing total efficiency by 10% or more. This improved performance translates into lower total cost of ownership, a reduction in CO2 emissions, and ongoing savings that buffer future energy costs.

Along with being an economical choice, the size-to-power ratio of the Bauer solution was a key factor. “The implementation of the Bauer BK right angle, helical bevel geared motor package also allowed us to reduce the machine’s width om 137-in. to 101-3/4-in. — which is a huge win for our customers,” Crosley explained.

The compact BK right angle, bevel geared motor featured permanent magnet synchronous motor (PMSM) technology that reduces heat losses from the rotor by 100% and total losses by approximately 25% while increasing total efficiency by 10% or more.

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Design Notes The new RD10 units provide smoother acceleration and deceleration with no “cable popping,” reducing the risk of damaging strands.

A footswitch and central operator controls with handheld speed pendant allow the operator to wind material onto a reel or a coiling head. The footswitch can be “jogged” without tripping the drive — allowing easy packaging of the spooled material. Dynamic reel braking reduces “over spin.”

RD10 units generate lower ambient noise compared to mechanically driven units.

A Boston Gear 700 Series speed reducer is used on the machine’s smaller ejection drive. The 700 Series is the industry standard for modular worm gear construction. Units feature a rugged fine-grained cast-iron housing for maximum strength and durability. DW

A Boston Gear 700 Series speed reducer is used on the machine’s smaller ejection drive. The 700 Series is the industry standard for modular worm gear construction.

Altra www.altramotion.com

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Introducing the latest in ultra-low profile capacitance.

What do you get when you take the energy density of an aluminum electrolytic and engineer it to fit a rectangular case that is 2mm or 3mm thin? The ULP. A capacitor that takes up to 70% less board space when compared to solid tantalum capacitors. For hold-up applications the size and cost savings are extraordinary.

For technical information and samples visit cde.com/ulp

Cornell Dubilier 6-20.indd 31

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Design Notes

Linear bearings set the stage in

entertainment industry application Edited by Mike Santora â&#x20AC;˘ Associate Editor

The staging company was supplied with rails in a variety of lengths. The Hevi-Rail line was considered the best fit, partly because it offered the option of welding multiple butt joints within the structure.

A renowned entertainment company was tasked with creating a complex and movable staging apparatus for an upcoming major performing artistâ&#x20AC;&#x2122;s tour. To build the stage, they needed a rugged linear bearing system that included a large quantity of heavy load-bearing rail. Along with materials, flexibility was also essential to the design. Therefore, having consistent products om the same manufacturer would serve as building blocks for the entire system. This would include fixed systems as well as telescoping platforms.

Along with these requirements was a quick delivery date, since the tour would begin in weeks. Speed would be essential to keeping the tour on schedule.

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This project began with a simple customer inquiry made to the PBC Linear website.

The company responded by contacting the customer and evaluating their needs and the full scope of the project.

The customer was already knowledgeable regarding linear bearing systems, was also well-known to PBC Linear. With the completion of the project, the PBC Linear engineering team provided the staging company with efficient options and solutions that were not available elsewhere.

A er first evaluating the specifications of the customer’s request, along with the available inventory, the PBC Linear engineering team discovered that the lead time for the project was unattainable.

This led to more in-depth discussions regarding the customer’s overall needs, allowing engineers to provide a different set of options based on available inventory. This early engagement helped to influence the customer’s design and ultimately provide a solution resulting in a successful, on-time delivery of the project.

The staging company was supplied with rails in a variety of lengths. The Hevi-Rail line was considered the best

fit, partly because it offered the option of welding multiple butt joints within the structure. In other words, they could now combine smaller lengths to form more specific rail lengths instead of cropping a large number of 20- lengths that had initially been requested. This option of welded joints gave the system designer more eedom to use the building blocks creatively.

It was evident om the beginning that the Hevi-Rail line would be optimal for the stage project. Parts of the enormous stage would be required to move up and down, as well as side to side, while having the stamina to remain productive over the entire tour. The designers and engineers were comfortable with welding and building steel fabrications, and would need products that were strong, reliable, and easy to work with. The rails and bearings would also need to be easily integrated into a system built with stationary steel supporting members. The Hevi-Rail line fit all of those needs.

The PBC Linear team achieved a high level of satisfaction in this application by employing good communication and flexibility throughout the entire project and meeting the deadline. Delivery of this high-profile project was handled in just one shipment, requiring 144 bearings and over 2,000- of rail. DW

PBC Linear PBCLinear.com

DESIGN WORLD

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Design Notes

The perfect balance for large rotors Edited by Mike Santora â&#x20AC;˘ Associate Editor

The installation minimizes the time required to balance a rotor and the latest upgrade will reduce that time even further.

High-speed balancing facilities are used to ensure the optimum performance of large pieces of rotating equipment, such as steam or gas turbines. Sulzer operates two of the very few independent facilities in the world, and the site in Texas recently underwent an upgrade project to improve both its flexibility and efficiency.

Electrical generators are vital to creating the electricity we all use in our everyday lives, and with increasing demand, reliable performance is essential to minimize the risk of blackouts. The Sulzer team supports these critical assets with a comprehensive range of maintenance services, including high-speed balancing.

The independent, high-speed balancing facility in La Porte, Texas, is a specialist piece of diagnostic equipment designed to test some of the worldâ&#x20AC;&#x2122;s largest turbine

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Sulzer can balance turbomachinery up to 30-ft (9 meters) in length, 8.5-ft (2.59 meters) in diameter, and up to 50’000 lbs (23 tons) in weight to speeds up to 40’000 rpm.

rotors. Equipped with a vacuum chamber, it can run complete turbine rotor assemblies at full operating speed, and beyond if necessary. The installation minimizes the time required to balance a rotor, and the latest upgrade will reduce that time even further.

The bunker itself is designed to accommodate turbomachinery up to 30- (9 meters) in length,

8.5- (2.59 meters) in diameter, and 50,000 lbs.

(23 tons) in weight to speeds up to 40,000 rpm.

Vibration diagnostics are used to analyze the radial vibration at the bearings to ensure that the best balance is achieved at operating speed as well as minimizing the deflection and vibration amplitudes during ramp up and coast down.

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Design Notes

The new drive motors can run briefly at 250% of the nominal rating, offering 2500 hp (1’850 kW) that can be used to start larger rotors rolling.

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Taking stock The original installation used two 500 hp (370 kW) direct current (DC) motors installed in the 1990s. The two motors were connected inline, giving a 1,000 hp (740 kW) output operating independently. These were connected to a three-speed gearbox, which in turn was connected to a single-gear speed increaser. There is also the capability to add a third gearbox which is a turbo-drive.

The drive system’s design offered a maximum capacity of 150% of the motor power for a short time to start the rotor rolling. This equated to a maximum of 1,500 hp (1,110 kW) dual motor drive that could be configured to turn the rotor at, or above, its normal operating speed.

Having achieved the balancing assessment at a particular speed, a rotor must be brought back to a standstill to apply balance weights before the procedure can continue. With the old system, a regeneration drive acted as a brake, and also fed the energy generated by the slowing rotor, back into the grid.

Drive upgrade The upgrade project would involve replacing the motors with alternating current (AC) alternatives rated at 500 hp, and new drives. The new drive motors can run briefly at 250% of the nominal rating, offering 2500 hp (1,850 kW) that can be used to start larger rotors rolling, increasing the facility’s capacity.

The new system remains as a dual-motor drive, but now the motors are always operated together and share the load between them, with the second motor fitted with an encoder that is used to calculate the speed of the rotor. The two drives are also linked together in a master/ follower arrangement to ensure optimum performance of the motors.

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COVERED BEARINGS. Gaining control The original control system allowed the engineers to input inertia settings, which accounted for many variables relating to the rotor being balanced, including weight, length, and blade/impeller design.

Rotors could be classified into one of six inertia groups and this would determine the configuration of the balancing drive system. These settings were fine-tuned over many years of operation, but there was still some room for improvement.

To complete a balancing procedure, the engineers input the desired speed setpoint, and the motors are engaged to start the rotor turning and then bring it up to the required speed.

Using vibration diagnostics to analyze the radial vibration at the bearings and the mid-span deflection is essential to ensuring that the best balance is achieved at operating speed while minimizing the deflection and vibration amplitudes during ramp up and coast down.

Process improvements The new system uses precision torque control to regulate the speed of the rotors being balanced and this offers considerable refinements to the original system. The initial torque required to start the rotor turning can be minimized, reducing energy consumption. Also, the torque required to bring a rotor up to a pre-set speed can also be optimized, being reduced as the target speed approaches.

The improved accuracy in speed control offers a more stable platform to conduct the balancing procedures, while the enhanced ability to accelerate and decelerate the rotor all combine to reduce the overall time required to complete the balancing procedure.

Simultaneously, the regeneration drive continues to act as a brake and recover a large percentage of the energy used to accelerate the rotor on each cycle.

In addition, the gear ratios of the gearboxes have been programmed into the drive system, and the encoder can calculate the speed of the rotor based on the gear selection that is being used.

The improved control system offers much greater precision and flexibility and

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reduces the amount of time required to complete a balancing procedure.

Long-term benefits Despite having the same power rating, the new motors are considerably smaller than the originals, reducing the overall power train length by 3- (900 mm).

They are also much more energyefficient, reducing the overall costs for the facility.

However, the biggest gain has been in the control system, which is now a digital, touch-screen installation. The entire balancing facility can be operated om two human-machine interfaces (HMIs) that offer greater control and precision.

The modern drives and the encoder provide better speed control, allowing the balancing so ware to deliver even more accurate results.

The next investment will involve upgrading the gearboxes to allow the motorâ&#x20AC;&#x2122;s full potential to be realized.

In the meantime, the demand for this facility continues to rise as larger rotors can now be accommodated, and customersâ&#x20AC;&#x2122; projects can be completed on shorter lead times. DW

MOLDED NEOPRENE & URETHANE SURFACES

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Sulzer www.sulzer.com

www.designworldonline.com

IN STOCK! ROLLERS & BUMPERS

LOCATE YOUR DEALER ONLINE!

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Internet of Things

EtherCAT terminals enhance incremental signal analysis

The EL51xx EtherCAT Terminals have built-in incremental signal analysis functionality. Incremental encoders have become indispensable in many applications due to their compactness and low-price points. The EL51xx series is for analysis of 5 V incremental encoders via RS422 and TTL signals. These four new high-performance I/Os feature eXtreme Fast Control (XFC) technology and enable analysis of incremental signals in the controller in an even more space-saving and cost-effective manner.

The EtherCAT Terminals acquire incremental signals with high equencies up to 5 MHz and feature many parameterization options and integrated functions that enable optimum adaptation to control tasks. Each terminal offers an integrated sensor supply, which is parameterizable to 5, 12 or 24 V. Users can easily connect encoders with differential RS422, 5 V TTL or open collector interfaces. Based on internal pull-up resistors, no external wiring is required for open collector analysis. Additional 24 V digital inputs can save,

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lock and set the counter value. The EL51xx series now includes:

• EL5102: 2-channel incremental encoder interface, 5 V (RS422, TTL, open collector) • EL5112: 2-channel incremental encoder interface, 5 V (2 x AB or 1 x ABC RS422, TTL, open collector) • EL5122: 2-channel incremental encoder interface, 5 V single-ended (TTL, open collector) • EL5131: 1-channel incremental encoder interface, 5 V with two parameterizable 24 Vdc outputs

AUTOMATION

A range of additional integrated functions, such as rotary axis functionality, workpiece measurement and standstill monitoring enable data preprocessing directly in the I/O terminals. The measurement of period, equency and speed with a resolution of 10 ns is also available. In addition, the terminals implement a duty cycle measurement of the incoming signal. Due to the optional interpolating micro-increment functionality, the EL51xx terminals can determine even more precise axis positions for dynamic axes. The synchronous reading of the position values with other process data in the EtherCAT system occurs via the highprecision EtherCAT distributed clocks. This enables simple and precise synchronization of controller tasks. DW

CHEMICAL

MATERIAL HANDLING

EVENT, THEATER & LIGHTING

FOOD AND BEVERAGE

ROBOTICS

Beckhoff Automation www.beckhoff.com

TRAYCONTROL 550 TPE

WHAT DO YOU THINK?

TRAYCONTROL 550 TPE is a flexible, oil-resistant control and power cable. The special combination of TC-ER, PLTC-ER and ITC-ER allows this cable to be used as a connecting cable for AC, DC or control wiring in accordance with NFPA 79. this cable is approved for open, unprotected installation in cable trays to the machine. Its outstanding oil resistance (Oil Res I/II) guarantees a long service life for industrial applications in dry, damp and wet environments.

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Internet of Things

Sinamics S120 drive platform enhanced with Ethernet connectivity

The Sinamics S120 drive system has been expanded to include Profinet, Ethernet TCP/IP and EtherNet/IP connectivity, for maximum flexibility for industrial Ethernet communication while offering innovation for those wanting a single network for the entire plant.

Whether a Greenfield project with multiple vendors or an OEM supporting different platforms on their machines the importance of industrial Ethernet connectivity for drive systems is today’s top requirement.

“In many instances, plant managers have the requirement for a single-plant network, particularly with large automotive, packaging, plastics, metals, food and beverage as well as material handling companies,” says Craig Nelson, Siemens product manager, Sinamics S drives. “Our Sinamics drives provide communications without limits to a specific network type.”

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Sinamics S120 drives support, as standard, Profibus DP and Profinet to ensure seamless communications between all the components involved in a typical automation solution, including HMI (operator control and visualization) and I/O. Additional higher-level functions including Safety Integrated telegrams and synchronized mechanisms for even the highest-level motion applications are also included in these innovative solutions.

Profinet can transmit operating and diagnostics data simultaneously

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D

to enterprise-level systems using standard IT mechanisms (TCP/IP) for an integrated factory environment. The new addition of an EtherNet/ IP stack offers another option for Sinamics users.

Having the flexibility to communicate with the most common automation systems via Profinet, EtherNet/IP or basic Ethernet TCP/IP makes the Sinamics drive system easily adaptable to the current Industrial Ethernet boom.

Sinamics S120 drives handle nearly any drive requirement and facilitate vector, servo and variable- equency drive (V/Hz) applications with the choice of single- or multi-axis offerings. It offers a modular design and system architecture, combined with new communication connectivity features.

With a wide power range (0.25 – 1,600 hp), highly scalable solutions, including safety integrated functionality and convenient start-up with automatic configuration of the drive system, through the innovative Drive-CLiQ interface, Sinamics S120 is a powerful solution for a host of applications, including packaging, plastics molding and extrusion, textile, printing and paper machines, handling and assembly systems, machine tools, rolling mills and test stands. DW

Siemens Corp. www.usa.siemens.com/eip

WE’VE TAKEN ANOTHER STEP IN THE RIGHT DIRECTION. ALL FOUR OF THEM. Two new compact pumps that deliver high flow, efficient, and quiet performance.

WHAT DO YOU THINK?

KNF’s two newest compact compressor/vacuum diaphragm pumps deliver in several important directions at once. Together they offer maximum flow rates from 7-30 L/min, producing pressure greater than 36 psig and vacuum down to 100 mbar abs. A gas-tight, condensate-tolerant, and temperature-resistant version is available.

Connect and discuss this and other engineering design issues with thousands of professionals online

The two new pumps are particularly well-suited for use in wound and medical compression therapy, respiratory care devices, environmental monitors, and gas sampling.

Take a step in the right directions with KNF at knf.com/en/us/compact

DESIGN WORLD

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CAE Solutions

KIA’s European design studio, led by Gregory Guillaume, is a pioneer in integrating new technologies into their design workflow. With a digital 3D department, design teams and visualization experts, its goal is to always exceed expectations – both for KIA customers and the company’s leadership in South Korea.

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DESIG

Driving the future with XR collaboration in car design

North American & Japanese Electrical Plug Differences While the NEMA 5-15 and the Japanese JIS C 8303 cords look alike, there are some critical differences. While the width of the blades appear similar, the Japanese blades are at least 1 mm shorter.

Also, the mains power in America is 125V while in Japan it is 100V. The Alternate Current cycle in North America is 60Hz, and in Japan it is both 50 and 60Hz. If you plug a 50Hz into a 60Hz main and the appliance has a heating element or a motor, then the motor could burn out, start a fire, or give the end user an electrical shock.

Typically Japanese wire sizes range from 0.75 to 2.0 mm2. This translates to AWG sizes 18 to 13 respectively. However, just like North American Hospital-Grade plugs, the Japanese Hospital-Grade plugs also bear a “green dot,” though unlike NEMA 5-15s, 6-15s, and 6-20s H-G plugs, they will not plug into 250V power mains unlike its North American counterparts

KIA Motors has always been an industry leader when it comes to implementing new and innovative tech in their design process. Now, with Varjo XR-1 supported

by Autodesk VRED, the designers are moving into an immersive photorealistic environment. The benefit is that global design reviews can go from days to an hour.

Photorealistic, real-scale and hands-on – seeing is believing Thomas Unterluggauer is the the Europe Design Center of KIA Motors Creative Manager CGI. He’s wearing the Varjo XR-1 headset as he works on a KIA model in the studio; moving seamlessly between the real and virtual car in front of him, and making changes on the fly. What he’s seeing and doing in the KIA studio hasn’t been possible until now.

When KIA’s European team tried out Varjo’s VR headset for the first time, they were impressed by the clarity and the resolution of the headsets.

“For the first time, we could literally see the metallic flakes in the paint and perceive the depth and quality of the material shaders. We could see the beauty of the details more than ever before in the virtual world. Varjo is the only device capable of this level of clarity and sharpness,” Unterluggauer says.

Seeing more details in the car exterior was a breakthrough. But when Unterluggauer and the team got to explore the Varjo XR-1 mixed reality device, they realized they could also use it to take their design work to new heights.

With Varjo XR-1, designers can work with their colleagues in the physical design space they’re used to and collaborate on photorealistic, real-scale virtual car models while seeing their hands and bodies. In an immersive mixed reality experience like this, they’re able to talk as they go, give immediate feedback, and run more engaging reviews.

“Immersive collaboration works more naturally than we expected. This is something I’ve always wished for,” adds Gregory Guillaume, Vice President of Design at KIA Motors Europe.

At the end of a mixed reality session, Unterluggauer takes off the Varjo XR-1 headset and looks back into the room. “It’s fascinating how quickly you adapt to the mixed reality.

You’re tricked into thinking for a moment that reality is wrong, that there is something missing. It’s completely different to any other experience I’ve ever had in VR,” he says.

CONTACT CUSTOMER SERVICE AT: (800) 662-2290, or at info@interpower.com for more information.

®

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KIA’s workflow changes up a gear with VR/XR Located in Frankfurt, Germany, Kia’s Europe Design Center is helping to change perceptions of the Kia brand across the continent as well as worldwide. Its dedicated team of designers create concept cars of the future as well as production models for both Europe and the global market.

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November 2020

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CAE Solutions

With Varjo XR-1, KIA designers can review new virtual car models next to physical ones; or take a physical clay model and overlay parts of it with virtual data. For instance, in interior design, it allows them to overlay digital content onto a physical seating buck.

The ability to design and collaborate with Varjo’s photorealistic VR/XR and Autodesk VRED is a game-changer for KIA’s designers.

Until recently, the automotive design process relied on 2D reviews on screens and powerwalls, followed by physical clay models and prototypes to further refine and develop the surfaces.

As manager of the studio’s digital department, Frank Hübbe knows that a 2D model is always a projection that lacks volume.

“Although you can use keyboard, mouse, and screen to work efficiently in 2D, you’ll never get a fully realistic impression of the car,” he says.

Today, KIA Europe’s designers are complementing their entire workflow with virtual and mixed reality. The teams are using VR/XR technologies to make their visualization work more effective and showcase projects in new ways.

For example, designers can review a virtual model directly against a physical model in the same room, or even augment an existing clay model with virtual details.

“With VRED and the Varjo XR-1, you have the context of the real world and the flexibility of the virtual world,” Hübbe says.

Remote collaboration when the world needs it most In the midst of a global pandemic, the ability to collaborate remotely and reliably with teams across the globe has never been more crucial.

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With COVID-19 currently preventing most business travel, KIA Europe has turned to Varjo’s VR/XR and Autodesk VRED’s virtual collaboration feature to continue working with the other global studios. Designers can collaborate on the same photorealistic models from wherever they’re based around the world, trusting that everything from the smallest details to the full-scale appearance of the car looks correct.

As Gregory Guillaume says, until now, if he wanted to discuss a model with the design management at KIA’s global headquarters; he’d have to fly to Korea to do it. Reviewing a digital model with design management always took a minimum of four days. “Now, I can do it in one hour,” he says. The ability to carry out design reviews virtually presents KIA with the opportunity to save time, work and money.

And while professionals worldwide are currently struggling with often unreliable phone and video conferencing technology, Guillaume has had promising experiences with this new collaboration technology.

Despite the complexity of the VR/XR hardware and visual rendering software, his team hasn’t had any reliability issues with the Varjo XR-1 and Autodesk VRED at all.

“You’d think this is so much more complicated than a video call. But collaboration has been very reliable,” he says. Guillaume and his team can be in the same virtual room with the design management team and look at and discuss the same car model in perfect detail.

“That’s only possible if we trust what we’re seeing and the tools we’re using. It amazes me that something so complicated is working so naturally and easily.”

Despite all the restrictions and uncertainties that come with the global pandemic, using Varjo and Autodesk VRED is enabling KIA to continue their design collaboration with studios across the globe.

“This technology is bringing us together at a time when we can’t be present in the same physical place,” Guillaume says. DW

Autodesk www.autodesk.com

DESIGN WORLD

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CAE Solutions

COMSOL Multiphysics Version 5.6 to be released in Fall 2020

An electric motor simulation in COMSOL Multiphysics version 5.6 where a clip plane is used for easier access to the inside of the model for assigning material properties and loads.

COMSOL, Inc., provider of so ware solutions for multiphysics modeling and application design, is offering a preview of the upcoming release of COMSOL Multiphysics version 5.6 at the COMSOL Conference 2020 North America, October 7â&#x20AC;&#x201C;8.

COMSOL 5.6, to be released in fall 2020, brings faster and more memory-efficient solvers, better CAD assembly handling, application layout templates, and a range of new graphics features including clip planes, realistic material rendering, and partial transparency. Four new products expand the modeling power of COMSOL Multiphysics for the simulation of fuel cells, electrolyzers, polymer flow, and control systems.

Clip planes, solver efficiency for multicore and cluster computations, and improved handling of CAD assemblies Clip planes are one of several foundational upgrades to the COMSOL graphics rendering engine and enable easier selection of boundaries and domains inside of complex CAD models. Other graphics news in the new version include visualizations that are partly opaque and partly transparent; realistic material rendering of, for example, steel, glass, and water; and the ability to make imported images part of a visualization.

The solution time has decreased by 30% or more for many types of simulations. The solvers are significantly more efficient with respect to computation time and memory usage for multicore and cluster computations. Handling of larger CAD assemblies has improved with more robust solid operations and easier detection of gaps and overlaps in assemblies.

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Application templates and control knobs New application templates, available in the Application Builder, which is integrated in COMSOL Multiphysics, provide standardized layouts that include input fields, buttons, ribbon tabs, and graphics windows with options for desktop, tablet, and smartphone layouts. A template wizard guides the user to create an organized user interface based on any COMSOL Multiphysics model. In the Application Builder, the suite of user interface elements, or form objects, has been extended with knobs that can be controlled by dragging and rotating with the mouse pointer or touch input.

Introducing the Fuel Cell & Electrolyzer Module The new Fuel Cell & Electrolyzer Module provides engineers with state-of-the-art modeling and simulation tools for hydrogen fuel cells and water DESIGN WORLD

11/4/20 3:08 PM

TRACO POWER North America, Inc. http://us.tracopower.com salesusa@tracopower.com +1 (408) 916-4570

ATEX & HAZLOC CERTIFIED

Power

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80 W

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VADJ Range

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88.0%

24 V

23.5-28.0 V

90.0%

Output Voltage

TIB-EX Series DIN RAIL POWER SUPPLIES

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TIB 120-112EX

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94.0%

24 V

23.5-28.0 V

94.0%

48 V

47.0-56.0 V

94.0%

24 V

23.5-28.0 V

95.0%

48 V

47.0-56.0 V

95.0%

24 V

23.5-28.0 V

95.0%

48 V

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95.0%

UL 60950-1

ATEX II3G

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360 W 720 W

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C

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CAE Solutions electrolyzers, along with general-purpose tools for realistic fluid flow and electrochemical simulations based on COMSOLâ&#x20AC;&#x2122;s multiphysics technology. Using the new module, engineers can include charge transport, electrode reactions, thermodynamics, gas-phase diffusion, porous media flow, and two-phase flow when analyzing and optimizing technology for hydrogen vehicles and energy storage.

Introducing the Polymer Flow Module With the new Polymer Flow Module, modeling and simulation can be used to design and optimize processes involving non-Newtonian fluids, ensuring the quality of these fluids within the polymer, food, pharmaceutical, cosmetics, household, and fine chemicals industries. The new module can account for a multitude of multiphysics effects. Examples include when the properties of a fluid vary as a function of temperature and composition, to model curing and polymerization, or when a non-Newtonian fluid affects a mechanical structure, such as for a biological fluid moving through a peristaltic pump.

Introducing LiveLink for Simulink Control systems engineers can use the new LiveLink for Simulink product for co-simulation of COMSOL Multiphysics and Simulink om the MathWorks. LiveLink for Simulink makes it possible to insert a COMSOL Multiphysics block into a Simulink model for running nonlinear COMSOL Multiphysics simulations in the time domain driven by Simulink. This product is useful for automotive and aerospace industries, including battery simulations and digital twins.

Introducing the Liquid & Gas Properties Module The new Liquid & Gas Properties Module is used to compute properties for gases, liquids, and mixtures such as density, viscosity, thermal conductivity, and heat capacity as functions of composition, pressure, and temperature. Having high-quality fluid and fluid mixture properties allows for more realistic acoustics, CFD, chemical, and heat transfer simulations.

Faster and more memory-efficient solvers for a range of applications Users working with large models having millions of degrees of eedom have seen great

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Gas volume fraction in a polymer electrolyte membrane water electrolyzer analyzed with the new Fuel Cell & Electrolyzer Module.

improvements in solver performance over the last few versions of COMSOL Multiphysics.

In version 5.6, the general performance improvements give around a 50% decrease in assembly and solution time for midsized benchmark models. For performance on clusters, the finite element assembly and solution time has decreased by 30% for many types of analyses. Another improvement for users running on clusters includes an upgraded domain decomposition method that can now be used for a wider range of simulations. For acoustics simulations, a new boundary element method formulation enables analyses of an order of magnitude larger acoustic volumes.

For CFD simulations, the solution time on clusters has decreased by about 30% using iterative solvers and about 50% using domain decomposition. A new eigenvalue solver called FEAST, well suited for parallel computations, has several important uses, including mode analysis for optical waveguides and laser cavities. In the Optimization Module, a new general-purpose, gradient-based solver called IPOPT has important applications in, for example, shape optimization.

Laminated iron cores, parasitic inductance, and ferroelectric materials The material library included with the AC/ DC Module has been extended to include 322 magnetic materials om Bomatec.

The material data includes several types of permanent magnets, such as NdFeB, SmCo, and AlNiCo, with electromagnetic- and temperature-dependent properties. The AC/ DC Module now provides specialized tools for the extraction of parasitic inductance with L-matrix computations, which is essential to printed circuit board design. For nonlinear magnetic analysis, laminated iron core losses in electric motors and transformers can now be accurately represented using a new set of DESIGN WORLD

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November 2020

MAKE PARTS ANYWHERE. Basement-friendly.

Garage-friendly.

Office-friendly.

Tormach’s line-up of compact mills, lathes, routers, and bandsaws are designed to set up where traditional CNC machine tools can’t dream of fitting.

Plus they run on single-phase power, so they’re likely to operate in your space without any major or minor upgrades.

Operator-friendly, too.

Our machines run on PathPilot control software. It’s easier to learn and use, and it works with your favorite CAD/CAM. And when you buy from Tormach, you get all of PathPilot. Unlike most CNC companies, we don’t charge thousands to unlock function-extending modules.

Buyer-friendlier.

We recently adjusted prices to help our customers keep making and developing ideas through these unprecedented times. We’re now offering our PCNC 440 at a new list price, with our Entry Package starting at $5,390.

Go to tormach.com/440/design to explore and build yours.

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CAE Solutions An app for analyzing a truck-mounted crane with realistic material rendering and control knobs.

nonlinear material models. A new option for resonance equency computations makes this important functionality available in the AC/DC Module with functionality for coupled finite element and electrical circuits eigen equency computations. This enables computation of low to medium resonance equencies of coils and other inductive devices. A new advanced ferroelectric material model for electrostatics makes it possible to analyze dielectric materials with polarization saturation and hysteresis, with applications for ferroelectric capacitors and energy harvesting devices.

Fast port sweeps and scattering The RF Module and Wave Optics Module provide a new option for port sweeps, enabling faster computations of full S-parameters or transmission, and reflection coefficient matrices. This functionality can be applied to the

analysis of passive 5G components such as microwave filters with a large number of ports. A new modeling tool for approximate asymptotic scattering allows for quick far-field and radar crosssection (RCS) analysis for convex-shaped objects. A new set of postprocessing

Wear-Free Linear Position Sensor That’s A Snap To Design In Novotechnik’s TP1 Series of magnetostrictive position sensors provide unlimited mechanical life, high accuracy and are easy to design into your application. Output interfaces include analog with programmable end-points, start/stop, SSI, and quadrature.

Key TP1 Series specs include: • Resolution to 1 µm • Accuracy of 10 µm for digital outputs • 50 to 4,500 mm stroke lengths • Sealed to IP 68 • Conforms to industry standard dimensions For complete specifications, features and applications visit www.novotechnik.com/tp1

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Call to talk to an engineer about your application today.

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Novotechnik U.S., Inc. Telephone: 508-485-2244 Email: info@novotechnik.com

11/4/20 3:14 PM

tools makes it easier to visualize and analyze polarization, with important applications for a variety of periodic structures including metamaterials for optics and microwaves. The new version of the Ray Optics Module includes faster ray tracing and specialized tools for scattering om surfaces and within volumetric domains.

Transient contact, wear and crack modeling, and poroelasticity in composite shells The mechanical contact functionality available in the Structural Mechanics Module and MEMS Module can now be used for simulating transient impact events. For users of the Structural Mechanics Module, contact analysis additionally features new functionality for analyzing mechanical wear with dynamic removal of material. Further news in the Structural Mechanics Module includes new tools for crack modeling, providing J-integral and stress intensity factor computations as well as crack propagation based on a phase-field method. Lower-dimensional elements can now be placed inside solids. Uses include the modeling of reinforcements for anchors, rebars, and wire meshes.

For fluid flow in porous structures, the pore pressure causes mechanical stresses and the volume changes may affect the flow in a strongly coupled fashion.

In the Composite Materials Module, the functionality for analyzing such poroelastic effects has been expanded to include composite shells. Applications include the simulation of layered soil, paperboard, fiber-reinforced plastic, laminated plates, and sandwich panels.

The suite of nonlinear multiphysics material models in the MEMS Module now includes ferroelectric elasticity, which can be used for modeling nonlinear effects in piezoelectric materials such as hysteresis and polarization saturation. This functionality is also available by combining the AC/ DC Module with either the Structural Mechanics Module or the Acoustics Module.

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Nonlinear acoustics, mechanical ports, and improved room acoustics analysis With the addition of nonlinear acoustics capabilities, users of the Acoustics Module can simulate high-intensity focused ultrasound for use in noninvasive therapeutic medical applications as well as ultrasound imaging. The new version also allows for analysis of sound distortion in mobile device loudspeakers that may be caused by nonlinear thermoviscous effects. New mechanical port conditions, available in the Structural Mechanics Module, Acoustics Module, and MEMS Module, make it easier to analyze vibration paths and mechanical feedback in applications having propagation of ultrasonic elastic waves, such as ultrasonic sensing and nondestructive evaluation.

Engineers working with improving the sound quality of rooms and concert halls will appreciate the new room acoustics metrics available in the Acoustics Module, including reverberation time, definition, and clarity based on ray acoustics simulations. In addition, the new version provides faster impulse response for ray acoustics. A new boundary element method formulation enables analyses of an order of magnitude larger acoustic volumes with applications within, for example, sonar research and development.

Shallow water equations and directional surface properties for heat radiation Researchers and engineers working with hydrological applications will benefit om the new option for simulating the shallow water equations now available in the CFD Module. The new functionality solves for water depth and momentum with an option to use a digital elevation map (DEM) to speci the seafloor topography. In all add-on products with support for porous media flow, new centralized handling of porous media properties gives users a much better user experience for multiphysics simulations of porous media. The Particle Tracing Module has new functionality for droplet evaporation, which is important for understanding the spread of contagions as well as a range of industrial processes.

In the Heat Transfer Module, new functionality for surface-to-surface radiation enables defining surface properties that are sensitive to the direction of heat radiation. Applications include radiation simulations involving surfaces that have a texture or pattern that is reflecting and absorbing heat radiation differently in different directions; for example, the passive cooling of solar panels. A new modeling tool for phase change interfaces makes it possible to simulate eeze-drying processes.

Material Library for corrosion and automatic reaction balancing The Corrosion Module now includes a material library with more than 270 instances of polarization data used to predict where there is risk for corrosion or

Model of a slot die coating with a shear thinning fluid. The injection speed and the speed of the die are very important in order to obtain a coating of uniform thickness. www.designworldonline.com

hydrogen

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CAE Solutions â&#x20AC;˘

Electromagnetics Parasitic inductance computations with L-matrix extraction â&#x2014;? Material models for laminated iron cores used in motors and transformers â&#x2014;? Ferroelectric material model for electrostatics â&#x2014;? 322 magnetic materials om Bomatec â&#x2014;? Coupled RF, thermal, and stress analysis tutorial for 5G applications â&#x2014;? Faster ray tracing, scattering in domains and om surfaces for ray optics â&#x2014;?

Multiphysics model of a cascaded cavity filter operating in the millimeter-wave 5G band, including temperature changes and thermal stress. The visualization demonstrates the new functionality for partial transparency.

embrittlement due to hydrogen evolution in a structure. The Chemical Reaction Engineering Module features a new tool for automatic reaction balancing with stoichiometric coefficient calculations as well as three predefined thermodynamic systems. The predefined systems have a wide range of applications including dry air, moist air, and water-steam mixtures. In the Chemical Reaction Engineering Module, a new reactive pellet bed modeling tool enables multiscale modeling of pellet beds with macroscale mass transport in pores and microscale transport in spherical pellets. The new reactive pellet bed functionality supports a variety of diffusion models and arbitrary reaction kinetics with applications in, for example, catalytic converters in auto exhausts used to break down polluting gases such as nitrogen oxides (NOx).

Highlights in Version 5.6

â&#x20AC;˘ General updates â&#x2014;?

â&#x2014;?

â&#x2014;?

â&#x2014;? â&#x2014;?

â&#x2014;? â&#x2014;?

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Nonlinear acoustics for highintensity ultrasound Sound distortion in mobile device loudspeakers due to nonlinear thermoviscous effects Mechanical port conditions for analyzing vibration paths and mechanical feedback New boundary element method (BEM) formulation for large scattering volumes including sonar applications Room acoustics metrics including reverberation time, definition, and clarity using ray acoustics Faster impulse response for ray acoustics Waveform Audio File (.wav) export

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• Fluid & heat l Shallow water equations interface l Faster and more memory- efficient CFD solving l Droplet evaporation for particle tracing l Directional surface properties for heat radiation l Phase change interfaces • Chemical & electrochemical l Material library for corrosion l Realistic fluid models for dry air, moist air, and steam l Automatic reaction balancing l Reactive pellet beds for concentrated solutions • CAD Import Module, Design Module, and LiveLink products for CAD l Easier detection of gaps and overlaps in assemblies l More robust solid operations for imported CAD models and CAD assemblies l Measuring dimensions and automatic parameter creation for the constraints and dimensions functionality l Faster and more robust ECAD import

A transient contact simulation of striking a golf ball with an iron.

DW

COMSOL www.comsol.com

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Submarine target strength visualization using the new boundary element method (BEM) formulation suitable for large simulations. The scattered field sound pressure level is here computed for 1.5 kHz in water 100 m from the submarine. In the figure, the acoustic wave, from the sonar ping, is incident on the submarine from the left.

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Retooling the online world Manufacturers are upgrading and expanding their presence online with improvements to help designers with everything from online ordering to new design tools.

Edited by: Miles Budimir Senior Editor

The global pandemic has shifted much of our lives online – with many of us working from home, meeting with friends over Zoom, or schooling our kids online. With so much of life, including engineering and design, taking place online these days (and seemingly for the foreseeable future), it’s no surprise that we’re devoting more attention to these online spaces.

That’s just what many manufacturers have done in 2020. From retooling web tools to better reach out to new markets, to placing more offerings online to make them more accessible to potential buyers, here’s a look at what some manufacturers have done to help designers.

New markets, new focus One thing manufactures are doing is using their online presence to reach out to new markets or expanding existing ones. Case in point – a new online encoder selection tool that targets the needs of the MRO market. Sensor manufacturer POSITAL has released an intuitive online

The EncoderMatch portal from POSITAL focuses on the MRO market for incremental encoders.

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Yaskawa’s new Yaskawa Compass is a software interface tool that aids engineers designing 3D printing, machine tools, and robotic applications.

tool called EncoderMatch.com. This new web platform, which combines a search engine, product configurator and ordering tool, is aimed at the MRO/spare parts business.

Maintenance staff and technical buyers can quickly find cost-effective replacements for encoders in existing machines or systems – regardless of the original manufacturer. The EncoderMatch portal provides users with access to information about matching products from the POSITAL portfolio. When a fully compatible replacement is found, the portal provides a detailed data sheet for the specified fill-in encoder. Once an order is placed, the required product is quickly assembled at POSITAL’s digital factory in Slubice, Poland. Thanks to its highly flexible “mass customization” production system, delivery is usually within five days, and faster still for express orders.

“With EncoderMatch we are targeting a new market”, notes Christian Fell, head of POSITAL’s North American business.

“While most of our existing customers have been OEMs in a variety of industries, we’re now opening up our digital system to a new set of customers.” EncoderMatch is about the huge global after-market or MRO business, where there is a constant 56

need to find replacements for an installed base of millions of devices. POSITAL’s initial entry into this huge and complex market is focused on incremental encoders.

“Incremental encoders represent 90% of the North American market for standalone encoders, which makes these devices a good starting point for EncoderMatch”, says Fell.

Spare parts are also at the center of a new online tool from NORD Drivesystems, with the company launching a new online Spare Parts Shop. The online tool lets designers locate, select, order, and track spare parts quickly and conveniently, with added features such as account-specific pricing, a favorites list for commonly ordered parts, and an inquiry/support option that connects users directly to NORD’s e-business team.

With the Spare Parts Shop, users can easily find parts matching their NORD DRIVESYSTEMS unit by entering the serial, order, or existing part number, then selecting the required parts via the unit’s interactive parts diagrams. A “share via email” function allows designated colleagues or customers to receive an email that includes a PDF of the appropriate diagrams, a complete bill of material, current availability, and a direct link back

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to the interactive diagram within the shop.

Items in the cart can be downloaded as a PDF to serve as a simple quote document.

NORD’s Spare Parts Shop has sophisticated search capabilities and filters for its modular FLEXBLOC components, NEMA C-face motors, and ac drives.

Available inventory from all three U.S. plants is linked to the shop so users can choose which facility the parts will ship from.

Orders are then shipped standard delivery or Next-Day air via NORD prepaid carriers.

Upping component visibility online Other companies are placing more of their component offerings online. For example, Allied Electronics & Automation recently expanded its online selection of motion control and power transmission products.

As part of the company’s ongoing efforts to enhance product availability in high-demand categories, they’ve expanded their ready-toship inventory of motion control and power transmission components to more than 2,000 SKUs – helping engineers, purchasers, maintainers, fleet and facility managers, and inventors build, maintain and renew their machinery.

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bushings, belts, sprockets, couplings, clutches, pulleys, motors and lubricants, among others. These are from leading suppliers such as Baldor-Reliance, Koyo, Martin Sprocket & Gear, and TB Woods and designed for a wide range of environments including industrial applications, production lines and conveyor systems.

In addition to continuously expanding inventory of more than 3.5 million products, designers shopping the Allied website benefit from tens of thousands of 360-degree high-resolution images, more than 1.1 million up-to-date product data sheets, expert advice on a wide range of topics, responsive customer service, and a connection to the company’s global DesignSpark online engineering community.

Tools to aid advanced manufacturing But it isn’t just selection tools and expanded inventories getting all the

attention. New design tools are also coming online. Case in point – the Drives & Motion division of Yaskawa America recently released Yaskawa Compass, a new software user interface tool for advanced manufacturing. Yaskawa Compass is a CNC navigator, a graphical user software package applicable to multiple applications in 3D printing, shape cutting, machine tools and robotics.

“Compass is designed with creativity in mind allowing machine manufactures to brand and easily customize screens to include core machine attributes and customer needs with little programming requirements” says Rosemary Burns, Yaskawa’s Advanced Manufacturing Segment Manager.

Coupled with the company’s MP3300iec motion controller, Compass provides advanced plug-in solutions that can simply be dropped onto a screen.

Prebuilt plug-ins include extruder, spindle, temperature control, stepper control, linear and rotary tool changer, 2D path planning

and more. All plug-ins are developed in C#, so machine builders can also easily create and import their own machine plug-ins.

Key features of Yaskawa Compass include a machine and screen configurator, prebuilt plug-ins, an alarm history and tool manager, as well as a part cycle time measurement tool and a 2D viewer with live TCP updates.

To supplement the use of Compass with MPiec controllers, Yaskawa has added advanced motion control features to its MotionWorks IEC library. Some of these include bed leveling compensation, extruder pressure advance control, tangential control and ability to create custom G-codes and kinematics.

Burns added, “Consider hybrid machinery: Yaskawa Compass empowers machine manufacturers with versatility for both additive and subtractive applications to easily implement and customize features while streamlining their development cycle”. DW POSITAL www.posital.com NORD www.nord.com Allied Electronics & Automation www.alliedelec.com Yaskawa www.yaskawa.com

NORD’s Spart Parts Shop simplifies the process of finding and ordering spare parts for its drive systems.

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Round linear guide or profile linear guide?

Here we outline how to choose a linear guide for a given application and environment.

Lindsey Brimage and Eric Schultz • Thomson Industries Ian Miller • Motion Industries Canada

Designers of linear motion systems often find themselves weighing the pros and cons of round versus profile (also known as square) linear guides. Many considerations come into play while trying to determine which technology to implement; this is only further compounded when environmental extremes are a concern. Too often, the choice of linear guide technology is made late in the design process and based on assumptions.

Taking time to perform a nuanced review can make the difference between a simple design and a complex one, affecting performance, assembly time and total cost.

Round and profile rails are often interchangeable functionally, but there are marked differences even within those categories. Making the right choice for your application can spur significant advantages in cost, performance and durability. This article discusses how those differences play out in applications complicated by environmental extremes. Issues of fluid or solid particulate egress, temperature extremes, corrosion, shock and vibration design considerations will all be discussed.

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The selection of round or profile (square) rails can make a difference in cost, performance and durability, depending on the application. | courtesy of Thomson Industries

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Commonly used for hydraulic test benches, round rails position hydraulic pumps/motors for testing. The forgiving nature of the round guides make them the suitable choice for the application. | courtesy of Motion Industries

Before going through these complicating factors, it is important to remember the pros and cons of both round and profile linear guides in an undemanding environment.

Understanding these technologies and how they can be best applied to an application is always the first step in good design practice.

Round rails for forgiving installations Round rail is the older of the two technologies and has been around for about 80 years. Typically, the most economical option (relative to component cost) round rails have a lower load capacity and looser accuracy. The design of the round rail is very forgiving; this forgiveness can be either a strength or a weakness depending on your application. For applications where loose tolerances are acceptable or where low component costs are more critical than tight tolerances, round rails are an excellent option.

Round rails are self-aligning and very forgiving of issues that arise from poor parallelism or variation in rail height for systems using more than one rail. This technology provides a smooth and low drag platform. The eloquently simplistic profile boosts highly effective sealing and a natural contamination resilience. In addition, round rails donâ&#x20AC;&#x2122;t need the time and expense of 60

mounting surface machining and are the only option for end-supported applications.

Profile rail (also known as square rails) for tighter accuracy Profile rail is the newer of the two technologies and has been around for about 40 years. Typically the more expensive of the two options, profiled rail has a higher load capacity and much tighter accuracy.

The design of the profile rail isnâ&#x20AC;&#x2122;t forgiving, and this strictness can be of either great benefit to or a complicating factor for your design. The nature of this technology lends itself well to applications where extremely tight levels of precision are required, or where excessive loading is inherent to the task at hand. The compact nature of the system can help to reduce the overall size of the equipment, but higher preloads could increase in drag.

Further, the nature of the profile rail mounting and installation process (including surface machining) makes it very unforgiving of poor parallelism or variation in rail height for systems that use more than one rail. Manufacturing systems using profile rails need higher precision. Their elaborate, albeit compact, profile also suffers from more complex sealing and comparably poorer contamination resilience.

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For a smelting plant application, this piece of an aluminum ingot handler utilizes profile (square) guides. Profile guides were selected because of the heavy load and high accuracy requirements. | courtesy of Motion Industries

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Fluid-exposure considerations when specifying linear rail Exposure to fluids such as water, fog, and high humidity can lead to corrosion of either rail type. Under pressure (as in washdown situations) fluids can wash lubrication away. Exposure to corrosive fluids such as chemical sprays, fuel oils, acidic food products, hydrocarbons, urea and fertilizers can introduce safety threats as well as contribute to wear, downtime and performance degradation.

Both round and profile guides will differ in their fluid handling abilities based on sealing, lubrication type, material selection, coatings, mounting and standards compliance, which is particularly important in the medical and food industries.

Profile rails may have some advantages in wet environments because their compact size provides more flexibility in mounting.

However, round rails have the advantage where forgiving tolerances, nonstandard geometries, or end-supported configurations are required.

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The equipment frame of this hydraulic test bench, which is finished and in use, protects the round rails from damage and contamination. | courtesy of Motion Industries

For both round and profile guides, full-contact seals and proper lubrication will prevent rust from developing on the raceways of steel components. Seals on round guides tend to cause less drag due to their simple circular geometry, but low-drag options are available for profile rail assemblies. Profile rail carriages may also employ longitudinal seals that protect against ingress from the bottom of the assembly.

Material selection is another key component of the fluid handling ability of a system. Round rails have an advantage in that they can use nonhardened stainlesssteel shafting. This makes them attractive

for clean environments such as those found in the semiconductor and medical industries as well as for as well as for the harsh environments of food processing. Higher loads may need hardened shafting. This can be accomplished with advanced coatings, which can extend component life 200-fold.

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Coating options are comparable for both round and profile rails and in both cases, increased corrosion protection may involve tradeoffs with hardness. For example, Armaloy chromium coating provides moderate corrosion resistance and hardness of 78 HRc. In contrast, austenitic stainless steel such as 300 series is more corrosion resistant but more expensive — and has HRc hardness levels only in the 20s. Austenitic stainless steels are typically only recommended for use with plain-style bushings. Martensitic stainless steel, such as 440C, also offers improved corrosion resistance over carbon steel but can reach hardness levels in the 50s — and thus can be used with certain proprietary ballbearing linear bushings.

In fact, other factors may come into play when considering coating options.

Stainless steel, for example, is an especially good choice for food-grade environments or other applications in which users might be concerned about flaking off of the plating.

Well-chosen machine geometry, orientation, and guarding can also improve its ability to handle excessive fluid.

Orienting the guide in a way that will minimize fluid penetration into bearing surfaces or that will promote runoff will also improve fluid handling. Profile rails are more compact, so they can provide more flexibility if standard mounting geometries are possible. The quality of the mounting surface finish is key to having the most flexibility during profile rail installations.

To more facilitate installation flexibility, profile rails come in different mounting configurations. They can, for example, bolt from top or bottom and offer multiple methods to cover and protect bolt holes from debris, including cover strips, plastic rail plugs and metal rail plugs.

When more flexibility is required, round shafts have the advantage. They can be configured in many ways to facilitate holding the ends of the shaft and can even provide structural support in a larger assembly. Options to implement reduced diameters, flats or to drill through the case of the shaft, on center or radially, add to mounting flexibility. The self-aligning design of round rails is also more forgiving 64

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of poor parallelism and variations in rail height.

Safeguarding linear guides against solid particulate Solid particulates such as metal, wood chips, extremely fine glass, ceramic dust or flour get into moving parts and impact wear and performance. Particulates can fall onto round or profile rails or may be airborne. Guide manufacturers address dust and particulate handling through sealing and wiper designs that protect against solid contaminants that land onto bearing surfaces.

Getting a robust seal on a profile rail is challenging because wipers must conform to the ball tracks which are ground in the rail and may increase drag — in fact, twice as much drag as with round linear bearings.

Low-drag wiper designs for profile rail carriages help to minimize this problem but don’t eliminate it.

Profile rails might use scrapers to remove heavier particulate or bellows to shield raceways from any dust or particulate accumulation. Round rails have natural debris-shedding capabilities due to the curvature of their shafts. Although profile rail tracks are hidden from direct access, they don’t necessarily shed debris.

How round and profile rail handle extreme temperatures Extreme temperatures tend to have the greatest effect on plastic components, such as seals and recirculation mechanisms.

Temperatures above or below the lubrication’s rating can cause components such as base oil, thickener and additives to separate and reduce. Fluctuations in temperatures can cause condensation, which leads to corrosion as well as thermal expansion and contraction in steel and aluminum.

Round rails can accommodate all-steel or stainless steel bearings with no plastic components. Both steel and stainless steel provide a wider operating temperature profile, but the stainless steel bearings have less load capacity than steel. Also, the plastic end caps and recirculation tubes in profile rail often prevent them from being used in extreme temperatures.

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Vibration and shock resistance Constant torque and movement can weaken a component over time and cause failure. Shock loading, as with an instantaneous impact load, affects all bearings. The heavier the load, the greater the problem, and because profile rails can handle heavier loads, shock is more of an impact force. In all cases, however, the rail is scaled to the capacity of the normal load and not to the shock load. The greatest impact is with heavy machinery, where the shock is more detrimental just because of the pure mass involved.

Profile rails are also more tolerant of heavy impacts because they offer various preload options, which can make them more resistant to other impacts that don’t affect the rolling element.

Round rails are less tolerant of impact due to their natural clearance fit. They do however outperform profile guides when a fluid driving force is applied to the rail because they are less likely to pull up on race areas than are profile rails.

round rails have the clear advantage. There are many useful online tools available that help users weigh the tradeoffs among various hazardous conditions.

For more information, watch the video at tinyurl.com/y3n5ajos on mounting options for round shafting. DW Motion Industries | MotionIndustries.com/ designworld

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Round or profile rail — the final verdict The decision on whether to use round or profile rail depends on the application. As always, begin by establishing the motion profile and the essential performance characteristics. Then evaluate the options according to their advantages or disadvantages for each environment.

Profile and round rails can both be used in wet, corrosive, dusty and high shock and vibration environments, as long as the considerations are made for their design differences, accessories and overall precision and load requirements.

Where precision beyond the capability of round rails is essential in hazardous environments, coatings may be specified — or the designer will need to factor in the operational limits and incremental costs of the profile rails.

Profile rails may have some advantages in wet environments because their compact size provides more flexibility in mounting to avoid moisture. However, if forgiving tolerances, nonstandard geometries, or end-supported configurations are required,

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I n t e r n e t

o f

T h i n g s

Equipment-as-a-Serviceâ&#x20AC;&#x201D;

a look at three technologies

These IIoT tools can help put the EaaS model to work in your machinery quickly and affordably

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With the impact of recent economic upsets still playing out, many equipment manufacturers may be feeling pressure to transform the way they do business. Equipmentas-a-service (EaaS) is an alternative business model that may help OEMs and machine builders adapt in a time when customers are eager to reduce capital expenditure.

Josh Eastburn Director of Technical Marketing

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EaaS involves renting out or providing access to equipment and collecting payment periodically, rather than selling the equipment outright. This payment model enables end users to pay for costly or infrequently used equipment as an ongoing operating expense, which can open new markets for you as a machine builder. When you become a service provider as well as a manufacturer, your company also has the potential to capture more revenue by taking responsibility for additional services, like integrating, maintaining, and even operating equipment. As your internal efficiencies improve, this relationship can actually reduce operating expenses for your end users.

Common pricing models for EaaS include time- or usage-based methods and operational or financial outcome-based methods. What matters most, however, is that you and your customers agree on how to appropriately assess, measure, and report the value delivered by your equipment. This is one of the biggest obstacles for vendors seeking to adopt this business model.

Therefore, regardless of which pricing model is used for a given application, the ability to remotely monitor equipment may be necessary in order to make pricing details transparent for both you and your customer. For instance, it may be difficult to manually track and report the hours of operation of a large installed base or to count the number of

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Figure 1: Industrial edge devices like the groov series from Opto 22 combine intelligent signal processing and control with embedded tools for data processing, cybersecurity, and IT communication.

work cycles completed by a robot in order to produce an accurate invoice.

Along with remote data acquisition for billing, OEMs already using this model find that acquiring and analyzing the performance data of installed equipment can be an important new asset. That data can be shared with end users as an additional service, or you can use it to design and operate machinery more efficiently.

While there are many considerations, and even precautions, related to transitioning into this way of doing business, thanks to growing interest in the industrial internet of things (IIoT), the technology needed to make it DESIGN WORLD

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possible is readily available. Combined with appropriate network infrastructure, these technologies can connect remote equipment with back-end systems from anywhere in the world.

Here are three examples of IIoT technologies that can quickly make your equipment EaaS-ready.

Edge Computing The foundation of an EaaS implementation is secure edge data processing and connectivity. Itâ&#x20AC;&#x2122;s becoming easier to create this foundation, because sensors and other smart remote devices are becoming more capable. Rather than requiring layers of supporting middleware, like PLCs, PCs, or

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SCADA/OPC servers, the latest industrial edge devices include the processing, communications, and security capabilities needed to be first-class participants in a distributed system.

In addition to intelligent signal processing and control logic, these devices typically provide multiple media interfaces (serial, Ethernet, WiFi, cellular, and so on) and support IT communication standards like DNS, DHCP, HTTP/HTTPS, REST APIs, SSL/TLS encryption, and VPN. And unlike consumer IoT devices, industrial edge devices are designed to rigorous standards for operating temperature, electrical safety, and hazardous environments.

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Internet

of

Things

Industrial edge computing addresses critical physical-layer requirements in a tidy package, providing the foundation for application-layer connectivity.

Figure 2: Node-RED is a powerful open source IoT platform that is still light enough to run on an embedded processor

infrastructure. With a variety of options available, itâ&#x20AC;&#x2122;s possible to quickly retrofit existing equipment using edge I/O or to completely redesign equipment around edge connectivity using an edge controller.

The first case will generally be preferable for vendors seeking an affordable way to experiment with EaaS, since I/O signals can be connected to an edge I/O module in parallel with the existing control system and without modifying control logic. Some edge I/O can be powered over Ethernet or provide flexible I/O options to further simplify installation.

Edge controllers include more powerful processors, expandable I/O, and more programming and communication options than edge I/O systems. Taking this approach means migrating control logic to a new platform but can be a good choice when designers are planning to leverage

other edge processing capabilities, like local database management or multiprotocol device integration. For new machine designs, edge controllers provide more flexibility for future development than PLCs with less maintenance overhead than PCs.

Node-RED A common obstacle to industrial connectivity is the need to integrate data from many types and brands of devices communicating via different OT or IT protocols. This obstacle has given rise to IoT platforms designed specifically to interface with, transform, and integrate data from disparate sources. These platforms are the glue for large-scale IIoT systems and can provide the framework for EaaS applications as well.

Many proprietary IoT platforms are available, but thanks to IBMâ&#x20AC;&#x2122;s Emerging Technology Services Group, there is also an open-source option, running on Node.js, called Node-RED. It has taken the IT world by storm with over 2 million downloads since 2013 and is growing in popularity for industrial applications as well.

Node-RED boasts a library of more than 2,500 nodes that you can combine into visual data flows to create programs

Figure 3: An MQTT broker serves as the communication hub for industrial data publishers and subscribers, each communicating through a single secured connection.

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that extract, transform, and load IoT data (Figure 2). Functions range from serial device communication to data visualization to database transaction management. A partial list of supported databases includes InfluxDB, MySQL, MSSQL, Cloudant/ CouchDB, MongoDB, Firebase, and Oracle DB. And since Node-RED is an open platform, you can also leverage Node.js libraries to create custom nodes if needed.

The complete Node-RED package includes a runtime engine and browserbased development environment but is still light enough to run on an embedded processor. Running on top of an edge device that provides a secure interface to the digital world, Node-RED lets you send machine data anywhere it needs to go.

MQTT By itself, Node-RED is capable of sending machine data directly into remote or cloudhosted databases, but this can become costly if an application requires frequent communication over a metered cellular connection. Cost may also become an issue as networks of connected equipment grow.

Of the many communication protocols available, MQTT (formerly MQ Telemetry Transport) may be the most beneficial for addressing this issue because of its lightweight, highly efficient format.

MQTT was originally designed by IBM and Arcom Control Systems (now Cirrus Link Solutions) to address cost and stability issues in distributed TCP/ IP SCADA networks for Phillips ‘66. They abandoned the traditional poll-response communication model in favor of a brokered publish-subscribe model in which a central server (the broker) manages data delivery for the entire network (Figure 3).

MQTT-enabled field devices and gateways publish data to the broker when they detect a change in a monitored value, rather than responding to cyclic update requests. The broker then routes published data to any registered subscribers, which can be backend software applications or even other field devices (think: Twitter for machines).

Combined with its streamlined payload—as small as two bytes—the communications model used by MQTT

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results in an 80-90% reduction in overall bandwidth consumption compared to traditional poll-response communications.

This efficiency allows MQTT networks to scale up to millions of connections.

The architecture also has important implications for data integrity and security. Since the MQTT server cannot store or modify data, only distribute it, each publisher is the single source of truth for its data, reducing the potential for discrepancies and data “siloing.”

Additionally, MQTT connections are device-originating (outgoing), so that only the broker is required to have open firewall ports. Field equipment can be completely locked down while still permitting bidirectional communication. The broker alone manages user authentication, data access rights, and message delivery, simplifying network management and allowing each client to remain anonymous to other network members. In combination with TLS encryption and certificates of trust to authenticate the identity of connected endpoints, secure site-to-site MQTT communication is feasible even over public networks.

MQTT was also designed with a very simple specification, resulting in a lightweight implementation that can run on constrained field devices. NodeRED supports MQTT communications natively, and there are several open-source implementations available through the Eclipse Paho project. Several popular and robust MQTT server implementations are available as well, both in commercial and free, open-source varieties.

Fortunately, open-source technology options like Node-RED and MQTT support this kind of experimentation. As a designer, you don’t have to commit to costly up-front licensing agreements in order to develop the communications infrastructure you need to support the new business model.

Both technologies are easy to get started with as well, and a proof of concept can probably be built in a couple of days.

Times of economic turbulence can be fertile ground for innovation. Could this be the right time for you to try something new? DW Opto 22 opto22.com

WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

Making the switch Experts caution manufacturers who are considering an equipment-as-a-service model to prepare their organization for a significant transition. Determining the appropriate pricing model is crucial, and your customer service group should expect to become ongoing partners with end users, rather than merely offering after-sales support. A gradual transition may be the best option, steadily increasing the number of customers with service agreements and decreasing the number of capex sales.

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Basics

of security in

RFID readers

Well-publicized hacks illustrate why contactless credentials demand sophisticated security measures that can evolve as fast as the cracking techniques used by bad actors.

Kiran Vasishta • ELATEC, Inc.

In recent years, multinational corporations including Cathay Pacific, Facebook, and Uber have been heavily fined for security and data protection violations. This period has seen a rise in data protection laws as more and more information is gathered and shared online. As such, it becomes crucial to asses security capabilities when choosing an embedded device that touches potentially sensitive data.

RFID readers can transmit personal or user identification data either to a host system such as a PC or to an endpoint such as a human machine interface (HMI). A passive RFID transponder, soft credential such as a mobile phone app using BLE/NFC or smart cards and other contact-based credentials all can carry sensitive data or personal information.

It’s more common for smart card or contact-based credentials to store personal information such as names, addresses or date-of-birth than in contactless credentials where an identification number may be used.

There are numerous security vulnerabilities related to low frequency (125 kHz) contactless transponders. One can find references to vulnerabilities online that discuss how to easily access unprotected static card information. Adversaries may then clone this credential that may be used for triggering action such as granting access to a facility or unlocking a computer.

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One approach to passing encrypted data over the air employs Telaeris XPressEntry mobile access control hardware and software that integrates with existing security systems for mobile identity verification. XPressEntry access control software runs on any Windows Mobile or WinCE-compatible handheld device. A server provides synchronization of data to and from connected handhelds.

Some references also highlight vulnerabilities in Wiegand type interface about intercepting the data signals to capture card value. The Wiegand protocol is among the most widespread protocols for proximity card reader systems. A Wiegand card contains two short wires which store data magnetically. When the card is pulled through the reader, the wires transmit the either high or low voltage signals to create binary data for authenticating the card credentials. (A third Wiegand wire provides a common ground). The problem is, inexpensive Wiegand hacks are easy to find. Consequently, some older RFID transponders and communication interfaces are now considered fundamentally compromised.

There are a series of questions designers should ask when developing RFID apps.

The first is whether the situation requires

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encryption capabilities. If it does, can the reader involved execute cryptographic algorithms?

Where encryption is necessary, designers must determine the exact channel where this needs to be enforced. It could be that the host interface requires the exchange of encrypted data or protected data must pass over the air interface. Bear in mind that crypto facilities only work when they are configured correctly. There have been instances where key cards have only encrypted the UID but left other personal information unencrypted and vulnerable to interception.

Furthermore, many types of contactless transponders can store data and encrypt or lock these segments with cryptographic keys. A card reader must not only decrypt the memory and access the data but also provide an easy means for the end-user to www.designworldonline.com

carry out this operation. In many instances, endusers have their own customized cryptographic keys for their credentials and are unwilling to share these keys with the maker of the card reader. To handle these situations, the card reader must have the capability to accept custom keys from someone other than its manufacturer. This can be facilitated in multiple ways, such as implementing high-level APIs, by allowing the user to write applications for the card reader, or by means of a GUI enabling the end user to enter keys.

Another question to ask is whether the reader and cards must exchange encrypted data. If so, of course, the card reader must be able to support the exchange. Some don’t.

In a typical scenario, the card reader behaves as a medium to facilitate data collection and transfer between the transponder and the host system. The host system can either be an endpoint that locally validates the presented credential, or it can be a microcontroller that sends data over the network November 2020

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Deconstruct a Secure Access module (SAM) on a smart card and this is what you’ll see. The SAM stores the cryptographic keys to access applications and data. Once on the SAM, the keys can never leave -- an attacker would not be able to extract the raw key material from the chip. Whenever the reader accesses the card, the SAM typically acts as a proxy between the reader application and the smartcard application so unencrypted/unauthenticated reader-side communications are wrapped into encrypted/authenticated communications forwarded to the smartcard application. Alternatively, the SAM could simply compute short-term data such as responses, session keys, and so forth, for authentication and encryption. The reader application then integrates data then into the communication protocol. In contrast, SAM-less approaches demand that the reader application be given the keys necessary to access the card application.

The reader application typically runs on a platform that is incapable of sufficiently protecting the secret key material, thus generating a security risk.

to the cloud or to a database for validation and authentication.

If there’s a need for encryption between the RFID media and the reader, the appropriate credentials are required.

There are use cases wherein smart cards or passports store personal information such as name, address, date-of-birth or biometric data. The card reader must host encryption algorithm engines such as AES, DES, 3DES, or the capability to implement custom algorithms.

In cases where smartcards or contactbased credentials are used, the host system typically drives the communication in its entirety. So the card reader must also have: ● Software capabilities such as Personal Computer Smart Card (PCSC) or Chip Card Interface Device (CCID) modes of communication. PCSC is the interoperability standard set for 72

integrating smart cards and smart card readers into the mainstream computing environment. CCID is a USB protocol that allows a smartcard to connect to a computer via a card reader using a standard USB interface. Drivers to facilitate communication with the host also enable easy software integration. ● Hardware support for communication standards such as ISO7816 and the presence of Secure Access Modules (SAM) slots and other contact-based interfaces.

ISO7816 deals only with contact smart cards and defines aspects of the card and its interfaces such as the card’s physical dimensions, the electrical interface, card logical structure, various commands used by the application programming interface, and so forth. The SAM can be used for cryptographic computation and secure authentication and physically can either be

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a SIM card and plugged into a SAM slot in a reader, or an IC in a housing on the smart card.

Some applications require a mutual authentication between SAMs and RFID media. Some readers support this kind of transaction, but others don’t. Typically, SAMs are used to generate application keys based on a specific master key or to generate session keys. They also enable secure messaging between the RFID media, the reader, and the host system.

Many contactless credentials hold memory segments that are encrypted with cryptographic keys. These keys are often stored in SAMs and supplied to card reader manufacturers. This practice not only ensures the security of the keys but adds a step in the authentication process. The card reader in this case should first perform authentication operations with the SAM and then carry out a series of cryptographic and DESIGN WORLD

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E l e c t r o n i c s

bit-manipulations between the contactless card and the SAM. This operation can be further secured by adding a key diversification step. The card reader must be able to support such a scenario both in the hardware as well as in the software.

Many end-users require the card reader to natively support such a scenario and have the ability to provide high-level APIs to help in their implementation.

In addition, high-security applications demand the transfer of data in an encrypted format.

One can ensure end-to-end encryption/ security with the help of SAMs. In such an architecture, the reader facilitates mutual authentication with the RFID media and the SAM, thus transferring protected data over a radio link and also ensuring the security of encryption keys. The reader can also transfer data encrypted by the SAM to the host system.

Note that the safety of distributing SAMs, as well as administering the installation process within the reader, should be treated as a separate issue and tackled accordingly. There is also a possibility of the readers being stolen or the SAM modules being dismounted from the reader. If these scenarios are possible, they must be factored into the overall security procedures.

Note as well that the Wiegand card and the Wiegand interface for data transmission is 40-year old technology.

While Wiegand cards are still in production, they have been largely replaced by newer and cheaper forms of access cards. However, these new cards are still based on the Wieganddata format. That format is susceptible to interception as the data are available in plain text.

Also, the Wiegand interface introduced in the 1980s remains in wide use despite various security vulnerabilities. This technology no longer conforms to current security standards. There are other technologies that can offer higher security from interception and support encrypted data exchange. Various industrial products output a code in Wiegand format. Often this is an inconvenient form for reading to a PC or other device having only a RS232 serial port. So readers frequently employ Wiegandto-RS232 converters that transform Wiegand 26-bit 37-bit formats to a RS232 data stream.

Additionally, can the reader be tampered with? If so, how much do you care? As an example, card readers attached to multifunction printers (MFPs) for releasing print jobs usually aren’t strategic. Tampering with the reader can put the printers offline but will not compromise the safety of your documents. Typically, if the card reader is sabotaged, the MFP software prevents the release of any information.

On the other hand, high-security environments such as data centers need greater protection. There are several technologies such as mechanical and optical tamper detectors that can be embedded directly on the card reader for protection against threats.

Tamper switches are built-in to many types of equipment, and external tamper switches can be used with equipment lacking a built-in switch. Mechanical micro switch or plunger-type tamper switches are the most common types. Tamper switches usually detect when the cover of the device is removed. Alternatively, they can also detect when an RFID reader is removed from the wall.

Downloads At some point, card readers generally will require some kind of software or firmware update. The process is quite similar to that for phones and PCs except the software or configuration updates might require encryption. For example, suppose an application just reads static card numbers from an RFID media or isn’t using data protected by encryption keys. Neither the firmware nor the configuration need be encrypted simply because these files do not carry any sensitive information.

On the other hand, suppose data read by the reader contains personal information or proprietary corporate information. The data must be encrypted, and the readers must hold the cryptographic keys. In such a scenario the configuration software or firmware must also be encrypted because it also holds sensitive information. Encrypted configuration software or firmware poses no security risk, so it can be shared with customers or with the card reader manufacturers for updates.

To navigate such issues, integrators must work with subject matter experts and establish requirements and objectives.

Security planning generally takes place after the development of the concept, system architecture, and data flow. Both for security features and overall ease of implementation, it’s best to use readers flexible enough to accommodate likely future changes and adaptations. DW References ELATEC Inc., https://www.elatec-rfid. com/

Printer manufacturers often integrate RFID readers in their products to provide secure printing. In this context, the TWN4 product family is a frequent choice because of its easy upgrade and update in the field. TWN4 products, such as the TWN4 MultiTech 2 BLE PCB visible here, support features such as remote firmware updates or authentication via smartphone instead of RFID card.

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Ultrasonic bearings

help smooth out flat glass applications Construction glass, automotive glass, or other special glasses are the largest segments of the growing flat glass industry. Growth drivers such as technological innovation and energy consumption challenge the various glass product’s properties and production processes.

Edited by Mike Santora

Technical progress always leads to new, demanding requirements. Substrates are becoming thinner than ever; materials vary from flexible and fragile to specially treated surfaces (e.g., adhesive).

Time and again, processes are carried out in high-temperature environments. All this leads to an additional demand for sophisticated handling solutions.

Challenges in the processing of glass Contactless handling systems are already available to prevent scratches, marks, or damage, often with air bearings. However, there is still a risk of particles being deposited on the surface by movement in the air. In addition, flatness often cannot be guaranteed with materials that are unstable in shape. For some processes, such as surface inspection, the material must be as flat as possible to avoid evaluation errors.

With the help of the patented ultrasonic bearing, substrates can float evenly on an air film generated by vibrations and thus be kept contact-free and flat during handling. In addition to gripping, floating support is also possible during the continuous transport of thin glass.

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The Glass gripper, RobotOverhead.

How does the ultrasonic technology work?

The ultrasonic movement of the socalled Sonotrode creates a supporting gas film (air or process gas) between the Sonotrode surface and the substrate. The substrate floats on the resulting gas film at intervals of 10-150µm, depending on the application. Higher hovering heights can also be achieved in special cases. By using buoyancy forces due to vacuum, handling from above is also possible. In this way, any mechanical surface contact is avoided.

The physics of the ultrasonic bearing results from the flow dynamics and not from acoustic principles. The gas pressure in the gap between the workpiece and the vibrating surface increases due to the cyclic compression and decompression of the thin gas film. Therefore, it is necessary to realize a uniform oscillation pattern to generate constant floating forces over DESIGN WORLD

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the entire Sonotrode. The vibrations are not transmitted into the substrates and do not lead to any impairment of the substrate material.

With the repulsive forces of the ultrasonic bearings, the substrate can be moved without any friction even at very high speeds. In combination with vacuum, attractive forces can be applied simultaneously, which allows handling from above. Also, flexible materials can be “smoothed” without contact by this technique, i.e., they can be held in a uniformly centered position.

The force profile of ZS-Handling handling systems is similar to that of a conventional air bearing, but no compressed air supply is required. This means, that in a cleanroom environment, the laminar airflow — unlike with Bernoulli grippers — is not disturbed by high flow velocities. No particles can penetrate www.designworldonline.com

Levitating substrate.

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through external air or via pipes and, in new production lines, the costs for the compressed air supply can be saved.

The purity requirements for the production and processing of glass are high. The handling systems from ZSHandling can be used in cleanroom classes up to ISO 1.

By avoiding surface contact, and without dynamic turbulence in the ambient gas, no damage, micro-scratches, micro-cracks, or contamination can damage the substrate. Handling on machined or coated surfaces is possible without contact, allowing more degrees of freedom in process and machine design.

During handling, the substrate achieves a high level of flatness.

The systems can be used in all atmospheric processes and in up to 20% partial vacuum processes. This requires fewer resources, such as energy or compressed air, than a standard air bearing.

Another advantage is the optional temperature control of the handling system. To realize drying processes optimally, glasses are moved through several heating and cooling zones. Precise temperature control is necessary for an optimal process result. For example, in the first zone, the temperature is regulated between 40° and 100°, in the second between 80° and 180°. The ultrasonic tabletops are heated from the underside with a ceramic infrared radiator. Each table is further divided into individually controlled heating zones. In the third zone, the tables are cooled by a cooling water circuit under the table surface.

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Gripper with housing, inspection cameras, and sensors.

Exemplary requirements of a use case: The glass substrate, which is to be gripped with a gripper and deposited again, has a size of 1500 x 925 mm and a thickness of 200 µm.

It is flexible and consists of four laminated layers (PET/PET/PI/PET). The flatness before gripping is approx. +/- 0.5 mm. The glass foil is to be gripped, checked with inspection cameras, and deposited at another location.

The solution includes the RobotOverhead gripper, including holder and electronics. It consists of three Sonotrodes with a vacuum chamber, which are held together in a housing. To produce a uniform repulsion by ultrasound and suction by vacuum, many small holes are distributed over the Sonotrode. This also smooths the glass foil.

In total, the gripper measures 1600 x 1025 mm with lateral openings for edge stops, sensors, and cameras for inspection. The height is approximately 100 mm, with fans and valves for switching the vacuum on and off around 250 mm. With the uniform ultrasonic oscillations of the Sonotrode, a flatness of +/- 75 µm can be achieved over the entire substrate.

The complete process sequence in glass production and processing is fully automated. With the help of ultrasonic oscillations, thin glass is held in a flat position on the evenly generated air film, so that scratches or any other contact is eliminated. Furthermore, the laminar airflow in the cleanroom is not impaired by turbulence, thus preventing the transfer of particles. DW ZS-Handling | zs-handling.com

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I n t e r n e t

o f

T h i n g s

Can standard I/O systems simplify designs?

When OEMs can standardize their designs with one family of I/O products, it simplifies their efforts and gives them the flexibility to adapt controller platforms as needed.

Matt Hou Electrical Engineer Dinkle International

O

Original equipment manufacturers (OEMs) of machinery and process systems come in all shapes and sizes, serving a variety of industries, but they all rely on some type of input/output (I/O) hardware to interface field devices with the controller platform. The I/O is the nervous system used by the controller brain to monitor and command the sensors, valves, motors, and much more.

OEMs are experts when it comes to the design, fabrication, and operation of their equipment. Each OEM typically has a preferred automation platform, but in cases where they deliver systems to different end users, those very users may impose requirements regarding makes and models of programmable logic controllers (PLCs) and human-machine interfaces (HMIs). Quite often end users are sensitive to the PLC and HMI platform selection because they need to match the standards and personnel training at their facilities.

Therefore, OEMs are looking for a middle ground where they can maintain consistency in their designs while delivering customer-requested automation

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Figure 1: Designers want standardized remote I/O systems with the right features and compact form factors for use in main control panels, remote panels, and anywhere else they are needed.

platforms. One way to do this is to standardize on a remote I/O system which is easy to work with, comes in a variety of signal configurations, and integrates with any type of PLC platform. This article identifies how standardizing on common I/O systems can help OEMs simplify their work and gain flexibility.

Benefits of standard I/O systems Reliable data communications with I/O connected to field-located sensors and actuators is essential for proper real-time equipment control. Additionally, I/O is needed for data collection and analysis by historians, manufacturing execution

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systems, enterprise resource planning, and other systems.

More than ever, users are installing large numbers of input points, moving beyond basic control, and applying a greater focus on gathering data for analysis.

Seamless connectivity between the field data and supervisory computing systems is foundational for industrial internet of things (IIoT) initiatives.

Designers need an I/O system for control and data monitoring which can be implemented consistently across their entire product line wherever it is needed (Figure 1). Switching I/O systems based on customer-requested controllers

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adds complexity and cost. However, using standardized I/O systems lets both designers and end users achieve their goals.

Most PLC automation vendors offer their own remote I/O systems to integrate specifically with their controllers. Even when these vendors tout some level of improved alignment between their PLCs and remote I/O, these vendor-sourced products tend to come at a price premium and with constraints.

OEMs need independent I/O solutions that give them more options, not less.

Remote I/O basics Basic wired I/O signals use voltages and currents to transmit information from a field

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Internet

of

Things

Figure 2: Remote I/O systems, like the Dinkle iO-GRID M, feature compact and modular form factors, support for the most popular industrial communication protocols, and easy push-in wiring.

device to an I/O module, which in turn communicates with a controller. Discrete (sometimes called “digital”) point signals are either “on” or “off.” Analog point signals vary over a certain signal span to indicate a range of values. Inputs supply field information to a controller, and outputs send controller commands to the field devices.

There are many voltage, current, and wiring standards for each of these four basic I/O point types, and there are other special considerations such as how fast a point responds, accuracy, whether an interposing relay dry contact module is required, and other factors.

I/O signals may be located anywhere on a machine or equipment. While it is possible to wire all these items back to a central location, it is more convenient to install I/O modules in logical locations close to the field signals, especially where there are high quantities of I/O points localized together. This approach is called remote I/O because it is located away from the controller.

Any remote I/O must use some form of networking and communications protocol to interact with the controller. Today a prominent industrial networking method is Ethernet, but there are still many applications where classic RS-485 serial communication makes sense. No matter what the network, the goal is to minimize cabling and maximize connection distances.

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Remote I/O key features When OEMs can standardize on a single remote I/O system, they can design their equipment with common I/O panels. This reduces engineering, fabrication, and longterm support efforts.

Following are key features to look for with any remote I/O system (Figure 2): Compatible with standard industrial communication protocols Supports flexible and expandable architecture arrangements Compact form factors with fast assembly Simple wiring Wide selection of I/O modules for any signal type Easy configurability Clear indication of module and point ID and status Meets IEC and UL standards Economical

• • • • • • • • •

There are many industrial communication media types and protocols. Modbus TCP over Ethernet and Modbus RTU over serial cable are two of the most widely recognized and implemented industry standards. Therefore, any remote I/O solutions should be compatible with these for best interoperability with a range of controllers. Remote I/O systems with options for gateway or master modules provide the most architectural flexibility, allowing users to scale designs from the www.designworldonline.com

smallest to largest installations. A wide selection of I/O modules ensures users can get what is needed to satisfy any industrial field application.

Space is always at a premium, so compact form factors using a modular arrangement—often with a power and communications bus plate which accepts snap-in I/O modules—is the most popular way to install the right quantity and configuration of I/O wherever it is needed.

For some applications users may need washdown-rated devices, but remote I/O is more commonly selected for cabinetmounting arrangement protected by an enclosure.

The remote I/O system’s physical arrangement should also allow for easy servicing in the future. While screw-type terminal blocks have been the typical connectivity method in years past, many machine and equipment designers have moved to push-in design terminals to enable fast and tool-free installation with long-term stability, even in high vibration environments.

Most I/O modules have some on-board settings for configuring how they respond to and transmit field signals. When PLC automation vendors also offer remote I/O, they may point out some native configuration capabilities between the PLC and the remote I/O. However, these same capabilities may limit the usefulness of such I/O with other automation platforms.

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Figure 3: Remote I/O always saves on wiring material costs, and often helps SIs design spaceefficient automation panels for every type of control situation.

the remote I/O to be configured locally using simple software and a standard micro-USB cable. Users can perform all the necessary configuration, even on the benchtop before installation, and enable the remote I/O to work equally well with any controller of choice.

When the I/O is configured, commissioned, and operated over the years, it is important for it to offer clear indication, usually via LED lights, to indicate status. Clear module and point marking provisions also improve serviceability.

Designers will also want I/O modules meeting the typical UL and IEC requirements found throughout industry.

If all the preceding features are available, then a final consideration is usually price. Fortunately, remote I/O systems engineered using standards to work with many controller types are often the most economical choice.

I/O Integration Examples One packaging OEM supplies relatively widespread arrangements of systems

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creates production lines from many singlestation machines. Because they selected an ultra-compact remote I/O system that can communicate with the majority of PLC brands, they have flexibility to design the I/O into any type of station, and easily integrate it with any PLC required by the end user.

using conveyors, boxers, sealers, labelers, and more. The OEM used Dinkle iOGRID M remote I/O, enabling them to apply standard I/O products distributed throughout the various equipment types, and automated by a single PLC. Installation time was reduced by 40%, setup costs were reduced by 50%, and they had flexibility to incorporate any type of field equipment.

In another case, a systems integrator (SI) was tasked with automating water treatment equipment in a multi-level factory. The process equipment included storage tanks, sedimentation tanks, and pump controls distributed throughout the factory (Figure 3). By incorporating remote I/O, the entire plant could be automated with a single PLC, with wiring material cost reduced by 40%. Choosing an independent brand for remote I/O reduced the hardware cost for this portion of the automation by 50%. Future expansion is easy over Modbus, and the SI can apply the same concepts on other upcoming projects using any type of PLC. An OEM of machinery used to manufacture automotive components www.designworldonline.com

Standardized remote I/O simplifies OEM designs Reliable remote I/O systems are needed

by OEMs of automated machinery and process systems for real-time control and IIoT monitoring. Many designers may lean toward using I/O offered by their automation platform vendors. However, when OEMs are faced with integrating many makes and models of controllers, or with an increased need for IIoT monitoring, many find that choosing a standardized I/O solution helps them maintain commonality in their designs and reduce costs. Modular remote I/O is a popular way to realize these benefits and achieve seamless connectivity from the field up to supervisory systems, while providing greater design flexibility. DW

Dinkle International www.dinkle.com

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TUESDAYS Working remotely is going to get a little less remote.

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Each week, the organizers of DeviceTalks conferences will bring a lively, informative and enjoyable opportunity to catch up with medtech colleagues, gain insights on our evolving sector, and make new essential connections to help you move forward.

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INNOVATION & FINANCE PROTOTYPE & PRODUCT DEVELOPMENT MANUFACTURING & SOURCING REGULATORY, REIMBURSEMENT & MARKET DEVELOPMENT NEW TOOLS AND TECHNOLOGY Each DeviceTalks Tuesday will kick off with a quick briefing from the Editors of MassDevice and Medical Design and Outsourcing. These presentations will give attendees insights on what trends will be moving medtech in the days to come.

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Medical www.designworldonline.com

A Supplement to Design World - November 2020

How

decontamination could solve the

COVID-19 mask shortage problem

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11/4/20 8:08 AM

M e d i c a l

T i p s

Smith+Nephew

Sara Schneider, director of robotics program management at Smith+Nephew | courtesy of Smith+Nephew

is taking the road less traveled with its ortho surgical robotics British medtech giant Smith+Nephew chose a different path in the ortho surgical robotics space. One of its top robotics program leaders explains how it could make all the difference.

Chris Newmarker | Executive Editor

FASTER, SMALLER AND MORE ACCESSIBLE — those are the three descriptors that Sara Schneider uses to describe Smith+Nephew’s Cori robotic knee surgery system, which launched over the summer.

As the director of robotics program management at S+N, Schneider faced the challenge of making the design and engineering choices behind the company’s next-gen surgical robot.

The Cori robot is a big deal for Smith+Nephew because ortho surgical robotics is a hot area for medtech, even as the COVID-19 pandemic causes health systems to scale back elective procedures.

Stryker has enjoyed a great deal of success with its Mako robots, and Zimmer Biomet is seeking to compete with its Rosa systems. Smith+Nephew is making a bet with a system that isn’t the size of a mini-fridge with an arm, that doesn’t rely on pre-operative imaging, and that includes a handheld cutting tool that can fit a particular surgeon’s techniques.

“There’s more flexibility in the approach when you have that handheld piece that’s not anchored into this mammoth piece of equipment,” Schneider said.

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She later added: “I think that the next few months, if not the next few years, will really show us how beneficial that technology is in the hands of surgeons.”

Schneider is an engineer who grew up in Boston. She got involved in ortho surgical robotics after she and her husband moved to Pittsburgh and she took a job as a program manager at Blue Belt Technologies, creator of the Navio robotics system. After S+N acquired Blue Belt and its Navio system for $275 million in 2016, Schneider gained a reputation as an organized manager who could keep the many moving pieces of a project on track. She rose DESIGN WORLD

11/4/20 8:37 AM

Schneider and her Smith+Nephew colleagues made a faster surgical tool (center) and a console (bottom) that was the size of a large book volume when creating the company’s next-gen Cori ortho surgical robotics system. Optical cameras (top) track the procedure so that the spinning of the tool’s burr automatically turns off when its outside of the operating area — the robotic feature of the system. | courtesy of Smith+Nephew

through the ranks to become director of robotics program management.

The Navio system had all of the basic ingredients that would eventually go into the Cori. Instead of using pre-planning and imaging to guide the robot, the surgeon places small, reflective discs at strategic places around the surgery site. The discs bounce back infrared light to optical cameras that serve as a tracker.

Once the system has registered the key parameters of the surgery site, the surgeon uses a pointer tool to digitally “paint” over the bone surface that needs to be removed. The DESIGN WORLD

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surgeon then uses a handheld cutting tool that has a robotic feature that automatically halts the spinning of the tool’s burr if it’s outside the painted area.

“The way that we described this very simplistically is that you could almost perform this surgery with your eyes closed. As long as the surgeon is bringing it close enough, the system will decide, ‘Am I going on or off?’”

Schneider said.

The Navio system was a good start for Smith+Nephew. But after a few years on the market, company officials decided it was nearing its intended www.designworldonline.com

life from a design standpoint. To create the next-gen Cori system, Schneider’s team focused on making the surgical tool faster and reducing the overall size of the system so that it could easily go into the outpatient centers that are increasingly becoming popular for orthopedic surgeries.

The new handpiece, according to Schneider, is significantly faster in terms of bone removal and cutting efficiency — reducing surgical time so that the patient has less time under anesthesia and the surgeon can manage their practice more efficiently.

“We had to make a lot of design decisions about, ‘How are we going to design this handpiece? What optical camera are we going to use? What are the specifications of the CPU (central processing unit) that we’re going to use to achieve those specifications that we’ve set for ourselves?’” Schneider said.

The Cori system is about a quarter of the size of the Navio. While the Navio system stood 3 ft off the ground, the November 2020

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Cori’s console is the size of an Oxford English Dictionary volume and sits on a table.

“I’m working with the technical team and the marketing team to say, ‘How do we meet this user need?

How do we compress all of the electronics that we had in Navio into this small console that that’s really more desirable from an OR standpoint?’” Schneider said.

“We had a lot of discussions about, ‘How can we still maintain an ergonomic and aesthetically pleasing console shell without taking up a significant amount of space?’

There are trade-offs between product specifications — performance versus size versus cost of goods. There was a lot of putting our heads together and figuring out, ‘How can we balance all of those inputs to give the user the most valuable product?’”

Fortunately, electronic components technology had progressed enough in just a few years that Schneider and her colleagues had more advanced, compact components to swap into the Cori’s design.

“I’ll credit the engineers for just the layout of all the components. There’s a lot that goes into designing how they all stack amongst one another,” Schneider said.

Now that the Cori system is launched for knee applications, Schneider and her colleagues are looking to expand the platform to surgeries on hips and other joints. They’re also looking at additional attachments and accessories to improve user experience, and there’s the prospect from an R&D standpoint of packing in more artificial intelligence capabilities down the road.

“There’s no shortage of work, and we’re excited about what’s to come,” Schneider said.

Schneider recalled that when she joined Blue Belt Technologies in 2014, she was one of only a handful of women in the Pittsburgh facility. These days, about a third of the employees in the robotics group are women — a development Schneider credits to Smith+Nephew’s dedication to hiring women and running robust mentorship programs.

Half of Schneider’s eight direct reports, in fact, are women.

“If you hire a lot of people that have the same viewpoints and opinions, you’re not going to have folks challenge one another. And when that starts to happen, you don’t end up with the most superior product,” Schneider said. “When I’m looking at hiring people again, I’m thinking about, ‘How can I bring in a new person with a new viewpoint that can challenge the voices that we already have on our team?’” M

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With cold and flu season upon us, public health officials worry about a resurgence of COVID-19 and personal protective equipment shortages. Protecting frontline workers will likely include decontaminating face masks.

How decontamination could solve the COVID-19 mask shortage problem Nancy Crotti Managing Editor

A

spike in COVID-19 cases this fall and winter could leave healthcare facilities with renewed shortages of personal protective equipment — particularly masks.

Hundreds of frontline healthcare workers have died from the virus since the pandemic struck in China in 2019, bringing the need for effective face masks into sharp relief. But despite the efforts of 3M and other companies worldwide to boost production of the most effective filtering masks — N95s — there still might not be enough.

N95s, which filter out 95% of airborne particles, were designed for industrial use; for medical use, they should be discarded after every patient encounter, according to the Centers for Disease Control and Prevention (CDC). But pandemic-induced shortages have forced healthcare providers to wear the same mask for full shifts and for hospitals and clinics to seek ways to reuse them.

A number of researchers have studied the efficacy of mask decontamination systems. As of September 4, the FDA had granted emergency use authorizations (EUAs) for 10 decontamination systems,

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nine of which use vaporized hydrogen peroxide (VHP) and one that uses supercritical carbon dioxide — a fluid/gas combination created by pressurization.

The National Institute of Occupational Safety and Health (NIOSH) has also said that ultraviolet germicidal irradiation, VHP and moist heat have shown the most promise.

Other methods under study include peracetic acid and ethylene oxide.

Medical Design & Outsourcing talked to a researcher who recently studied mask decontamination methods for effectiveness in killing the virus and in not damaging masks or their straps. CoNovember 2020

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M e d i c a l

T i p s

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lead investigators Dr. Anand Kumar, an infectious disease and critical care specialist at the University of Manitoba’s Health Sciences Center, and Jay Krishnan, senior biosafety officer at the National Microbiology Laboratory of the Public Health Agency of Canada in Winnipeg, studied seven possible decontamination methods. The researchers have submitted the study for publication.

“The study basically demonstrates which methods might be most effective and easily implemented,” Kumar said in an interview. “We basically found that a couple of them were particularly strong, and a couple that we had hoped would work didn’t.”

Their conclusions: The best and most practical method is the application of moist heat at about 70 °C (158 °F) for an hour or so at about 25% humidity, which helps kill the pathogen. Moist heat decontamination can easily be done in bulk, and leaves no chemical residue that would require extra aeration time. It can even be performed in hospital blanket heaters, Kumar posited.

“Most can be adjusted to 70 degrees, and if you put a large pan of water in it, you’d hit 22% humidity,” he explained. “That means you can do it in any ward in North America. Most of them have these blanket heaters.”

Vaporized hydrogen peroxide is not as easily accessible, but the researchers found it to be effective. Peracetic acid fogging also worked well.

“It’s not routinely used in most places, but it is a technique that can be quite easily performed,” Kumar said of peracetic acid. “You can set up to do it quite easily.”

Ethylene oxide, which is widely used to sterilize medical devices, also worked well, but required 24-hour aeration to eliminate toxins. “Between the toxicity and the long cycle time, I don’t think it’s really practical,” Kumar said.

Ultraviolet light (UVC), which has been touted as an effective decontaminant, failed in the Winnipeg study.

“If you actually do the decontamination as suggested by some other groups and dissect the mask, you would find a fair amount of virus still there,” Kumar said. “The ultraviolet light does not penetrate through the multiple layers of most of these kinds of masks.”

Educational institutions including Duke University have received EUAs to set up mask decontamination equipment in dedicated spaces.

Michigan State University’s Animal Care Program received one of the most recent EUAs for this purpose in July.

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The animal care program in Lansing, Mich., has used vaporized hydrogen peroxide for years to decontaminate rooms between uses by different animals and projects, according to veterinarian Dr. F. Claire Hankenson, director of campus animal resources and a professor of pathobiology and diagnostic investigation. On March 31, Michigan’s governor and the university president contacted the veterinary center to ask if staff would consider mask decontamination.

Hankenson co-authored a study on the efficacy of vaporized hydrogen peroxide (H2O2) to decontaminate masks in an unused 20,000 ft2 building. H2O2 was delivered to rooms using robotic HaloFoggers, dispersing H2O2 vapor and increasingly concentrated microdroplets as a fog for a timed

period based on cubic footage of rooms.

Published in May in Applied Biosafety, the journal of the Association for Biosafety and Biosecurity, the peer-reviewed study determined that it’s possible to clear a variety of N95 respirator types and sizes of potential bacterial and viral agents using VHP in a controlled fog/dwell/exhaust cycle.

Hankenson described how it works: After the prepared masks are loaded in the rooms, the VHP decontamination cycle takes six hours. Once complete and effectiveness is verified, the equipment is packaged and picked up by staff from participating healthcare and first responders’ facilities. The process is designed to reduce the possibility of cross-contamination and ensure each piece of equipment is returned to the original user.

The Michigan State system can

decontaminate up to 7,000 respirators daily, which the authors wrote “will address the predicted surge of COVID-19 cases in the state, and ultimately allow each respirator to be reused multiple times.

There is no other public site in the region with our capacity to offset the continued supply chain issues for PPE needs.”

In addition to helping keep frontline healthcare workers and first responders safe from COVID-19, Hankenson hopes the decontamination program will save users money. She has found that prices for N95 masks can range as high as $5 apiece, but the Animal Care system will be able to recycle them for about 25 cents each.

“The most gratifying thing was just this incredible coming together of experts who were interested in doing whatever they could to help the community,” Hankenson added. “It was incredibly rewarding to work with everybody.”

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MEDICAL

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Innovative Incision Technologies: Custom Blade Assemblies and Specialty Needles Enabling better patient outcomes through innovative incision technologies has always been one of Cadence’s main objectives. As a leading manufacturer of custom sharps for medical device OEMs, we provide our customers with expert solutions for surgical cutting, piercing, and delivery.

Cadence’s flexible manufacturing processes allows OEMs the ability to fully leverage all of their possible design ideas. We also offer a variety of custom sharps combined with multiple material and coating choices. When superior cutting or piercing performance is required for a device to be a functional success, Cadence is the partner of choice for custom surgical or medical sharps.

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Due to the addition of a urethane based flexibilizer, EP30DPBFMed offers both a higher abrasion resistance and a higher elongation when compared to a typical epoxy system. At room temperature, it has an elongation at break of 20 to 40%, and Shore D hardness of 30 to 50. It is useful in applications where low stress is important, due to its low modulus value. This compound is electrically insulative with a volume resistivity greater than 1014 ohm-cm. EP30DPBFMed is serviceable over a wide temperature range from cryogenic 4K to 250°F.

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Product World High-performance integrated motion control line Emerson Emerson.com/PACMotion The new PACMotion servo motion control portfolio offers an integrated automation solution for industrial applications. The portfolio includes a new motion controller that connects directly into the PACSystems RX3i programmable logic controller backplane for high-speed, high-precision performance with synchronized

with PACSystems RX3i controllers, simplifying the architecture for

motion for up to 40 coordinated axes, enabling end-users to scale

seamless integration while enabling higher speeds and greater precision.

up their motion systems without sacrificing performance.

The complete PACMotion portfolio includes motion controller,

The patented technology enables precise, jerk-free positioning, preventing material slippage and production losses while improving

servo motors, servo drives, and motion configuration software

machine efficiency. On-the-fly electronic reconfiguration allows users

for applications in packaging, printing, material handling,

to implement rapid changeovers without stopping production to deliver

semiconductors, food & beverage, and general manufacturing. The

shorter production runs and increased machine use.

new PACMotion PMM345 motion controller operates exclusively

SOL-28 solar dampers for solar-panel motion designs ACE Controls acecontrols.com ACE Controls now supplies SOL-28 solar dampers for solar-panel motion designs needing compression and extension forces of 14 to 2,252 lb and strokes of 1.97 to 15.00-in. The main purpose of SOL-28 solar dampers is to protect photovoltaic (PV) solar tracking systems from damage caused by the adverse effects of harsh weather conditions. The dampers have a piston-rod diameter of 0.55-in. and can survive operating temperatures from -30° C to 80° C — even to one million cycles. A wear-resistant surface coating on the dampers provides a long-lasting, highquality appearance. Plus, the damper’s heat-treated rod delivers exceptional performance and life expectancy.

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

Axial groove now on mounted spherical roller bearing

Quick-change robotic arm gripper

Regal Beloit RegalBeloit.com

Kurt Workholding kurtworkholding.com

The Time Saving axial groove (TSAG) is now in the inner ring bore on the Sealmaster

The RV36 Robotic Gripper is a two-finger parallel

Unitized Spherical Roller Bearing (USRB). It allows users easy removal and the ability to

gripper featuring a patent-pending design that allows

reuse the shafting with minimal cleanup.

automated finger/end effector changes without

Many methods exist to remove a mounted bearing from a shaft, but the Sealmaster

changing the gripper body itself. Quick change jaws

USRB bearing with Time Saving axial groove makes bearing removal easier. Its patented

allow users to save on gripper-body expenses and create

design eliminates interference with the burr created by the setscrew by using axial

greater part-holding flexibility.

grooves at setscrew locations that run the length of the inner ring. The axial groove

Loaded with features, the compact Kurt RV36 Gripper

in the inner ring bore is designed to provide clearance from the burr created when the

comes standard with integrated electronics featuring

setscrews are properly torqued to lock the bearing to the shaft and extends the entire

sensors that ensure fingers and parts are in place and

length of the inner ring for removal in either direction.

ready for production. High-strength aluminum alloy keeps gripper weight to a minimum while a hard-coat finish reduces wear and increases life in the field. Smaller gripper size allows easier storage where space is a premium.

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Product World Spring applied brakes with extra thin design Miki Pulley mikipulley-us.com The BXR power-off engaged brake may serve as an emergency brake, and a holding brake, important for protecting compact designed automated systems. These BXR spring-applied brakes provide versatility in space and weight savings. Their low-profile design is 2/3 the thickness of other brakes in the Miki lineup.

Successful articulating joint applications where cantilevered load must be minimized, the extra thin BXR brake operates in this way: to open the brake and allow free rotation, voltage flows to the coil. When power is disengaged from the coil, internal compression springs push the armature plate toward the rotor disc, halting it against the top plate. The square/splined rotor hub affixed to the input shaft interfaces with the rotor disc holding rotational movement.

The Miki Pulley BXR brake is also a space and weight saving option for servo motor applications. Operating specifications are: • Brake torque: 3.688 ft-lb ~ 40.566 ft-lb: (5N · m ~ 55N · m) • Brake outer diameter: 3.287 ~ 7.280-in.; (83.5mm ~ 185mm) • Ambient Temperature: 14° ~ 104° F; (-10° ~ 40° C)

DC switching solid state relays Carlo Gavazzi gavazzionline.com CARLO GAVAZZI has launched the RM1D Series, a comprehensive family of DC switching solid state relays. The RM1D Series is designed for applications that demand critical response times, rapid cycling, and high reliability. They are suitable for use in transportation, off-grid, and renewable energy systems that run off batteries, as well as DC heaters, solenoids, valves, fans, and other equipment that requires DC switching.

Their low power dissipation output MOSFET creates superior thermal performance, which reduces the size or even eliminates the need for a heat sink. The RM1D Series uses direct copper bonding (DCB) and a housing free of any molding mass to increase reliability and performance, making them a suitable solution for packaging, transportation, conveyors, plastics, and other industries and applications.

Features: • Maximum output ratings: 100A @ 60VDC,

• 4-32 VDC control voltage range

• 50A @ 200VDC, and 10A @ 500VDC

• 100µs maximum response time

• Low power dissipation output MOSFET

• 3750 Vrms isolation between input and output

• Switching frequency up to 1,000 Hz

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

Farm duty and open drip-proof motors

MicroSmart FC6A plus PLC upgrade

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IronHorse MTF2 series farm duty motors are totally

EtherNet/IP communications are now being added to the MicroSmart

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starting current and are used to power agitators, augers,

EtherNet/IP scanner capabilities, the FC6A Plus can now connect with

compressors, conveyors, feeders, hay hoists, grinders,

a monitor, and control any I/O, variable speed drive, motor controls,

blowers, and for other general-purpose heavier materials

or other intelligent automation device using this popular industrial

applications.

protocol. In addition, the FC6A Plus can be configured as an EtherNet/

New IronHorse MTDP series open drip-proof three-

IP adapter, allowing it to interact with other peer and supervisory

phase motors range in size from 1hp to 50hp at 1800

systems, such as PLCs and HMIs.

rpm and 3hp, 5hp, and 7.5hp at 3600 rpm. Frame sizes

All new FC6A Plus CPUs will ship with the latest firmware and

are available from 143T to 326T. All models have a rolled

EtherNet/IP connectivity already installed and ready for use. For FC6A

steel frame; frame sizes up to 256T have cast aluminum

Plus CPUs already in service, users can obtain the current WindLDR

end bells, while frame sizes of 284T or larger have cast

software (version 8.15.0 or later) for free and then use it to easily

iron end bells. All frame sizes have a fixed base.

perform the upgrade.

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Product World uEye SE cameras with fourthgeneration Sony Pregius sensor

Spring-loaded LVDTs

IDS ids-imaging.com

These spring-loaded LVDTs are used for surface measurement of paper, rubber, paneling,

NewTek newteksensors.com

and other materials as part of quality control processes in sawmill, wood processing, paneling, rubber, and automotive production plants. Outfitted with precision wheels and

The high-resolution sensor IMX541 from the

other accessories for active monitoring of materials along a line or conveyor, the Spring-

Pregius S series has now been integrated with

Loaded Gage Heads are mounted at different points of the manufacturing line to make

the versatile uEye SE camera family. With its

multiple contacts of a product surface for measuring thickness, flatness, and other surface

1.1-in. format, the 20.35 MP CMOS sensor is

parameters. Data collected from the gaging probes enables operators to monitor a product

compatible with C-mount lenses. The industrial

profile for abnormalities or an out-of-tolerance spec.

cameras feature a practical USB3 Vision

The Spring-Loaded LVDTs have a stainless-steel probe assembly and hermetically-sealed

interface, delivers 20 fps, and will be available

construction that enables operations in harsh industrial conditions such as exposure to

from September either as board-level models

water, sawdust, flying chunks of wood, and other debris. The gage heads also perform over

or with a robust metal housing.

wide operating temperature ranges (-65 to 185°F) with linearity of ±0.15% of full range.

Pregius S — the fourth generation of CMOS image sensors from Sony — makes BSI (“Back Side Illuminated”) technology available for the first time in global shutter sensors.

The benefits are smaller pixels (only 2.74 µm, which allows a significantly higher pixel density), higher resolution, and improved

High purity nickel strip for battery applications Ametek ametek-ct.com

quantum efficiency and sensitivity.

This specialty metal strip and wire manufacturer reports increased levels of global demand for its high purity nickel strip products across a number of sectors. The company’s precision nickel strip is engineered for critical battery connector applications in the electronics, medical, electric vehicles, defense, aerospace, and oil and gas markets. SMP uses wrought powder metallurgy to customize the strip, achieving a 99.98% purity, which delivers 15-20% higher conductivity than traditional cast strip materials and, therefore, greater power transmission in batteries.

Along with nickel strip, AMETEK SMP Wallingford also manufactures a range of hightolerance custom shaped wire products, shaped components, and thermal management materials. Products can be customized and are used in multiple specialist applications across the world.

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

Effective tool change designed with inductive miniature sensors Baumer baumer.com In modern processing centers, inductive sensors are the components of choice for monitoring the motor spindle clamping process. Integrated into the spindle, they must be small and offer high repeatability to ensure smooth tool changing at all times. Baumer offers a high-performance portfolio of miniature sensors for the intelligent design of effective spindle solutions. This can either involve a classic design with three switching sensors or a smart design with one measurement sensor.

In drive and clamping solutions, the sensor technology is integrated in the motor spindle. Given this confined space, the sensors must therefore be as small as possible, yet very powerful. This Swiss sensor manufacturer offers the market’s largest portfolio of miniature and sub-miniature inductive sensors with micrometer measuring accuracy. One example is the inductive proximity sensor IFRM 03, with a diameter of only 3 mm. It is available in various lengths, starting at a mere 12 mm. Yet its miniature housing contains the complete evaluation electronics that are responsible for the high repeatability switching points as well as the precise analog measurement values. In addition, these industrial-grade sensors are robust, EMC-stable, and comply with the protection class IP 67.

Wheel drive with high torque-density brushless DC motor ElectroCraft electrocraft.com The MPW Wheel Drive has a high torque-density brushless DC motor with a heavy-duty integrated planetary gearbox mounted inside the hub of a lightweight aluminum wheel with custom tread. Designed for mobile robot applications, the MPW combines optimum performance with highefficiency, quiet operation, and long life.

ElectroCraft MobilePower MPW series wheel drives have an integrated design that provides increased performance and reliability compared to traditional motor/gearbox/wheel combinations.

• The MPW52 (150 mm Wheel) provides a best in class peak torque of 12.4 Nm (110 lb.in) at 2.4 meters/second, while carrying up to 68 Kg load (150 lbs.) per wheel.

• The MPW86 (200 mm Wheel) provides a robust peak torque of 35 Nm (310 lb.in) at 1.9 meters/second, while carrying up to 227 Kg (500 lbs.) per wheel.

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Back Page ADVERTORIAL

Edge Controllers Bridge OT

and IT Systems

By Derek Thomas Vice President of Marketing & Strategy

•

Machine Automation Solutions at Emerson

Edge controllers integrate advanced computing and so ware capabilities to deliver local analytics and generate insights at the machine control layer. By augmenting machine operation with advanced capture and processing of local sensor and device outputs, personnel can quickly assess issues and take appropriate action. But what happens when a user progresses and needs to connect multiple data systems together into large data pools? Embedded, secure connectivity will ensure systems are future-proofed and enable:

• Connection to local or remote • • •

displays for dashboards and other visualization needs Transfer pre-processed data to on-premise or cloud-based historians and databases Integrate analytics information with plant-or enterprise-level systems Inner-outer loop data interchanges for logic optimization and machine learning

Each of these use cases needs secure connectivity to ensure system integrity, so an industrial edge controller must incorporate the appropriate physical communication ports, modern industrial protocols, and security features. As explained in prior articles in this series, the most advanced industrial edge controllers have separate, virtualized operating systems (OSs) that run independently, but can securely communicating with each other via OPC UA. One OS is a programmable logic controller providing real-time deterministic control, and another OS provides Linux-based, open computing for analytics and other applications.

To guarantee machine performance is unimpeded, edge controllers have dedicated communication ports for each OS, which ensures network traffic separation between the machine network and industrial internet of things (IIoT)

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connections. The real-time part of the edge controller works best for timesensitive communications, for example, to a variable equency drive in a control loop.

The Linux part of the edge controller works well for other types of communication, such as higher-level computing systems and the cloud.

Like most modern devices, edge controllers provide Ethernet and other ports to enable hardware connections.

Where edge controllers stand out is their ability to support a variety of industrial networking, IIoT, and other advanced protocols, such as OPC UA, MQTT, PROFINET, and SRTP. OPC UA The comprehensive, modular, and scalable nature of OPC UA lets users create a “system of systems,” an integrated overall industrial automation system built om many subsystems of all sizes interacting seamlessly with each other. Clients and servers are defined as interacting partners.

OPC UA defines how information is modelled and communicated with specific security, contextualization, and objectoriented features.

OPC UA uses a built-in set of services for handling security certificates and establishing secure client/server sessions at the application level, channels at the communication level, and socket connections at the transport layer. The protocol provides native mechanisms for www.designworldonline.com

clients to discover available servers, manage and distribute certificates and trust lists, and mediate with the certificate authority.

MQTT MQTT uses a publish-subscribe model, which reduces required bandwidth, or data transfer capacity, compared with poll-response. Each device on the network transmits (publishes) data only when it changes, sending that data to a central server, which broadcasts only to other network clients that have tuned in (subscribed) to receive these updates. Poll-response protocols transmit data cyclically at a predefined rate, even if nothing is changing.

MQTT clients, which can be so ware applications or other field devices, subscribe to only the data they need.

Communication happens as needed, and state awareness is maintained with only a small heartbeat om each device over a persistent, secure connection. This allows even lowpower devices on low-bandwidth networks to form smart integrated systems. These systems can scale up to millions of connections, and all data published by each device can be subscribed to by any number of client applications—like maintenance databases, performance monitoring tools, inventory and financial systems— or cloud-based analytics platforms.

DESIGN WORLD

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PROFINET PROFINET is a robust plant-level network that provides uninterrupted communications using a media redundancy protocol (MRP) in a ring network configuration for communications recovery within milliseconds a er networking loss due to a single cable, device, or switch failure.

Users can design these networks with external switches to form a ring, or designs can be simplified incorporating on-board embedded multi-port switches inside edge controllers.

For the most critical applications, edge controllers can be installed in pairs on an MRP ring. One controller is the primary, while the other controller is the hot-backup and is configured to take over seamlessly if the primary fails.

SRTP SRTP works well for communications om an edge controller to an asset management system (AMS) or a supervisory control and data acquisition (SCADA) system. It provides encryption, message authentication and integrity, and replay attack protection in both unicast and multicast applications.

These four protocolsâ&#x20AC;&#x201D;OPC UA, MQTT, PROFINET, and SRTPâ&#x20AC;&#x201D;can be used simultaneously if required and in a variety of applications, some of which are explained below.

Analytics information provided to an AMS or a SCADA system is o en used to aggregate data om multiple sites. A machine builder might use an AMS to gather analytics information om hundreds of machines installed worldwide. This information could then be used to improve support for existing machines, for example by providing predictive maintenance. Examination of analytics data can improve designs for new machines.

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A SCADA system could gather analytics information om edge controllers installed at hundreds of pumping stations in a water/ wastewater system, or om scores of electrical substations. In either case, this information could be used for remote control and monitoring, and for analysis to improve operations.

Edge controllers are an enabling technology able to collect data om a variety of field located sensors, and om other control devices, such as VFDs. Once the data are collected, they can be analyzed locally for immediate improvements. Multiple connectivity options allow industrial edge controllers to transmit the results of analytics and other information to most any type of display, storage system, or other platform.

Transmitting field-sourced little data to higher level big data systems is fundamental to beginning and expanding a digital transformation effort. Industrial edge controllers are uniquely equipped and located to perform this role as they can connect with all types of field devices, gather and process the data, and securely transmit it to other systems.

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SALES

Ad Index

Jami Brownlee jbrownlee@wtwhmedia.com 224-760-1055

ABB Motors & Mechanical ...................................9 AllMotion ....................................................................4 Altech Corporation ................ Cover spread,15,17 Apex Dynamics, USA ............................................83 Aurora Bearing Company ...................................18 AutomationDirect ...................................................1 Azoth ..........................................................................55 Boker’s Inc. ................................................................48 Bunting Magnetics ................................................28 Canfield Connector ................................................48 Carlyle Johnson ......................................................23 Clippard ......................................................................79 Cornell Dubilier Electronics, Inc. ........................31 Del-tron ......................................................................62 DeviceTalks ...............................................................86 Diamond Wire Spring ............................................36 Digi-Key ......................................................................13 Exair Corporation ...................................................5 Fairlane Products ...................................................37 FAULHABER MICROMO ........................................IBC Harwin ........................................................................65 HELUKABEL USA ...................................................39 HYDAC Technology Corporation ......................61 Interpower .................................................................43 J.W. Winco, Inc. ........................................................18 John Evans’ Sons, Inc. .........................................30 Keystone Electronics Corp. ................................3 KNF Neuberger .......................................................41 Master Bond ............................................................28 Miki Pulley U.S. ........................................................14 Nason .........................................................................29 NB Corporation .......................................................21 NBK America LLC ....................................................45 New England Wire Technologies & New England Tubing Technologies ..........75 Novotechnik .............................................................50 OKW .............................................................................64 Opto 22 ......................................................................27 PBC Linear ...............................................................2 Regent Controls .....................................................53 Rolec ...........................................................................78 Sager Electronics ...................................................73 SEW Eurodrive .........................................................BC SIKO Products ..........................................................11 Smalley Steel Ring .................................................35 Spartan Scientific ...................................................44 THK America, Inc .....................................................IFC Tormach .....................................................................49 TRACO Power North America, Inc. ...................47 Trim-Lok .....................................................................25 TTI, Inc. .......................................................................7 Ultra Motion ..............................................................63 Whittet-Higgins .......................................................19

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0

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Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. c. Total Paid and/or Requested Circulation of 15b (2), (3),telemarketing and (4)) (Include direct written (Sum request from(1), recipient, and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.)

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33,998

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a. Total Number of Copies (Net press run) (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail®)

LEADERSHIP TEAM

36,313

Total Distribution (Sum 15cPrint and e) b.

Total Requested andofPaid Copies (15c) + Requested/Paid Electronic copies (16a)

0

0

0

0

33,998

33,998

1,924

806

0

0

0

0

318

179

2,242

985

36,240

34,983

73

2

36,313

34,985

93.8%

97.2%

6,000 39,998

Date

6,000 39,998

42,240

40,983

94.7%

97.6%

Total Requested Copy distribution (15f) + Requested/Paid Electronic copies (16a) g. c.

Copies not Distributed (See Instructions to Publishers #4, (page #3)) I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form d. or Percent who omits material information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil Paid and/ororRequested Circulation h. Total (Sum of & 15f and g) copies (16b divided By 16c x 100) sanctions (including civil penalties).

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17.

16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication.

17. Signature and Title of Editor, Publisher, Business Manager, or Owner 18.

November 2020 Date

10/8/2020

November 2020

How

COVID-19 mask shortage problem

Medical Tips Supplement Cadence........................................................................93 Master Bond ..............................................................90 Nitto Kohki USA ........................................................92 Stock Drive Products/ Sterling Instrument ..........................................90 11-20_V1.indd

$125.00

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WTWH Media, LLC 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

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decontamination could solve the Medical Tips cover

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www.designworldonline.co

m

3. Filing Date

0 2 5 _- 1 4 6 5. Number of Issues Published Annually

12

Pat Curran, Senior Digital Media Manager

Medical

2. Publication Number

87

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