Design World April 2017

www.designworldonline.com April 2017

INSIDE:

LINEAR MOTION: Fighting Cancer with precision motion control PAGE 46

HARSH ENVIRONMENTS: Making WirelessHART truly wireless PAGE 82

MECHANICAL: 6 bearing killers and how to stop them PAGE 94

Effects of PID

and machine parameters on positioning system performance 54

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www.designworldonline.com April 2017

INSIDE:

LINEAR MOTION: Fighting Cancer with precision motion control PAGE 46

HARSH ENVIRONMENTS: Making WirelessHART truly wireless PAGE 82

MECHANICAL: 6 bearing killers and how to stop them PAGE 94

Effects of PID

and machine parameters on positioning system performance 54

APRIL DW COVER 2017_fit for gatefold_FINAL.indd 1

4/3/17 4:47 PM

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I n s i g ht s

Making technical education more local Talk to many component manufacturers and you’ll hear the phrase “local for local,” meaning that they’re strategically placing facilities near their customers. So, instead of one manufacturing plant in China, they may have one in China, one in the U.S., one in Brazil and one in the Czech Republic. Now, the University of Florida is developing a plan in the sunshine state that might be education’s version of local for local.

Allen Carlson, the retired CEO of Sun Hydraulics, is now working with the University at their Innovation Station-Sarasota County, to assist with this project. Allen told me that he and his staff connect the local needs and opportunities of engineering and tech companies with the assets of the university. Carlson interviews local companies to determine what their needs are—typically around capability and capacity. The other side of the project is that they’re connecting the infrastructure of the local colleges to teach engineering classes for University of Florida College of Engineering.

So a high school senior could apply directly to the University of Florida—and be accepted— but opt to take classes at a local institution such as State College of Florida or Santa Fe Community College. Core classes, like calculus, would be taken locally. It may take a student one or two years to complete those core classes. At the end of the classes, they automatically transfer to the University of Florida’s main campus in Gainesville (about a three hour drive from Sarasota).

“At the end, you complete their engineering program at the University of Florida Gainesville, and end up with a University of Florida engineering degree with no asterisk. You’re a full University of Florida engineering graduate,” Carlson said.

So is this an approach for all land grant institutions across the U.S.? Carlson said that he thinks each community, each state, has a different need or requirement.

“Programs in each state are going to be a little bit different because they’re going to be tailored to the local community, the businesses in the community, and the assets of the university,” he said. “It’s not a cookie cutter approach—it’s what’s needed.”

Other institutions, such as the University of Texas in Austin are doing a lot of work in this area, and I expect that we’ll see this educational model grow in the coming years, to combat the soaring costs of higher education. Local for local can make a lot of sense, whether in making goods or making future engineers. DW

Pa ul J. He n ey - Edi tor i al D i re ctor phe ney@wtwhme di a.com

On Twitter @ DW—Editor

4

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Te s c h l e r o n To p i c

The likelihood of ending up as a white-collar crook Suppose you were the one who set the prices your company charged for its products. Further suppose two of your chief competitors called and suggested the three of you collude on a bid for an upcoming contract. Simply put, they wanted to engage in price fixing. Price fixing is not just unethical but also illegal. People have gone to jail for it. So of course, in this hypothetical example, your reply would be a forceful no.

Most business professionals could probably give a sophisticated and carefully reasoned argument against engaging in this kind of illegal action. But the evidence is that the same individuals who can state a good case for acting honestly may also be the ones who end up behind bars for ethical lapses.

Eugene Soltes, a Harvard Business School professor, noticed this ambiguity when he studied white collar criminal cases.

He summarized his findings in a book called Why They Do It. “No student graduates with a plan to become successful and then, later, to engage in some fraudulent behavior that could lead to prison and professional ruin.

Yet, even at (HBS), where every student has the intellectual capacity to successfully resolve and avoid decisions that could lead to prison, there have been more than two dozen graduates who’ve engaged in white collar crime,” he writes.

Soltes points out that it’s easy to see decisions that deserved more attention in hindsight, but not in the heat of the battle.

And that’s one of the problems with trying to teach ethics in a classroom: “Most of the significant challenges associated with decision making have already been vastly simplified or eliminated by identifying the salient issues. So the judgments reached during classroom discussions of ethical dilemmas can reflect a decision-making process that bears no resemblance to one used to resolve such dilemmas in day-to-day life,” he says.

It’s easy to see how things can go awry when there is a fine line between criminal behavior and innovative solutions to business problems. For example, some of today’s most noteworthy entrepreneurial efforts have arisen out of exploiting loopholes in regulations, or in interpreting regulations aggressively to get around business obstacles. Once people get in the mindset of finding ways around legal or regulatory obstacles, the boundaries between what’s illegal and legal can become blurry. Worse, the media tends to celebrate entrepreneurs who exploit loopholes and applauds them as being inventive. But sometimes courts interpret these kinds of shenanigans as simply being unlawful.

Of course, engineers get involved in their share of ethical dilemmas. Evidence is that

they are just as prone to heat-of-the-moment lapses as anyone else. Perhaps the most notorious example might be that of 1970s-era Ford Pintos bursting into flames when rear ended. Dennis Gioia, now a professor at Penn State, was a vehicle recall coordinator at Ford when the Pinto problem emerged. He says all his available patterns and experiences at the time suggested that the Pinto case was not a red flag. Apparently, the engineers involved had similar reactions. Among other things, frequencies of occurrence were low and comparable to those of kindred models. Gioia says this cognitive “short cut” let him process the Pinto case and move on to others. He now teaches the Pinto case to MBA students as a cautionary tale about ethical considerations.

Rachelle Hollander, director of the National Academy of Engineering’s Center for Engineering Ethics empathizes with engineers in situations like that which unfolded at Ford.

“Ethics is thought of as a deliberative practice that needs to be worked on over time. I have great sympathy for people who don’t realize they are doing something unethical until it is pointed out to them,” she says.

And in today’s high-pressure/fast-tomarket climate, there’s often little time to reflect on the ethics of any single decision. As Hollander observes, “People don’t want to do the wrong thing, but they are often not in an environment that encourages them to do the right thing or that helps them figure out what the right thing is.” DW

Le la n d Te sc h le r - Exec u t i ve Edi to r ltesc h ler@wtwh m edi a .co m

On Twitter @ DW—LeeTeschler

6

DESIGN WORLD

Lee Teschler Column 4-17_Vs2.indd 6

April 2017

3/31/17 3:35 PM

Engineered elasticity Application specific designs Integrated attachments, One piece solutions Exotic materials...no problem

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Te c h n o lo gy Fo r wa rd

Yes, your microwave could be spying on you Recently, the news media was filled with the story of Kellyanne Conway, a senior counselor to President Donald Trump, claiming that microwave [ovens] at Trump Tower were turned into cameras and used to spy on Republican presidential candidate Donald Trump.

| istockphoto.com

Like many, at first I laughed at the suggestion. Then I thought about the Internet of Things (IoT). Regardless of the politics here, the idea of an appliance, like a microwave oven or coffee maker, listening to you is not that farfetched when you consider the potential reach of the IoT. Appliances that are voice enabled are listening to you. Are they recording you?

Yes, some are.

Ms. Conway is not an engineer so her explanation of an eavesdropping microwave was incomplete and her motive is not to educate anyone on the science of such appliances. But an internet-connected microwave is not impossible. (I doubt that it will “turn into a camera,” although any microwave could come with a camera. And, the microwave oven certainly could be recording anyone’s voice.)

General Electric is supposed to have a smart refrigerator that you can access while grocery shopping to make sure you don’t miss an item. Washing machines connect to the internet to gather data on water usage and frequency as well as how the appliance performs. Toaster-appliance manufacturers seek to internet-enable their products to see how often they are used and gather other data engineers will use to improve the design. “Smart” light bulbs already exist. Same with internet-enabled home thermostats and even garage door openers.

Your front door can be internet-enabled and opened by your smart phone. And don’t

forget your TV; some brands are definitely listening in as you watch and maybe comment on the content.

It is well within the realm of possibility that these devices can “spy” on you, if you define spying as listening or recording. A major purpose of these internet-enabled appliances is to gather data on how you interact with these appliances, you know, to find a way to sell you more stuff.

The other purpose is to help build artificially intelligent systems. Users of products like the Echo, whether they are aware of it or not, are participating in the education of Amazon’s artificial intelligence program. GE has an AI program. Google has one too. AI is the next phase of product development. So these devices may not store your words for posterity, but they are using them to learn how we speak, how we phrase things, and eventually how we think.

Is this spying? Perhaps. Does it matter to you? That’s the question—How much of your privacy will you trade for innovation and convenience? DW

Le sli e La n gn a u - M a n ag i n g Edi to r lla n g n a u r@wtwh m edi a .co m

On Twitter @ DW—3Dprinting 8

DESIGN WORLD

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April 2017

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» Gree n E n g i n e e ri n g

6 ways to keep an eye on energy use at the plant n Paul J. Heney • Editorial Director

Reducing energy usage has long been a focus for building facility and operations managers. Not only are costs and meeting codes a concern, but so is measuring up to the social expectations of being a good corporate citizen. Many energy-saving technologies come with large monetary outlays and often require longer term planning. But there are also a host of solutions that can quickly, easily and inexpensively deliver significant savings.

1 Room/area occupancy sensors Many areas within your facility might not be occupied for extended periods during the work day such as conference rooms, restrooms, and storage rooms. Now add all those areas that are unoccupied after hours—the energy costs can really add up. Room and area occupancy sensors can turn off the juice when it isn’t needed.

If budgeting is a challenge, start small by installing some occupancy sensors in the least occupied spaces and then slowly expand coverage. The additions will ultimately pay for themselves many times over.

2 Wall switch dimmers Lighting dimmers are an often overlooked, yet very effective energy savers, and dimmers combined with timers or occupancy sensors are very effective energy reducers. One common “best practice” is to set the starting lighting level at 50%. If more light is needed, it can be turned up.

Not only do dimmers save money by reducing power sent to bulbs, but they can also extend bulb life. Incandescent and halogen 10

DESIGN WORLD

Green Engineering_4-17_Vs1.indd 10

April 2017

bulbs have been shown to last up to 20 times longer when used with a dimmer.

When used with LED bulbs, the savings can be greater still.

3 Plug load controls Essentially a high-tech, large-scale, more customizable version of the occupancysensing power strip, plug load controllable and wireless receptacle controls help eliminate so-called vampire power draw throughout an entire building.

Products like Legrand’s Wireless Receptacle Control leverage lighting control sensors for improved ROI. Plug load controls provide an estimated 10% energy savings and meet new energy codes which require that 50% of all 15 & 20A, 125V receptacles be controlled automatically in areas such as private offices, open offices, modular partitions, and computer classrooms.

4 Digital daylight controls Why do we waste energy in spaces that are already well lit by natural light? We don’t have to—there are a host of daylighting controls that automatically reduce electric light levels based on the amount of natural light available through windows or skylights. These devices, such as dimmers and photosensors, can reduce energy consumption by as much as 40%.

5 Shading systems Shades can reduce heat, glare and energy cost. While we usually enjoy having natural sunlight coming through our windows, the

heat from the sun can affect a plant’s HVAC load.

It is possible to easily manage natural light for energy savings with automatic motorized shades, which can be programmed to raise and lower to keep lighting and temperature at optimum levels.

6 Occupancy-sensing (OS) power strips Power strips draw electricity whether or not the devices they serve are turned on. So, even if equipment is in use 8-10 hours per day, the power strips draw energy 24 hours per day.

When you consider that many of the devices that are plugged into the power strips are left on unnecessarily, you realize how much energy is wasted.

OS power strips have a motion sensor that senses when a room or area is no longer in use and automatically shuts off power to individual outlets. Because there may be devices that must receive power at all times, many power strips offer a number of “live” outlets that receive power 24/7. OS power strips give an added level of energy control for noncritical devices that don’t need power during unoccupied periods. DW Legrand North America | legrand.us

WHAT DO YOU THINK?

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Co ntent s |

April 2017 • vol 12 no 4

|

designworldonline.com

F E AT U R E S

46 54

66 76

LINEAR MOTION Fighting Cancer with precision motion control Medical devices used for diagnosing and treating cancer are taking advantage of advances in measurement and motion control.

MOTION CONTROL Effects of PID and machine parameters on positioning system performance Design or sizing mechanical components for automated designs is most effective with an understanding of motion controllers. That’s because limited controller under-standing limits opportunities to optimize automated design cost performance.

CABLES

82

HARSH ENVIRONMENTS

88

3D CAD

94

MECHANICAL

Not your father’s flat cable Innovative design enhancements make flat cables strong candidates for applications where round cable was once the natural choice.

FLUID POWER

Making WirelessHART truly wireless Advanced lithium batteries extend the reach of WirelessHART and other communications protocols to help the IoT expand into extreme environments.

How 3D CAD promotes a functioning digital thread The work toward a common digital thread is moving forward as industry addresses the challenges of developing end-to-end, readily accessible information on systems.

6 bearing killers and how to stop them Bearing failure can grind operations to a halt, resulting in significant lost time and production. Here are six common factors that can cause bearings to fail, and what you can do to prevent them.

99-107 www.bearingtips.com

A Supplement to Design World - April 2017

ON THE COVER Photo: istockphoto

Sealing basics for fluid power rookies Sealing alone is the most important contributor to the impressive might of fluid power systems and components.

Design equipment faster, smarter, and under budget with TiPS from leading suppliers. | istockphoto.com

Bearing Tips 4-17_Cover.indd 99

A | S |B |P|E

A | S |B |P|E

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12

DESIGN WORLD

CONTENTS APRIL 2017_first page_Vs3.LL.indd 12

April 2017

4/5/17 8:35 AM

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3/1/17 3/31/17 11:43 3:24 AM PM

The best temperature control valve you’ve never heard of

4 .2 017 D E PA R T M E N T S

24

4 Insights 6 Teschler on Topic 8 Technology Forward 10 Green Engineering Every valve in our highly versatile product suite uses an innovative phase change paraffin wax that accurately expands and contracts to control temperature and flow.

16 Design For Industry 24 Design Notes 32 CAE Solutions

Self-actuating fluid temperature control technology has its benefits

36 Internet of Things

• Uniform fluid temperature in industrial or commercial applications

44 Robotic Trends

• Protects personnel and valuable equipment from exposure to thermal extremes

1 08 Products

• Replaces externally powered valves and actuators

120 Ad Index

• Simplifies and reduces system components • Reduces maintenance and operating costs It’s simple. As the world leader in self-actuated temperature control solutions, we pride ourselves on the high-quality manufacturing process, problem-solving approach and innovative engineering techniques used to produce self-actuated valves and custom products where no effective solution currently exists.

Visit our website for an interactive timeline of ThermOmegaTech’s 30+ years of fluid temperature control innovation at www.ThermOmegaTech.com/solved.

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Contents APRIL 2017_second page_Vs1.indd 14

14

DESIGN WORLD

April 2017

4/3/17 8:59 AM

Follow the whole team on twitter @DesignWorld Videographer Manager John Hansel jhansel@wtwhmedia.com @wtwh_jhansel

EDITORIAL

GRAPHICS

Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler

Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com

Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Solid Silicone Sheet Silicone Foam Silicone Sponge

MARKETING Digital Marketing Director Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia Marketing Manager Stacy Combest scombest@wtwhmedia.com @wtwh_stacy

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Custom

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Marketing and Events Coordinator Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen

(ECD) Electronically Conductive

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Design for Industry | f o o d a n d b e v e r a g e

Electric cylinders are clean-in-place compatible The easier it is to clean a machine in food and beverage applications, the better. The ERD hygienic all-stainless-steel electric cylinders are designed to IP69k rating specifications for clean-in-place, hightemperature, high-pressure caustic wash downs. They are also available with a 3A- and USDA-approved option that meets requirements for over-food production in meat (livestock), poultry and dairy processing. They are designed with roller screw and ball screw options.

Forces range up to 7868 lbf (35.6 kN) with stroke lengths up to 40 in. (1016 mm) and achievable speeds to 40 in/sec (1473 mm/sec). The smooth-body hygienic design eliminates the need for actuator guarding fixtures, which simplifies machine design and lowers costs.

“The hygienic ERD is a perfect solution for food and beverage applications such as pressing, pumping, cutting or slicing,” said Aaron Dietrich, director of marketing, Tolomatic, Inc. “As an electric actuator, it is a perfect alternative to pneumatic or hydraulic cylinders, providing better motion control and higher efficiency while eliminating contamination concerns.”

ERD hygienic actuators are compatible with a variety of third-party servomotors suitable for hygienic food processing, creating a flexible, clean-in-place, electric linear motion solution.

Motor mounting can be in-line with the actuator or in a reverse-parallel configuration that reduces over-all length and allows for rear pivot mounting. DW Tolomatic | tolomatic.com

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Design for Industry | f o o d a n d b e v e r a g e

Neglecting function safety can cost in food processing Jorgen Saxeryd, safety products and functional safety advisor to ABB’s food and beverage offers some tips on ensuring safety.

In 2014 in the UK, a large food manufacturer had to pay a £800,000 fine after a serious industrial accident. An engineer was trapped by the machinery while examining a conveyor belt and suffered major injury and ongoing nerve damage. An investigation revealed that this dangerous accident could have been prevented if a guard was in place on the machine.

Across the globe, there are a variety of different regulations for food processing plants. In particular, North America and Europe have strict regulations for safety in these potentially dangerous environments. This also applies to the safety of employees in the processing plants and employers who fail to make adequate safety considerations can face large fines. Not only can these authorities enforce these in the case of accidents, they can also be enforced during regular inspections.

In Europe, the Machinery Directive 2006/42/EC requires machinery to be

designed and built so it can be used safely. In food processing plants, there are many dangerous machines for which plant managers should follow safety regulations, or the plants may face closure or high fines. Machines such as decanters operate at high centrifugal forces and it is not unknown for the machine’s g-forces to reach more than 2000 times gravitational force.

This is clearly a dangerous environment for employees to work in, however as these machines are essential for use, the key concept is the management of risk.

In the 1970s, the increase in heavy machinery such as the creation of the steel press led to increased safety guards.

Since then, many safety conscious companies undertake a risk analysis in the initial stages of machine development. In the case of decanters, it is not possible to remove the risk, but it is possible to mitigate the risk to an acceptable level by putting safety guards such as enclosures or emergency stops into place.

1.800.933.4915 www.designworldonline.com

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Design for Industry | f o o d a n d b e v e r a g e

Complete Motion Solutions Pneumatic, Electric & Hydraulic Actuators

As companies become more knowledgeable about regulations and regulations become more stringent, the need for retrofitting old equipment with additional safety measures may arise.

Although it may seem instinctive, where there is a dangerous moving machine, the safest answer is not always to shut it away behind an enclosure or barrier.

In the food processing industry, companies should consult functional safety experts who have experience in the sector. The experts will for example suggest equipment such as light grid, which perform an emergency stop on a machine when the light grid is broken by an object. These devices are more appropriate for the food processing sector than using physical guards or barriers as they allow easier access for maintenance and washdown, essential for hygiene in food processing plants.

Managers of food processing plants in all countries, regardless of the country’s regulations, should consider safety as a priority in their plant.

From the safety of single pieces of equipment to line safety and then plant safety, plant managers need to be aware of what they can do to mitigate risks. Plant managers not only have a responsibility to put in place an accurate safety strategy to protect their employees, but they also need to protect their businesses from costly infringements of worldwide safety regulations, as proven in the many cases gone by. DW ABB | abb.com

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PHD offers an extensive line of pneumatic actuators that are known for

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

long life and high quality. We have 60 years of developing and delivering productivity solutions. Our product offerings include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots. From single actuator solutions to multi-unit systems, PHD and Yamaha Robotics can provide complete solutions for practically any application requirement.

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phdinc.com/dw417 • 1-800-624-8511 18

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Design for Industry | h a r s h e n v i r o n m e n t s

High speed data transmission in harsh environments The Max M12 product line includes board level connectors that mate to a PCB board with straight or right angle solder pins. The connectors transmit data in environments where there is high vibration, moisture, salt, dirt and debris. Applications include camera and communication systems on construction, mining and agricultural equipment. It can also be used in rail and mass transit communication systems and for ruggedized factory automation.

The field installable and repairable Max M12 offers discrete connections that seal in harsh environments without requiring overmolds. The connectors are based on IEC 61076-2-101 and SAE J2839. They are backward compatible and can be mated with any standard M12 connector with the same indexing.

The Max M12 is rated to 4 A, and can withstand extreme temperatures ranging from -55°C to 125°C. All versions of this connector are IP67 or above, making them dust- and waterproof, resistant to high-pressure wash downs and water immersion. They are designed to endure a salt spray test for up to 240 hours.

This enhanced Max M12 PCB header mates to an in-line that can withstand connector-to-cable retention forces of 444 N and contact retention forces to 110 N. The in-line mate is housed in an HDM 12 EX impact resistant metal or plastic shell and both are available as 90° right angle or straight versions. The metal version is required for shielding. Both the 4- and 5-pin configurations are available with A, B, D and P polarity codes. Additional pin counts and codes are available upon request. DW Amphenol Industrial Products Group | Amphenol-industrial.com

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Design for Industry | o f f - h i g h w a y

Direct drive offers more tractive force The MCR-T radial piston motor, for compact tracked loaders and other tracked vehicles, comes in frame size 10. This unit is approximately 20% shorter than conventional radial piston motors on the market and offers around 10% higher starting torque for more tractive force. For improved efficiency, especially over long distances, the MCR-T units also allow high travel speeds at low diesel engine rotational speeds.

The compact dimensions mean that the motor completely fits in the track width of compact loaders. To do this, it was necessary to shorten the overall length by 20% compared to traditional designs, which is why Rexroth developers integrated the fail-safe, multi-disc holding brake into the outboard portion of the motor housing.

The mechanical efficiency can also be seen in the starting torque, which has been improved by 10%.

The MCR-T can withstand higher radial forces with its improved load distribution. The optimal position of the drive shaft allows the use of a simpler sprocket in comparison to conventional radial piston motors. Larger bearings that are flushed with case oil reach a service life that is up to 30% longer. An integrated flushing valve supports the cooling of the oil when used in closed hydraulic circuits, which therefore also lengthens the service life. The MCR-T’s service life lowers the total cost of ownership of the mobile working machines in which it is fitted.

MCR-T radial piston motors are for continuous high rotational speeds so that compact tracked loaders can also cover longer distances. With the control valve integrated in the motor, the operator can gently and smoothly shift between travel speeds with the soft shift mode operating in both directions. The motor then runs with reduced displacement, reducing oil flow in the circuit and improving system efficiency. Additionally, the direct drive of the MCR-T results in greater efficiency and lower noise than typical gearbox-based solutions.

MCR-T motors function with a differential pressure of up to 400 bar and the largest version achieves an output torque of up to 8,500 Nm. The displacement of the series ranges from 620 ccm to 1,340 ccm. DW Bosch Rexroth | boschrexroth.com

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5 POWER TRANSMISSION

Design for Industry | m e d i c a l

RETAINING DEVICES &

More conveying options for medical applications The SmartFlex flexible chain conveyor platform, available in an additional 85 mm width standard option, gives designers more options for applications in medical as well as packaging, food, assembly and other industries. With this addition, SmartFlex Conveyors are now available in 4 standard widths: 65 mm (2.6 in.), 85 mm (3.3 in.), 105 mm (4.1 in.) and 150 mm (5.9 in.). Other sizes that can be specially ordered include: 45 mm (1.8 in.), 180 mm (7.1 in.) and 260 mm (10.2 in.).

These conveyors are engineered to exact customer specifications and shipped in sub-assemblies for fast and easy installation. With the Online Configurator D-Tools, users can design and engineer simple or complex conveyors to meet their needs in minutes. This configuration tool delivers a complete 3D CAD assembly model for instant validation of fit.

Accessories such as infeed and exit powered transfers allow smooth end transfers for products as small as 3 in. in diameter. For additional flexibility to move product up or down and around equipment, the SmartFlex Helical Curve, Spiral, and Alpine conveyors are available.

The SmartFlex Helical Curve allows incline or decline movement through corners and straights, and provides capability for vertical incline with minimal space. The SmartFlex Spiral is capable of twisting 360° degree turns to move product vertically with a small footprint. Both the helical and spiral conveyors have chain design that allows the conveyor to maintain speeds and loads through the angled curve.

Specifications, features and benefits of the conveyor include: • Aluminum single-piece frame • Navigates very tight corners with wheel and plain bend options • Multiple product transfer options for end and side transfers • Speeds up to 250 feet per minute • Load capacity up to 600 pounds • Multiple chain types including low friction, friction insert, conductive, cleated, roller top and magnet top DW

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

ation ell Autom w k c o R ed on OEM andardiz nd has become an rtnerJoa is st a n Pa ies echnolog utomatio t A l ll ro e t n w k o c t within Roc vironmen n ithin the e w n r e ig n s e rt when pa ed flexibility gram. Th rs ro e p e rk in o g n w Net Joa’s e rm gives hines. the platfo ized mac m o t s u c g designin

Integrated control system shortens custom development process Converting machine builder Curt G. Joa, Inc. keeps

its multidisciplinary engineering team well staffed at all times. It must. The company’s current customer list includes global manufacturers who require custom machines that can take six to nine months to build.

The machines are massive, occupying two floors with a footprint measuring 60 meters long. They accomplish multiple manufacturing processes, including accepting roll-fed paper material in a continuous motion and automatically splicing products.

As customers sought more detailed production information from their machines, Joa’s engineering team began partnering more closely with them to better understand the type of machine and production data they needed.

Not surprisingly, as machine complexity increased so did the design and development time required.

Smarter machines with more automation, communication and integration capabilities entailed more programming and documentation time for the engineers. The lengthy pre-production phase extended company investment and delayed delivery of machines to customers. With new machines capable

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of producing 1,200 units per minute, each day customers must wait delays their potential for increased production output and profits.

Joa standardized on Rockwell Automation control technologies, and has become an OEM partner within the Rockwell Automation PartnerNetwork program. The design environment within the platform gives Joa’s engineers flexibility when designing customized machines.

To further help streamline the machine design process, Joa relies on several design-software programs. One of which is the EPLAN Electric P8 electrical design software from EPLAN Software & Services, an Encompass Product Partner within the PartnerNetwork program.

The engineers use templates within the electrical schematic designs as a base and then

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4/3/17 11:06 AM

» De sign Note s

customize based on each customers’ needs. A schematics generator then helps create documentation needed for manufacturing, purchasing, panel building, modeling and more.

EPLAN software integrates with AllenBradley ControlLogix controllers through the Rockwell Software Studio 5000 Architect application. This bidirectional data transfer helps improve startup time by reducing the need for manually re-entering control data from engineering tools into the Rockwell Software Studio 5000 software.

Joa implements remote-access capabilities on up to 90% of the machines it produces.

This allows any qualified customer engineer to open up a portal with a VPN connection, access the HMI to see controller operating data, and render the necessary changes.

All software on the machines is running on VMWare virtualized servers using thin clients.

There is no longer a need for a large-capacity, expensive server, and the virtual environment provides a robust, secure and IoT-ready architecture using fewer servers to run the HMI and other software.

Although Joa customizes each of its machines, the various design-software systems let the machine builder standardize much of its machine design process. Up to 80% of the database content can be standardized on EPLAN modules.

With more leadtime in the early design stages, customers benefit too. They have more opportunity to refine system features, ensuring greater satisfaction after delivery. It also gives Joa’s mechanical engineers more time to perfect their designs.

One of the biggest benefits of improved workflow is Joa’s ability to compress delivery times. Faster delivery and commissioning is a competitive advantage for the business.

Looking ahead, Joa plans to build on the synergy between EPLAN and Rockwell Automation as their global-market footprint grows and more customers embrace big data. Most of its customers now have some cloud-based capabilities, and they are looking for more ways to capture key data in smart machines. DW Rockwell | rockwellautomation.com

s each of a customize Jo h g u o h lt A esign, the various d s e in ch a m its the machine

ems let software syst of the maardize much builder stand 80% of the process. Up to chine design ndardized nt can be sta te n co se a b ta da odules. on EPLAN m

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» D e s i g n N o te s

Ken Korane • Contributing Editor

Vacuum lifting system for skid steers Vacuum lifting systems for skid steers are

an alternative way for handling concrete slabs, steel plates and other material. Vacuworx, Tulsa, Okla., has developed an array of vacuum-lifting systems tailored for the mobile-equipment industry.

The SS 2 atta chment lets The newest addition, the SS 2 vacuum lifting sysa machine lift st eel plate, tem, reportedly improves the versatility of the venersaw cut concrete able skid steer. The SS 2 attachment lets a machine , granite and marble slab lift steel plate, saw cut concrete, granite and marble s, landscape pavers and othe slabs, landscape pavers and other materials. And, acr materials. cording to company officials, the system does it faster and safer when compared to other lifting mechanisms like manual-intensive chains, slings and hooks. The SS 2 can also be used with a variety of mini-excavators or small cranes using a clevis-hook connection.

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The vacuum system, which features a hydraulically driven vacuum pump, readily mates to any skid steer. Quick-connect hydraulic hoses and a universal mounting plate make attachment quick and simple, which helps maximize productivity.

The compact, aluminum design weighs just 98 lb (without mounting plate) but has a lifting capacity up to 2,716 lb. The vacuum pump operates using the auxiliary hydraulics from the host machine (minimum 10 gpm required with maximum pressure of 3,000 psi).

The vacuum pump maintains a constant vacuum in a pressure reservoir. When activated, the system pulls a vacuum between the integrated 24 x 24 in. vacuum pad and the object to be lifted, providing a powerful positive seal. Tough elastomer-pad seals on the perimeter of the vacuum pad cover the material to be lifted and create the necessary suction. The vacuum seal holds until the operator activates the release — even in the event of a power failure.

The SS 2 is suited for floor, sidewalk, driveway, road and landscaping projects. Not only is vacuum lifting a safer alternative than hooks and chains, said Vacuworx officials, it also increases output and productivity. According to the company, vacuum-lifting systems can handle up to 10 times more material than conventional methods, are safer for workers, and help reduce the risk of accidents and lower payroll and insurance costs.

Related Vacuworx vacuum and hydraulic lifting systems are designed for many applications and lift capacities. Standard models lift a variety of materials including steel, plastic and ductile iron pipe, concrete pipe, pre-cast concrete slabs, culverts and road barriers, saw-cut concrete, and steel plate.

Lifters can be attached to excavators and backhoes (with or without a coupler system), wheel or track type loaders, cranes, pipe layers, skid steers, forklifts and knuckle booms and can also be mounted for a variety of in-plant applications. DW Vacuworx | vacuworx.com

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Neocortex G2R (thanks to its nce) can artificial intellige een drink differentiate betw s as well as tie brands and varie cans faster used and unused kers. than human wor

Robotic flexibly sorts and restocks airline beverage trays The Neocortex Goods to Robot Cell from Universal Robotics (soon to be Universal Logic — and no relation to Universal Robots) is now working in its fourth real-world application. The Neocortex Goods to Robot Cell (Neocortex G2R for short) automates the normally manual task of unloading and restocking airline beverage carts after flights end and the carts return to airline catering kitchens.

More specifically, the Neocortex G2R flexibly sorts and replenishes myriad 12-ounce beverage cans for payback on retrofits or new installations in less than a year. It typically fills a prescribed assortment at 30 drawers per hour – saving 25% versus human labor.

The Neocortex G2R includes both hardware and software — a Yaskawa Motoman MH12 six-axis robot and Universal Logic’s Neocortex artificial intelligence module — plus the automation setup, conveyors, racking for beverages, safety barriers, installation, onsite testing and operator training, and ongoing remote diagnostics and software upgrades.

Airline-hub catering kitchens spend copious time replenishing beverages consumed in-flight from 9.5 million U.S. flights annually. Pitching already-opened 28

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cans, sorting by brand leftover unused beverages, and then packing an assortment of new beverage cans into ATLAS trolley drawers (per carrier specifications) are part of the job.

Universal is offering the Neocortex G2R for this application with airline-industry veteran NxtGen Robotics.

The Neocortex G2R Cell handles sensor connection, calibration, PLC and robot communication, path planning, obstacle avoidance, vision guidance, inspection, database management, and learning.

“The robot Cell functions as a sensorinformed learning and control system, so it excels in tasks that currently require semi-skilled labor,” explained Hob Wubbena, V.P. of Universal Logic. “Other potential applications we see

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4/3/17 11:11 AM

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Within the beverage-cart-restocking application, Neocortex artificial intelligence handles inbound returned cans that are upright, tilted and lying flat. It also determines cans that are opened and partially used, or unused and returned. If the can is unused, Neocortex identifies the brand by directing the robot to pick it up and read its label. It then reuses these cans for the next new drawer it assembles — supplementing with new cans as needed based on the prescribed assortment.

The Neocortex G2R Cell is the first plugand-play robotic work cell for high-mix applications that must also handle high-volume applications scaled to a human form factor.

It’s easy to deploy like collaborative robots but with the speed and strength of an industrialrobot base. Neocortex artificial intelligence provides humanlike flexibility at speeds far faster and more consistent than manual labor.

So the Neocortex G2R Cell can handle cartons, bottles, tubes, bags, or cans for up to 1,000 picks per hour. DW

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»»

» CA E S o lut i o n s

SmartUQ: Uncertainty quantification for more realistic engineering and systems analysis Bruce Jenkins • Ora Research

SmartUQ is a software tool for uncertainty quantification (UQ) and analytics that heightens fidelity of engineering and systems analysis by taking account of real-world variability and probabilistic behavior.

Uncertainty quantification is the science of quantifying, characterizing, tracing and managing uncertainty in both computational and real-world systems. UQ seeks to address the problems associated with incorporating real-world variability and probabilistic behavior into engineering and systems analysis. Nominal—that is, idealized—as opposed to real-world simulations and tests answer the question: What will happen when the system is subjected to a single set of inputs? UQ moves this question into the real world by asking: What is likely to happen when the system is subjected to a range of uncertain and variable inputs?

UQ got its start at the intersection of mathematics, statistics and engineering. Drawing together knowledge from each of those fields has yielded a family of system-agnostic capabilities that require no knowledge of the inner workings of a system under study to make predictions about its likely behavior. A key strength of UQ methods is that they require information only about the system’s input/output response behavior. Thus, a method that works on an engineering system may be equally applicable to a financial problem that exhibits similar behavior. This makes it possible for many different industries to benefit from advances in UQ. Why UQ? Uncertainty is part of every system. It can arise from variations in measurement accuracies, material properties, use scenarios, modeling approximations and unknown future events. Uncertainty in model 32

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Sources of uncertainty.

Source: SmartUQ

boundary conditions, initial conditions and parameters adds to the challenge of determining whether a design meets all its requirements and whether it is optimal.

Most simulations are deterministic: the simulation response(s) are provided based on a given set of model inputs. Often, the engineering design effort will attempt to account for uncertainties indirectly by using extreme model initial or boundary conditions and/or material properties.

Simulation results obtained from these input conditions are then compared with criteria derived from a legacy of physical test data.

However, the practice of using extreme model conditions in this way may well fail to model reality with fidelity, and can easily overlook and omit various sources of uncertainties. Moreover, by not accounting for simulation uncertainties, the next steps may be difficult to decipher, as there can be numerous reasons for lack of agreement between simulation results and legacy testbased criteria.

UQ: Probabilistic, not deterministic In contrast to that deterministic approach, UQ is a probabilistic approach that systematically accounts for sources of simulation uncertainties. That approach makes it possible to devise corrective actions when simulation results don’t agree with physical test data.

UQ methods are rapidly being adopted by engineers and modeling professionals across a wide range of industries because they can solve previously unanswerable questions. UQ methods make it possible to: • Understand the uncertainties inherent in almost all systems.

• Predict system responses across uncertain inputs. Quantify confidence in predictions.

• Find optimized design solutions that are stable across a wide range of inputs.

• Reduce development schedules, physical prototyping costs and unexpected product failures in use.

• Implement probabilistic design processes.

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SEAL

» CAE S olutions

and

DELIVER

UQ methodology for statistical calibration. Source: SmartUQ Why now?

As computational resources have become dramatically more available and affordable, and simulation and testing have grown increasingly sophisticated and revealing, it has become possible and feasible to accurately predict behavior of more and more real-world system designs. Today, the frontier of engineering design has advanced to rapidly predicting the behaviors of systems when subjected to uncertain inputs. Monte Carlo methods require generating and evaluating large numbers of system variations, thus becoming computationally too expensive to apply to large-scale problems. More recent methods such as those incorporated in SmartUQ have made UQ easier to apply to small system designs, and feasible and affordable to use on large ones. “There’s never been a better time to start including uncertainty in your engineering process,” the company observes.

Sources and types of uncertainty Uncertainty is an inherent part of the real world, SmartUQ notes. No two physical experiments ever produce exactly the same output values, and many relevant inputs may be unknown or unmeasurable. Uncertainty affects almost all aspects of engineering modeling and design. Engineers have long dealt with measurement errors, uncertain material properties and unknown design demand profiles by including safety factors

and extensively testing design prototypes.

But deeper understanding and quantification of the sources of uncertainty will yield step-function gains in fidelity and quantified confidence of decision-making.

Uncertainties are broadly classified into two categories: aleatoric and epistemic.

• Aleatoric uncertainty is uncertainty that is beyond current ability to reduce by collecting more information. Thus, it may be considered inherent in a system, and parameters with aleatory uncertainty are best represented using probability distributions. Examples are the results of rolling dice or radioactive decay.

• Epistemic uncertainty is uncertainty resulting from lack of information that could theoretically become known, but that is not currently accessible.

Thus, epistemic uncertainty could conceivably be reduced by gathering the right information, but often is not because of the expense or difficulty of doing so. Examples include batch material properties, manufactured dimensions and load profiles.

Common uncertainty sources in simulation and testing Any system input including initial conditions, boundary conditions and transient forcing April 2017

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» CA E S o lut i o n s

UQ Inverse Analysis solutions.

Source: SmartUQ

functions may be subject to uncertainty.

These inputs may vary in large, recordable but unknown ways. This is often the case with operating conditions, design geometries and configurations, loading profiles, weather, and human operator inputs. Uncertain inputs may also be theoretically constant or follow known relationships but have some inherent uncertainty. This is often the case with variations in measured inputs, manufacturing tolerances and material properties.

Uncertainties in simulation and testing appear in boundary conditions, initial conditions, system parameters, and in the systems, models and calculations themselves. They fall into four categories:

1 Uncertain inputs.

2 Model form and parameter uncertainty.

3 Computational and numerical error.

4 Physical testing uncertainty.

Uncertain inputs—Any system input including initial conditions, boundary conditions, and transient forcing functions may be subject to uncertainty. These inputs may vary in large, recordable, but unknown ways. This is often the case with operating conditions, design geometries and configurations, loading profiles, weather, and human operator inputs. Uncertain inputs may also be theoretically constant or follow known relationships but have some inherent uncertainty. This is often the case with measured inputs, manufacturing tolerances and material property variations.

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Model form and parameter uncertainty— Every model is an approximation of reality.

Modeling uncertainty is the result of assumptions, approximations and errors made when creating the model. This can be further broken down into model form uncertainty— uncertainty about the model’s ability to capture the relevant system behaviors— and uncertainty about parameters within the model.

Using gravity as an example, the Newtonian model of gravity had errors in the model form that were corrected by general relativity. Thus, there is model form uncertainty in the predictions made using the Newtonian model of gravity. In addition, the parameters of both these models, such as gravitational acceleration, are subject to uncertainty and error. This uncertainty is often the result of errors in measurements or estimations of physical properties and can be reduced by using calibration to adjust the relevant parameters as more information becomes available.

Computational and numerical uncertainty— To run simulations and solve many mathematical models, it is necessary to simplify or approximate the underlying equations, and this introduces computational errors such as truncation and convergence error. For the same system and model, these errors can vary among different numerical solvers, and are dependent on the approximations and settings used for each solver. Further numerical errors are introduced by the limitations of machine precision and rounding errors inherent in digital systems.

Uncertainty in physical testing—In physical testing, uncertainty arises from uncontrolled or unknown inputs, measurement errors, aleatoric phenomena, and limitations in the design and implementation of tests such as maximum resolution and spatial averaging. These uncertainties result in noisy experimental data, and can necessitate replication and reproduction of scientific experiments to attempt to reduce the uncertainties in desired measurements.

UQ puts “error bars” on simulation results One of the primary objectives of running simulations is to resolve critical programmatic issues in complex systems.

This requires a high degree of confidence in the relevance of simulation results to the real world. Unfortunately, the bottom line is you don’t know how good the simulation results are without quantifying their certainty. Uncertainty quantification effectively provides “error bars” on the simulation results.

For engineers, the benefit of UQ is to become better aware and informed of the uncertainties present in simulation results when using them to make critical design decisions. Better informed decision-making leads to better product development outcomes. DW SmartUQ LLC | https://www.smartuq.com/

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»»

» CA E Solution s

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The Analysis and Viewer software “3D_Analyzer” tool provides comprehensive analysis functions for 3D models. It was developed in cooperation with leading companies in the plastics industry. The 3D_Analyzer Viewer analyzes wall thicknesses, undercuts and demolding angles as well calculates projected areas of components and assembly groups of complex plastic parts.

It is easy to operate and is suitable to experts and users without CAD know-how. In the Viewer, calculations take place quickly and precisely.

During the process, the wall thickness check also detects areas with heavy changes in wall thickness. Due to the fully automatic calculation of the projected area, the clamp force and thus the machine design can be determined with just a few mouse clicks without any CAD knowledge.

The 3D_Analyzer Viewer generates color gradients to indicate wall thicknesses and demolding angles. Moreover, the Viewer has dynamic cutting as well as measuring functions.

Analysis functions are supplemented by geometric model comparison, to indicate differences between models of different formats. Additionally, for DMU examinations, there is a function to determine collisions in assemblies as well as to calculate clearances between all single parts or components and all surrounding parts. The latest version enables the creation of explosion views that can be animated as well as drawing creation as DWG files.

The Viewer can read all common CAD formats such as CATIA V4/V5/V6, NX, Creo, Solidworks, Inventor, STEP, JT and many other ones. From within the Viewer, models can be saved in JT, CT as well as a PDF file. Floating licenses with a borrowing function enable a simple, flexible use of the software within and outside of companies. DW

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I nter net of Things

......................................... ............................... ....................... .................. ............. .......... ....... ..... ...

Drive web server access module .

Sinamics V20 Smart Access web server module mounts directly onto a drive, transforming a

mobile device or laptop into a virtual operator panel for drive control. This module provides a WI-FI hot spot, which facilitates setup, programming, commissioning, production monitoring and maintenance on machines and production equipment.

The module has a simple, embedded graphical user interface (GUI). No separate app is required, nor is a written operator manual needed.

Communication distance is up to 100 meters, enabling access to drives located in difficult to reach areas. Using WPA2 security, the web server module works with both iOS and Android operating systems, along with commonly used HTML5-capable web browsers such as Chrome, Safari, Internet Explorer and others.

A built-in, multi-color LED quickly shows status readout.

Security features enable limit / restrict operator access and control function.

In use, the Sinamics V20 Smart Access module requires only a few steps to set-up and no installation or download of additional software is needed. The onboard Quick Set-up Wizard makes commissioning fast and easy, enabling all of the following: entering and checking motor data, activating connection macros for digital inputs/outputs, selecting application macros and activating pumps, fans, compressors and other devices, plus the common and frequently used parameters on the drive can be set for motor start, acceleration, deceleration, min./max. speed, and so on.

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Users can monitor drive status including speed, current, voltage, temperature and power, as well as drive servicing, with an overview of alarms, faults and individual values. Fault codes can be transferred with e-mail to a local service provider. Parameter adjustment, motor test functions and full data backup, storage and sharing with fast firmware downloads can all be accomplished with the web server. DW Siemens Digital Factory | usa.siemens.com/sinamics-v20

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A next-generation accelerometer is for long-period monitoring of the physical

condition of high-value assets. With its low power capabilities, the ADXL372 micropower high-g MEMS accelerometer targets Internet of Things (IoT) solutions where shock and impact on a unit during storage, transit, or use would adversely affect its function, safety, or reliability. Representative assets include materials inside shipping and storage containers, factory machinery, and battery powered products where there may be lengthy quiet periods punctuated by spontaneous, severe impacts.

The ultralow power MEMS sensor has an “instant on” feature and can wake up immediately to acquire the entire waveform, which significantly reduces standby power drain. The resulting low current requirement of less than two microamps while waiting for an impact typically yields years of operation from a single small battery when the sensor is used in a motion-activated system. By using the ADXL372 MEMS accelerometer as part of a remote edge-node device in an IoT application, transient events can be captured and

categorized by a localized processor beforehand by being sent to the cloud or other data center with a wireless link. Keeping the analysis localized saves power, time, and prevents unnecessary transfer of data for an event that is actually insignificant.

The wide bandwidth of 3200 Hz and dynamic range of ±200 g also fits a diverse set of asset health-monitoring applications including monitoring of concussions for indication of Traumatic Brain Injury in both athletes and military personnel. DW Analog Devices | analog.com/internet-of-things

4000V Isolated Gate Driver Module

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Phase-leg IGBT Modules: • up to 600A/600V • up to 600A/1200V • up to 450A/1700V ORDERING INFORMATION IXIDM__ DESIGNATORS

      

DESCRIPTION Module Configuration Isolation Voltage Gate Current Positive Gate Voltage Negative Gate Voltage Negative Gate Voltage Package Information

SYMBOL 1 40 1, 3 15 05 15

DESCRIPTION Two Isolated Gate Drivers 4.0 kV 10 A, 30A 15 V -5 V -15 V O – Open Frame, M - Molded

PART NUMBERS AND ORDERING OPTIONS: IXIDM1401_1505_O - two isolated gate drivers with 10 A gate current , 15 V positive and -5 V negative gate voltage, open frame version.

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IXIDM1403_1515_O - two isolated gate drivers with 30 A gate current , 15 V positive and -15 V negative gate voltage, open frame version.

IXIDM1403_1505_M - two isolated gate drivers with 30 A gate current , 15 V positive and -15 V negative gate voltage, molded version.

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Raptor’s slotted clamp rings offer more clearance at the bolt holes for an easier installation than competitive designs.

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I nter net of Things

IIoT smart spherical roller bearings

Safe grip three-lobe knobs

• Safe – ample lobes provide an effective and safe grip even when wearing gloves.

Designed as an off-the-shelf approach for quick turnaround needs, the Industrial Internet of Things (IIoT) Smart PT Select Mounted Spherical Roller Bearings suit conveyor and fan and blower applications in the aggregate, air and fluid handling, cement, and material and package handling industries. A suite of digital technology is built into and around this bearing.

• Easy to Keep Clean absence of recesses ensures easy cleaning and prevents accumulation of unhealthy residues and dust.

These bearings offer: • Product specific QR code — each bearing tag features a laser-etched QR code for

• Corrosion Resistant – AISI 304 stainless steel inserts are suitable for equipment which requires frequent cleaning.

quick access to product specific information such as how to videos and instruction manuals from their mobile device.

• Dedicated mobile app — The Bearing Mobile Pro app includes the capability to scan the product specific QR code found on each bearing.

• Engineered bearing seals for increased product life — standard triple lip and clearance seal provide maximum ingress protection against contaminants; clearance seal reduces operating temperatures at higher speeds; and features nitrile material with protective metal shield. DW

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I nter net of Things

N EWS: ..................................... ........................... ................... .............. ......... ...... ... . Opto 22 partners with IBM for IoT applications development Industrial automation manufacturer and Internet of Things application toolset provider Opto 22 announced acceptance into the IBM® Watson IoT™ Partner Ecosystem. This partnership provides developers with a full stack toolset for building applications that connect real-world signals and data from industrial “things” to the digital world of information technology, mobile, and cloud computing.

Legacy equipment holds valuable untapped data that is needed to improve business processes and decisions in almost every enterprise and every industry. The partnership between IBM and Opto 22 enables developers to rapidly design, prototype, and deploy applications to connect existing industrial assets to the IBM Watson IoT platform and share their data, capabilities, and resources with other connected systems and assets, to build the Industrial Internet of Things (IIoT).

Through this partnership, developers and systems integrators have a concise toolset for connecting the OT and IT domains. The partnership combines more than 40 years of OT domain expertise and innovation from Opto 22 with more than 100 years of IT domain expertise and innovation from IBM. Combining open technologies like RESTful APIs and Node-RED with proven computing platforms like the IBM Watson IoT platform decreases development time, eliminates the need for expensive middleware, reduces risk for customers, and gets solutions to market faster.

The Watson IoT Platform reduces the need to focus on developing analytics systems and provides everything needed to harness the full potential of the Internet of Things. Rather than reinventing the wheel, developers can tap into the already built toolset provided by the IBM Watson IoT Platform.

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I nter net of Things

Developers can connect, set up, and manage edge-processing devices like programmable automation controllers from Opto 22 and apply realtime analytics, cognitive services, and blockchain technology to the data generated by these devices.

Cognitive APIs deliver natural-language processing, machine-learning capabilities, text analytics, and image analytics to help developers realize the potential of the cognitive era with the IBM Watson IoT Platform.

Connecting existing industrial assets to IT systems requires translating the electrical signals (voltage and current) in the physical world to the bits and bytes of the digital world. Opto 22, respected worldwide for its 42-year history of product quality and innovation, manufactures the I/O and controllers that translate signals at the network edge from industrial assets into the language cloud computing systems like the Watson IoT Platform understand.

Opto 22 products provide industrial automation protocol support, including Modbus/TCP, EtherNet/ IP and OPC UA. These industrial products also communicate and support well-known Internet technologies to support IIoT applications.

Where edge computing, decision making, autonomous control, data collection, and logic solving need to occur, Opto 22 products fuse together a rugged industrial control platform with open technologies like a built-in HTTP/HTTPS server, RESTful API, and Node-RED nodes to easily collect data from the edge and move it into the IBM Watson IoT Platform.

“The industrial automation and control industry is in transition right now,” says Benson Hougland, Vice President of Marketing and Product Strategy. “A product development strategy based on proprietary and closed technologies is outdated. The future of industrial automation and process control lies in the rising API and data economies made possible through open standards-based technologies. Our objective in partnering with IBM is to enable IIoT developers to build their applications faster using well-known and proven Internet tools and technology like Node-RED, RESTful APIs, and the IBM Watson IoT Platform.”

April 2017

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Ke l l e r m i c r o p r o c e ss o r - b a s e d s i g n a l c o n d i t i o n i n g p r o v i d e s o u t s ta n d i n g a c c u ra cy , s c a l e a b i l i t y , a n a lo g + d i g i ta l o u t p u t s , a n d a c t i v e t h e r m a l c o m p e n s at i o n t o p r o v i d e t h e m o s t v e r s at i l e O E M p r e ss u r e m e a s u r e m e n t s o l u t i o n ava i l a b l e .

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Designed on open standards and built for harsh industrial environments, Opto 22’s SNAP PAC System integrates hardware and software to simplify understanding, selecting, and applying an automation system. The SNAP PAC System consists of these integrated components:

• SNAP I/O—analog, digital, and serial I/O modules for wiring

directly to field devices, machines, and sensors. Wide variety of signal types; 1 to 32 I/O points per module; most I/O modules are guaranteed for life.

• SNAP PAC brains—intelligent I/O processors for distributed control on Ethernet and serial networks • SNAP PAC controllers—standalone or rack-mounted

industrial controllers with networking options and a RESTful API, or a software-based controller • PAC Project Software Suite—easy-to-use flowchart-based

control programming, HMI (human-machine interface) development and runtime, plus optional OPC server, database connectivity software, and software-based controller for PC-based control

• groov—an easy-to-use tool for building and using custom

Canfield Connector offers a complete line of highquality sensors at value pricing. We offer tie rod and groove mount products to cover a full range of applications.

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mobile operator interfaces and system dashboards to monitor and control systems and equipment from any web-enabled device Opto 22 has provided a recipe for developers to get started in connecting industrial systems to the Watson IoT Platform, as well as a video walking developers through the steps. Developers can access a trial version of the Watson IoT Platform on the IBM website. DW Opto 22 | opto22.com

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»»

R o b o t i c

T r e n d s

Putting humans at the center of robotic design Edited by: Paul J. Heney • Editorial Director

At the recent Hannover Messe Preview in Germany, a new collaborative industrial robot was unveiled, dubbed Franka Emika.

“I strongly believe that Franka Emika is a game changer not only in intelligent robotics but also far beyond, opening the doors to a new world of connected digital intelligence accessible to everybody. My goal is the democratization of automation,” said founder Sami Haddadin.

The robot was developed, its creators say, to solve six problems that are still restricting manufacturers from implementing robotic assembly:

• Integration, programming and tooling is too expensive and extremely time consuming.

• Solutions are custom-made and lack reusability and adaptability. Consequently, investment is project specific and cannot be depreciated over several projects.

• Complicated programming procedures limit flexibility as industries depend on highly skilled experts—especially in the electronics market, which has very short product life cycles and therefore requires frequent production rearrangements.

• The current robotic solution costs cannot compete with labor costs at production sites.

• Deployment by existing staff at the production facility is not possible.

• Lack of sensitivity severely limits the robot’s product assembly capabilities.

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R o b o t i c

Franka Emika, which features 7 degrees of freedom, is a first-generation collaborative robot system that is designed to assist humans. The construction is completely modular, ultra-lightweight. It has a highly integrated mechatronic design, sensitive torque sensors in all joints, and human-like kinematics, making the system unique. Based

on the “soft-robotics-control,� inspired by humans, Franka Emika is able to recognize and process even the slightest contacts—to react within milliseconds.

The robot has access to a continuously growing online world of apps, which permanently expands Franka Emika’s skills. Users can also seamlessly stream its data tom connect with Industry 4.0 applications.

Pilot is Franka Emika’s direct user interface on the Franka Arm. It provides quick-buttons to customize the apps and to execute their features. The pilot is essential for teaching the robot via demonstration. For example, the user can simply press the guiding button and take the robot by hand to teach it what to do. After it learns the task, it operates

T r e n d s

autonomously. Franka Hand can grasp firmly and quickly for high performance and flexible pick and place. The fingers can be exchanged to optimally grasp a wide variety of objects.

Due to its force-sensitivity and compliance, it can release and lock the fixture mechanism of its fingers by itself. Hence, different optimized fingers can be seamlessly integrated into any automation processes, and manual tool exchanges become almost unnecessary. DW Franka Emika | franka.de

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with precision motion control Medical devices used for diagnosing and treating cancer are taking advantage of advancements in measurement and motion control.

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Medical technology, as well as precision measurement / motion control advances, have come a long way in recent years. With continued R&D in both, new and exciting combined developments have emerged. That’s the case with the advent of a new dedicated solution for breast cancer radiotherapy.

Patients treated on the GammaPod will likely only need between one to five treatments in order to eradicate certain breast cancers, which is much shorter than the current six-week, five days a week course of radiation.

This revolutionary new system by Xcision Medical Systems, LLC of Maryland is called the GammaPod, and is currently in clinical trials at the University of Maryland School of Medicine in Baltimore. At the core of this new machine is a moving bed for a prone patient and a patented two-cup system that holds and stabilizes the breast with the target. This allows a targeted and powerful dose of radiation using 36 Cobalt-60 sources that can be administered in new and unique ways, with less dose to normal tissue.

April 2017

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The GammaPod from Xcision Medical Systems aims to eliminate early stage breast cancer with as little as one treatment. A highly accurate and targeted radiation dose means less dosing to healthy tissue.

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Rotary servo table drives optoacoustic imaging system Scientists at Tomowave Laboratories use technologies based on light and sound to make imaging systems for the healthcare industry. These technologies use optoacoustic and laser ultrasonic methods to produce modalities such as a laser optoacoustic ultrasonic imaging system, which uses pulses of laser light with a dark red color. (Optoacoustic tomography (OAT) is a technique for generating highresolution images of biological tissue that scatters light waves, typically biological tissue.)

Biological tissue absorbs this light, causing it to heatup by a fraction of one degree. The resulting temperature increase causes an increase in pressure, which generates ultrasonic (optoacoustic) waves. The imaging scanner uses arrays of transducers to measure these ultrasound waves at different locations to generate images of internal tissue of different human and animal organs, such as breast or prostate. These systems listen to the sound of light, allowing doctors to detect and diagnose cancer and other conditions.

Recently, engineers at Tomowave developed a system that combines light and sound to generate three-dimensional images of tissue submerged in the imaging module, primarily the tissue of small animals used for research purposes and development of new contrast agents or therapeutic methods.

This optoacoustic tomography system is the first of its kind to produce functional 3D images of biological tissue with equally high resolution in each volumetric direction. The system provides comprehensive information on anatomy and function. These images are especially useful for studying the distribution of blood and its oxygenation level.

Imaging module Preclinical research systems rotate the object of study, while the module itself rotates in systems used in clinical settings such as breast imaging systems. Noninvasive breast imaging systems apply the same technology to produce three-dimensional volumetric optoacoustic images and a stack of two-dimensional ultrasonic images, allowing for image co-registration.

These systems produce scans at different wavelengths in minutes with minimal patient discomfort. Custom software processes the volumetric data according to the specific items of interest, which may include hemoglobin content, oxygen saturation and vasculature visualization.

The imaging system uses a PSR180UT low-profile rotary servo table from IntelLiDrives to rotate the imaging module at a constant speed, which is programmed in advance. A real-time precision encoder output allows synchronization of the image capture with the motor’s position, allowing the system to reconstruct the images in three dimensions.

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The optoacoustic tomography system’s imaging module uses a 360-degree rotation to generate three-dimensional images. | courtesy of Tomowave

“The emergence of accelerated partial breast irradiation (APBI) as a breast cancer treatment option is an example of personalized medicine replacing a one-size-fits-all approach,” explains Xcision’s VP of Engineering Peter Maton. “This has the potential to change the way early detected breast cancer is treated, to the point of sometimes eliminating surgery altogether, and at a lower cost than traditional procedures.”

Design for accuracy and redundancy The moving bed and cup system are unique to the GammaPod. The movement is designed using precise motor controls, gear boxes, and linear bearings, as well as five linear encoders on the bed and two rotary encoders on the bowl system. The encoders provided by HEIDENHAIN provide absolute position values from the moment they are switched on. Even movements that occur while the system is without power are translated into accurate values once the system is powered up again.

“Using HEIDENHAIN’s absolute encoder system has allowed us to minimize the uncertainty of the zeroing process otherwise required for incremental encoders and the timeconsuming nature of it,” explains Maton.

The absolute encoders are used for a secondary positional measurement to verify correct positioning which ensures the accuracy of the delivered dose. The direct mounting and absolute calibration provide real-time quality assurance of the bed positioning system.

One of the key design goals of the GammaPod system is to create a practical, and comfortable means of prone treatment and Xcision executives believe they’ve accomplished that.

A patient will approach the GammaPod bed while it’s in a vertical position, step on and position the breast cup to be locked to the bed, which will then gently glide into the horizontal position.

With a patient lying face down on the machine bed, rather than on their back, the breast to be treated naturally falls further away from the chest wall, helping to minimize dose to organs in that region.

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EQN 1023 absolute rotary encoders from HEIDENHAIN are used on the drive systems to ensure alignment accuracy of the radiation sources and collimators.

The five absolute LIC 4100 linear encoders are incorporated within the GammaPod table, which serve to monitor the table’s position, and thus verify the patient’s position. These linear encoders are directly mounted on the two table support columns. On each column, Xcision separately monitors the height and lateral offset of the table and the fifth monitors the length axis.

The linear encoders are rigidly mounted to the table. “This gives us an absolute stable positioning readout because they are directly mounted to the things we are controlling. With that, we have accurate confirmation of XYZ position in order to be sure the cup is in the correct location for the radiation,” adds Maton.

The LIC 4100 exposed encoders are characterized by permitting absolute position measurement both over large traverse paths (up to 28 m), at high accuracy and at high traversing speed, although Xcision only needs around 400 mm of travel.

The absolute nature of the linear encoders is critical because it allows for detection of primary system failure or calibration error.

According to Maton, with the redundant secondary system, the position of the patient is confirmed to be free of such failure or calibration errors, thus ensuring treatment of the correct location in the breast.

“We control the radiation on/off and beam size by relative rotation of two bowls, one holding the sources and the other holding the blockers/collimators. We utilize two drive systems that must be controlled within a tight tolerance,” explains Maton. The two HEIDENHAIN EQN 1023 absolute rotary encoders on the drive systems provide independent confirmation of the alignment accuracy.

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The GammaPod uses five HEIDENHAIN LIC 4100 linear encoders mounted to the table to monitor position of the table and the patients on the table.

ensures that we know the radiation sources are in the right position at all times, relative to the blockers / collimators,” explains Maton. “So in real time, the readings are being checked in both primary and secondary systems. We had started off with relative magnetic encoders in our design, but they were not satisfactory for a couple of reasons.

First, we had the problem of having to rotate very slowly in order to find the zero point at each power

up, and second, it turned out they weren’t linear enough for our needs. So the HEIDENHAIN absolute encoders were the better answer to drive our system.”

Treatment delivery As mentioned, Xcision’s GammaPod uses a two-cup system to encapsulate the breast for treatment. The inner cup is designed to

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M ot i o n constrain the shape of the breast. Suction between the cups gently pulls the breast to completely fill the inner cup, and immobilize it. The patient is imaged on a CT scanner, then without removing the cup, moved to the treatment device and the cup is locked into the treatment bed. A copper wire (referred to as a fiducial marker) embedded in the cup is used to establish a 3D coordinate system which is used for treatment planning to create the bed position sequence (control points) for the treatment.

The focused and concentrated dose of radiation is delivered according to this sequence.

The focus means that the dose will fall off sharply outside the target volume, reducing dose to healthy breast tissue, organs such as the heart and lungs, and to the skin. This decrease in collateral dose minimizes unwanted exposure and side effects.

The planned treatment is based on the established coordinate system and motion control, and includes a specific amount of time for the radiation beams to remain in each position in order to achieve the correct distribution of dose.

The system is designed to match a planned dose and delivered dose within one millimeter. DW HEIDENHAIN | heidenhain.com Xcision Medical Systems | xcision.com Tomowave | tomowave.com IntelLiDrives | intellidrives.com

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Effects of PID

and machine parameters on positioning system performance Boaz Eidelberg, Ph.D., • President • Optinet Inc. 54

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Most mechanical engineers aren’t familiar with servo control. That’s because servo control is mainly associated with electrical engineering — and mechanical engineers are mostly tied up with CAD work. But they may be involved in the design of highperformance servo-controlled systems in which mechanical parameters (such as stiffness, mass, and damping) are interchangeable with proportional, integral and derivative parameters of a PID controller. So, the design or sizing of mechanical components for automated setups should be done with good understanding of the motion controller and its associated filters. That’s because without controller insight, it’s hard to optimize the cost performance of automated systems.

As we’ll explore, a tutorial webtool can highlights the relationship between key machine and controller parameters, as well as basic servo definitions and the process of optimizing machine performance and stability. The tool interface is shown in Figure one: Overview of the tutorial webtool. Based on a simple positioning system model, it lets users change both PID and mechanical parameters of the model and observe their effects on system performance.

Design or sizing mechanical components for automated designs is more effective with an understanding of motion controllers.

That’s because lack of controller understanding

Relationship of servo parameters and mechanical phenomena PID servo parameters and mechanical design parameters of high-performance automation tools are closely related. It’s best to analyze overall system cost and performance by accounting for both as early as possible in development. One self-study webtool can demonstrate the effects of both servo and mechanical parameters of a typical positioning system on its dynamic performance and stability. The tool we demonstrate lets users select stage parameters that characterize the actual plant — and then use iterative strategies to select an optimal set of PID parameters to maximize overall system performance for robust, safe, and stable operation.

Block diagram and system modeling The block diagram of the model as shown in Figure two: Block diagram of the model represents a simplified closed-loop servo system of a positioning stage. It includes a PID controller, a stage (plant), feedback loop, reference position command Xr and actual stage position X. X is sensed by an encoder or by any other positioning feedback device. The stage model (as shown in the figure’s block diagram) is represented by simple mass, spring, and damper parameters — M, K, and B respectively. They are the most influential mechanical parameters on the dynamic performance of most positioning systems.

limits the optimization of | image: istockphoto.com

designs.

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The tool’s block diagram is shown on the upper right. Input parameters are in yellow boxes. Results are in blue boxes. Settling time after a step input is shown on the upper chart. Frequency responses of the plant PID controller (as well as closed-loop and open-loop transfer functions) are shown on the bottom. Access this tool at optineer.com and clicking on ANALYSIS and then PID control. From there, click EXAMPLE and then RUN. Also use the tool for learning by changing system parameters and clicking RUN again to observe their effects on results.

As shown in figure two, a driving motor force F acts on the stage block as an input and results in the actual stage position X as an output.

Similarly, position error E = Xr - X acts as an input to the controller block and results in the motor force as an output.

The time-domain relationship between the output X and the input Xr is given by the following two differential equations: MA + BV + KX = F(t) for the stage — where A = dV/dt and V = dX/dt F(t) = Km*(Kp*E +Ki*∫ Edt+Kd*dE/dt) for the PID controller — where Km is the motor constant and Kp, Ki and Kd are the PID gains.

Transfer functions and phase angles The explicit relationship between the output X and input Xr of the closed-loop servo system requires simultaneous solution of the two differential equations. The solution is simplified from differential equations in time domain (t) to algebraic equations in frequency domain (s) by using their Laplace transform. The Laplace transform H(s) of our closed-loop transfer function is represented:

( )=

( ) ( ) 1+ ( ) ( )

Where K(s) = PID transfer function; G(s) = Plant transfer function; and H(s) = Complex number as a function of frequency (s) with both magnitude (gain) and phase angle (Ph).

Gain is often measured in dB= 20*Log10(gain).

The phase of output X with respect to input Xr is measured in degrees. A phase of 0˚ means that actual position X is in phase with the reference position Xr. At the same time, it is 180˚ out of phase when it feeds back into the controller with a minus sign (-) as shown in the block diagram of Figure two: Block diagram of the model.

Similarly, a -180˚ phase lag means that the output signal feeds back into the controller with a -360˚ phase shift.

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That makes it a positive feedback inside the controller and a source for possible instability of the closed-loop servo system.

Plant frequency response and stability of closed-loop servo systems When we RUN the webtool after clicking EXAMPLE, the results in the blue boxes (below the stage parameters) show two important stage characteristics of any automation system — the lowest natural (resonance) frequency and the damping coefficient. High performance machines are typically designed for high stiffness K and low moving mass M to get the highest value for the lowest natural frequency.

The frequency response (Bode plot) of the stage is shown in Figure three: Frequency response of the stage (plant).

In this figure, we see that the gain has an approximately constant value all the way up to the natural frequency. At the natural frequency, the gain increases with a peak bounded by the magnitude of the damping coefficient. Then with increasing input frequency, the gain drops at a rate of 40 dB/ decade, where a decade is defined as the ratio of two frequencies which is equal to 10.

Similarly, the phase starts at zero degrees in low frequencies. It then reaches -90˚ lag at the natural frequency and ends up at -180˚ phase lag at very high frequencies.

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C o n t r o l Real dynamic systems have multiple natural frequencies and usually multiple axes. But the single-axis model in this webtool is a good performance estimator of most positioning systems.

Optimal choices for the simple model have mass, stiffness, and damping parameters that yield the lowest natural frequency and damping coefficient of the more complex system. These two-system characteristics are easily measured for any complex system by an impact test and an accelerometer that traces settling time decay.

PID controller frequency response Many control systems have (in addition to a position-feedback loop) inner velocity and current feedback loops. Yet they all share the same basic closed-loop transfer function H(s) as shown in figure three.

The difference is in the complexity of their H(s) expression and the numbers of zeros and poles, with which the controller filters are shaped. A zero is a frequency at which the gain becomes zero, and a pole is the frequency at which the gain goes to infinity.

Although these complex filters are beyond the scope of this tool, the PID as used in our model is considered a classic filter, which is used in many controllers. It is simple (having only one pole and two zeros), relatively easy to understand, and a good one with which to start training for an intuitive understanding of servo-system performance.

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M o t i o n When we click RUN, the corner-points results of the integral and derivative gains appear in the blue boxes below the yellow PID parameters. Corner points are the frequencies where the integral gain and the derivative gain cross the proportional gain.

Together they define the shape of a trough, as shown in Figure four: Frequency response of the PID controller.

Looking at the gain of the PID frequency response in Figure four: Frequency response of the PID controller, we see that the integral contribution on the left side of the trough amplifies the error signal at low frequencies and attenuates it at high frequencies. The derivative on the right side amplifies the high frequencies and attenuates the low frequencies. The proportional gain (in between the two corner frequencies) defines the bottom of the trough. So if we want to reshape the trough and move the corner point of the integral gain to the left (for example) we decrease the integral gain.

But if we want to move the corner point of the derivative gain to the right, we decrease the derivative gain and vice versa. Similarly, if we want to raise the bottom of the trough we increase the proportional gain ... and if we want to raise the entire trough, we increase the motor constant.

Looking at the phase diagram of the PID as shown in figure four, we see that starting at low frequencies the integral gain adds a lag of 90˚ (-90˚) to the input signal of the controller. Similarly, the derivative gain adds a lead angle of 90˚ — and the proportional gain does not affect the phase, but it may affect the way the lead and lag frequencies connect. The reader may test these trends by making the changes in the webtool and observing the results on the trough position and shape.

In a general machine design, the proportional gain Kp and the motor constant Kf act as mechanical stiffeners K which improve the response time. The derivative gain Kd acts as a mechanical damper B which attenuate high oscillations. The integral gain Ki may act (in some cases) as a mechanical attenuator such as the inertial effect of a moving mass M. However, in positioning systems it is mostly used in overcoming position errors due to friction.

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Open-loop frequency response and phase margin When we multiply the two transfer functions — including the plant G(s) and controller K(s) — we create the open-loop transfer function K(s)G(s), as shown for our EXAMPLE in Figure five: Frequency response of the open-loop transfer function. The open-loop frequency response is an important visual aid for phase margin and gain margin, which are the indicators of system stability.

From the expression of the closedloop transfer function H(s) we see that when the open-loop transfer function K(s)G(s)= -1 (and output signal X is a mirror image of the reference signal Xr) the denominator of H(s) becomes zero and the gain of the closed-loop transfer function goes to infinity and makes the system unstable. The physical meaning of this expression is that when an output

signal X has a -180˚ phase angle with respect to the reference position Xr — meaning that it is a mirror image of the input reference signal Xr — it enters the controller with a (-) sign, which adds another 180˚ to it.

The result is a total of -360˚ phase lag that makes the output signal X in phase with the reference signal Xr and therefore act as a positive feedback. This positive feedback tends increase the position error instead of reducing it —potentially making the system unstable. To become unstable, the feedback of actual position X needs to be positive, but it also must be equal or greater than the reference signal Xr with a gain equal or greater than 1. In this unstable condition, the servo controller pumps in external energy to the system that continuously increases the oscillation amplitude of the stage.

If we look at the response to the step input in time domain as shown in Figure six: System response to a step input in time

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domain, we see an oscillatory yet stable profile. If we then look at the open-loop frequency response, as shown in figure five, we see that the phase angle, which corresponds to a gain of 1 (0 dB), is equal to about -130˚ ... and the difference between -130˚ and -180˚ is +50˚. This is a safety margin to stability, which is called phase margin. It measures the angle, from the phase at an openloop gain of 1, to the -180˚ line, which make the system unstable.

Servo systems are typically tuned to a phase margin of 30˚ to 40˚.

Bandwidth considerations for design work Another aspect of the closed-loop transfer function H(s) is that when the open-loop gain K(s)G(s) is very high, the closed-loop system gain is about 1. When the open-loop gain is very low, the closed-loop transfer function resembles the open-loop transfer function. So we may expect that the closed-loop transfer function will be close to 1 until the open-loop transfer function crosses the open-loop line of gain = 1 (0 dB). The frequency at that point is called the position bandwidth.

Consider one example. In the open-loop plot of our EXAMPLE in figure five, position bandwidth is around 10 Hz. So we expect the servo system to drive the stage with a very small position error in all frequencies lower than the bandwidth.

Above the bandwidth frequency, the servo system may be incapable of following the input position without error. Similarly, if disturbing forces act on the stage at higher frequencies than the bandwidth, the servo may be incapable of rejecting them, and other means (such as feedforward loops — beyond the scope of this article) may be required.

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Shown here are corresponding labels of phase margin, gain margin and the position bandwidth.

Servo tuning example exercise As a tutorial exercise of our EXAMPLE, let’s try to improve the natural frequency of the stage by increasing its mechanical stiffness K by a factor of 10. (Here, we simply add a zero to the stiffness value and then click RUN.) We see that natural frequency increased (as expected) by a factor of sqrt(10) to 41.1 Hz. Also notice that the bandwidth dropped from its original value of 10 to about 1 Hz and the settling-time response became sluggish. That’s because when we increase the stiffness by a factor of 10, the stage gain dropped by 20 dB and the crossover frequency of the open-loop transfer function moved to the left. This shift decreased the position bandwidth and slowed down the stage.

To increase the low-frequency gain (which was lost in the previous iteration) we may try to increase the integral gain Ki by a factor of 10 (by adding a 0 to the integral gain value Ki and clicking RUN). Results in Figure seven: Servo tuning process with PI gain changes show the left side of the trough increased, bandwidth went back to about 10 Hz, and the resulting response became faster yet oscillatory.

Gain margin example exercise In the last tuning example, we reached a bandwidth of about 10 Hz with a 90˚ phase margin. As mentioned, this is one condition to ensure system stability. Another condition for stability is gain margin — the distance (in dB) between the zero-dB line and the open-

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loop gain curve at a frequency where the phase is -180˚. Figure eight shows it to be about 15 dB, which occurs at about 80 Hz. The chart in figure eight also shows the phase margin and the bandwidth as discussed earlier.

The rationale of the gain-margin requirement for stability is like that of the phase margin. When the phase is -180, we need to ensure that output is lower than the input with a gain magnitude of less than 1. Otherwise, the servo will command the motor to add increasing energy to the system, which increases output indefinitely — and makes the system unstable. Under such conditions, any small noise (such as RFI, EMI, or small floor vibrations) may run the system unstable. Results may be noticeable as loud audible noise, high vibration, and (at high enough gain and low enough damping) a possible catastrophic failure. Servo systems are typically tuned to gain margins greater than 15 dB. Mechanical improvements for better design performance To attenuate the ringing effect as shown in figure seven and shorten the settling time response, we can try to increase the mechanical damping. As shown in figure nine, increasing the mechanical damping B by a factor of 10 gives a smoother motion profile and reduced settling time — from longer than 200 msec in the previous iteration to 120 msec in this one.

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M o t i o n

C o n t r o l

System optimization with multiple iterations We may continue the iterative process of tuning system parameters for optimal performance by trial and error or by recommended tuning processes. Several widely used tuning techniques involve a PID parameter that is changed until the stage starts ringing. Then, the parameter value is reduced and the next parameter is increased until it resonates the system again. This process continues until the designer gets a good settling profile and the settling time is minimized to an acceptable value. An example of what a good tuning profile may look like in time domain is shown in Figure ten: Optimal system performance. Settling time in this iteration is reduced to 46.6 msec.

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Note that the webtool presented in this article is provided as a courtesy of Optinet Inc., but the company doesn’t warrant the tool’s results. It’s the responsibility of the user to validate results by other means — as with comparisons with results from other tools, common sense, third-party expert opinions, or test results with a high-performance motion controller. The webtool is primarily intended as a self-study tutorial of simultaneous effects that PID and mechanical parameters have on the performance and stability of automated mechanical systems. DW

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C a b l e s

Not your father’s f lat cable

Innovative design enhancements make flat cables strong candidates for applications where round cable was once the natural choice.

Edited by: Mary C. Gannon • Senior Editor

Flat cable has been around for about 60 years, since Cicoil invented the ribbon cable for IBM computers in 1956. Over the decades it has been a favorite in high end computing, military and aerospace, robotics and motion control devices. Its advantages include superior flexibility, electronic noise abatement, and packaging efficiency. Its limiting factor over this time has been the need for unique termination techniques—prepping for connectors has largely required hand work. A new type of flat cable has been developed by Cicoil Corporation that promises to put this last hurdle into the past, opening the potential for engineers to take advantage of flat cable advantages while using the common cable prep tools and automated processes currently in use with round cables.

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10

top reasons to use flat cables

1. Reliability – The simplicity of flat cable with its parallel conductor geometry eliminates many of the common sources of wiring errors and malfunctions. Conductors are registered one-toone with the terminating connector or board so proper contact assignment is almost automatic.

2. Weight reduction – The use of flat cable often eliminates much of the conventional wire weight. Such things as redundant insulating materials, fillers and tapes are unnecessary. In addition, the composite flat cable construction is mechanically strong enough to eliminate the need to include large conductors for strength. The copper cross-section can thus be reduced to only that necessary to carry current loads or to satisfy voltage drop requirements.

3. Space efficiency – Elimination of unnecessary insulation,

fillers, and tapes reduces the bulk and physical volume of flat cables.

Additionally, their low profile enables flat cables to hug surfaces and take advantage of tight or normally unused space. A rectangular cross-section lets flat cables stack or layer with almost no wasted space between cables, providing maximum conductor density for a given volume.

4. Flexibility – Flat cable is extremely flexible when bent in the plane of its thin cross-section. This flexibility has been used in applications where continuous or high flexing is necessary, as in drawers, doors, rotating arms, and so forth.

5. Greater strength – Flat cables have high strength because all conductors and insulators equally share tensile loads.

6. Consistent electrical qualities – The conductor spacing is fixed and the geometry of the cable is constant. This geometry brings consistent electrical qualities that include impedance, capacitance, inductance, time, delay, crosstalk and attenuation.

7. Greater current-carrying capacity – Flat cables

have greater surface-to-volume ratios than their round-cable counterparts. Consequently, flat cables dissipate heat more efficiently. This thermal efficiency lets them handle a higher current level for a given temperature rise and conductor cross-section.

8. Reduced skewing effects – Conductors have the exact

same physical and electrical length and a consistent and continuous dielectric. This minimizes time delays between signals within a given flat cable.

9. High-density interconnections – Flat cable has a high wire-to-cable cross-sectional density. So layers of flat cable pack more efficiently and provide a higher conductor density than in round cables.

10. Ease of handling – Flat cable folds and bends readily, conforms to the mounting area, fastens easily with clamps, adhesive, or double-faced tape, eliminating the installation and lacing difficulties associated with round wire cabling. Conductors are visible and in a fixed position within the dielectric, a factor that simplifies coding, inspection, and circuit tracing.

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C a b l e s

Typical Round Cable Elements

Flat versus round

Most cable is round, which is a generally useful geometry. Examine an ordinary round electrical cable and you’ll typically find insulated wires in a bundle surrounded by several layers of other “filler” material. These layers are there to retain a round profile and to minimize frictional heating as the cable moves. Surrounding the wires and fillers is an outer jacket that holds it all together and

provides some level of protection against outside elements. But, while round cable is normally fine for general use, there are drawbacks with this construction.

Because it incorporates these multiple layers of wires, insulation, and fillers, heat dissipation from the wires can be problematic in round cable. Despite measures to reduce it there is still frictional heat produced inside the cable during repetitive motion cycles.

Add to this the issue of electrical impedance alteration as conductors inside the cable move relative to one another.

With flat cable each conductor is kept parallel with neighboring conductors to form the flat profile. Unlike round cable, conductors in flat cables don’t move within the encapsulating jacket so their electrical qualities remain constant. Similarly, the conductors in the cable all have the same physical and electrical length. Thus signal skewing and differential time delays between signals in the cable stay at a minimum.

Flat cable, as produced by Cicoil, isolates each conductor within the cable, keeping them stable and stationary. The result is that they need no low-friction tapes or fillers. This has the added advantage of reducing both weight and volume, which provides maximum packaging efficiency. And the greater surface to volume ratio of the flat form factor also dissipates heat far better. The larger surface area and heat dissipating capability enables

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C a b l e s flat cables to carry a higher current for a given temperature rise, and for conductors of a given cross section.

Furthermore, the flat form factor means that within the plane of its thin cross section, flat cables exhibit far more inherent flexibility than equivalent round cables.

Ultimately, where signal-to-noise purity, flexibility, heat, weight and volume efficiencies are paramount, flat cables have better inherent performance values than found in round cable.

Until now round cable deficiencies have been tolerated, and engineered around, because it is very common and tooling exists for efficient terminating and assembly.

“Unlike round cable,

Designed to Perform

conductors in flat cables don’t move within the

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encapsulating jacket so their electrical qualities remain constant.

Similarly, the conductors in the cable all have the same physical and electrical length.”

EZ-Flexx addresses these termination challenges

A new generation of flat cable combines ease of use with inherent advantages. Called EZ-Flexx, it is constructed to be as easy to work with as common round cables, while also providing a long flex life and all the other features and benefits of traditional, highperformance flat cable. Ordinary manual or automated wire stripping tools can handle the stripping process. Conductors comprising an EZ-Flexx flat cable are easily split from the cable body revealing a traditional round

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C a b l e s Flexx-Sil on the Shore Scale

shape for common terminating techniques.

The process is straightforward: Split out the individual conductors in the cable, strip the outer jacket from the end of the conductors, strip the inner conductor insulation, and apply the connector in the usual way.

It is useful to understand the capabilities of modern EZ-Flexx flat cable by examining some older flat cabling technologies.

As noted earlier, the flat ribbon cable was introduced by Cicoil in 1956 for early mainframe computers. Ribbon cable allowed companies like IBM to replace bulky, stiff round cables with a low-profile alternative that could be terminated easily through use of insulation displacement connectors (IDCs). Ribbon cable is inexpensive and has a standard geometry.

A point to note is that ribbon cable is not really comparable to modern flat cable such as EZ-Flexx. It was not designed for repetitive flexing, as the PVC jacketing of most ribbon cables is relatively brittle (Cicoil’s IDC ribbon cables, however, feature hi-flex wires and jacketing). Plus, ribbon cables use just a single

Traditional Flat Cable Profile

Red = Deleted Material

New EZ-FlexxTM Profile

wire gauge for all conductors (28 AWG) which limits their use. And finally, ribbon cable can emit electromagnetic interference in the absence of extra shielding.

Another type of flat cable uses a simple external sheath, often of PTFE (branded by Dupont as Teflon), to enclose bundles of conductors. Unlike ribbon cable or extruded flat cable like EZ-Flexx, wires in the PTFE jacket are not held in place within the jacketing material. They can creep from their initial position, or be pulled out of place, by forces from the terminating connections. To head off such difficulties, PTFE flat cable may employ clamps at regular intervals along the

cable. PTFE jackets are also relatively brittle, and can crack with repetitive flexing, exposing the internal wires.

Another type of flat conductor technology is that of flex circuits. These are basically flexible versions of printed circuit boards.

They are usually comprised of conductive traces either screen printed or plated onto, or sandwiched between, flexible plastic substrates.

The usual application for flex circuits is in forming a connection between circuit boards where space is at a premium and the geometries involved are difficult for ordinary connectors to handle. Flex circuits

Flexx-Sil Physical and Chemical Properties

70

Property

Unit

Test Method

Value

Temperature

°C

ASTM D2137 & UL 94HB

-65 to 260

Hardness

Shore A

ASTM D2240

65-70

Water Absorption

% vol. change

ASTM D471

<+5

Tensile Strength

PSI

ASTM D412

>800

Elongation at Break

%

ASTM D412

>400

Tear Strength

lb/in Die B

ASTM D624

280

Brittle Point

°C

ASTM D2137

-70

Flame Retardant Temp.

°C

UL94HB & IEC332

260 min

Decomposition Temp.

°C

PTL 13057

446.2

Combustion Temp.

°C

PTL13057

710.3

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C a b l e s

are generally not designed to handle repetitive motion. Moreover, because their conductors have dimensions that are on the order of circuit board traces, flex circuits have a limited ability to handle high power levels or lengthy trace runs.

Flat versus contoured cable

Cicoil extruded flat cables are defined as a group of conductors (electrical, liquid or gas tubing, fiber-optics) aligned in parallel, and completely, seamlessly encapsulated in an insulating, protective jacket. Cicoil invented the patented extrusion process employed to manufacture this type of flat cable.

EZ-Flexx flat cables consist of a variety of color-coded PFA-insulated electrical conductors, and Teflon or polyurethane tubing elements, which are encapsulated overall within an ultra-pure, engineered rubber jacket.

This proprietary engineered rubber is called Flexx-Sil, and delivers a number of useful properties. The distinguishing feature of EZFlexx flat cable is the combination of roundprofile conductors extruded with a Flexx-Sil encapsulation that maintains the individual round wire form factor needed for common hand and automated stripping equipment.

The Flexx-Sil jacket strips easily from the PFA insulated conductors, and the PFA insulation strips easily from the conductor wires. A thin Flexx-Sil rubber strip — part of the overall extrusion — connects each of the individual elements to form the flat cable. Multiple conductor bundles can be separated out from a single cable, each terminated with their own connector.

Each conductor is kept parallel with neighboring conductors. And, unlike round cable or PTFE “sheathed” flat cable, the conductors in an EZ-Flexx cable are held securely within the encapsulating Flexx-Sil jacket and don’t move, so their electrical qualities remain constant. Virtually any type of electrical conductors required for power, signal, video and data may incorporated into EZ-Flexx cable. This includes bare wire, insulated and shielded conductors, twisted pair, tri-axial, and coax, etc., in sizes of 4 to 44 AWG, plus non-electrical conductors such as fiber optics and fluid tubing.

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What to expect from EZ-Flexx

EZ-Flexx flat cables work well in applications characterized by extreme environments, motion, and challenging space constraints.

They are particularly durable, and advantageous where other kinds of cable fall short. For example, EZ-Flexx cables operate at extreme temperatures ranging from -65° to 260°C (-85° to 500°F). In contrast, ordinary PVC cable jacketing starts to decompose when the temperature reaches 140°C (284°F), and starts to melt around 160°C (320°F).

EZ-Flexx cable excels at motion applications because the wire is extremely supple, as it is made from multiple bundles of fine 40-44 AWG base strands. This contrasts

with a standard 24 AWG wire which is typically comprised of just seven, larger 32AWG base strands, which results in a stiffer wire with larger bend radii that doesn’t stand up to repeated flexing.

Because a flat profile takes up less volume than comparative round wire when stacked or bundled, EZ-Flexx saves valuable space. And because they naturally flex in a single plane, and incorporate the durable Flexx-Sil jacketing, they often don’t need conduits or cable tracks—minimizing space, weight and noise, not to mention cost.

These cables are encapsulated with jackets made of Flexx-Sil. This engineered rubber developed for Cicoil’s exclusive use,

FLEXX-SIL® OUTER JACKET (CLEAR)

COLOR-CODED PFA INTERNAL JACKET

SHIELDING ULTRA-FLEX WIRE BUNDLES TEFLON® OR POLYURETHANE TUBING

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C a b l e s Flat cable, like this one pictured in black and white, was first used on mainframe computers. These cables were not as easy to flex and could break, unlike Cicoil’s modern flat ribbon cables. is ultra-pure, durable, and extremely versatile. Flexx-Sil rubber is extruded seamlessly around each cable element to form a single flat cable, and it is crystal clear so the individual conductors are visible. And the PFA jacket insulating each of the conductors is color coded for easy gauge size identification anywhere along the cable length.

Flexx-Sil provides flexibility while protecting conductors against sudden impact, severe vibration, and extreme G forces. It registers a Durometer value of 65 (Shore A); a SuperTuff version goes

Depiction of Frequency Waves

INNOVATING SHOCK & VIBRATION SOLUTIONS

up to 85 (Shore A). And it doesn’t wear, crack or deform when exposed to tight bending, continuous flexing or operational stress.

Flexx-Sil requires no conduit for protection. It is tear resistant, and is self-healing from small punctures.

Flexx-Sil encapsulation also features longterm integrity, with near zero particulates, making EZ-Flexx Cables Class 1 Clean Room rated. And it maintains flexibility and operation integrity in extreme temperatures, as already noted. Flexx-Sil has passed UL 94V0 flammability testing.

It is also waterproof (including immersion), resists most chemicals, and operates for years in intense UV and sunlight conditions. The formulation features virtually zero impurities, zero halogen, and a strong molecular bond meeting NASA’s Spec 1124 for outgassing.

Summary

EZ-Flexx flat cable has introduced a new paradigm in flat cable design — one that reduces the need to engineer around the performance limitations of round cable.

The innovative cable marries flat cable performance-enhancing attributes such as Flexx-Sil jacketing and ultra-flex, fine-stranded wire conductors, with a physical profile matching that of standard wires found in common round cable. EZ-Flexx introduces the first flat cable ready for use with industrystandard assembly tooling and presents a costeffective solution. DW

Cicoil | Cicoil.com

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Sealing basics for fluid power rookies Sealing alone is the most important contributor to the impressive might of fluid power systems and components Josh Cosford â&#x20AC;˘ Contributing Editor 76

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F

l

u

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o

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e

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Without sealing, fluid power wouldn’t exist. The material construction of the pumps and actuators has been important, of course, but even a hundred years ago the technology existed to build steel components capable of thousands of pounds influential contributor to high power of fluid power systems realized today.

Before I get too deep into details of fluid power sealing applications and installations, I’ll start with a primer on how a seal works. A seal has one job; separate two spaces from each other to prevent fluid (air or liquid) from reaching the other side. This job can be simple and easy, such as with an O-ring trusted to remain stationary and keep pressurized air or oil from escaping the component in which it’s installed. The seal can get more advanced, such as with a dynamic seal designed to separate high pressure fluid while allowing movement between two sliding or rotating surfaces.

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| Courtesy of Trelleborg Sealing Solutions

of pressure being exerted upon them. However, sealing technology has been the single most

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F l uid Powe r

Pressure acts outward

Cross section of a U-cup.

The O-ring is literally as elementary as a seal can be; simply a round cord of rubber shaped in a circle. It is typically a static seal, meaning it remains stationary to prevent pressurized fluid from escaping a pump case, cylinder cap or cartridge valve et al.

However, they can be used in economical dynamic applications, | courtesy of Freudenberg-NOK such as a rod or piston seal in an air cylinder, or the spool seal in a directional valve.

When used as a static seal, there are only considerations for pressure capacity and fluid compatibility. Higher pressure O-rings are made from a harder synthetic rubber to prevent extrusion out of gaps in the components. Also, should exotic fluids be used in a hydraulic system, synthetic polymers resistant to these fluids can be used to improve longevity.

Sealing between two moving components is critical to any fluid power system, because without that movement, a cylinder is just a steel rod and a motor is just a shaft. The challenge in sealing two 78

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moving components is that the seal must not exert excessive friction to impede movement, but should be strong enough to seal effectively. There is a balance between these two extremes, and often the individual application dictates what type of seal is used.

The lip seal is the most common seal used in dynamic applications, because it exerts little friction—especially at low pressure—but its inherent nature ensures excellent sealing at high pressure. The lip seal cross section often looks like a U, so it is often referred to as a U-Cup. The shape

is such that it only seals in one direction, so when used as piston seals, you need two of them each piston to contain pressure in extension and retraction.

You can also see by the shape of the U-Cup that pressure exerted upon the seal forces the lips apart, increasing sealing as pressure rises. Lips seals tend to have less static friction than other types of seals, such as an O-ring combined with backup rings.

Unfortunately, the U-Cup has poor sealing at low pressure, especially in static applications where the cylinder is meant to hold a load.

More advanced seals have been developed, which marry various technologies resulting in a more superior all-around seal. The loaded U-Cup is now a top choice for high quality piston seals, which places an O-Ring inside a lip seal to “energize” or push the lips outwards under low pressure. Obviously static friction (and breakaway pressure) will be higher with a loaded U-Cup over a standard U-Cup, but it’s still not as bad as with a loaded O-ring or T-seal, which have an interference fit.

The loaded U-Cup is still a U-Cup, so it has the effect of increasing sealing as pressure rises. Although the level of pressureinduced sealing is less than a full U-Cup, it provides an excellent compromise between two mechanisms. A further evolution of the loaded U-Cup is the crown seal, which looks liked an inverted loaded U-cup with the O-Ring on the bottom side. The crown seal, which can be molded or machined from one pieced of polymer or made from two to four components, is excellent for very high pressure applications.

How a seal is installed is just as important as it shape or composition. Under

As it is placed under pressure, an O-ring deforms and fills in gaps, sealing them.

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small, you risk excessive leakage, especially at low pressure.

Whether an O-Ring, piston seal, shaft seal or mechanical seal, the cavity dimensions must be accurate as to prevent damage, leakage, friction, increased wear or fitment issues. All seal manufacturers list the seal installation requirements in their catalogues, so be sure to heed them.

After the seal type and installation is carefully considered, the specifics of the application must be considered. Early dynamic hydraulic seals were made from leather, which would be pressed or molded into usable U-cup or V-packing shapes capable of holding over 1,000 psi or more.

Although leather is still available today, I’ve literally never seen one in a current application. Dynamic seals could also have been made from impregnated fiber materials, which can also be moulded. Static seals could have been made from cork or even natural rubber. Most naturally sourced materials are perfectly suited to handle a fair magnitude of pressure, but were poor for longevity.

As synthetic rubber technology improved, they antiquated the use of natural materials in fluid power applications.

Buna Nitrile synthetic rubber is now the most common material used for hydraulic component sealing, as it has good general fluid compatibility, is easy to manufacture, and when properly applied, is capable of high pressure applications.

Nitrile is a versatile rubber for most hydraulic applications, but it’s not always the best choice when the going gets tough.

Exotic fluids, such as high-water based fluids used in fire resistant hydraulic applications, are not compatible with nitrile.

In these cases, polyurethane is used, which is suitable for use with additives such as glycol. Polyurethane is also excellent for high pressure and high temperature applications, although if extreme heat is seen, there are other options.

For high temperature applications, fluorocarbon (aka Viton) seals are often used. Depending on the type of fluorocarbon used, this synthetic polymer can handle over 400° F (although very few fluids can). The downside to fluorocarbon is that it is softer than what can be had in nitrile. Because of its softness, Viton is often de-rated for pressure—such as a piston lip seal, for example.

The softness of rubber is rated using shore hardness or durometer. A higher durometer rubber is more rigid and resistant to forming than the jelly I described earlier.

Standard 70 durometer nitrile rubber is good for general applications where pressure is moderate. As pressure increases, seals can be damaged or extruded, so 80 or 90 durometer polymers can be applied, which resist deformation better.

Seals are indeed the unsung heroes of fluid power. They are necessary for hydraulic to achieve its legendary might, but are often overlooked for their importance. A little thought put into seals will ensure your fluid power application is efficient, reliable and performs optimally. DW

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Without backup ring Pressure

Pressure

Low pressure

Protusion

High pressure

With backup ring Pressure

Pressure

Low pressure

High pressure

Backup washers are used to prevent O-ring extrusion.

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H a r s h

E n v i r o n m e n t s

Advanced lithium batteries extend the reach of WirelessHART and other communications protocols to help the IoT expand into extreme environments.

Making WirelessHART Sol Jacobs

VP and General Manager Tadiran Batteries

truly wireless

For more than three decades, the HART (Highway Addressable Remote Transducer) communications protocol has been essential to factory automation. Nearly 30 million HART-enabled devices are currently in use worldwide, supporting a wide range of applications, including process control and asset management, safety systems, machine-tomachine (M2M), and system control and data automation (SCADA).

The HART protocol employs Bell 202 Frequency Shift Keying (analog phone caller ID technology) to superimpose digital signals on top of analog signals, providing an easily configurable low-cost field communications solution. However, experts believe that nearly 85% of all devices that could potentially use the HART protocol current do not, largely due to the expense of wiring, which costs roughly $100 per foot. This cost constraint is even more problematic in remote, environmentally sensitive locations, where logistical, regulatory, and permitting requirements can delay projects and cause expenses to skyrocket. Fortunately, for many remote applications the need for hard-wiring has been largely eliminated by the

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Harsh E n v i r o n m e n t s

LiSOCL2 Primary Cell

LiSOCL2

Bobbin-type with Bobbin-type Hybrid Layer Capacitor

Li Metal Oxide Li Metal Oxide Alkaline

LiFeS2

LiMnO2

Modified for high capacity

Lithium Iron Disulfate

CR123A

Modified for high power

Energy Density (Wh/1)

1,420

1,420

370

185

600

650

650

Power

Very High

Low

Very High

Very High

Low

High

Moderate

Voltage

3.6 to 3.9 V

3.6 V

4.1 V

4.1 V

1.5 V

1.5 V

3.0 V

Pulse Amplitude

Excellent

Small

High

Very High

Low

Moderate

Moderate

Passivation

None

High

Very Low

None

N/A

Fair

Moderate

Performance at Elevated Temp.

Excellent

Fair

Excellent

Excellent

Low

Moderate

Fair

Performance at Low Temp.

Excellent

Fair

Moderate

Excellent

Low

Moderate

Poor

Operating life

Excellent

Excellent

Excellent

Excellent

Moderate

Moderate

Fair

Self-Discharge Rate

Very Low

Very Low

Very Low

Very Low

Very High

Moderate

High

Operating Temp.

-55° to 85° C, can be extended to 105° C for a short time

-80° to 125° C

-45° to 85° C

-45° to 85° C

0° to 60° C

-20° to 60° C

0° to 60° C

“Remote wireless devices that require long-life power predominantly rely upon primary (non-rechargeable) lithium batteries.”

development of WirelessHART, ZigBee, LoRa and other low-power wireless communications protocols that deliver high reliability and extended battery life to challenging environments.

WirelessHART and similar communications protocols enable extended battery life for all sorts of wireless devices that will be seamlessly integrated into the burgeoning Industrial Internet of Things (IIoT), enabling ‘big data’ analytics to increase productivity and workflow throughout all industrial sectors, including transportation infrastructure, energy production, environmental monitoring, manufacturing, distribution, healthcare, and smart buildings, to name a few. As part of this technology shift, wireless mesh networks will be used to form redundant, self-healing networks.

Choosing between consumer and industrial grade batteries Remote wireless devices that require long-life power predominantly rely upon primary (non-rechargeable) lithium batteries. However, a small percentage of applications will be well suited for some form of energy harvesting device in combination with a rechargeable Lithium-Ion (Li-Ion) battery to store the harvested energy.

Since a remote wireless device is only as reliable as its power supply, each device must be optimized based on application-specific requirements.

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Generally, the more remote the application, the more likely the need for an industrialgrade lithium battery. Inexpensive consumer-grade alkaline batteries can be considered for certain applications that are easily accessible and which operate within a moderate temperature range. However, alkaline batteries are not well suited to long-term industrial applications due to inherent limitations, including low voltage (1.5 V or lower), a limited temperature range (0°C to 60°C), a high self-discharge rate that reduces life expectancy to as little as one to two years, and crimped seals that may leak.

The low initial cost of a consumer-grade battery is often highly misleading, as the typical cost to replace a battery far exceeds that of the battery itself. For instance, consider all the labor costs involved to replace batteries in a remote fluid flow monitoring system or in a structural stress sensor attached to a bridge abutment. To accurately judge whether a short-lived consumer-grade alkaline battery is a worthy investment, you must calculate the lifetime cost of the power supply, factoring in all the labor and material costs associated with future battery replacements.

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4/3/17 3:16 PM

•

Industrial grade lithium batteries are commonly specified when the following performance features are required:

Small size—when a small form factor is required, the battery’s energy density needs to be as high as possible.

•

Voltage—Higher voltage may allow the use of fewer cells.

Reliability—the remote sensor is deployed in a hard-to-reach location where battery replacement is difficult or impossible, and the flow of data cannot be interrupted by poorly functioning batteries. ong operating life—the self-discharge • Lrate of the battery can be more than

the device usage of the battery, so initial capacity must be high and self-discharge as low as possible.

• Wide operating temperatures—

this is especially critical for extremely

hot or cold environments.

QM35

• •

Lifetime costs—Replacement costs over time must be taken into account.

Trade-offs are inevitable, so your list of desired performance attributes needs to be prioritized.

Choosing among primary lithium batteries If the application calls for an industrial grade lithium battery, then several performance variables may need to be considered, including: energy consumed in active mode (including the size, duration, and frequency of pulses); energy consumed in standby mode (the base current); storage time (as

normal self-discharge during storage diminishes capacity); thermal environments (including storage and in-field operation); equipment cut-off voltage (as battery capacity is exhausted, or in extreme temperatures, voltage can drop to a point too low for the device to operate); annual self-discharge rate (which can be higher than the current drawn from average daily consumption); and cost considerations.

Lithium battery chemistry is suitable for long-term deployments because its intrinsic negative potential exceeds that of all other metals. Lithium is also the lightest non-gaseous metal, and offers the highest specific energy (energy per unit weight) and energy density (energy per unit volume) of all available battery chemistries. Lithium cells, all of which use a non-aqueous electrolyte, feature a normal operating current voltage (OCV) that ranges between 2.7 and 3.6V. The absence of water allows lithium batteries to endure more extreme temperatures.

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Diameter (max)

[cm]

Li-Ion

Industrial Grade

18650

1.51

1.86

Length (max)

[cm]

5.30

6.52

Volume

[cc]

9.49

17.71

Nominal Voltage

[V]

3.7

3.7

Max Discharge Rate

[C]

15C

1.6C

Max Continuos Discharge Current

[A]

5

5

Capacity

[mAh]

330

3000

Energy Density

[Wh/l]

129

627

Power [RT]

[W/liter]

1950

1045

Power [-20C]

[W/liter]

> 630

< 170

Operating Temp

deg. C

-40 to 90

-20 to 60

Charging Temp

deg. C

-40 to 85

0 to 45

Self Discharge rate

[%/Year]

<5

<20

Cycle Life

[100% DOD]

~5000

~300

Cycle Life

[75% DOD]

~6250

~400

Cycle Life

[50% DOD]

~10000

~650

Operating Life

[Years]

>20

<5

Numerous primary lithium chemistries are commercially available, including iron disulfate (LiFeS2), lithium manganese dioxide (LiMNO2), and lithium thionyl chloride (LiSOCl2) chemistry (see Table 1).

Consumer grade lithium iron disulfate (LiFeS2) cells are inexpensive and deliver the high pulses required to power a camera flash.

However, these batteries have limitations for industrial applications, such as low voltage (1.5 V), a narrow temperature range (-20° to 60° C), a high annual self-discharge rate, and crimped seals that may leak.

Lithium Manganese Dioxide (LiMNO2) cells, including the popular CR123A, provide a space-saving solution for consumer products, as a single 3V LiMNO2 cell can replace two 1.5 V alkaline cells. LiMNO2 batteries can deliver moderate pulses, but suffer from low initial voltage, a narrow temperature range, a high self-discharge rate, and crimped seals.

Bobbin-type lithium thionyl chloride (LiSOCl2) batteries are particularly wellsuited for wirelessHART and other lowpower communications protocols that draw low amounts of average daily current.

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Bobbin-type LiSOCl2 batteries deliver the highest capacity and highest energy density of any lithium cell, along with an exceptionally low annual self-discharge rate (as low as 0.7% per year), thus enabling certain wireless devices to operate for up to 40 years on a single battery. Bobbin-type LiSOCl2 batteries also deliver the widest possible temperature range (-80° to 125° C) and feature a more rugged glass-to-metal hermetic seal.

The unique attributes of bobbin-type LiSOCl2 batteries make them suitable for industrial applications such as tank level monitoring and asset tracking, where remote sensors must endure extreme temperature cycling. A prime example is the cold chain, where wireless sensors are required to monitor the transport of frozen foods, pharmaceuticals, tissue samples and transplant organs at carefully controlled temperatures as low as -80° C. Certain bobbin-type LiSOCl2 batteries have been proven to operate successfully under prolonged test conditions at -100° C, which far exceeds the maximum operating temperature of other battery types.

Battery operating life is largely influenced by the cell’s annual energy usage along with its annual self-discharge rate. As a result, more energy is often lost through annual battery self-discharge than through actual battery use. For this reason, WirelessHART devices are designed to conserve energy by operating mainly in a ‘stand-by’ mode that draws nominal current, then periodically awakening only if certain pre-set data thresholds are exceeded.

When specifying a bobbin-type LiSOCl2 battery, you should be aware that the battery’s annual self-discharge rate can vary significantly based on how the cell was manufactured and the quality of its raw materials. For example, the highest quality bobbin-type LiSOCl2 cells can feature a self-discharge rate as low as 0.7% annually, thus retaining nearly 70% of their original capacity after 40 years. By contrast, a lesser quality bobbin-type LiSOCl2 cell can have a self-discharge rate as high as 3% per year, causing nearly 30% of available capacity to be lost every 10 years due to annual self-discharge, making 40-year battery life virtually impossible.

High pulse requirements Standard bobbin-type LiSOCl2 cell are normally designed to deliver low current.

In order to deliver the high pulses required for two-way wireless communications and/ or remote shut-off capabilities, a standard bobbin-type LiSOCl2 cell can be combined with a patented hybrid layer capacitor (HLC). The standard LiSOCl2 cell delivers the low background current needed to power the device during ‘standby’ mode, while the HLC works like a rechargeable battery to store and deliver the high pulses needed to power data interrogation and transmission.

An alternate solution is to deploy a supercapacitor that stores high pulse energy electrostatically rather than chemically.

Supercapacitors are suitable for consumer electronics, but not generally used in industrial applications due to inherent performance limitations, including an inability to provide long-term power, linear

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4/3/17 3:22 PM

discharge qualities that do not allow for use of all the available energy, low capacity, low energy density, and high annual self-discharge rates (up to 60% per year).

Supercapacitors linked in series also require the use of cell-balancing circuits that draw additional current.

Opportunities for energy harvesting In certain instances, a HART-enabled device can be powered by energy harvesting, with Lithium-ion (Li-ion) rechargeable batteries utilized to store the harvested energy.

Use of an energy harvesting device is often dependent on numerous factors, including: the expected operating life of the device; the reliability of the energy supply; environmental parameters; size and weight restrictions; and the total cost of ownership. Photovoltaic cells are the most common method of energy harvesting, with some applications drawing energy from equipment vibration or from RF/EM signals.

Consumer-grade rechargeable Li-ion cells may work sufficiently for wireless devices that are easily accessible and that only require a maximum battery operating life of 5 years and 500 recharge cycles along with a moderate temperature range (0° to 40° C). However, if the device is intended for long-term deployment in a remote location or extreme environment, then the application will likely require an industrial grade Li-ion battery that can operate for up to 20 years and 5,000 full recharge cycles, and offers an expanded temperature range of -40° to 85° C (see Table 2).

Unlike consumer batteries, industrial grade rechargeable Li-ion cells can deliver high pulses (5 A for a AA-size cell) to power advanced, two-way wireless communications. These ruggedly constructed cells also feature a hermetic seal whereas consumer batteries use crimped seals that may leak.

Looking to the future Wireless communications will provide a critical foundation for the IoT, which promises to revolutionize modern industry by enabling greater convergence and interoperability between devices. This paradigm shift will be supported by the latest generation bobbin-type LiSOCl2 batteries, including hybrid cells that deliver the high pulses required for advanced, two-way communications. The future is also bright for energy harvesting devices that team up with industrial grade rechargeable Li-Ion batteries to deliver long-term power supply solutions.

These advanced lithium battery chemistries will extend the reach of wireless connectivity far beyond the factory floor to all external environments that will soon be encompassed by the IoT, making WirelessHART truly wireless. DW Tadiran Batteries | tadiranbat.com

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How 3D CAD

promotes a functioning digital thread The work toward a common digital thread is moving forward as industr y addresses the challenges of developing endto-end, readily accessible information on systems.

Jean Thilmany â&#x20AC;˘ Contributing Editor

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3D CAD

The computer-aided design that defines a product geometrically drives more than just that part’s manufacturing process. The model begins a digital thread—a digital conversation, if you will— that enables on-going product and manufacturing innovation long after the part has cleared the manufacturing floor.

“The digital thread is the communication that connects elements of the engineering and manufacturing process that have traditionally been separated—such as the electronic and the software design information,” says Don Tolle, PLM consultancy CIMdata’s director of the systems engineering and simulation practice.

“Everyone is going digital, so we need to figure out how to connect the digital design process and spread it forward into things like plant design and layout and the servicing of systems once they’re in use,” Tolle says.

“The thread is the means of continuing to connect product data and information long after the product has been sold or is in place. And it’s more important than ever in the face of changing business models and the coming Internet of Things,” Tolle says.

“While that digital thread is gaining in importance in this age of advanced manufacturing, Industry 4.0 and the Internet of Things—all of which call for automation and the exchange of data—significant challenges still exist to ensuring the thread is maintained in a central technological location and readily accessible to all potential users,” Tolle says.

Those affected by the technology are finding ways—mostly through vendor mergers and acquisitions and potential standards setting—to house a complete digital thread.

The digital twin is the virtual product as represented in a computer system—often many computer systems, such as the CAD, BIM, and analyses applications and any other software used to create or describe the product.

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Lifecycle Tool

Lifecycle Tool

Change Management

Lifecycle Tool Requirements Management

3D CAD

Tool A

Linked Lifecycle Data (OSLC)

Lifecycle Tool Change Management

The Oasis Open Standards Network proposed a standard that defines a way to connect information across systems to maintain the digital thread. Oasis maintains the Open Services for Lifecycle Collaboration, which develops standards for software lifecycle tools to share data.

Lifecycle Tool Quality Management

“The digital thread is needed to ensure an up-to-date digital version of the product is always maintained and available,” Tolle says. That digital version is called the product’s digital twin.

The digital twin is the physics-based representation of the product, the virtual product as represented in a computer system— often many computer systems, such as the CAD, BIM, and analyses applications and any other software used to create or describe the product.

Maintenance and billable hours The digital twin—and its attendant thread of information--needs to be readily available to give feedback and information about how the product is functioning in the field, to help service the product, and to act as a virtual prototype in case product The people who service the changes are needed.

For example, the digital twin could be used to make predictions about how an engine— whether aircraft already built and hard-to-access system will operate under certain conditions. employees or engine-maker Take the case of a high-value industrial pump that operates underground. personnel—need the digitial “The twin would give the operator the speed and temperature conditions the twin to determine proper pump functions within, so the operator could monitor for those things in real operating conditions and how time and if they’re exceeded he could shut that system down before it gets to best to service the engine. failure,” Tolle says.

“The digital twins need to be continually updated to remain current.

So that’s where the digital thread comes in,” Tolle says.

“If every year I upgrade software or electronics, then I want to set up so I can go back to the core digital information, which might exist in PLM or three or four different systems and see the current information for these systems and check it against the twin to make sure the twin is valid,” Tolle says.

The digital thread can’t fray, as he puts it, or the digital twin won’t be around for reference. And estimates have shown that in the not-too-distant future billions, even trillions, of digital twins may be maintained within the industrial space.

“The conversation is relevant in a time of changing business models,” he adds. Aircraft engine makers, for example, offer what they sometimes call “power by the hour.” That is, the engine manufacturer will maintain the engine even after it’s placed in the aircraft. Some ship makers that provide naval ships have proposed following suite.

The people who service the engine—whether aircraft employees or engine-maker personnel— need the digital twin to determine proper operating conditions and how best to service the engine.

Clearly, the people who will call upon the digital thread go beyond the engineers tasked with originally creating the part or product.

“For example, the 3D model is used to program the robotic vision-systems tasked with helping build the part,” says Keith Vozel, product manager for software at robotics maker Yaskawa Motoman.

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3D CAD

Products, of course, are more than just mechanical systems. They include software, electronics, and possibly even chemical and other types of engineered systems. Those looking to create a digital thread seek a way for all the systems used in product creation to interact.

Here, the digital thread ensures the vision system is programmed so robots can construct the product to within tolerances.

Getting systems on speaking terms “So many products are, of course, more than just mechanical.

They include software, electronics, and possibly even chemical and other types of engineered systems. That’s why those looking to create a digital thread seek a way for all the systems used in product creation to interact,” Tolle says.

That means all the systems that go into product creation— the mechanical and electrical CAD, the product lifecycle management, the analyses, the computer-aided manufacturing, the ALM, the enterprise resource management, the service lifecycle management and many more applications need to speak back and forth in a common language and potentially on a single, common platform, he adds.

“That interoperability is one of the greatest challenges to the digital thread,” Tolle says.

“You can keep electronics and mechanical systems the same, but when you download a product software update, you’ve got new functionality,” Tolle says. “The digital thread lets you know: If I download new software is the rest of the system equipped to handle what the software will tell it to do?”

“Likewise, if software update drives the product to do something it wasn’t originally designed to do, the digital thread helps users evaluate what’s going on,” Tolle says.

“Software vendors are attempting to get systems talking by carrying out mergers and acquisitions that would connect the systems used by everyone who has a role in the product,” he adds.

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“PLM was always intended as end-toend connection, but in many cases it wasn’t able to do that,” Tolle says. “But now the larger vendors are filling the gaps with their acquisitions.”

Arena Solutions cloud-based PLM system also includes a quality-management system, an application lifecycle management system (used by software developers), a supply-chain-collaboration and a requirements-and-defect-management system. These systems tie the engineering, electrical, mechanical, and software developers and bring in manufacturing as well.

Siemens PLM recently purchased Mentor Graphics, which makes electronic design automation software and CD-adapco, maker of simulation software. In 2015, Siemens PLM purchased Polarion, which makes ALM software.

“So they’re trying to bring in all that information—the electronics and the software side of things, and connect those,” Tolle says.

Based on its history of automation, GE has released its Predix cloud platform, which the company says will help users create models that span the entire system. GE calls

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3D CAD

Predix the operating system for the industrial IoT. The company has business units in many industries, including aircraft, power plants, manufacturing, and transportation and Predix will be used to help design all those systems and connect them with Internet of Things connection.

PTC also seeks to be a player in design for IoT. The company has acquired ThingWorx, an IoT platform provider and Axeda, which provides cloud-based software for managing connected machines.

ThingWorx also has an agreement to offer semiconductor manufacturer Analog Devices customers an integrated sensor-to-cloud environment on the platform. PTC also purchased Kepware Technologies, a maker of manufacturing connectivity tools; ColdLight, for machine learning and predictive analytics; and Vuforia, which makes augmented reality tools; and Servigistics, a service parts management tool.

“IoT gives PTC an opportunity to “improve the capabilities, value proposition and differentiation of our CAD, PLM, ALM and SLM offerings,” wrote James Heppelmann, PTC chief executive officer, on the stock market analysis and insights blog Seeking Alpha.

“As we land these new logos, we’ll work to expand our position by introducing SLM, which is really the killer app for IoT, as well as ALM, PLM and even CAD technologies over time,” Heppelmann wrote. Service lifecycle management is used to understand and following system service needs as the system operates in the field.

These companies systems would maintain a digital thread—but only within the company software.

The Oasis Open Standards Network, an independent standards organization, has proposed a standard that defines a way to connect information across systems to maintain the digital thread. Oasis maintains the Open Services for Lifecycle Collaboration, which develops standards for software lifecycle tools to share data.

“The standard would help with data loss that can happen when information moves between systems,” Tolle says.

“When you move data from one system to another it’s a conversion and at the

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boundary something gets lost, that’s been one of the challenges of the digital thread,” he says.

“The work toward a common, digital thread is moving forward as those in industry address the challenges to get to means for end-to-end, readily accessible information about a system,” Tolle adds.

“Everyone sees the problem and understands it, but moving from one paradigm to another takes time, and there’s challenges along the way as you get everyone on board the same train,” he says. DW

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4/3/17 3:29 PM

6

bearing killers

and how to stop them

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m

M e c h a n i c a l

Bearing failure can grind operations to a halt, resulting in significant lost time and production. Here are six common factors that can cause bearings to fail, and what you can do to prevent them.

Jerry Rhodes General Manager of Engineering Fundamentals & Physical Testing The Timken Company

No matter the application, the proper functionality of bearings is essential to optimize operations. Whether a bearing is a cylindrical, spherical, ball or roller bearing, its precise design and engineering require special attention to ensure it’s working correctly. Bearing failure means downtime, maintenance and a major blow to operational efficiency—and in many cases, that failure can be easily prevented.

While the number of applications requiring dependable bearing operation are countless, the common reasons for bearing failure are fairly narrow. Though improvements in technology, design and user training have helped reduce failure incidents, understanding how and why bearings commonly fail is critical.

Here are six common reasons for bearing failure, and how you can act to make sure they don’t bring your operations to a halt:

1:

Improper Handling and Installation. Proper bearing care begins when the bearing first arrives at the application site. From the shipping dock, to storage, to installation, proper handling and care is necessary to ensure the bearing will function as intended.

Bearings are designed and engineered to operate at specified loads. Overloaded bearings can fracture components, and left unchecked can lead to more serious damage or consequences.

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M e c h a n i c a l

2:

Marks cut into the metal or peeling metal indicate a more severe lubrication/heat issue and should be addressed immediately.

fficiency

Even the smallest imperfections can shorten a bearing’s lifespan, and many nicks and scratches occur before the bearing is even put into use.

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Even the smallest imperfections can shorten a bearing’s lifespan, and many nicks and scratches occur before the bearing is even put into use. Damage can occur when a bearing is in storage; therefore, if stocking bearings prior to needing them on your plant or shop floor, make sure the proper storage techniques are being followed. Don’t remove the bearing from the manufacturer’s original packaging unless absolutely necessary; if it must be removed, store in anticorrosive wrapping, and apply the appropriate preservatives to the bearing first.

When ready to install, cleanliness is critical. Technicians should perform the work in as clean an environment as possible, using clean tools, and should take care not to remove any of the preservative coating. Carelessness is the most common cause of damage to the bearing throughout the installation process. Poor handling while removing the outer races from housings or wheel hubs, for instance, can leave burrs or high spots in outer race seats. Tools can inadvertently gouge housing seats, leaving imperfections that can increase rolling contact stress, limit fatigue life or fracture machine components in the worst cases— all the more reason to ensure your installation processes are conducted with care and precision.

Improper Lubrication. Lubrication is the lifeblood of proper bearing operation, and it is dependent on several variables in any given application.

Most bearing manufacturers and suppliers will recommend a specific lubricant type, grade, supply system, viscosity and additives for the application. They will also provide the amounts of lubricant that should be used and how often it should be changed or replenished. More application-specific recommendations and details including loading, speeds and sealing are often included as well.

Just like the bearings themselves, lubricants must be stored properly. Shelf life, temperature, filtration and other precautions will again be available via your bearing/lubricant supplier.

Technicians should adhere closely to these recommendations—bearing compatibility and performance depend on it. Underfilling and overfilling, mixing and matching lubricants, and changing lubrication at irregular intervals can all result in significant damage that can bring your operations to a standstill.

3:

Overheating. A primary function of proper lubrication is to prevent the overheating of bearings and associated components. Overheating can lead to damage and ultimately breakdown for a variety of reasons related to the lubricant. Higher temperatures can be caused by ambient temperatures, process temperatures, and severe operating conditions that can increase rolling contact friction. Likewise, lower ambient temperatures can have a negative effect—lubricant viscosity increases at lower temperatures and can cause improper flow and therefore compromise protective benefits. Your lubricant supplier can provide the ideal operating temperature change.

Technicians can and should do more than simply follow supplier instructions to ensure lubricants are performing properly and keeping their bearings at the appropriate temperatures. Be vigilant about monitoring bearings for heat-related trouble signs

4/3/17 3:32 PM

M e c h a n i c a l

that can impact lubrication and ultimately the bearing itself. In order of severity, these symptoms include: Bearing discoloration. This will occur as a result of metal-to-metal contact, a sure sign of a lubrication issue. Look for gold and blue discoloration on races and rollers; lubricant staining is common in mild cases, while the metal itself may be discolored by excessive heat in worse cases.

Peeling and scoring. Marks cut into the metal or peeling metal indicate a more severe lubrication/heat issue and should be addressed immediately.

Localized scoring. This occurs due to the breakdown of the lubricating film which causes direct contact between components.

Address immediately.

Cumulative wear. High localized heat can alter the geometry of the bearing itself, resulting in a locked-up bearing that can cause significant additional damage.

4:

Contamination. Even the tiniest of foreign particles can interfere with the lubrication that enables a bearing to function as intended. There are a number of contamination sources, depending on the application.

Shop dust, sand, fine metal particles from nearby machining, water and dirt can all interfere with the lubricant that keeps a bearing operating, and can damage the bearing itself.

Particles rolling through the bearings and rolling elements will cause premature damage, increasing stress and shortening overall bearing life.

The best protection against contamination is a proper seal, which must be matched with the given application to offer the best possible performance. This information should be available through the bearing manufacturer. Generally, seals should be regularly checked for hardening and cracking around the radial lip; they should be replaced as soon as possible if any visible damage is detected.

Contamination can occur at other points in the bearing lifecycle. Technicians should routinely test oil and grease samples for solid particles. Additionally, when bearings are removed for inspection, technicians should make sure to wash, dry and then coat bearings with the appropriate preservative before packing away, using the proper storage techniques.

5:

Overloading. Bearings are designed and engineered to operate at specified loads, and when pushed beyond those limits, trouble can occur. Overloaded bearings can fracture components, and left unchecked can lead to more serious damage or consequences.

Like overheating, warning signs of overloaded bearings should be monitored constantly. Abnormal noises and vibrations, overheating, the presence of metallic chips in lubricant filters, and overall diminished performance of the bearing can all indicate that a bearing is operating beyond its load limits. The higher the overload, the greater the damage. Other indications include the fatigue, pitting or flaking away of bearing materials, roller fracture, peeling, and potential plastic deformation or subsurface fracture of the rolling elements or raceways.

Timken | timken.com

6:

Corrosion. Bearing applications in harsher industrial environments are more susceptible to corrosive damage caused by rogue fluids or corrosive atmospheres that can interfere with the protective lubricant.

Corrosion can lead to wear, which can in turn lead to bearing failure.

Like overloading, subpar performance due to corrosion can often be detected by increased vibration and noise during operation. Corrosion can be identified by reddish and brown discoloration found on the bearings and raceways—not to be confused with the discoloration caused by overheating.

Ensuring that the proper seals are being used, and that those seals are not damaged, is one www.designworldonline.com

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of the best ways to prevent corrosion on the bearing and raceways.

External seals can also be used in more extreme environments if necessary.

Thorough documentation of your bearing installation and maintenance processes can help ensure technicians are being diligent in their monitoring of these six common causes of bearing failure. Recordkeeping can help identify trends in bearing performance, forecasted maintenance, and the length of service intervals. Include date, equipment model and serial numbers, bearing assembly and serial number, and the bearing’s manufacturer in your documentation.

In many cases, bearing damage can progress over time. Periodic or continuous condition monitoring (vibration, temperature, lubricant sampling, etc) can aid equipment and process operators define trends over a bearing lifecycle. Establishing specific operating limits can help define the most appropriate interval for bearing replacement.

Armed with this information, more informed decisions can be made to ensure operations keep your business running smoothly, efficiently and profitably. The Timken Company has numerous resources, both online and through its service engineers, who can help troubleshoot and increase your operational efficiency. DW

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B all bea r i n gs

Application analysis for

lubrication of rolling bearings

For the reliable operation of rolling bearings, correct lubrication is a vital and all too often overlooked factor.

By Daniel Stöckl and Klaus Grissenberger application engineers at NKE Austria GmbH in Steyr The main purpose of a lubricant is to separate the metal surfaces of the bearing’s components with a thin lubricating film to prevent wear. At the same time, the lubricating film reduces friction and therefore power dissipation, resulting in reduced energy consumption of the whole system.

About 40% of all premature bearing failures are caused by lubrication problems. The reasons are varied and start with mistakes during bearing installation – like insufficiently cleaned bearing locations, incorrect grease packing, and damaged seals and covers – as well as incorrect maintenance, such as failure to re-lubricate on time or using to much or not enough lubricant.

Some problems can be traced back as far as the design stage of an application, with designers paying too little attention to the bearing arrangement and lubrication system.

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flange and roller end faces in addition to the rolling friction between rolling elements and raceways. Insufficient lubrication in this area quickly leads to permanent damage of the contact surfaces, culminating in a premature bearing failure. Cylindrical roller bearings, which are designed to absorb axial loads, also experience sliding friction between the guide flanges and roller end faces. Sliding friction also occurs between cage and rolling elements and – with ring-guided cages – between cage and guide ring.

The following are some critical points to consider when designing a bearing configuration’s lubrication system and selecting a lubricant.

Bearing load The key here is the relationship between the loads occurring during operation and the bearing’s load capacity.

Bearings are already considered highly loaded at 15% of their dynamic load capacity. At this load level, the use of lubricants with EP (extreme pressure) additives should be considered. Impact loads and vibrations can also affect the choice of lubricant.

Bearing size and type The type of bearing used generally affects the lubrication requirements. Tapered roller bearings or spherical roller thrust bearings, for example, exhibit a sliding friction between guide

Bearing operating temperature Temperature has a decisive impact on the lubricant’s viscosity and therefore also the separating effect of the lubricant film. To ensure reliable bearing operation,

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» Inner ring of cylindrical roller bearing after operation with excessively mobile oil.

the chosen lubricant must be of a viscosity that is suitable for the operating temperature. Many mineralbased oils age increasingly quickly when continuous operating temperatures exceed +70°C. This can be avoided by using partly or fully synthetic oils.

Low operating temperatures may also have a negative impact. This is especially true for greaselubricated bearings, since typical greases become considerably stiffer at lower temperatures, increasing the rotation resistance of the bearing. Oil (sump) lubrication, on the other hand, generally results in increased losses due to splashing.

Within reason, temperature peaks should also be taken into account. Considering a lubricant’s service life and the resulting re-lubrication and oil change intervals, exaggerated assumptions or excessive cautiousness often results in unnecessarily conservative and therefore economically unviable configurations.

» Inner ring of cylindrical roller bearing after operation with sufficiently viscous oil.

Ambient temperature of bearings This is especially relevant for arrange-ments with an automatic re-lubrication system. The lubricant usually reaches a higher temperature at the bearing location April 2017

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B all bea r i n gs

» Friction at rolling contact and guide flanges. than it has in the feed lines. At low ambient temperatures the grease can stiffen in the lines to the extent that it can no longer be fed to the bearing in sufficient quantities.

Bearing speed range Beside temperature, the bearing’s running speed also affects the lubricant’s separating action which in turn affects the choice of lubricant viscosity. As a general rule, the higher the speed the better the surfaces are separated and the lower the lubricant’s viscosity can be. On the other hand, high speeds (at or near the bearing’s limit speed) also result in higher losses and therefore higher operating temperatures. This may make a circulating oil lubrication system necessary, which can cool and filter the oil.

At very low speeds a full separation of the surfaces cannot always be ensured.

Brief running at low speed, however, for example at start-up, is not normally a problem. A lubricant with appropriate wear protection additives should be considered in these cases.

Possible bearing contamination Contamination can have various sources.

Dirt, etc. can enter through seals and vents while wear particles from surrounding machine components as well as production residue my be present inside an application.

The lubricant itself can also contain contaminants if not stored correctly. These

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contaminants then enter the system when re-lubricating bearings or during an oil change. Beside solid particles, contaminants also include moisture and chemicals.

In addition to technical factors, the costs of both lubricant and complete lubrication system must be considered.

To achieve the ideal balance between technical configuration and cost, the system requirements must be drawn up with care. A neglect of individual aspects is often the cause of problems later on.

Conversely, if excessively high demands are made on the lubricant or unrealistic assumptions about the operating conditions, costs for the lubricant or the lubrication system can rise quickly and unnecessarily. As there are many different lubricants to choose from, consult the lubricant manufacturer when selecting a product.

Using a few application examples, here are some of the effects of lubrication on the function of bearings.

Example 1: Cylindrical roller bearing in a PTO transmission As part of a theoretical consideration of the bearings in a power take-off (PTO) gearbox, the lubrication was investigated more closely. It was found that, under the given operating conditions, the lubricant’s viscosity was much too low to form a sufficiently effective lubricant

film. Increased wear and a reduced service life would have been the logical consequence. The use of a more viscous, i.e. thicker lubricating oil was recommended.

As a precaution, a practical test was performed, in which two identical gearboxes were filled with the lubricating oils to be compared and run for a period of 500 hours. In the subsequent survey, discolorations and initial signs of wear were clearly visible on the functional surfaces of the bearing run with the thinner oil. The bearings operated with the thicker oil did not show any signs of wear.

The customer’s fear that the thicker oil would result in higher power dissipation proved unfounded. On the contrary: the gearbox with the more viscous oil exhibited lower losses and therefore also a reduced operating temperature. This can be attributed to the better separation of the metallic surfaces in operation, which more than compensates the slightly higher fluid friction.

Example 2: Spherical roller thrust bearings in a cooling water pump for a thermal power plant During test operation of a large cooling water pump, (concrete volute pump, i.e. a centrifugal pump with vertical shaft in a cast concrete housing) the axial bearing at the drive end repeatedly exceeded its permissible operating temperature, resulting in an automatic shutdown. On closer inspection, the use of an unsuitable lubricant for this application was identified as the culprit.

The oil in question was a pure hydraulic oil, which did not in any way meet the bearing’s requirements in terms of either composition, i.e. AW- / EP-additives, or viscosity.

The high measured operating temperature was the direct result of the metallic contact and resulting friction especially between the side faces of the rolling elements and the guide lips of the shaft locating washers. This resulted

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» Concrete volute pump with vertical shaft.

Solutions Designed

Excellence Manufactured in irreversible damage to the bearings’ functional areas within just a short time, in effect preventing reliable long-term operation. The bearings had to be replaced at considerable expense on site.

By changing to a suitably viscous oil selected for the application parameters and the use with spherical roller thrust bearings, a reliable separation of the contact surfaces and a low operating temperature were achieved. The plant has now been in fault-free operation since 2009.

Example 3: Deep groove ball bearing in a screw pump The screw pump in this example delivers fuel – both heavy and light oil – to marine diesel engines. To allow the oil to be more readily pumped and injected into the combustion chamber, it is first heated up. Consequently, the screw bearings are also exposed to the high temperature of the fuel oil.

To realize the simple bearing concept required by the customer, i.e. a deep groove ball bearing with integrated seals, engineers conducted a theoretical analysis of the setup. At the bearing temperature of +150°C initially estimated by the customer, a satisfactory solution was out of the question: The lubricant’s calculated service life based on this operating temperature, and the associated life of the bearing, fell clearly short of the required values.

Following further consultations with the client, a temperature measurement was carried out on a test setup to determine the actual operating conditions. The result was a maximum bearing temperature of “only” +130°C. With the selection of a lubricating grease for this temperature range, in cooperation with a lubricant manufacturer and by maximizing the amount of grease in the bearing, the specified service life could then be achieved.

As can be seen from the above examples, the operational reliability of bearings can be improved by correctly assessing and adjusting the lubrication. As a general rule, the sooner the issue of lubrication is addressed, the easier and more cost effectively potential problems can be avoided. DW

Satisfaction Guaranteed

Design · Manufacture Service · Repair Ball Bearings, Cylindrical, Spherical, & Tapered Roller Bearings American Roller Bearing Company 400 2nd Avenue NW Hickory, NC 28601 (828) 624-1460

Made in the U.S.A.

NKE | nke.at

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Lubri ca n t s

When to use solid film lubricants Solid film lubricants consist of a dry surface coating in the form of a chemically bonded surface or as a solid structure that dispenses a dry film as it rubs against bearing components.

By Joyce Laird • Contributing Editor According to Nadeem Bhatti,

not recommended to use a normal

of normal grease would get so high that the grease would literally turn into a rock. Therefore, a special cage is used that contains a solid film lubricant to help lubricate the bearing during operation.”

grease or oil.

“One example of a special case is extreme temperature. The temperature of the application where the bearing is being used may be too high or too low for wany standard bearing lubricant. Extreme temperatures can potentially degrade the grease or oil, creating a viscosity that would be too high or too low for the lubricant to function effectively,” Bhatti says.

“For example, bearings used in liquid nitrogen or liquid natural gas pumps would benefit from solid film lubricants. These bearings are exposed to cold temperatures resulting from the liquid being handled by the pump. The viscosity

How to make a perfect application fit The most common condition to recommend use of solid lube bearings involves temperature, but there are also other applications that benefit from solid film lubrication. Bhatti says that this includes bearing working in very highly corrosive environments. “When a bearing is exposed to water, cleaning solution or even acid, we would advise using a specific dry lubricant or solid film lubricant based on what the corrosive material is. It’s important to evaluate underlying environmental conditions for each application to determine the best lubricant.”

Applications Engineer at NSK Corporation, solid film lubricants are used in special cases where it is

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“Semiconductor production is an application where very clean, low outgassing bearings is required. Use of a standard grease releases gas and particles that contaminate and compromise the application,” he adds. “For example, NSK DFO bearing s are used in clean room environments (compliant with Class 10) and vacuum environments (up to 10-7 Pa) where outgassing particle generation becomes a problem if standard bearings are used. DFO bearings are coated with solid lube on the rings, ball and cage.”

One of the more exotic applications is in the area of liquid and liquefied gas applications. “These are transferred and kept at somewhere around -100•C,” Bhatti says. “The bearings used in the pumps used in these systems get extremely cold. The liquid gas that flows through them and would freeze any normal lubricant into a rock. In this case, we use a cage so a small layer of lubricant is deposited onto the raceway continually to keep the bearings rolling.

It is also used in a lot of other oil and gas type applications.”

“On the other end of the spectrum, furnace conveyor bearings see temperatures up to 400C. Normally, the user would use high temperature grease or no grease at all for these bearings.

However, grease degrades quickly and using no grease at all results in premature bearing failure. For high temperature applications we recommend the spacer

joints that fit between each bearing like a little puck. They are made out of a solid lubricant material and keep everything lubricated and working well. Dry lubricant spacer joints extend bearing life in high temperature applications.”

YS bearings with spacer joints made of alloy-based, self-lubricating material (sintered alloy) between balls. They are suitable for high-temperature (up to 350•C) and vacuum environments.

SJ bearings have solid lubricant spacer joints mounted between two balls in a “peapod” cage design structure.

These bearings are suitable for high temperature(up to 400C) in normal atmosphere or under vacuum conditions.

“The equipment requiring these bearing is very valuable. Bearings that require solid lubrication are more expensive than a standard bearing assembly, but they are necessary to maintain operation. Overall, the initial investment to install specialty bearings is only a small fraction of the overall cost. In many cases, the reduced downtime when moving from standard to specialized bearings reduces maintenance up to four-fold on productions. That is a huge cost savings,” Bhatti says.

Working together is always the best solution Whenever there is a question about what bearing lubricant method is best, it goes

back to understanding the full scope of the application.

“The customer should contact the bearing company. When working with NSK for example, we want to know the total scope of the application. Then we can guide the end user through the process and suggest the best solutions. NSK SPACEA (Special Environment) product guide covers all kinds of specialty bearings including the solid lubricant type bearings. It’s set up in a way that the end user can select their application and then follow the guide through some of the parameters such as: Do you need high temperature? Do you need bearings to work in a highly corrosive environment? Do you need something that is vacuum compatible, and so forth.”

“NSK application engineers work with customers to determine the best solution.

We employ several different methods to administer solid film lubricants and find the best solution to meet specific application needs.”

In conclusion, Bhatti says that many of the solutions that all bearing manufacturers have available today were created as a result of a new customer requirements.

“Every step forward that has been made in developing new formulations for special bearing lubricants grew out of receiving difficult bearing applications from our customers.” DW NSK | nskamericas.com

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Lubrication

Bearings eliminate

lubrication, maintenance from medical equipment Edited by Mike Santora • Associate Editor

Dialysis machines clean toxins from the blood of patients suffering kidney and liver failure using semi-porous membranes, or filters. A global company that manufactures equipment for cleaning these filtration systems had been using grease-lubricated, porous sinter bearings for handling and positioning them. The lubricant posed both aesthetic and functional concerns in the clean rooms where they are manufactured.

Demanding conditions Cleaning these systems with hot water and steam made for an extremely humid operating environment. A constant ambient temperature in excess of 70° C was causing the lubricant to form a film on the surface of the mating shaft, reducing the clearance and eventually causing it to seize. Short linear strokes, low speeds and low loads produced stick-slip effects as well.

Engineers at GGB Bearing Technology reviewed the application and recommended replacing the sinter bearings with its engineered plastics bearings. Made of modified, highperformance thermoplastic resins with solid lubricants and reinforcing fibers, these lightweight, corrosion-resistant bearings provide low friction and high wear resistance over a wide range of both dry and lubricated operating conditions.

Engineered plastics bearings GGB recommended its EP 43 engineered plastics bushing material.

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integrated PTFE lubricant which minimizes stick-slip and aramid fibers to reduce friction, increase wear resistance and provide noise-free performance. Because the bearings require no additional lubrication, the need for maintenance is eliminated and pollution of clean room environments is avoided.

GGB developed custom bearings providing prototypes for testing and technical support. The bearings

underwent extensive testing under worst-case conditions and were adopted for this application. DW GGB | ggbearings.com

The EP 43 engineered plastics bushing material is a reinforced and modified PPS-based compound. It contains homogeneously integrated PTFE lubricant which, minimizes stick-slip, and high-performance aramid fibers to reduce friction, increase wear resistance and reduce noise.

4/3/17 12:04 PM

BEARINGS

American Roller Bearing Company Beyond the basics: American . The M2 V-flat design split cylindrical solves a number of problems: • • •

The “V” section increases split line contact minimizing pressures on both the race and the rollers.

The “V” has the added benefit of preventing the raceway halves from misaligning laterally.

The “flat” sections minimize the contact in the seal area optimizing seal performance.

Reducing surface pressures on the split line and rollers provides smoother operation and longer service life. Preventing lateral shifting of the raceway halves keep the raceway shoulders perfectly aligned providing superior roller guidance and eliminating damage to the rollers and shoulders. Minimizing the split in the seal area allows less seal gap for better sealing and improved seal life with the added benefit of assuring solid parallel surfaces for the fasteners.

AMERICAN ROLLER BEARING COMPANY 402 2ND Avenue NW Hickory, NC 28601 Phone: 828-624-1460 www.amroll.com

MADE IN THE U.S.A.

It’s not a web page, it’s an industry information site Stay current with the latest electronic tips, resources, and news, visit eeworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the electrical design engineering community.

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Prod uc t World Programmable rotary sensors Novotechnik U.S. novotechnik.com/vx31E The Vert-X 31E Series of programmable rotary sensors are touchless magnetic angle sensors with a permanent magnet that can be secured to an application’s rotating shaft. There is no direct mechanical linkage between the shaft and the measuring system, and therefore no wear.

Key specifications for Vert-X 31E include 31 mm profile, 0 to 360°

measurement range, resolution to 14-bit, repeatability of 0.1° or better, and maximum hysteresis of 0.1°. Eight output options are available: 0.1 to 10 V, 0.5 to 4.5 V, 4 to 20 mA, 10 to 90% of power supply, SSI, PWM, Incremental and SPI.

Electromechanical linear actuators Thomson thomsonlinear.com PC Series precision linear actuators are now available with an optional, pre-mounted and pre-tested servo motor. Bundling linear actuators with servo motors simplifies ordering, reduces the need for additional validation after installation, increases reliability, and reduces costs.

Benefits:

• Optimum motor matching. All PC Series linear actuators can be ordered with a broad selection of

Kollmorgen AKM servo motors, fully-integrated and tested.

• Easier sizing and selection. Downloadable and configurable 3D CAD models contribute to the selection process.

• Fast and reliable installation. Once the actuator/motor combination is selected, the RediMount motor mounting

system speeds implementation by reducing the time spent aligning the actuator and motor.

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

Fully Integrated Display

Modular encoder for blood pumps Heidenhain heidenhain.us The RENCO RCML15 rotary encoder is noted for its modular design without an integral bearing. This is just one reason it is widely used as a feedback solution in many automated medical devices throughout the world, and is now commonly found in motors being made for blood pumps as well. It has a compact design with a low profile at a height of only 8.9 mm, as well as its self-centering mounting from

Data Image USA - www.dataimagelcd.com - 407.478.4064 heldred@dataimagelcd.com

a patented slide lock mechanism. With its OPTO-ASIC technology, the RENCO RCML15 offers functionality with the smaller dimensions.

Teflon coatings ™

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Coatings can be applied to: • metals • elastomers • ceramics • composites • rubber • glass

Master Bond masterbond.com EP30LP-2 is a two component epoxy with a low viscosity and a

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volume resistivity of more than 1014 ohm-cm, making it wellsuited for potting and encapsulation applications. This system

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This system is formulated to cure at room temperatures or more

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rapidly at elevated temperatures.

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Use of the Teflon™ mark requires a direct trademark license.

Customers and distributors of Donwell can only resell LICENSEE’s product as licensed with the Teflon™ mark.

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Prod uc t World Entry level rotary module ETEL etelusa.com The DXR+ is now available as a stand-alone rotary module that has the exact same physical characteristics as its predecessor, the DXR, but with improvements in stiffness which has a direct impact on the control bandwidth of any XY stage that is supporting it.

The new DXR+ sports a toothless ring design, similar to an ironless linear motor but in a

rotary shape, ensuring zero-cogging along with cross-roller bearings providing high moment load capacity and high stiffness. It is equipped with a Numerik Jena RIK4 encoder with 18,000 lines per revolution that can be read as either 1 VPP or a TTL signal output.Â

Three-phase power analyzer Carlo Gavazzi GavazziOnline.com The WM20 is a modular class 0.5S (kWh), 3-phase power analyzer for single, two and three phase systems. It is capable of measuring most relevant instantaneous electrical

Surge protection

variables, harmonic distortion, and energy

Automation Direct automationdirect.com/power

generation or consumption.

Four versions are

available to manage up to 600 Vac systems with a choice Mersenâ&#x20AC;&#x2122;s Surge-Trap Type 1 STXR series is a one-piece device that

of either a one or five amp current transformer input. All

requires no assembly and can be used at the machine or the main

information gathered is available on an LCD display and can be

panel to protect equipment from downtime and/or damage associated

transmitted by one of the available communication protocols:

with power spikes and surges. Available in 120-600 Vac models and

including Modbus (RS-485, TCP/IP), BACnet, (RS-485, TCP/IP)

a 200 kA short-circuit current rating, these devices are suitable for

and Profibus.

use in ANSI/UL Type 1 or 2 SPD installations, such as ac distribution, power supplies, drive protection, fire alarms, control panels, and more.

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2017

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Imagineering Imagineering is now AS9100C Certified for Printed Circuit Boards and Assemblies. This certification is an internationally recognized standard focused on quality requirements necessary in the Defense and Aerospace industry.

With over 30 years of experience in the PCB/contract manufacturing industry, with a customer list that includes technology leaders such as Whirlpool, Siemens, Motorola, Honeywell, and GE., Imagineering is known for its same day prototype and aggressive quick-turn offering and is proud to be one of the industry pioneers in having created a truly Web-based approach to the quoting and ordering of PCBs, components and assembly, at one place and all at one time.

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Imagineering has harnessed the technical know-how to enable the quick turn assembly processes in 24 hours rather than days.

These new process’s include state of the art machines, like stencil-less jet printers and proprietary PCB assembly turnkey quote systems which give customers a quote in minutes, not in days or weeks, and a fully assembled prototype PCB in 24 hours, after receipt of all materials.

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PCBA Quotes Online allows you to input the project data and receive a guaranteed quote in minutes.

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We are also AS9100C/ISO9001:2008 certified further expanding our ability to not only serve the consumer market but the Aerospace and Defense markets as well.

A major time waster was the slow quoting process, which often resulted in days for a customer to get a quote. Our new more interactive, intuitive software such as Instant

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Prod uc t World Intelligent pump drive Yaskawa yaskawa.com The U1000 iQpump has low harmonic distortion in a space-saving design, along with the same on board intelligent pump-specific features and protection as the standard iQpump1000. This single component drive allows seamless user transition with low distortion levels without the need for additional countermeasures like passive filters or multi-pulse arrangements.

Features:

• Integrated input fusing to provide 100kA SCCR

• Eco-Mode to achieve near across-the-line THD

• LCD operator with Hand/Off/Auto and Copy function

• Internal real-time clock for event stamping

HMI workstations increase plant safety

4.3-in. HMI IDEC IDEC.com/usa

Eaton gecma.com

The HG1G display is TFT Color LCD with a resolution of 480 x 272 pixels, 65K colors, and 800 cd/m2 brightness. This resolution produces an improved viewing experience, and the increased brightness makes screens visible in direct sunlight. Viewing can be configured for either portrait or landscape, with a viewing angle of 60° from top, 65° from the bottom, and 70° from left or right.

The HG1G HMI supports multiple communication protocols, up

to four simultaneously. The serial port can support both RS-232C and RS-422/485 communications simultaneously, and the Ethernet port can support up to four Hosts and three User communication protocols at the same time.

MTL GECMA HMI workstations, now have two new products – a Thin Client (TC) and Personal Computer (PC) version. The TC version is designed for virtualization applications, for example for batch control. The workstation works with a client server in the safe room across a LAN. This saves space in the cabinet as users don’t need a dedicated PC and the user can control up to 255 HMIs from a single server.

The PC version is stand-alone working across the LAN. Its

system hardware meets the needs of the most complex applications with high computing power demand, for example packing. The workstation has a ‘watch dog’ function which automatically monitors the operating system and if there is no input from the system it automatically re-starts itself.

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Prod uc t World Two lubrication options for cam followers IKO ikont.com There are now two different long-term lubrication technologies for cam followers: a self-lubricating solution for the cam follower itself, as well as an external mechanism that lubricates the bearing surfaces against the rail.

This line of C-Lube cam followers include a thermoset solid lubricant pre-

packed into the bearing space for long lasting, maintenance-free operation. Stud diameters are available from 5 to 20 mm.

Overhung load adaptor design

Voltage transducer

Zero-Max zero-max.com

NK Technologies nktechnologies.com

The Model 650 Overhung Load Adaptor has heavier duty bearings,

This high-performance VTD-BD is applicable on circuits to 600 Vdc. It

stronger shafts and a longer profile. This new SAE B Model 650 is in

has a fully isolated +/-5 Vdc or +/- 10 Vdc output signal in response

the middle of the OHLA sizes ranging from the smallest 200 SAE “A”

to dc voltages that change polarity. The VTD-BD is housed in a DIN

mount model to the largest 1500 SAE “F” mount model.

rail or panel mount case, and is available in a variety of ranges to suit

The 650 model has a heavy duty cast iron housing, 130,000

many primary voltages. Applications include dc-powered operations

PSI stress-proof steel shaft and heavy duty spherical roller bearings.

such as arc welding, shunt wound electric motors and compound dc

Designed for either face or foot mounting applications, the 650

motors, which are commonly used to power lifting cranes on docks,

model handles speeds up to 3500 RPM. Additionally, manufactured

and in the wood processing industry.

to ISO 9001:2008 quality standards, this new model OHLA provides a solid, permanent mounting surface.

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Produ ct Wo rl d Pre-configured geared bearing Nexen nexengroup.com

4-channel intrinsically safe modules WAGO wago.us

This new Geared Bearing package comes with a zero backlash gear mounted and dialed in on a high-

There are now two 4-channel intrinsically

capacity bearing.

safe modules approved for wiring to devices located in hazardous zones 1/21 and 0/20.

Features:

These modules reduce the size of the control

• High Indexing Precision:

cabinet.

As low as ± 30 ArcSec with repeatability as low as ± 5.0 ArcSec

• Zero Backlash: Based on RPS technology, the Geared Bearing offers a rigid, zero backlash system

The 750-539 module is a 4-channel

intrinsically safe digital output module that is engineered to operate intrinsically safe solenoid valves. The 750-486 module is

• High Output Load Capacity: Supported by precision grade, high load

a 4-channel intrinsically safe analog input

capacity cross-roller bearing

module for monitoring field devices. Each

• High Speed: Handles speeds up to 632 RPM

configured for measurement ranges of

channel on this module can be individually 0 to 20 mA, 4 to 20 mA, or 3.6 to 21 mA.

Spring applied brakes for servo and stepper motors Inertia Dynamics idicb.com

Type FSB brakes decelerate or hold inertial loads when the voltage is turned off.

These brakes can be mounted to a bulkhead or motor. FSB brakes are rated up to 100 Lb-in static torque and fit motors up to 5.3-in. OD. Features:

• 12V, 24V, 90VDC or 120VAC windings

• Static torque to 100 lb-in.

• Bore sizes from 1/4 to 3/4-in.

• Low current consumption

• Metric bores & special voltages available

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2017

Fluid Power Technology Conference Presented by

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F r o m b a s i c s t o a d v a n c e d f l u i d p o w e r, sessions will target the following:

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Produ ct Wo rl d Servo motors Rockwell Automation rockwellautomation.com These Allen Bradley Kinetix VPC servo motors can run machines at higher speeds and higher torque, improving machine throughput. A cooling fan and cooling fins on the motor provide increased torque and power output. In addition, encoder options with improved resolution and accuracy provide more precise and responsive control.

The Kinetix VPC servo motor also helps reduce machine downtime

in multiple ways. It uses larger, more robust bearings to improve L10 bearing life by up to 60%. An optional single cable for power and feedback helps reduce installation, setup and maintenance time compared to dual-cable motors.

Linear position sensor for extreme environments Alliance Sensors Group alliancesensors.com LA-25-R series LVDT linear position sensors handle the extreme industrial environments found in steam and hydro power plants; paper, steel, and aluminum mills; die and stamping presses; building and bridge monitoring; and industrial automation and fluid power systems. Available in ranges from 3 to 15-in. (375 mm) full scale, the LA-25-R is suitable for roller gap positioning, process valve displacement, and head box and actuator position feedback with the durability needed to withstand hostile conditions.

Features:

• Enclosed core in 3/8-in. diameter core extension rod with a 5/16-24

or 8 mm male threaded end

• One-inch (25.4 mm) diameter heavy wall aluminum housing

• Continuous operation to 250°F (120 C)

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Prod uc t World Workholding towers for precision clamping Kurt Workholding kurtworkholding.com These high-density CarvLock workholding towers enable precision machining with eight or twelve clamping stations in both manual and hydraulic models. Equipped with easily changeable jaws, the towers provide maximum setup flexibility and fast changeover.

Each tower station has either a 3 or 4-in. jaw

opening and provides repeatable clamping to 0.0002-in. with a maximum clamping force of 5,870 to 7,460 lb., depending on model.

Corrosion resistant Neptune chain Tsubaki ustsubaki.com/index.html These improved Neptune chains have a new surface treatment that resists corrosive conditions longer without compromising the strength and durability of the chain. Neptune chain is also environmentally friendly and compliant with RoHS requirements and is not manufactured with hazardous elements. The G8 Series Neptune chain comes in a variety of options including single and multi-strand drive, single and double pitch, attachment, British Standard and made-to-order chain.

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It’s not a web page, it’s an industry information site So much happens between issues of Design World that even another issue would not be enough to keep up. That’s why it makes sense to visit designworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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SALES

AIGNEP USA ....................................35,49 All Motion ................................................4 Allied Electronics .................. Cover,5,42 Allied Moulded Products, Inc. ............ 58 Aurora Bearing Company .................. 49 Automation Direct .....................Gatefold Automation Direct .................................1 Baldor Electric ..................................... 38 Bergquist, A Henkel Company ...........63 Bird Precision ...................................... 20 Bison Gear ..........................................IBC Bodine Electric Company ...................69 Brogan & Patrick Mfg. ........................ 60 Canfield Industries ..............................43 Caplugs .................................................11 Centritec Seals A Carlyle Johnson Company .........33 Clippard Instrument Laboratory, Inc. .............................BC CS Hyde Company ...............................15 Data Image Corporation......................109 Del-tron Precision, Inc. .......................59 Design-2-Part ......................................113 DieQua ................................................. 68 Digi-Key Electronics ............................13 Donwell Company ..............................109 DSM Somos ......................................... 90 Eaton Hydraulics .................................79 Elesa USA Corporation ....................... 39 Equipto .................................................85 Fluid Metering ......................................43 Fluid Power Technology Conference ....................................116 Helical Products Company Inc. ............7

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A Supplement to Design

HYDAC International ............................21 iCONN Systems ................................... 98 igus Inc. ................................................29 Imagineering .................................. .3,111 Interpower ........................................... 30 IXYS .......................................................37 Keller America ......................................41 Lemo USA ............................................ 93 Maple Systems ....................................65 Master Bond .........................................35 Motion Industries / Eaton .................. 50 NB Corporation ....................................19 NBK America LLC ................................ 52 Neugart USA Corp. ............................. 53 Novotechnik .........................................51 OKW USA ...............................................25 PBC Linear .......................................26,27 PHD Inc. ................................................18 Proto Labs ..............................................9 QA1 ........................................................16 Quantum Devices Inc. .........................85 Sorbothane ..........................................74 Stock Drive Products / Sterling Instrument ...................... 20 Tadiran Batteries .................................81 Tech-Etch, Inc. .....................................31 The Lee Co. ...........................................57 Therm Omega Tech ..............................14 Trim Lok ................................................17 UBM ............................................ 71,73,75 Ultra Motion ............................................2 Universal Robots USA, Inc. .................61 Visumatics Industrial Products .........45 Whittet-Higgins ....................................23

Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Garrett Cona gcona@wtwhmedia.com 213.219.5663 @WTWH_gcona Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference

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EVP Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

FOLLOW US ON

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Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

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Bearin g Ti ps Su pplement

World - April 2017

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