DESIGN WORLD APRIL 2020 by WTWH Media LLC

Fastener Engineering

www.designworldonline.com

April 2020

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inside: MOTION CONTROL: Selection and customization of universal joints for optimized operation

p. 142

LINEAR MOTION: Linear actuators—it’s electric

p. 148

THE ROBOT REPORT: COVID-19: a wake-up call for robotics developers

p. 88

Mechanism design using geometric constraints page 152

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Are we focusing enough on research? One of the things that’s most enjoyable about covering the design engineering space is seeing, on a continual basis, the amount of new technology being used in so many industries, om the component to the system level. But it’s important to realize that much of what feeds that pipeline of new tech is the invention that’s happening in research and development. R&D happens in multiple places — in corporate facilities, across much of academia, and in governmentsupported national laboratories. Our sister publication, R&D World, recently published its annual Global Funding Forecast for this important sector, and it’s worth noting that China has nearly caught up to the U.S. in terms of being the world’s leading R&D investor. If current spending trends continue, the baton will be passed to them in about 2025. What’s more, Asia is now the leading region for R&D investment, with more than a 44% global share. And fully 50% of the worldwide spending may be in Asia before 2030. Recently, the report by the Task Force on American Innovation, “Second Place America? Increasing Challenges to U.S. Scientific Leadership,” noted that China and other countries are boosting investments in research and growing their STEM (science, technology, engineering and manufacturing) workforces. It explained that emerging economies, particularly China, are playing a greater role in scientific discovery and innovation and challenging established U.S. leadership in critical research fields. Further, it asserted that China has overtaken the U.S. in total research publication output as of 2016 and is now the dominant producer in engineering, physics, chemistry, geosciences and mathematics. The report also noted that other countries continue to invest heavily in higher education, turning out more science and technology graduates. The U.S. trails the top eight countries in the European Union as measured by the total number of bachelor’s degrees in science and engineering awarded since 2000. The U.S. has been used to being the leader in so many areas of engineering and technology, but is this era finally coming to a close? For the past few decades, we’ve seen warning signs — just think of our falling rankings in mathematics and science scores for schoolkids. I see R&D as another strong barometer of what’s to come in engineering technology, and the readings it’s giving are concerning. It’s not too late, but we all must tell our elected officials as well as our corporate leaders that R&D funding is critical to our future success in so many fields. DW

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Teschler on Topic DIY ventilators?

Not unless there’s a zombie apocalypse News reports of the Covid-19 virus have given a lot of space to the shortage of respiratory ventilators. The Society of Critical Care Medicine claims at least 950,000 U.S. patients could need ventilators but hospitals only have 160,000. One response to statistics like these has been a movement among open-source promoters to initiate community-designed ventilators that can be inexpensive and assembled quickly. There are several of these efforts afoot. Canada has one called the Code Life Ventilator Challenge. Others are being coordinated om hackaday.com and helpfulengineering.org to name just two. Schools that include M.I.T. and the University of Minnesota have groups working on their own lab-built ventilators. But there is one thing to keep in mind about these well-intentioned efforts: It’s unlikely any of them will result in hardware able to treat Covid-19 patients, at least not in the U.S. The reason concerns the regulatory requirements of the U.S. Food and Drug Administration for any kind of life-critical gear used on human patients. These regulations aren’t just bureaucratic paperwork. They are in force because it turns out to be relatively easy to kill someone on a ventilator. The ventilator itself can cause pneumonia, blood clots, collapsed lungs, and other kinds of lung damage. Covid-19 patients on ventilators might well wonder what will take them out first, the virus or the ventilator. The FDA requires that most new medical devices undergo lengthy laboratory and animal testing to answer basic questions about safety. Only then are they tested on people. However, medical devices can forego this testing if they can be proved to be “substantially equivalent” to similar devices already commercially available. One of tests used to decide about equivalency is whether the new device has “technological characteristics” that resemble those of existing equipment. That brings us to open-source ventilators. One project I saw used a ziplock bag as a bellows. In no way, shape, or form is a backyard project like this technologically similar to anything in a hospital. The only circumstances in which you’ll see such cobbled-together ventilators is in a societal collapse as portrayed in The Walking Dead TV series. That said, FDA has recently been handing out what are called emergency use authorizations for medical equipment. But when it comes to ventilators, the authorizations only pertain to the repurposing of medical devices already cleared by the FDA so they can be used as respiratory ventilators. Examples include anesthesia gas machines, CPAP sleep apnea gear, and emergency ventilators. However, the efforts directed toward open-source ventilators won’t be for naught. The Covid-19 crisis has caused numerous engineering minds to focus on ventilator design. My own prediction is that the result will be a relatively quick (at least for medical devices) drop in the price of commercial ventilators, perhaps by a factor of ten. And I expect the millennials in my office will never again live through a respiratory ventilator shortage. DW

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

Lee Teschler Column 4-20_V3.LL.indd 6

April 2020

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Technology Forward 5 data management trends for 2020

According to Infogix in its fourth annual list of challenges and opportunities in data management, “today, more data crosses the internet every second than was stored in the entire internet just 20 years ago. With that much reliance upon data, 2020 is the year that data quality becomes the epicenter of any data trend.” The company is a provider of data management tools. As organizations continue to push the limits with data storage and processing, data quality will be an underlying theme to ensure organizations can leverage data they can trust. Here are five trends to watch: 1. Real-time data will disrupt the future The massive amounts of data generated om various industry domains, including IoT devices, means organizations must react quickly to extract value om it. Traditional batch processing will not meet these changing demands. Thus, users are turning to eventdriven architectures to handle the streaming data. Distributed streaming platforms include Apache Ka a, ActiveMQ, Apache Pulsar, Amazon Kinesis and others. Users will need to ensure they work with vendors who can safeguard data quality to prevent data assets om

becoming liabilities and that can provide validation at a speed and scale to match data-in-motion. 2. Cultural change through data governance Data governance can improve enterprise data understanding and create a data-driven culture. Yet many still struggle to bridge the technical/business divide. Data governance encourages collaboration to build user- iendly tools that explain technical data in a business context and include critical institutional business knowledge. It also includes end-to-end data quality monitoring and metrics for technical and non-technical users. 3. Conquering bad data Historically organizations used to prioritize quality for revenue, reputation, or mission-critical data. That is changing. Complex regulatory compliance and the ever-increasing speed and scale of data are making organizations prioritize data quality for all enterprise data initiatives. By building a data quality-powered amework, organizations improve enterprise data value and resolve data quality issues before they proliferate across systems. 4. Maturing data privacy laws The European Union’s General

Data Protection Regulation (GDPR) was implemented nearly two years ago, serving as a global catalyst for data privacy legislation. In the U.S., states like Nevada and California have already passed sweeping legislation to protect the personal data of consumers. Noncompliant companies risk financial fines and reputational damage, prompting them to evaluate and address potential compliance gaps. Poorly maintained and poorquality data can easily result in compliance violations that impact the brand and the bottom line. 5. Self-service technologies on the rise Tools and technologies with machine learning and automation capabilities that enable self-service data analytics took off in 2019. Still, these tools are leveraged as part of a departmental project rather than an enterprise program. To scale enterprise-wide, organizations must encourage data literacy among users so selfservice analysis yields accurate and actionable results. Organizations must also establish policies for data access and usage, and ensure the accuracy of high-value data with key capabilities including timeliness, completeness and integrity checks. DW

Leslie Langnau • Managing Editor llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

April 2020

Tech.Forward.4-20_Vs2.LL.indd 8

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Green Engineering Paul J. Heney

• Editorial Director

New hearts for fuel cells When it comes to providing energy in electric engines, fuel cells are a great way to supplement batteries to increase the driving range. However, manufacturing fuel cells remains a cost-intensive process, so there are still relatively few vehicle models with this drive technology on the German market. Now the researchers at Fraunhofer IWU are working on a more cost-effective solution. “We take a holistic approach and look at all of the components in a fuel cell engine. It starts with the provision of hydrogen, affects the choice of materials that are directly involved in generating electricity in fuel cells, and it extends to thermoregulation in the cell itself and in the vehicle as a whole,” said Sören Scheffler, project manager at Fraunhofer IWU in Chemnitz. As a first step, the researchers focus on the heart of any fuel cell engine: the “stack.” This is where energy is generated in a number of stacked cells made up of bipolar plates and electrolyte membranes. “We are researching how we can replace conventional graphite bipolar plates with thin metal foils. This would enable stacks to be manufactured quickly and economically on a large scale and would significantly boost productivity,” said Scheffler. The researchers are also focusing on quality assurance. Every component in the stacks is inspected directly in the

April 2020

Green.Engineering.4-20_Vs2.LL.indd 10

manufacturing process. This is intended to ensure that only parts that have been fully examined make their way into a stack. In parallel, Fraunhofer IWU aims to improve the ability of stacks to adapt to the environment and to the driving situation. “Our hypothesis is that dynamically adjusting to environmental variables — also aided by AI — can help save hydrogen. It makes a difference whether an engine is used at high or low outside temperatures, or whether it is used on plains or in the mountains. Currently, stacks work in a predefined, fixed operating range that does not permit this kind of environment-dependent optimization,” said Scheffler. The Fraunhofer experts will demonstrate their research approach with their Silberhummel exhibit at Hannover Messe om April 20-24. The Silberhummel is based on a race car that was designed by Auto Union AG in the

www.designworldonline.com

1940s. The Fraunhofer IWU developers have now used new manufacturing methods to reconstruct this vehicle and create a modern technology demonstrator. Their aim is to outfit the Silberhummel with an electric engine based on advanced fuel cell technology. This technology will already be digitally projected into the vehicle at the Hannover Messe. The car body itself is also an example of the innovative manufacturing solutions and forming processes being further developed at Fraunhofer IWU. Here, however, the focus is on the costeffective manufacture of small batch sizes. The Silberhummel’s body panel was not formed with large presses involving complex operation with cast steel tools. Instead, negative molds made of easily machinable wood were used. A machine tool designed for this purpose pressed the body panel onto the wooden mold bit by bit using a special mandrel. DW

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Contents 4 • 2020

•

vol 15 no 4

•

designworldonline.com 53-60 www.bearingtips.com

A Supplement to Design World - April 2020

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

Bearing Tips 4-20_Cover.indd 53

4/9/20 9:44 AM

62-85 April 2020

164 142 _MOTION CONTROL

158 _FLUID POWER

Selection and customization of universal joints for optimized operation

Next steps in fluid power connections

In today’s rapidly advancing technology landscape, machinery and equipment must operate at maximum efficiency and with minimal downtime. Carefully selected components such as universal joints can prevent scores of machinery problems and help optimize operations. 148 _LINEAR MOTION Linear actuators—it’s electric

Manufacturers are making it easier to connect electric linear actuators to machines and systems, helping smooth the transition to the industrial IoT. 152 _3D CAD Mechanism design using geometric contraints

Use the power of geometric constraints within parametric CAD so ware to turbocharge development of synthesizing mechanisms.

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

Aerospace COVER_FINAL2_4-20.indd 62

4/9/20 9:47 AM

87-115 A Supplement to Design World - April 2020 www.designworldonline.com

COVID-19

a wake-up call for robotics developers

page 88

INSIDE:

Reduced effort, high value for automating hydraulic systems

• Blood-drawing robot shows promising results ...............................................................102 • Diligent Robotics designs Moxi to aid stressed clinicians ............................................................106

ROBOT REPORT COVER_4-20_FINAL2.indd 87

4/9/20 9:50 AM

116-140

Engineering

164 _MACHINE TOOL

April 2020

A supplement of Design World

Edge automation improves productivity

Shortages of skilled labor can be addressed by investments in automation at the edge.

Fastening technology Covering assembly, design, training, welding... plus, what to expect at this year’s Fastener Fair USA!

| AdobeStock.com

COVER_FASTENER ENGINEERING 4-20_FINAL.indd 116

4/9/20 9:59 AM

170 _MECHANICAL When to use pillow block bearings and why

Design engineers speci pillow blocks when bearings need to be supported outside of a machine enclosure. Typical applications include conveyors, overhanging fans and blowers, or long line sha s. Here, we take a closer look at when to choose pillow block bearings and other key details.

ON THE COVER A look at how parametric CAD tools can help you develop synthesizing mechanisms. | AdobeStock.com

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

2019

BRONZE REGIONAL AWARD asbpe.org

April 2020

CONTENTS.4-20_Vs3.LL.indd 12

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DESIGN WORLD

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4.20

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Insights

Teschler on Topic

Technology Forward

Green Engineering

Design For Industry

Design Notes

CAE Solutions

Internet of Things

174

Product World

176

Ad Index

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April 2020

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Follow the whole team on twitter @DesignWorld

EDITORIAL

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

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Design for Industry Food & Beverage

Eliminating distortion and creasing in shrink film France is heralded as a paradise for gourmets. The land of haute cuisine is renowned for its award-winning wines, outstanding cheeses and highclass natural mineral waters. One brand that has established itself as a leader among carbonated natural spring waters is Badoit, a bottler om SaintGalmier in the DĂŠpartement de la Loire, southwest of Lyon. â&#x20AC;&#x153;Beverage brands can clearly position themselves on the market through the nature of their presentation and design,â&#x20AC;? explains Christopher Stuhlmann, head of the Line Product Division at KHS. This is one reason packaging quality plays a key role. This aspect is especially important for Badoit. â&#x20AC;&#x153;As a premium brand our products not only have to differ om those of the competition in quality but also in appearance. The exclusive standard of our water must also be reflected in the packaging,â&#x20AC;? states Marie. The mineral water plant has therefore opted for bottles with a long, elegant neck, a unique feature on the French market.

April 2020

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While the unusual bottle shape is a blessing when it comes to brand recognition, it has proved quite a challenge for the shrink packers used by the water bottler â&#x20AC;&#x201C; also for its KHS Kisters packaging machines, some of which have been in operation for more than 30 years. â&#x20AC;&#x153;The long-necked bottle makes it difficult to produce a packaging quality which is outstanding in all respects,â&#x20AC;? Marie says. â&#x20AC;&#x153;The multipacks o en had creases in the film, the print was distorted or the packs werenâ&#x20AC;&#x2122;t stable enough to withstand the logistics.â&#x20AC;? In addition, the outmoded packaging machines were no longer state of the

DESIGN WORLD

4/9/20 12:40 PM

industrial art when it came to efficiency and sustainability and were increasingly limited in their technological capacity. â&#x20AC;&#x153;We were no longer able or prepared to accept these compromises in packaging quality and machine efficiency,â&#x20AC;? claims Marie. Badoit parent company, Danone Waters, launched a competition between its individual brands and production plants. â&#x20AC;&#x153;Danone Waters wanted a packaging machine which, thanks to significant developments in the shrink tunnel segment in particular, considerably improves the standard of the shrink film processing available to date,â&#x20AC;? says Stuhlmann. Here, it was especially important that the lettering and brand logo on the packs was neither distorted nor creased. Following promising tests, KHS was ultimately awarded the contract for the project. Under the supervision of Christian Schilling, head of the shrink tunnel development group at KHS, the machine and systems manufacturer put together an experienced team of design engineering experts. The expert teamâ&#x20AC;&#x2122;s first task was to develop new components for Badoitâ&#x20AC;&#x2122;s packaging machines. The packaging specialists in Kleve subjected all system parts to thorough testing. A er several optimization loops the improved components were integrated into the latest generation of the KHS shrink packer. â&#x20AC;&#x153;We then performed a series of further tests to make sure that our new developments satis Badoitâ&#x20AC;&#x2122;s high demands,â&#x20AC;? says Stuhlmann. Finally, the system passed its factory acceptance test and was shipped to Saint-Galmier. Here, the KHS team replaced the old KHS Kisters shrink packer om 1986 with the optimized packaging machine. The packaging experts then focused on optimizing the system and its processes under production conditions. â&#x20AC;&#x153;At first we werenâ&#x20AC;&#x2122;t able to fully achieve the required packaging quality with the combination of shrink film and machine used,â&#x20AC;? admits Stuhlmann. The specialists therefore spent the following

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months working on the various machine components, further developing, constructing, installing and testing them time and again. One major development on the new generation of machines was to distribute the hot air supply more accurately on both lanes. â&#x20AC;&#x153;Both are crucial for crease- ee pack quality as the optimum processing window for the partly inverse effects was limited,â&#x20AC;? Stuhlmann explains. The Dortmund company solved this problem with a specially designed central tunnel nozzle which will also be available to other projects in the future. The special air nozzles with their optimized perforated nozzle plates also help to create crease- ee packs. The KHS Kisters shrink packer can now process films of a much lower thickness. The machine also uses an optimum width of film per pack thanks to film web control. Badoit and its operators benefit om fully automatic film web control which is not only easy to handle but also ensures consistently high packaging quality. â&#x20AC;&#x153;With this new technical feature we were able to achieve the goal set by the customer, namely of providing optimum packaging quality while using the lowest possible amount of material,â&#x20AC;? smiles Stuhlmann. The team of experts also managed to boost the packerâ&#x20AC;&#x2122;s performance. On the further developed shrink packer up to 37,000 bottles per hour can be formed into packs of six on two lanes at the existing line speed. DW

KHS | www.khs.com

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Asymmetric XY stages are for applications that do not require identical travel lengths on the X and the Y axes. This format is an alternative to stacked stages. In these stacked configurations, the lack of lower axis torsional stiffness and the bending moments of the upper axis can limit the dynamic responsiveness of the stage. Three standard versions with asymmetric body designs / travel lengths are available, as well as custom versions. The company offers an array of precision motion control systems. DW

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O f f- h i g h w a y

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Gearmotors are o en used to power bucket elevators, conveyors, feeders, slide gates, and more in the grain industry, moving these components safely, reliably, and efficiently. The newest industrial gear unit available is the MAXXDRIVE XT. It comes in seven sizes in torque ranges of 130,000 to 660,000 lb-in. It offers the grain industry a symmetrical designed gearbox for mirror image installations, which reduces spare parts costs and downtime. It comes in seven sizes and provides a torque range of 130,000 to 660,000 lb-in. Other gearmotors available include the MAXXDRIVE, which offers output torque om 132,000 lb-in to 2,200,000 lbin and also suits heavy duty applications, such as bucket elevators, agitators, conveyor belt drives, mixers, mills, drums, or crushers. MAXXDRIVE is available as a parallel sha or helical bevel and comes in 11 sizes. Also available is a screw conveyor package that is available for both Clincher parallel sha and helical bevel gear units in a compact footprint. Closely stepped speed reduction ratios combined with a directly coupled gearmotor or NEMA C-face input design eliminates the need for top motor mounts, pulleys, belts, or guards. This minimizes parts inventory and eliminates belted input systems for easier system maintenance and more reliability. An energy efficiency rating of up to 97% rounds out the benefits. DW

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Design for Industry O f f- s h o r e

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HPHT environments

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The exploitation of hydrocarbon reserves within offshore oil and gas is strongly linked to several thermodynamic processes that determine the state and nature of the product at the point of arrival at the processing plant. Changes in temperature and pressure are the principle drivers as these also steer changes in phase, composition and viscosity. Considerations of these complex interactions should be at the heart of flow assurance, impacting the design, development and ultimately, the reliability of installations. Temperature is the easiest change to manipulate, by controlling thermal loss with specialist insulation, or by the provision of energy to the system through electrical or hot water heating. Integrating these two approaches can provide a particularly robust and

April 2020

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flexible level of control, expanding operating windows. Subsea thermal insulation, based on polymeric materials, is a proven solution for ensuring predictable heat loss in flowlines, risers, manifolds, Christmas trees and peripherals. Materials such as epoxies, urethanes, silicones, polyolefins and rubbers,

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have all been used successfully within their respective operational capability. Over time much of the “easily available” offshore oil and gas reservoirs have been exploited with Greenfield sites typically being found in deeper water. This can cause issues due to the more demanding conditions in these environments. Closed cell foams such as blown polypropylene, polymer syntactic polyurethanes and light urethane foams, widely used in the 0 to 300-meter interval, are unsuitable for deep water environments. They are no longer capable of operating without excessive compaction and the corresponding deterioration in performance. However, extended water depth capability for foamed materials can be achieved using mechanical foams, or “syntactic” materials with

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Design for Industry O f f- s h o r e small hollow glass microspheres dispersed in the polymer matrix. This offers an alternative solution to the above for water depths of around 2,500 meters. For ultra-deep-water environments greater than this, only incompressible, solid materials can be reliably used. These are generally associated with higher thermal conductivity and thereby poorer performance. Deeper wells with significantly higher operating temperatures also pose a challenge for both the insulation system in terms of chemical degradation or structural collapse and the corrosion protection system. Current requirements of an operating temperature of +150 oC to +180 oC limit the number of viable material types suitable to less than a handful. Recent developments within rubber technology have produced a handapplied product for application to Christmas trees, manifolds and jumpers. This high temperature rubber compound, capable of continuous hot-wet exposure at up to +180 oC, is an incompressible compact material containing no glass microspheres and has a low thermal conductivity of 0.165 W/m/K. Hand-applicable or â&#x20AC;&#x153;pack in placeâ&#x20AC;? systems have been discussed for HPHT environments over many years and have some distinct advantages over castable systems during the application phase. As there is no requirement for casting molds or tooling, there is a significant reduction in ont-end engineering, design and manufacturing time. Handapplicable systems are quick and easy to mobilize on site. Using automated mixing equipment, with a low user threshold, enables a high level of local manpower, allowing for increased project flexibility. Vulcanization temperature and time, along with a requirement for using autoclaves in the curing process have previously been concerns for project operations, limiting the applicability of rubbers for the insulation of complex structures. The development of low temperature vulcanization chemistries has obviated these concerns. Today, high operating temperature rubber systems can be vulcanized under control at

April 2020

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temperatures as low as +40 oC without the need for autoclaves. In conclusion, with new developments in technology, rubber systems are seeing a resurgence for high temperature, ultradeep-water fields, having advantageous thermophysical properties, convenient application practices and a high level of application flexibility. DW

Trelleborg Offshore www.trelleborg.com/en/offshore

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Design Notes

Smart bearings: The demise of slow-comotives

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

According to the TUC, the average rail commute in the UK takes an average of 2 hours and 11 minutes, each day. Also, last year more than one-third of trains failed to arrive at stations due to technical faults. Chris Johnson, managing director of industrial bearing supplier SMB Bearings, considers the future adoption of smart bearings and their impact on Industry 4.0. Bearing designs have stayed relatively consistent for decades. There have been new developments in the form of bearing materials like ceramic, hybrid, and plastic, and new lubrication options are now available in the newly discovered material, graphene. However, a new development could surpass even these: a collaboration between bearings and the Industrial Internet of Things (IIoT) that could provide value both across production processes and entire operations.

April 2020

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BEARING WHEEL COVERS. Digitalization is making a major change in how maintenance can be executed —specifically, with the adoption of IIoT-based smart bearings that can self-diagnose impending faults and failures using sensors integrated into the bearings themselves. These sensor bearings are different om traditional solutions, which usually involve a standalone sensor mounted near the bearing. Instead, the sensor is integrated to measure bearing speed and direction, which is then relayed to a control system. Sensor bearings work through a magnetic pulse generator ring. Alternating poles are mounted to the inner rotating ring, while the outer ring carries the sensor housing. As the inner ring rotates, the generator ring passes over the stationary magnetic sensor and detects the change in magnetic polarity. This process generates an electrical signal that is then processed and converted into direction of rotation and rotational speed data. Recorded data can then be transferred via a gateway to the cloud, where engineers will be able to access the information in real-time. Take, for example, smart bearings used in the railway industry. Measuring radial shi displacement allows the radial force on the sensor bearing to be calculated. This is mixed with innovative so ware, to give

accurate calculations of the displacement and torque of other bearings and elements. This advance allows information on overloading to be easily recorded and used to limit torques, or even switch off the drive if needed. By monitoring these critical assets, there’s a higher chance of avoiding unplanned stops for enhanced overall rail operations. Smart bearings also address a host of industrial applications, including the monitoring of thermocouple (speed and temperature) and accelerometer (vibration) levels. But, does this make them smart? It all depends on the key parameters that are to be monitored. A er all, anything can be sensed — the hard part is knowing what to sense and what the output signals mean. With smart bearings, engineers can adopt a proactive approach to maintenance by monitoring machine processes such as pressure, force, and vibration — each of which provides critical data for predictive maintenance. Real-time updates on the condition of bearings and other components allow for advanced diagnostics to be performed. Early warnings about any deterioration in bearing condition can also be accessed. Adopting a proactive maintenance approach has many benefits. When a piece of equipment malfunctions, the entire process comes to a halt while the problem

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Design Notes

With smart bearings, engineers can adopt a proactive approach to maintenance by monitoring machine processes such as pressure, force, and vibration â&#x20AC;&#x201D; each of which provides critical data for predictive maintenance.

is fixed. By accessing advanced data on the operating status of a machine, engineers can reduce downtime and prevent factors that cause breakdowns. Avoiding system or machine breaks also minimizes the need for repairs during operating hours. A proactive approach to maintenance also benefits the durability of a component or machine, specifically, by solving the root causes of a problem, rather than merely dealing with the signs of a pending error. The longer the machine or component lasts, the longer the replacement costs can be deferred.

What component could be better equipped to gather this critical data than a smart bearing? Bearings are typically located in the heart of all rotating applications, with rotational speeds, forces, and vibrations all impacting on them in some way. As industries continue to grow and develop, additional smart bearing sensor data is needed to more closely monitor proper bearing functions and optimize operations. Advancements in bearing technology, including data sharing and maintenance tracking, will continue to be researched and developed across more applications. In the railway industry, adding smart bearings will provide operators with real-time, on-board information on bearing health, and allow the detection of early bearing damage. Because train bearings are key elements in the integrity of railway wheelsets, the integration of condition monitoring will significantly impact railway operating costs and train safety. DW

SMB Bearings | www.smbbearings.com

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Design Notes

A new spin on rotary index applications

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

This photo shows the location of the Nexen clutches in the machine. After the spinning operation is complete, a new station will index over the clutch so it can be spun in its operation.

To save floor space, many machine builders are replacing an in-line process with a circular approach that tends to simpli the placement of rotational devices in a manufacturing environment. In assembly or multiple process applications, rotary index tables with multiple stations are gaining popularity. Index tables â&#x20AC;&#x201D; fitted with numerous workstations where various sub-processes execute â&#x20AC;&#x201D; rotate to the next station as each process is completed until the part is finished and removed. The types of processes occurring at each station are varied and may include machining, inspecting, cleaning, filling, or spinning a part. The complexity of a rotary indexing process is apparent in the difficulties of incorporating a spinning axis station on a rotary indexing table. In precision applications, a servo or stepper motor is traditionally integrated into each station so the motor can spin the workpiece upon part arrival. This configuration requires that each station has an individual servo motor. This also necessitates the incorporation of the essential cable management requirements that feed power to the traveling motors, while also managing feedback information transmitted to the servo drives. Undoubtedly, this process includes a series of sliprings and the various correlated cable management elements.

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Cutaway section of the 8-station index table, showing the servo clutch mechanisms located at the specific spin station locations. The actual clutch mechanism is blown up to show further detail. As the spin station is reached, the clutch mechanism is triggered to engage with the station, and the servo drives the workpiece as the process requires. The clutch then releases, and the index table can rotate to continue the next process.

For example, in an 8-station process where spinning occurs, each station requires a servo motor and the associated power and feedback elements, regardless of whether each individual axis station needs to spin. Therefore, if only three of the eight stations require a spin motion, the machine will need to carry five extra motors unnecessarily. What if a solution was available that only engages the process stations needing to spin? Servo motors are typically coupled

Design-Notes-4-20-Vs3.LL.indd 33

to their loads via a fixed member with many connection options, including rigid couplings, bellows style couplings, or couplings with flexible rubber inserts for misalignment. Each of these connections will work wonderfully until the servo needs to be physically disconnected, as in the case discussed here. Limited options are currently available to fully disconnect the load om the motor. Items such as magnetic couplings (a design that

always operates with a gap between two elements) struggle to maintain accuracy between the servo and the load due to the natural hysteresis in a magnet. Another option, engaging a V groove or drive cogs, does not address the need for exact alignment to prevent etting corrosion on the cogs. In considering each potential technology solution, maintaining a tight coupling with no slip is of paramount concern. In addition, alignment elements

4/9/20 12:57 PM

Design Notes

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required for certain coupling types add more complexity to the application. â&#x20AC;&#x153;The key to a successful solution is a coupling technology that is simple to align and will tolerate accelerating the station to the appropriate speed with no slippage,â&#x20AC;? Tony Kliber, IQa Engineering In an actual machine example, an eight-station rotary table was required for processing a workpiece. Of those eight stations, three required spinning as part of the process. Each station required a different spinning profile, the most aggressive being an acceleration om 0 to 3000 RPM in .25 seconds. A er the initial acceleration, the workpiece would decelerate to 0 in .5 seconds. At that point, it was critical that the workpieces were stopped in an orientation that prepared it for the next station (i.e., the servo could not slip at all during the accel/decel). IQa Engineering established a solution that eliminates the extra servos and associated power and feedback complexities of conventional solutions for spinning requirements. The innovative approach uses a modified Nexen iction clutch design providing a simplified mount between the servo motor and clutch. The clutch was mounted at three stations and is triggered at the appropriate station before spinning up. While this is not a typical use for the iction clutch, it held the most promise since its torque profile met the needs of this application. With the iction clutch engaged, the servo would then accelerate in 0.25 secs to 3000 rpm and hold speed throughout the specific process until stopped, at which point the clutch is disengaged. As a precaution, the mechanism was fitted with a sensor to detect any slippage. Initial testing using the servo-driven iction clutch showed that no slippage occurred and that the solution provided the necessary spin function â&#x20AC;&#x201D; while also simpli ing the design, saving costs, and minimizing space requirements. â&#x20AC;&#x153;We were excited to find that a er extensive testing, no slippage was detected during acceleration, meaning our design concept was solid,â&#x20AC;? says Tony Kliber of IQa Engineering. A er successfully implementing the Nexen solution, IQa realized significant benefits to the system in comparison to having a servo at every station. The resulting system is lighter and requires less energy to operate, reduced cabinet space, smaller fuses, and less wiring â&#x20AC;&#x201D; adding up to reduced manufacturing costs and improved OEE for the end customer. DW

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READY TO ROLL Compact, rigid and easy to install, IKOâ&#x20AC;&#x2122;s crossed roller bearings can handle complex loads in any axisâ&#x20AC;&#x201D;making them a great fit for motion systems with high load capacities, including robot, machine tool and other industrial applications.

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4/9/20 1:18 PM

Design Notes

Electronic position indicators for

baby formula packaging application Edited by Mike Santora â&#x20AC;˘ Associate Editor

The ETIL end-of-line packaging machine for trays with lids enables a precise and product-friendly packaging process. Electronic SIKO position indicators for monitored size changeover can be integrated as an option.

To ensure that form, fill and seal, and cartoning machines can be used flexibly, a system must be optimally adapted to changing packaging formats. ROVEMA, a manufacturer of packaging systems in the food sector, relies on monitored size changeover using the AP10 electronic position indicators with IO link om SIKO, a specialist for industrial measurement and drive technology. Powdered milk formula for babies is a sensitive product that must be filled gently and safely into appropriate foil bags and outer packaging. The packaging logistics behind it must be thought through to the smallest detail. ROVEMA offers comprehensive turn-key-systems for packaging processes such as these â&#x20AC;&#x201D; om primary packaging in tubular bags to secondary packaging for sales and tertiary packaging for transport. It is essential to have as much flexibility as possible in complex plant systems, despite specific product characteristics, to be able to produce different variants of products, tubular bag, and carton sizes. Size changeovers for various packaging formats must be smooth to ensure production processes are as efficient and

April 2020

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reliable as possible. Here, Rovema relies on SIKOâ&#x20AC;&#x2122;s AP10 electronic position indicators with IO link interface for monitored and reliable size changeover, both for cartoning machines and for form-fill-seal machines. Up to 40 adjustment points may be necessary to adapt all functions to a product variant within turn-key system such as this, as designed by ROVEMA for packaging infant formula. Changeover that relies on purely mechanical position indicators is highly susceptible to errors and inaccuracies. Similar competitor products were already being used before ROVEMA turned to SIKOâ&#x20AC;&#x2122;s electronic solution; however, they required an additionally integrated controller. This was more complicated to connect and also the more expensive solution. The AP10 from SIKO with IO link interface saves the costs for the controller and makes it much easier to integrate the position indicators as IO link devices into the machine control system.

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Ingo Hamel, Head of Innovation R&D at ROVEMA, explains: â&#x20AC;&#x153;IO link is a communication standard that is becoming increasingly widespread in the automation sector and is already being used more and more by us as an interface for sensors and actuators. It was therefore obvious to think about this for the size changeover. We already have longstanding constructive cooperation in the field of mechanical position indicators.â&#x20AC;? Moritz MĂźller, Product Manager PositionLine at SIKO, was pleased to act on the suggestion: â&#x20AC;&#x153;We were also already working with IO link and thus developed the AP10 with an IO link interface.â&#x20AC;? Infant formula is packaged in powder form in pack sizes ranging from 200 to 800 grams in the entire plant mentioned at the beginning. The powder is first filled into corresponding bags in parallel in two form fill and seal machines and then fed on two tracks to a horizontal cartoning machine. Here, one or two bags are placed in a folding box and provided with a dosing spoon before the box is closed. The ready-to-load boxes are then taken to the final packaging machine and packed into a transport carton. The last station is the customerâ&#x20AC;&#x2122;s palletizing system. All 40 adjustment points along the line must always be adapted to the new dimensions according to the respective packaging sizes. Most of the adjustment points are located in the cartoner and end-of-line packaging area, less so in the tubular bag machine. When a new size is needed, the corresponding recipe is selected in the controller, whereby all electronic position indicators receive the new setpoints directly via the IO link interface and display them clearly on the backlit display. The LEDs of the displays immediately switch to red, as the current position is now no longer correct. The operator then goes on to mechanically adjust all corresponding points to the new values â&#x20AC;&#x201D; another ergonomic advantage: The AP10 indicates the direction to the setpoint via the LEDs and the LCD with corresponding arrows, making it easy to visualize where the operator must go. If the position and setpoints then match exactly, the LED display changes to green: Position reached. This is how all the red position indicators are moved to start the new product. The advantages are no more paperwork and lists of values to tick off and document. All values are already available electronically and are transmitted directly to the position

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Design Notes

Electronic position indicators AP10 from SIKO for size changeovers: The status LEDs light up green, as the actual and target values match precisely.

The AP10 position indicators enable fast size changeovers and ensure greater process reliability. indicators. Changeover is faster as well as safer because the feedback of the LED lights is clear. The system can only be restarted if all the corresponding position indicators light up green. In this case, the position indicators for the setpoints are given a specific tolerance range based on a nominal value. The operator has the possibility of making fine adjustments within this and the position indicators light up green. If the operator leaves the area, the display switches to red. This margin can be advantageous in the event of packaging material fluctuations in the carton area. If the temperature of the hot-melt glue fluctuates or a cardboard box is slightly more creased, it may be useful to slightly adjust the guides or a contact pressure by a folding tool, for example. According to Hamel, this fine adjustment is welcomed by the operators who know the plant and product best: “The tolerance range allows the operators to make an independent assessment of the situation and gives them scope for action. This makes the processes more efficient and the employee feels involved.” IO link is a communication standard that is gaining ground internationally. Those who use IO link for their automation benefit om many advantages. As a standardized communication protocol that is subject to an international standard, IO link is

April 2020

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ROVEMA GmbH

manufacturer-independent. Accordingly, devices and masters can be developed as communication participants. Integration is possible via simple point-to-point connections at the lowest network level and the wiring effort is low compared to fieldbus interfaces. The AP10 displays are regarded as IO link devices, each of which is connected to an IO link master, which usually has eight ports. From the master, communication with the controller is via another high-performance protocol; in this case, SERCOS III (EtherNet/IP is also equently used by ROVEMA). Moritz Müller explains the reasons www.designworldonline.com

for not using EtherNet/IP throughout for communication, for example: “IO link is the much more cost-effective interface, which also makes significantly lower demands on the wiring and is thus also easily connected.” Hamel confirms the easy integration: “We were very pleased that the first commissioning worked right away — without a lot of cabling work and with simple parameterization and integration into the control system.” According to Moritz Müller, there is also a simple diagnostic function. IO link quickly shows which device may have a fault or needs DESIGN WORLD

4/9/20 1:02 PM

Cartoning machines have numerous adjustment points that can be easily adjusted during size changeover with the aid of electronic position indicators.

to be optimized. For this purpose, the position indicators can be exchanged during operation without having to open up an entire network ring. The affected device can be disconnected and replaced by a new one thanks to the star-shaped plug connection to the IO link master. The parameterization can then be loaded directly om the IO link master into the new (identical) device and thus accepted. Electronic position indicators for monitored size changeover are optionally available for all ROVEMA machines and systems. The end-user of the packaging plant for infant formula had all 40 adjustment points equipped with AP10 displays, because the ROVEMA benefits are obvious: faster changeover times and DESIGN WORLD

Design-Notes-4-20-Vs3.LL.indd 39

much less documentation effort, because everything is electronically stored and retrievable. The most important advantage is the significantly increased process reliability due to the red/green LED system; incorrect settings can no www.designworldonline.com

longer occur. About 50% of ROVEMA users choose this option for monitored size changeover in cartoning and end packaging technology. DW

SIKO | www.siko-global.com April 2020

4/9/20 1:03 PM

CAE Solutions Improve simulation time and accuracy

The latest release of Simcenter STAR-CCM+ so ware, part of the Simcenter portfolio of simulation and test solutions, includes improvements to simulation time and accuracy, and enhanced collaboration. These features deliver a comprehensive digital twin to drive predictive simulations. This release includes a new parallel polyhedral mesher for faster, more effective meshing, as well as a model-driven adaptive mesh refinement (AMR) solution. It also includes automatic coupled solver control for reduced set up time. Convergence speed is improved through a collaborative virtual reality (VR) feature in a CFD code for better team collaboration on simulation results. The fully rewritten parallel polyhedral mesher builds meshes up to 30 times faster than in serial, for a consistent mesh regardless of the cores used and a more effective mesh distribution with the same accuracy and robustness. New adaptive mesh refinement (AMR) technology intelligently refines the mesh based on the physics. This can lead to less user interaction as well as computational overhead and reduces overall mesh size. Collaborative VR in Simcenter STAR-CCM+ allows teams across the globe to interact in the same immersive virtual environment in real time, enhancing communication and decision-making. Multiple VR clients can be connected and synchronized to the same simulation, with avatars showing the location of other

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users and providing the ability to tether users to get the same experience. Simcenter STAR-CCM+ is an integrated solution for computational fluid dynamics (CFD) and multiphysics simulation that brings automated design exploration and optimization within the grasp of all simulation engineers. Simcenter and Simcenter STAR-CCM+ are part of Xcelerator portfolio, Siemensâ&#x20AC;&#x2122; integrated portfolio of so ware, services and application development platform. DW

Siemens Digital Industries So ware www.sw.siemens.com

DESIGN WORLD

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An easier way to work with multi-CAD environments Information (PMI) and attributes sent to downstream manufacturing systems. It will support data imported om Dassault Systèmes’ 3DXML format. A ont-end SmartController is for automated and simultaneous batch processing with multiple CAD data sources. EX8.2 version-up releases of ASFALIS, CADdoctor and Direct Translator are also available. DW

Elysium www.elysium-global.com/en/

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The Elysium so ware suite is integrated with MBD/MBE in Dassault Systèmes’ 3DEXPERIENCE platform to aid users in achieving fast, accurate, compliance-checked transfer of data in multi-CAD environments. This integration also ensures that custom quality checks, geometry/PMI/ attribute validation, and geometry simplification are done automatically within the 3DEXPERIENCE modeling, simulation and PLM ecosystem to create streamlined data workflows. Outside CAD and engineering data can also be brought into the 3DEXPERIENCE platform as tested, compliant data used for master models and derivates shared by OEMs and their suppliers in collaborative development. The so ware includes data checking and healing, complying with 70-plus quality and best-practice standards, data migration to new so ware versions, changeconfiguration analysis, data transfer, and preparation of data in major CAD vendor formats for development of master and derivative models used in supply chains. The system also includes 3D PDF reporting, optimization such as geometry simplification, and organizing and reviewing data comprised of Product Manufacturing

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CAE Solutions

Maple 2020 enhances problem-solving capabilities

Maple 2020, based on Maple mathematical so ware, offers a collection of enhancements for both long-time customers and those new to the program. The so ware delivers a more powerful math engine, new and improved tools for interactive problem solving, application development, student learning, document creation, and programming. Highlights include: • Greater problem-solving abilities with new algorithms and solving techniques in differential equations, calculus, abstract algebra, integral transforms, graph theory, physics, and other areas of math, science, and engineering. • Enhanced programming tools that help users find and fix problems in their own code. • Additional clickable math tools, improved tutors, and an expanded Student package to support teaching and learning linear algebra. • Enhanced signal processing abilities for the exploration of signals of all types, including data, image, and audio processing. • More flexibility and improved output for printing, export to PDF, and LaTeX export, making content easier to share and use outside of Maple.

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Maple 2020 provides new, more easily accessible Getting Started resources for an efficient introduction to fundamental Maple concepts. Additional improvements include new warnings that help users avoid common beginner mistakes, and improved messages to help users diagnose and recover om errors quickly. Maple is available in several languages including French, Spanish, Simplified Chinese, and Brazilian Portuguese. A Japanese version of Maple 2020 will be available in a few weeks. DW

Mapleso www.mapleso .com

www.designworldonline.com

April 2020

4/9/20 1:17 PM

Internet of Things

EtherCAT for compact conveyor control

The EP7402 EtherCAT Box can enhance control and cabling efficiency for motor-driven roller (MDR) conveyor systems. This compact controller is a two-channel motor output stage for BLDC motors used in MDRs, regardless of the conveyor or roller motor vendor. The EP7402 offers optimal conveyor control through zero-pressure accumulation (ZPA) logic in its firmware, programming in the TwinCAT 3 engineering environment and high performance EtherCAT industrial Ethernet communication. For conveying tasks in intralogistics, packaging, food and beverage, assembly and many other industries, the EP7402 offers several advantages: • IP67 rated and compliant with new electrical standards being enforced in 2020 • does not require a protective enclosure • measures just 174 mm x 60 mm x 36.5 mm • mounts in standard C-channel or L-brackets directly on the conveyor ame • one Cable Automation (OCA) via two B23 ENP hybrid connectors • multiple M8 sockets to support two MDRs per device and digital I/O for peripheral sensors, vision systems or junctions to the entire range of EtherCAT Box modules

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www.designworldonline.com

DESIGN WORLD

4/9/20 1:34 PM

ISO 9001 • ISO 13485

EAGLE STAINLESS Tube & Fabrication, Inc.

With the advanced technology and the expertise to deliver stainless steel exactly as you want it. The EP7402 offers MDR conveyor systems the robust functionality and built-in diagnostics of EtherCAT. Reductions in cabling cost, installation effort and equipment footprint are also possible using EtherCAT P. This OCA solution supplies both EtherCAT communication and 24 Vdc for roller motors and peripheral I/O, and enables easy daisy chaining back to machine controllers. Optionally, 24 – 48 Vdc versions are planned. The hybrid B23 cables can carry 28 A to distribute power to up to 16 MDRs. Industrial-hardened infrastructure will refresh power for further roller motors and a diverse range of field devices. The MDR controller allows integrated functional safety in the system architecture via TwinSAFE technology. As a result, conveying systems can incorporate standard e-stops, pull cords, light curtains and other safety devices into the EtherCAT P wiring solutions. The EP7402 is integrated into TwinCAT 3 automation software, which simplifies programming and commissioning. ZPA for local control is fully autonomous and can be selected with parameters. Built-in motor protection features include voltage monitoring, thermal overload protection and overcurrent protection. Further, Beckhoff offers an intralogistics framework for additional features based off function blocks available in the TwinCAT platform for control of the entire system. The TwinCAT IoT toolkit aids when installing EP7402 modules in data-intensive operations, such as digital transformation and Industrie 4.0 concepts. All MDR controllers can easily transmit diagnostic data back to TwinCAT Analytics for production dashboards and predictive maintenance in conveying systems. DW

Extensive tubing inventory Eagle stocks stainless, copper, brass and aluminum in metric, hypodermic and fractional tubing in an extensive assortment of grades. Cut-to-length tubing - Eagle can cut and de-burr any diameter in quantities from 1 piece to millions from lengths of .040” and longer with a standard tolerance of ±.005 on diameters of less than 1”. Closer tolerances are met quite often. Talk to us!

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April 2020

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4/9/20 1:35 PM

Internet of Things

Get ready for AIoT — artificial intelligence in the Internet of Things ecosystem Newark, a Development Distributor, recently published new research on the Internet of Things (IoT) which confirms strong adoption of Artificial Intelligence (AI) within IoT devices, alongside new insights on key markets, enablers and concerns for design engineers working in IoT. “AIoT” is a major emerging trend om the survey, demonstrating the beginning of the process to build a true IoT ecosystem. Research showed that almost half (49%) of respondents already use AI in their IoT applications, with Machine Learning (ML) the most used technology (28%) followed by cloud-based AI (19%). This adoption of AI within IoT design is coupled with a growing confidence to take the lead on IoT development and an increasing number of respondents seeing themselves as innovators. However, it is still evident that some engineers (51%) are hesitant to adopt AI due to being new to the technology or because they require specialized expertise in how to implement AI in IoT applications. Other results om Newark’s second Global IoT Survey show that security continues to be the biggest concern designers consider in IoT implementation. Although 40% cited security as their biggest concern in 2018 and this has reduced to 35% in 2019, it is still ranked significantly higher than connectivity and interoperability due to the type of data collected om “things” (machines) and humans, which can be very sensitive and personal. Businesses initiating new IoT projects treat IoT security as a top priority by implementing hardware and so ware security to protect for any kind of potential threat. Ownership of collected data is another important aspect of security, with 70% of respondents preferring to own the data collected by an edge device as opposed to it being owned by the IoT solution provider. The survey also shows that although many engineers (46%) still prefer to design a complete edge-to-cloud and security solution themselves, openness to integrate production ready solutions, such as SmartEdge Agile, SmartEdge IIoT Gateway, which offer a complete end-to-end IoT Solution, has increased. 12% more respondents confirmed that they would consider third party devices in 2019 than 2018, particularly if in-house expertise is limited or time to market is critical. A key trend om last year’s survey results has continued in 2019 and survey results suggest that the growing range of hardware available to support IoT development continues to present new opportunities. More respondents than ever are seeing innovation coming om start-ups (33%, up om 26%), who benefit om the wide availability of modular solutions and single board computers available on the market. The number of respondents adopting off-the-shelf hardware has also increased to 54% om 50% in 2018. Cliff Ortmeyer, Global Head of Technical Marketing for Newark says: “Opportunities within the Internet of Things and AI continue to grow, fueled by access to an increasing number of hardware and so ware solutions which enable developers to bring products to market more quickly than ever before, and without the need for specialized expertise. This is opening up IoT to new entrants, and giving more developers the opportunity to innovate to improve lives. Newark provides access to an extensive range of development tools for IoT and AI which provide

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off-the-shelf solutions to common challenges.” Despite the swi integration of smart devices such as Amazon’s Alexa and Google Home into daily life, evidencing a widespread adoption of IoT in the consumer space, in 2019 we saw a slight shi in focus away om home automation with the number of respondents who considered it to be the most impactful application in IoT in the next 5 years reducing om 27% to 22%. Industrial automation and smart cities both gained, at 22% and 16% respectively, underpinned by a growing understanding of the value that IoT data can bring to operations (rising om 44% in 2018 to 50% in 2019). This trend is witnessed in an industry where more manufacturing facilities are converting to full or semiautomation in robotic manufacturing and increasing investment in predictive maintenance to reduce production down times. The survey was conducted between September and December 2019 with 2,015 respondents participating om 67 countries in Europe, North America and APAC. Responses were predominantly om engineers working on IoT solutions (59%), as well as buyers of components related to IoT solutions, hobbyists and makers. DW

Newark www.newark.com

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

DESIGN WORLD

4/9/20 1:36 PM

10 Gigabit managed Ethernet switches

The LMX-1002G-10G-SFP suits intelligent transportation systems. O en times there may be 1000 mbps fiber links in place that need modern 10 gig speed links. The LMX-1002G10G-SFP devices can support the existing link with 1000 mbps SFPs installed and will run at 1000 mbps speeds when faster SFPs are placed at both ends of the fiber. The link can be upgraded to 10 Gbps speeds. This makes migrating om a gigabit speed fiber back bone to 10 Gbps possible by not changing out all the switches at one time. For applications that need PoE, Antairaâ&#x20AC;&#x2122;s LMP-1002G-10GSFP will provide up to 30 W per port and two SFP+ slots with speeds of 1000 Mbps or 10 Gbps, depending on the SFP used. You can mount the switch by DIN-Rail or wall mount (wall mounting plates included). For a PoE switch, which uses low voltage input as a power source, the LMP-1002G-10G-SFP-24 is a suitable choice with a voltage input range of 12~55 Vdc. DW

Fiber interfaces can extend a network out past traditional buildings, across campuses, and even om town to town. But for long distances, the fiber interfaces can make it difficult to manage switches that are remote. The LMP-1002G-10G-SFP, LMP-1002G-10G-SFP-24, and LMX-1002G-10G-SFP 10 gigabit switches are fully managed with Light Layer 3 capabilities. The management so ware can allow for redundancy which can be built into the network using Spanning Tree, Ethernet ring technologies or other available redundant features. These switches are industrial-grade equipment that is Ethernet ready for edge-level networking applications in manufacturing automation, security surveillance, power/utility, water wastewater treatment plants, oil/gas/ mining, and transportation. These devices support high-density Ethernet port connectivity with 10 gig fiber ports, long distance data transmission, and reliability.

Antaira Technologies | www.antaira.com

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When technology and expertise come together Phoenix Contact’s expertise spans a wide range of applications so that you can make power, control, and network connections with absolute confidence. With the LPCH 6 hybrid product, you can now make up to 5 power and 6 signal connections in one connector. By combining signal and power in one solution, you can eliminate individual connectors, saving space and cost in your application. It’s another great product from Phoenix Contact that allows you to Connect with Confidence. www.phoenixcontact.com/ConnectConfidence

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Internet of Things Microcontrollers help protect IoT connected devices against security threats The ultra-low-power STM32L5x2 microcontrollers (MCUs) emphasize security to assure better protected IoT-connected applications. Operating at clock equencies to 110 MHz, the STM32L5series MCUs start om the Arm Cortex-M33 32-bit RISC core with Arm TrustZone hardware-based security. First conceived for equipment such as desktops, mobile devices, and communication in astructure, trusted computing authenticates devices connected to a network by creating a protected execution environment for cyber-protection and sensitive code (cryptography and key storage) that blocks attempts to corrupt devices or so ware. A second, independent, execution environment allows for the running of untrusted code. The MCUs offer the eedom to include or exclude each I/O, peripheral, or area of Flash or SRAM om TrustZone protection, allowing sensitive workloads to be fully isolated for maximum security. TrustZone ensures support for secure boot, special read-out and write protection for integrated SRAM and Flash, and cryptographic acceleration, including AES 128/256-bit key hardware acceleration, public key acceleration (PKA), and AES-128 On-The-Fly Decryption (OTFDEC), to protect external code or data. The STM32L5 also supports active tamper detection and secure firmware installation. With this attention to security, the STM32L5 has been certified to PSA Certified Level 2. Additional capabilities include adaptive voltage scaling, real-time acceleration, power gating, and multiple reduced-power operating modes to enable the MCUs to deliver long runtimes, whether powered by coin cells or even through energy harvesting. A highly efficient switched-mode stepdown regulator can be powered up or down on-the-fly to improve low-power performance when the VDD voltage is high enough. The resulting ULPMark DESIGN WORLD

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scores, benchmarks developed by EEMBC, are: 370 ULPMark-CoreProfile and 54 ULPMark-PeripheralProfile at 1.8V. The STM32L5x2 MCUs offer 512 Kbyte dual-bank Flash for read-while-write operation to aid device management and the Flash ensures a high level of safety by supporting Error Correction Code (ECC) with diagnostics. There is also a 256Kbyte-SRAM and features to support high-speed external memory including single, dual, quad, or octal SPI and Hyperbus Flash or SRAM, and an interface for SRAM, PSRAM, NOR, NAND or FRAM. Digital peripherals for the STM32L5x2 include USB Full Speed with dedicated supply to keep USB communication even when the system is powered at 1.8V, and a UCPD controller compliant with USB Type-C Rev. 1.2 and USB Power Delivery Rev. 3.0 specifications. Smart analog features include a state-of-theart analog-to-digital converter (ADC), two power-gated digital-to-analog converters (DAC), two ultra-low-power comparators, and two operational amplifiers with external or internal follower routing and programmable-gain amplifier (PGA) capability. The STM32 ecosystem features its own www.designworldonline.com

STM32CubeL5 one-stop-shop so ware package, which includes Hardware Abstraction Layer and Low-Level drivers, FreeRTOS, Trusted Firmware-M (TF-M), Secure Boot and Secure Firmware Update (SBSFU), USB-PD device driver, MbedTLS and MbedCrypto, FatFS file system, and Touch Sensing drivers. In addition, the STM32CubeL5 features more than 300 project examples that can run on the STM32L552E-EV evaluation board, STM32L562E-DK discovery kit, and NUCLEO-L552ZE-Q. These projects can be compiled with the Arm Keil development tool, IAR or STM32CubeIDE toolchains, and are delivered with a STM32CubeMX configuration file, enabling easy customization and code update. DW

STMicroelectronics www.st.com

April 2020

4/9/20 1:37 PM

Internet of Things

FOR FASTER OVERLOAD PROTECTION

TORQUE LIMITER 9 Immediate disengagement 9 Compact and backlash free 9 Field adjustable

CC-Link IE industrial network specification CC-Link IE TSN will be the nextgeneration CC-Link network, succeeding CC-Link IE Field. TSN, time sensitive networking, is an addition to the IEEE Ethernet related standards becoming popular among industrial networks. It allows for the combination of real-time control communication with non-real-time information communication, while maintaining deterministic performance, a feat that is not possible with conventional industrial Ethernet. CC-Link IE TSN can also combine safety communication with standard communication on one network, making it possible to integrate servo, safety devices and standard I/O on one network. CC-Link IE TSN offers multiple features, including the integration of control communication and information communication, rapid system setup and advanced predictive maintenance, the maximization of motion control performance and the reduction of cycle times. TSN regulates a “time synchronization protocol,” which is used to detect time differences between CC-Link IE TSN devices. This failsafe keeps the devices synchronized.

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April 2020

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Water-resistant Power Over Ethernet bridge for wet and harsh environments The PoE Standard Bridge 1011 is built to withstand washdown procedures and exposure to chemicals. Key features include: • an IP54-rated dust- and water-resistant enclosure to protect against ingress om all directions. • a space-saving, mountable design and form factor used in Swi Sensors 1020 and 1030 bridges. • a single cable for power and Ethernet to eliminate the need for additional hardwiring and to ensure a consistent power supply. • compliance with Active 802.3af and 802.3at PoE standards for use in PoE systems. • 256-bit AES enterprise encryption to deliver the same level of security found in all Swi Sensors bridges. The wireless system gives a digital view of a facility with precise measurements, notifications, shi performance and more. This data, analysis and reporting improves the operational output and productivity of manufacturers and food service providers, even under harsh conditions. DW

Swi Sensors | www.swi sensors.com

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Metal Bellows Experts

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www.bearingtips.com

A Supplement to Design World - April 2020

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

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4/9/20 9:44 AM

B e a r i n g s

The less equently asked questions you should be asking about your

bearings

Speed ratings, loads, and cost are foundational questions for any new bearings system â&#x20AC;&#x201D; but what about the other, more in-depth factors like vibration, preload, or lubrication in lower temperatures? Here, we cover a few of the less frequently asked questions you might consider when designing your next bearing arrangement.

Edited by Mike Santora | Associate Editor

How do cold temperatures impact bearing lubrication? Cold temperatures can have several direct and indirect impacts on bearing lubrication and their selection criteria. Cold temperatures can have a direct influence on the lubrication selection process, or they may influence the lubricating system itself to allow a certain lubrication type or grade to be used successfully. Cold temperatures may affect the decision of lubrication type, such as using oil or grease. Cold temperatures could also drive the need for a more exotic type of lubrication, such as a solid lubricant, or even special additive packages based on potential limitations at extreme conditions. Other direct influences include the ability to move the lubricant to and om the bearing location, including the ability to circulate oil through lines om a sump, the ability to pump grease om a cartridge and through a fitting, or even to allow the lubrication to move around inside the bearing itself during operation without severely increased torque to turn. Increased diameter lubrication lines, higher-powered lubrication pumps, the need for inline heating and insulation, larger drive motors and gear drives, or even the need to move om a circulating oil system 54

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to a bath system, are a few examples of how cold temperatures impact bearing lubrication indirectly. Each example could have a direct influence on overall system complexity, size, and cost. Another example of how cold temperatures impact bearing lubrication selection is how the operating temperature of the bearings is affected during operation. A lower operating temperature may influence the selection of lubricant viscosity for a given set of operating conditions. It would have a direct effect on the calculated lube films/lambda ratios, which have a direct correlation to bearing performance and overall life expectations. As described, cold temperatures can directly impact bearing lubrication and its selection in many ways while also having a direct impact on the overall lubrication system design and delivery options. The cold temperatureâ&#x20AC;&#x2122;s impact on the DESIGN WORLD

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April 2020

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B e a r i n g s For slower-speed bearing systems, dimensional preload methods are common; these could include use of bearing component spacers machined to specific widths, clamping mechanisms such as a locknut to ensure a physically controlled axial offset in the bearing system or increased interference shaft or housing fitting practices to remove clearance inside of the bearings.

bearing lubrication system could potentially have a direct relationship on the bearing type and system configuration — the cold temperature can ultimately impact the entire equipment design. How can I reduce running noise? Before a solution to a given running noise issue can be implemented, the source of the running noise must be identified and clearly understood. In

many cases, the origin of the running noise is not the expected source, and only through investigation is the true source discovered. Running noise can come from anywhere in a given system, including nonrotating portions of the equipment or system such as vibrating cover, loose connectors, inadequate equipment supports, or even natural harmonic vibrations in the system based on geometry or insufficient stiffness

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in critical locations. Operating noise created by stationary components may be as simple as implementing a maintenance schedule for tightening connections or replacing worn items such as flexible mounts. Or, it may require modifications to provided increased robustness to an inadequate housing or cover to remove potential nature harmonics. Troubleshooting, as well as solving running noise related to rotating components in the system, can be more difficult due to the number of potential system variables. These variables could include, but are not limited to, shaft or coupling imbalance, drive belt tension levels, gear mesh variation or damage, or possibly bearing component variations or damage. Corrective actions to repair damaged components, system imbalances, and confirmation of rotating component settings such as bearing clearance and gear mesh specifications, are a few initial actions that may be taken before a full noise, vibration, and harshness (NVH) investigation is launched. However, if all design features and components appear to be in good working condition, this in-depth type of investigation may need to be pursued. With bearing running noise, many variables influence this, such as running accuracy of the bearings, surface finishes of the component contacts, roundness and waviness of the components, or operating setting variation throughout the operating temperature range. As related to these variables, the bearing configuration

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Cold temperatures may affect the decision of lubrication type, such as using oil rather than grease (or vice versa) or possibly drive the need for a more exotic type of lubrication, such as the solid lubricant shown with this bearing. and type may be directly related to the cause or solution for the running noise. Therefore, system design and overall cost may drive the level of acceptable noise; however, if there is a desire to reduce the running noise, there are various options available to fit the situation. What are the best methods for preload in a bearing system? Selecting the best method for applying preload in a bearing system is o en dependent on the subject bearing system under review. Not only do the bearing system arrangement and the configuration play a key role in which preload application methods may or may not be used, but more important is an understanding of the bearing systemâ&#x20AC;&#x2122;s intent or expected operating conditions. Initial temperatures, operating temperatures, operating load conditions, and adjacent equipment all have an impact on the preload in the bearing system. Some bearing systems need precise control of the preload, while others can use a wide range without concern. Some bearing systems need a preload source that can apply a fixed amount of preload across the entire operating condition spectrum. In contrast, others need a means of adjustable preload source to support

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various operating conditions the equipment experiences. Depending on these variables, along with many more that have not been mentioned, the best method for preload in one bearing system may not be acceptable for another. For slower-speed bearing systems, dimensional preload methods are common; these could include use of bearing component spacers machined to specific widths, clamping mechanisms such as a locknut to ensure a physically controlled axial offset in the bearing system, or increased interference sha or housing fitting practices to remove clearance inside of the bearings. For higher-speed applications or those that need a more precisely controlled preload setting throughout various loading conditions and the associated changes in thermal gradients, spring preload methods are common. These methods could include simple wavy springs to create an axial offset inside the bearing system, or possibly custom spacers that incorporate a coil spring and plunger arrangement. For high-speed applications, or those that require manual or even automatic adjustability to

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support various operating conditions during active operation, complex hydraulic or pneumatic systems may be incorporated in to provide the bearing system with an infinite range of adjustable axial preload setting. As described, every bearing system has a unique set of operating conditions and will have a different level of performance expectations â&#x20AC;&#x201D; making the selection of the best preload method specific to each one. DW Timken | Timken.com

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B e a r i n g s

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Speed ratings, loads, and cost are foundational FAQs for any new bearings system — but what about the other, more in-depth factors like vibration, preload, or lubrication in lower temperatures? Here, we cover a few of the less frequently asked questions you might consider when designing your next bearing arrangement.

Edited by Mike Santora | Associate Editor For unmanned vehicles that achieve hypersonic speeds, the performance of the combustion engine is paramount. Ball bearings play a crucial role in the fuel delivery system. A er calculating the basic rating life — the total number of revolutions before the first evidence of material fatigue occurs — engineers select bearings that will meet the design or desired life. The life of a bearing under actual operating conditions before it fails or must be replaced is the bearing service life. And if that service life precedes the desired time of operation for the vehicle, prohibiting it om reaching its destination, the dreaded MF occurs — mission failure. For a manufacturer of the propulsion system (jet engines) of these unmanned, hypersonic vehicles, optimization is critical. Every facet of operations — materials, working conditions, and controllable variables — must be optimized. These 58

April 2020

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details are imperative at hypersonic speeds where air molecules separate, and high-temperature effects stress the vehicle and its sub-systems. “Anything mission-critical has to be 100% reliable,” explained Steven Sanchez, Engineering Manager at AST Bearings’ headquarters in New Jersey. “The ability to accomplish the mission safely must be achievable and repeatable.” In its initial design of the engine, the manufacturer encountered a performance weakness: the bearing configurations selected yielded at most 30 seconds of vehicle life before experiencing a catastrophic failure (in some cases, bearing failure was almost immediate). Bearing failure at these high speeds

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For unmanned, hypersonic vehicles, optimization is critical. Every facet of operations — every material, working condition, and controllable variable — must be optimized. These details are imperative at hypersonic speeds where air molecules separate, and hightemperature effects stress the vehicle and its sub-systems.

results in fractured components and flying debris damaging other components, such as the turbine, and in turn, lead to complete engine failure. The manufacturer sought a more durable bearing configuration beyond the standard product offering, one that would allow their vehicle to operate for longer. The manufacturer reached out to AST to find a solution. AST engineers sought to improve the bearing life significantly, targeting a factor of 10, a projection that, if achieved, would substantially expand the capability of the end user’s vehicle.

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First, engineers considered dimensional constraints, mounting options, and bearing size. A common approach would have been to deploy larger bearings, which would increase the calculated bearing life (the bigger the bearing, the greater the load capacity). But they quickly dismissed the idea, as the cost for the manufacturer to retool the manufacturing process of the contiguous components would have been prohibitive. As a result, engineers needed to design a solution that fit in the existing bearing space. www.designworldonline.com

Next, using custom rolling element bearing analysis software, engineers modeled and ran multiple simulations to determine the elastic behavior of the vehicle’s existing ball bearings, which would provide insights into the cause of failure. After the analysis, they discovered that extreme axial forces from the turbine were causing potential ball truncation and edge stresses. Engineers then applied those findings to proposed modifications and assessed their impact. Having determined the failure mode and zeroed in on the root cause, the engineering team developed a series of April 2020

4/13/20 8:33 AM

B e a r i n g s The entire process was collaborative, with AST engineers engaging with the manufacturer to confirm whether the suggested changes were practical. The whole process took roughly three months.

BEARINGS

design modifications. These changes were introduced incrementally, and through the use of modeling and simulation, the efficacy was validated. Relocation of one of the bearing sets, along with changing the contact angle of the balls, solved the axial loading issue. “Changing the distance between the bearings on one common sha can greatly reduce the final loading per bearing; it was finding that ‘sweet spot’ that became the challenge,” Sanchez said. A later simulation, focusing on operating and environmental conditions, led to changing om

stainless steel to ceramic balls. This last tweak extended life even further. Later testing with actual hardware proved to be a success. “It’s a highly analytical process, you select one parameter, and you change it incrementally to gauge behavior,” said Sanchez. “Obviously, you’re trying to make moves that don’t make things worse. And as you make tweaks, you look for improvements that allow you to move onto the next sequence.” The entire process was collaborative, with AST engineers

engaging with the manufacturer to confirm whether the suggested changes were practical. The whole process took roughly three months. Collectively, those changes improved bearing life by a factor of 10 — the initial goal. The improvement eliminated premature failure in the bearings, delivering the performance boost that the manufacturer sought. DW AST Bearings | www.astbearings.com

Quality Bearings & Components (QBC) Condition Monitoring Leads to Big Benefits Machine breakdowns are often caused by bearing damage. Detect problems before equipment failure with easy-to-use QBC/BETEX monitoring tools designed for predictive maintenance. Bearing Checker is a portable, pocketsize instrument for evaluated shock pulse measurement. This hand-held tool also measures machine surface temperature with infrared light and can be used as an electronic stethoscope for listening to machine sounds. An increasing number of Facility Managers are using condition monitoring to reduce downtime, lower machinery costs and improve efficiency. Discover solution oriented condition monitoring, maintenance, and hydraulic tools for bearings and transmission parts at QBC.

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Aerospace/Defense

Designing Commercial How to Specify the Aircraft TRAS: Right Flexible Shafts What key characteristics of flexible shafts should a TRAS engineering team consider? Steve Grimes • Director, Sales & Marketing • S.S. White Technologies Inc.

Thrust Reverser Actuation Systems redirect aircraft engine thrust immediately after landing to brake. On commercial jets, these systems provide critical safety and maneuverability to pilots. Failure to deploy correctly during a landing could cause unsafe turning as an engine on one wing brakes while the other continues forward thrust. Even more dangerously, a poorly designed TRAS can rattle out of place during flight, effectively disabling an engine thousands of feet from the ground. Therefore, as is the case with most aerospace engineering, excellence in TRAS design is a necessity. Understanding the characteristics of a key functional component — the flexible shaft — is vital to a configuring a successful TRAS. As an engineering team begins the initial design phase for a TRAS, it should consider what makes flexible shaft technology appropriate for aircraft engines, and what specifications best serve the application. Figure A. For commercial airplane engines, flexible shafts move actuators that change the direction of cold bypass air.

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Figure B

Figure C

Aerospace/Defense Flexible Shafts in Basic TRAS Designs Commercial aircraft fly on Larger Turbo Fan gas turbine engines, and Thrust Reverser Actuator Systems operate by redirecting the cold “bypass” air, as shown in Figure A. In order to achieve this redirection, a series of four to six actuators moves the rear of the aft cowl backward to expose a matrix of openings on the side of the turbine (Figures B and C) while simultaneously blocking the bypass airflow (Figures D, E, and F), thus forcing the air through the midturbine exposure. The actuators must move together in a synchronized fashion; a non-synchronized deployment can lead to the system jamming. This results in asymmetrical braking, affecting the pilot’s ability to control the aircraft. Both principle system

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Figures B and C. During thrust reversal, flexible shafts translate the aft cowl to the rear to reveal a matrix of openings through which the bypass air is redirected.

types address this consideration with flexible shafts, so the lifetime torsional deflection of flexible shafts is an important characteristic for the successful operation of any commercial TRAS. Engineers must control the deflection angle of these flexible shafts in order to ensure actuators deploy and stow

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fully. Managing this element of the TRAS design plays a critical role in avoiding inadvertent deployment during flight by correctly locking into the stow position. In a hydraulic TRAS system, these flexible shafts are passive — their sole function is to ensure the actuators deploy and stow

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Figure D

Figure E

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Figure D. When deployed, actuators redirect bypass air through a midengine matrix. Figures E and F. The TRAS, seen here stowed and deployed on a Boeing 747, blocks bypass air from exiting the engine to the rear during landing.

Figure F

synchronously to prevent panels from jamming the system. In this design, the flexible shafts are contained within the hydraulic tubes that deploy the system, and so are lubricated by the hydraulic fluid. These systems generally support lower torsional loads. Alternatively, motor driven systems rely on flexible shafts both to ensure synchronization and to actually drive deployment. In this design, one or more electric motors generates torque, and flexible shafts are the only means of transmitting that torque from one actuator to the next. These systems offer higher torques than their hydraulic counterparts. Engineers must also account for load cases when designing flexible shaft systems for success, as different load cases can impact the useful life of these parts in different numbers of operation cycles. Key load cases to factor into the design process include Normal Operating (stow / deploy), Rejected Take Off [RTO] (deploy), Limit Load (proof/ acceptance test load), and Ultimate Load (failure/Ultimate Torsional Strength UTS).

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Key Flexible Shaft Characteristics for TRAS Applications Beyond the basic considerations of load, deflection endurance, and fatigue characteristics, a variety of additional flexible shaft characteristics define the componentsâ&#x20AC;&#x2122; utility in TRASs. These can be organized into three categories: Performance, Assembly/ Material, and Installation. Correctly positioning actuators is a necessary function of flexible shafts in these systems. This positioning depends mechanically on the angular position between the ends of each shaft. Therefore, angular deflection/torsional stiffness, which is proportional to applied torque and flexible shaft length, asserts itself as a key performance characteristic. Other important performance characteristics deal with stresses on the system. For example, TRASs must accommodate shock from a variety of sources, including back driving or static torque loads caused by system architecture or aerodynamic effect and torque spikes at the end of the stroke when the system hits its end

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stops when a system’s inertia may be absorbed by the torsional elasticity of its flexible shafts. Depending on TRAS configuration, flexible shafts’ ability to absorb shock loads can prove highly advantageous. Likewise, change in angular deflection over time should be controlled, as wear over a number of cycles can be expected to add additional rotational angular detection. Lubrication can lessen this consequence of repeated use. However, engineers should consider another factor before specifying a lubricant: operating temperature. Grease, for example, exhibits potential sticking effects at low temperatures — threatening to significantly increase the torque required to actuate the system and cause shafts to vibrate — although S.S. White engineers have developed mitigation techniques for such a scenario. Nevertheless, some vibration is unavoidable, including in flexible shafts’ static position, and must be considered in the engineering process as well. To best integrate flexible shafts into a cohesive and durable system, engineers must consider the long term and design with several material and assembly characteristics in mind. Firstly, materials should be selected with the following in mind: electrical bonding path, in case of lightning strike; tribological (bearing) couples, with suitable materials for bearings designed to contact each other; galvanic couples, with materials that guard against long term corrosion; etc. Different materials offer a number of distinct benefits for certain applications and can affect how flexible shaft constructions operate within a TRAS. More fundamentally, any system using flexible shafts must competently fit those shafts into an overall assembly. For this reason, engineers must give careful consideration to the radial clearance between the shaft and the casing. This clearance will

“To best integrate flexible shafts into a cohesive and durable system, engineers must consider the long term and design with several material and assembly characteristics in mind.” 68

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limit the amplitude of the helix, and also the wavelength, of the flexible shafts. This is often influenced by the support clamp spacing, and by the bending stiffness of the casing due to the tendency of a flexible shaft to helix during operation. Then, when determining the length of the flexible shafts in a design, engineers must factor in the likely routing of the shaft compared to the routing of its casing. The centerline path of the installed shaft may be longer than the housing, meaning the shaft should be longer in turn. In some circumstances, a devise may be needed to retain the shaft in its casing to ensure its correct positioning. Of course, the best designed system will fail if incorrectly or insecurely installed. If loose flanges

are specified, for example, the engineering team may decide to develop a feature to retain them and prevent their falling from one end to another. Installation can also be foolproofed, by designing assemblies of differing lengths. When this is impossible, as in the many cases for which both shafts with dominant characteristic in clockwise and counterclockwise directions are required to be of identical length, creative engineers may select differing fitting types— square and hexagon cross section fittings, or fittings with alternate numbers of spline teeth — to prevent a detrimental incorrect installation. Another option to design for quality installation involves a trade-off. Assemblies can be “locked in” to aid installers and prevent inner

flexible shafts from separating from their casing, but this can inhibit maintenance and examination. Engineering insight Whether designing a hydraulic or motor driven system, TRAS engineering teams must consider an array of flexible shaft characteristics early in the design process. Engineers at manufacturers can provide valuable expertise on the intricacies of flexible shaft performance and assembly, and can help specify a suitable flexible shaft solution for a specific application the first time. To ensure safe and efficient operation, engineers should consider torsional, wear, and assembly attributes among others — optimally, with insight from industry-leading application engineering professionals. AD S.S. White Technologies Inc. | www.sswhite.net

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Aerospace/Defense

First UAS customer

order for high-frequency XBAW RF filters

Akoustis Technologies Inc., an integrated device manufacturer (IDM) of patented bulk acoustic wave (BAW) high-band RF filters for mobile and other wireless applications, has announced a development order for a new C-band XBAW filter that will be used in Unmanned Aircraft Systems (UASs) for control and non-payload communication (CNPC) links. Under the new purchase order, Akoustis will develop and deliver samples of the XBAW filter for the UAS application by the end of September 2020 for testing and evaluation. The Company expects it will be able to deliver qualified XBAW filters and expects to receive orders for commercial product by the end of March 2021. CNPC is Command and Control (C2) frequency modulated radio intended for pointto-point or networked UAS operations for Beyond Line of Sight Operation (BLOS). The new customer is in the defense business, but the filter will have wider market applications including commercial and consumer drones and other aircraft. The new filter will operate in a key C-band frequency (within the 4-8 GHz frequency spectrum), that is under consideration for licensing by the FCC, where Akoustis has historically focused its development efforts and has delivered its first designs for highband WiFi, 5G infrastructure, 5G mobile devices and defense applications. The filter is expected to use the same supply chain and packaging as the current 5 GHz WiFi filters and 5G infrastructure filters. Jeff Shealy, Founder and CEO of Akoustis, stated, “With the continued sampling of our existing high-band WiFi filters, 5G filters and our defense solutions, we are experiencing interest from new peripheral applications for our high-performance XBAWTM filter products. We are excited to add the cutting-edge Unmanned Aircraft Systems market as a new business vertical which can leverage our existing technology and supply chain.”

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Aerospace/Defense The UAS XBAW WiFi filter features: • Low insertion loss passband filter • High frequency C-Band operation • Wide bandwidth • High rejection • Single ended Tx/Rx ports • High power rating, maximum +30dBm • Ultra small form factor 2.5mm x 2.0mm x 0.9mm • Performance over -40° C to 85° C • RoHS compliant, Pb-free package The UAS filter will be designed and manufactured using the Company’s patented XBAW process housed within the Company’s Si-MEMS Wafer Fab located in Canandaigua, N.Y. Akoustis has introduced several new filters over the past twelve months, including a 5.6 GHz WiFi filter, a 5.2 GHz WiFi filter, a 4.9 GHz band n79 filter for

small cell network infrastructure, a 3.8 GHz filter and five S-Band filters for defense phased-array radar applications and a 3.6 GHz filter for the CBRS 5G infrastructure market. The Company is also developing several new filters for the sub-7 GHz bands targeting 5G mobile device, network infrastructure, WiFi CPE and defense markets. AD Akoustis Technologies Inc. www.akoustis.com

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engineering innovation through MSC Nastran Computer-aided engineering (CAE) simulation software and services company MSC Software Corp. (MSC) recently founded the MSC Nastran Excellence Award to recognize the engineering and design innovation of its users around the world. MSC Nastran is a simulation tool used across nearly every kind of industry — from aerospace to medical technology. It is a widely used, trusted, and accurate Finite Element Analysis (FEA) platform for structural simulation. MSC Nastran has been the industry standard in aerospace since NASA’s Apollo missions, and is used to optimize the performance, lifespan and comfort of product designs across all industries. The Award celebrates MSC Nastran users’ work in FEA simulation to optimize everything from planes, trains, automobiles, white goods, ships, to spacecraft and beyond. Lauding the most interesting and diverse projects using MSC Nastran, the award will provide global recognition to the engineers, designers and manufacturers employing the full potential of the tool, and up to $1,000 in Amazon vouchers or donation to charity of choice. “MSC Nastran has fueled some of the greatest product innovations in the modern world over the past 50 years, from NASA’s foundational explorations into space, to supporting the mobility, engineering and medical tech today

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by predictively optimizing designs before prototyping. At MSC we want to celebrate excellence in FEA by shedding light on the incredible innovation happening today, and the many talented people around the world that are using MSC Nastran to design the future,” said Keith Hanna of MSC Software. Submissions to the award must be made publicly available during the 12 months before nomination, and can include papers presented at conferences, articles appearing in journals and magazines, and other original work documented in a publicly-available form, such as a research thesis. Projects should demonstrate quantifiable benefits such as quality or productivity improvements, environmental or economic cost reduction. They must push the boundaries of the MSC Nastran tool, with multi-physics applications encouraged. The full criteria and deadlines can be found on at www.mscsoftware.com/mscnastran-excellence-award-2020. AD

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Souriau

announces a range of REACH-compliant composite connectors for aeronautics

The goal of European REACH regulation is to improve health and environmental protection by banning the use of SVHC (Substance of Very High Concern) chemicals and at the same time promoting the competitiveness of the European Union’s chemical industries. Souriau, like most manufacturers, uses hexavalent chromium, one of the substances listed as hazardous, in the surface treatment processes for many of its connectors. Although the European Chemicals Agency has granted derogations of up to 12 years depending on the application, Souriau wished to anticipate this deadline. Souriau’s R&D has been working for several years on the implementation and validation of this change to its composite connectors, which affected both the products and the production lines. The first REACH connectors in the D38999 composite range were launched during 2019 and by next December, the entire range will be manufactured without the use of hexavalent chromium. An increasingly important part of the company’s D38999 range incorporates composite materials either with a nickel-plated finish or with no finish and is mainly intended for civil and military aeronautics applications. The advantage of the PEEK composite used, is that it offers high performance in severe environments, is corrosion resistant and weighs less than aluminum.

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Aerospace/Defense The challenge for Souriau was to find a REACH-compatible chemical solution for hexavalent chromiumfree treatment of the connectors. “We no longer use hexavalent chromium, which was previously needed to improve the adhesion of coatings on the composite substrate of our housings, said Thomas Pichot, R&D manager at Souriau. “We have developed and from now on are using a new preparation treatment, which allows us to ensure the adhesion of successive metal layers equally well without needing this substance. This builds on the approach we used for aluminum connectors, where we have also qualified hexavalent chromiumfree passivation in our zinc-nickel treatment process. All substitute products developed and deployed

according to the American standard MIL- DTL-38999 and the European standard EN3645. In addition to its qualification by accredited bodies, the process change has been validated by major aeronautics customers. As soon as the European REACH regulation was published, SOURIAU’s management and all the various teams realized there was a need for a vast program of innovation in surface treatment techniques in order to preserve connector manufacturing in France. The determination shown in the push to innovate and find alternatives to hexavalent chromium has added to Souriau’s achievements and demonstrated its know-how. As Nicolas Paumier, Product Manager D38999 composite explained, “Souriau’s proactivity in response to the REACH regulation

As soon as the European REACH regulation was published, SOURIAU’s management and all the various teams realized there was a need for a vast program of innovation in surface treatment techniques in order to preserve connector manufacturing in France. are now certified non-hazardous and fully compliant with all the various environmental regulations, including REACH. While the challenges are obviously of a technological nature, the benefits are largely ecological, since this changeover has already enabled us to halve the volume of hexavalent chromium used in our production site.”

shows its commitment to its customers, who also face the same issues, whether in terms of innovation, the environment or people’s health and safety. This new REACH range will have an impact on our orders for all these reasons, but also because it responds to the global demand from both customers and Europe.” AD

A PEEK plating solution unique in the world Souriau’s particular achievement has been to develop a chemistry that works with PEEK material. Plating on to composite material is nothing new, but not on this type of plastic which is especially used in the aeronautics industry. This solution, unique in the world, is qualified QPL,

Souriau | www.souriau.com

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Aerospace/Defense

Dynamometers suitable for high-torque low-speed testing

Force Control’s dynamometers featuring Positorq oil shear load brakes absorb extreme torque at very low speed (down to zero rpm), so that they can accurately capture data at these critical junctures, when dynos equipped with traditional load brakes cannot. Oil shear technology can provide instant load spikes and static lock-up of up to 3-times the continuous load rating. High cycle counts (up to 300 torque changes per minute) allow tests with a hammering effect on the tested product. Quick, controllable response allows virtually unlimited test capabilities, while their extremely quiet operation allows gearbox, transmission, or final drive noise testing. Hightorque, low speed testing is commonly used for testing life cycles, shock loading, overall machine life/performance and more for snowmobiles, forklifts, 2-wheel/4-wheel/6-wheel drive tractors or tracked vehicles, commercial truck axles, helicopter transmissions, gun turrets, winches, hoists, and more. Proven oil shear technology eliminates wear for service free endurance testing. A variety of sizes and arrangements for shaft mounting, flange mounting, coupled and vertical/horizontal mounting. Units can be supplied with torque arm and load cell, all controls for the cooling system and actuation. Oil shear technology is a system of providing a film of transmission fluid between the friction discs and drive plates of a mechanical multiple disc type of friction brake. As the discs and plates are brought together, squeezing the fluid film, it goes into hydroviscous shear. This phenomenon transmits torque through the fluid through laminar flow. This phenomenon is based on the laminar flow of the fluid film between the friction discs and drive plates. The fluid tends to flow in layers with each

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layer moving at consistently different speeds between the rotating friction disc and the static drive plate. As the pressure squeezing the disc and plate together increases the hydroviscous force of the molecules sliding past each other, it increases the torque. Therefore, simply controlling the pressure on the friction stack controls the torque. The torque is proportional to pressure on the friction stack which is controlled by actuation pressure. This pressure can be provided by a proportional regulator for pneumatically actuated units, or a proportional regulator or servo valve in hydraulically actuated, more responsive systems.

optional hydraulic actuation pump and motor, flow switches, fluid level sight gauge, optional tank heater, and heat exchangers. Heat exchangers can be oil-to-water or oil to air. The cooling system can be designed for one load brake or several. Some cooling systems are designed multiple load brakes, such as four-wheel vehicles using four brakes. The hydraulic actuation system can be built into the cooling unit using the same fluid. The load brakes using oil shear technology are available in a variety of sizes ranging from 50 Lb. Ft. (68 Nm) to 300,000 lb-ft (406,700 Nm) and can absorb up to 3000 thermal horsepower (2237 Kw). Mountings

Oil shear technology is a system of providing a film of transmission fluid between the friction discs and drive plates of a mechanical multiple disc type of friction brake. With the fluid layer between the friction disc and drive plate there is no tendency to stick slip or chatter at very low differential speed, providing a smooth transfer of torque down to 0 rpm. The second part of the equation is heat energy that must be dissipated from the system. Using oil shear technology, the fluid is circulated through the friction stack and is cycled out of the brake to a forced lube cooling system. The cooled fluid cools the brake components including the friction material, eliminating the typical degradation found in dry friction brakes. This also allows for a more compact load brake that can, in many cases, be directly mounted to the axle, or output of the test device. The cooling system typically includes cooling oil pumps, motors, filters, over temperature switches,

vary from flange mount, to foot mounts, to shaft mount. Custom designs and load carrying capacity are commonly developed for specific applications. AD Force Control Industries | www.forcecontrol.com

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Bunting CUSTOM MAGNETIC ASSEMBLIES FROM BUNTING At Bunting, we combine design expertise with advanced manufacturing capabilities to deliver you custom magnets and magnet assemblies. Our engineers work with you directly to design a custom solution for your application, and offer rapid prototyping so you can see how a magnetic assembly will look and perform well in advance of regular production. Bunting is the worldâ&#x20AC;&#x2122;s most diversified manufacturer of magnets, magnetic assemblies, and magnetic equipment. We have over 60 years of experience in the industryâ&#x20AC;&#x201D;experience that serves you. No matter how challenging your application is, we have the knowledge, expertise, and production capabilities to provide you with the custom magnetic assembly you need. Contact us to learn more today.

Bunting 12 Industrial Drive DuBois, PA 15801 800-437-8890 or 814-375-9145 Sales.DuBois@BuntingMagnetics.com

Cadence, Inc. New Game Changing Technology: All-In-One Manufacturing Combining conventional Swiss machining with laser processing is a cost-effective alternative to multioperational manufacturing. This single machine platform allows Cadence to perform several processes in just one step which reduces part handling and improves its precision. This game changing technology combines CNC machining, laser cutting, laser drilling, laser marking, and laser welding. Additional benefits include rapid prototyping, higher quality, and significant cost savings. LaserSwiss machining provides endless possibilities for new product development!

Cadence, Inc. 9 Technology Drive Staunton, VA sales@cadenceinc.com www.cadenceinc.com Tel: 540-248-2200 Fax: 540-248-4400

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CS Hyde Company ULTEM® PEI: The Essential 3D Printing Surface Who would of known 3D Printing would become such an essential manufacturing process? If your printing alternative face shields or other medical components you need a reliable surface to print on. CS Hyde Company is your source for custom size ULTEM® PEI Sheets backed with high temperature 3M® adhesive. This print surface is ideal for printing a wide range of commonly used thermoplastic filaments such as PLA, ABS, PETG, TPU, and more. This surface is durable and requires little to no maintenance. PEI is a fast installation upgrade that will speed up the additive manufacturing process. Sheets can be custom cut to fit at home printers to large format industrial printers. Visit our website to find a size that fits if not listed email us and we can cut it.

CS Hyde Company www.cshyde.com 800-461-4161

J.W. Winco, Inc. Standard Parts in Hygienic Design from JW Winco Standard Parts in Hygienic Design are optimized for minimal contamination and easy cleaning. JW Winco has now expanded its Hygienic Design line to include the new GN 8170 indexing plungers which are intended for use in hygienic areas. The wiper between pin and guide keeps the mechanism sealed. The high surface quality and the free of dead-space mounting prevent dirt from adhering and facilitate cleaning. Due to these specific properties, products in Hygienic Design can assist the production process in sensitive areas. Find out more at www.jwwinco.com.

J.W. Winco, Inc. Phone: 800.877.8351 sales@jwwinco.com www.jwwinco.com

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Drives for Complex Flight Systems maxon’s quality drives are found in complex flight systems. For example in autopilot systems for controlling flight altitude via mechanical control surfaces, in auto throttle systems as well as in the force feedback joystick of fly-by-wire flight control systems. To meet the requirements of the aviation industry, maxon has developed new production methods to electronically record the data of each individual product automatically during the manufacturing. This means even the highest certification requirements may be met. maxon’s brushless ECX series combined with planetary gearheads are ideal for such applications featuring: • High power packed into extremely small space • Precise speed or position control • Very high output torque • Narrow tolerances in the motor parameters • Easily modified to meet DO-160 ambient condition requirements • Learn more about the maxon solutions and visit aerospace. maxongroup.us

maxon precision motors, inc. 125 Dever Drive Taunton, MA 02780 Phone: 508.677.0520 www.maxongroup.us info.us@maxongroup.com

Atlantic Spring is a Dedicated Quality Parts Supplier Atlantic Spring began in 1925 and has become a fullrange manufacturer of custom springs, clock springs, flat springs, shaped wire springs, wire forms and assemblies. This expert provider of custom-focused manufacturing solutions is highly dedicated to the on-time delivery of quality, costeffective parts. The quality systems and CNC equipment used by Atlantic Spring assure consistency and reliability, while providing a lean manufacturing program. Our technical expertise and commitment to pushing the boundaries of engineering excellence make us one of the most innovative aviation suppliers in the market today. They also know our components made from exotic materials will continue performing as specified year after year—even in the most extreme operating conditions imaginable.

Atlantic Spring 137 US RT 202 Ringoes, NJ 08551 www.mwaerospacesolutions.com

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April 2020

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New England Wire Technologies Advancing innovation for over 100 years Why accept a standard product for your custom application? NEWT is committed to being the premier manufacturer of choice for customers requiring specialty wire, cable and extruded tubing to meet existing and emerging worldwide markets. Our custom products and solutions are not only engineered to the exacting specifications of our customers, but designed to perform under the harsh conditions of today’s advanced manufacturing processes. Cables we specialize in are LITZ, multi-conductor cables, hybrid configurations, coaxial, twin axial, miniature and micro-miniature coaxial cables, ultra flexible, high flex life, low/ high temperature cables, braids, and a variety of proprietary cable designs. Contact us today and let us help you dream beyond today’s technology and achieve the impossible.

NEW ENGLAND WIRE T E C H N O LO G I E S

Contact info: New England Wire Technologies www.newenglandwire.com 603.838.6624

Renishaw Renishaw’s Full Range of Styli for All Applications At Renishaw, we have expertise in probe and stylus design to develop a comprehensive range of CMM and machine tool styli to offer you the greatest possible precision. Our styli can be used on Renishaw’s CMM, machine tool, scanning probes and Equator™ gauging systems, as well as for sensors from other manufactures, to ensure maximum measurement accuracy. The importance of successful gauging depends very much on the ability of the probe’s stylus to access a feature and then maintain accuracy at the point of contact. We offer standard, custom, high-performance, and additive manufactured styli. Whatever your styli requirements, Renishaw has the solution for you.

Renishaw, Inc. 1001 Wesemann Drive West Dundee, IL 60118 usa@renishaw.com www.renishaw.com (847) 286-9953

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Stock Drive Products/Sterling Instrument Custom Gear Solutions for Aerospace SDP/SI designs and manufactures precision components for satellites, specializing in solar wing positioning. SDP/SI’s combination of design, manufacturing and assembly capabilities allows us to meet the critical tolerances and functionality needs of the aviation, defense, and space industries. We manufacture highprecision gears, gear drives, and high-quality machined parts for many of the top aerospace OEMs in the world. • 5-axis machining capability

• R.E.A.C.H. compliant

• 9-axis Swiss turning

• ISO 7 Class 1000 Cleanroom

• ITAR compliant – DDTC registered

• World class quality

• RoHS compliant

• Established 1950

We look forward to working with you.

Stock Drive Products/Sterling Instrument (SDP/SI) 250 Duffy Avenue, Hicksville, NY 11801 https://www.sdp-si.com sdp-sisupport@sdp-si.com (516) 328.3300

The Lee Company Miniature Latching Solenoid Valve for Power Sensitive Applications The Lee Company’s new Latching Solenoid Valve is the ideal solution for power sensitive applications. By incorporating permanent magnets into the coil design, this miniature solenoid valve offers a dramatic reduction in overall power consumption, particularly when operating with extended “ON” periods. Unlike traditional designs that require continuous voltage to energize the valve from its natural state, this latching solenoid requires only a momentary pulse of less than a Joule to switch to and remain in state. Available in both 2-way and 3-way configurations, this 2 position latching solenoid valve features Lee’s unique and patented MultiSeal™ technology which radically simplifies port layout, offers significant space savings, reduces machining costs and provides superior reliability over traditional sealing methods. Innovation in Miniature

The Lee Company 2 Pettipaug Road P.O. Box 424 Westbrook, CT 06498 ®

The Lee Company DESIGN WORLD

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inquiry@theleeco.com www.theleeco.com Tel: 860-399-6281 Fax: 860-399-2270

April 2020

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S U M M I T

E X P O

The Premier Engineering Events for Producers of Commercial Robotics Systems

SEPTEMBER 24-25, 2020 BOSTON HYNES CONVENTION CENTER BOSTO N , MA

robot ic ssum m it.com hea lthcarerobotic sforum .com EXHIBIT AND SPONSORSHIP OPPORTUNITIES For more information, contact Courtney Nagle 440.523.1685, cseel@wtwhmedia.com, P RESE NT E D BY:

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A Supplement to Design World - April 2020 www.designworldonline.com

COVID-19

a wake-up call for robotics developers

page 88

INSIDE:

• Robotics industry responds to the COVID-19 pandemic ...........................................................92 • How robotic guidance can improve neurosurgery outcomes .................................98 • Blood-drawing robot shows promising results ...............................................................102 • Diligent Robotics designs Moxi to aid stressed clinicians ............................................................106

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The Robot Report

COVID-19:

a wake-up call for robotics developers Robots need to be better than proofs of concept and can no longer depend on on-site support for edge cases. Improvements in these three areas will help accomplish that. Bastiane Huang â&#x20AC;˘ Product Manager â&#x20AC;˘ OSARO

Millions of Americans have started to work om home amidst the current COVID-19 pandemic. Retailers have struggled with supply while nervous consumers are hoarding everything om toilet paper to hand soap. Across the globe, Chinese e-commerce giant JD began testing a level 4 autonomous delivery robot in Wuhan and running its automated warehouses 24 hours a day to cope with a surge in demand. Suddenly, autonomous machines need to be better than just proof of concepts. They can no longer depend on on-site engineering support for edge cases. They must be robust enough to work independently across various real-life situations.

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THE ROBOT REPORT

4/14/20 7:44 AM

In some ways, the epidemic accelerates an automated future that’s already on its way. It has exposed problems that have long existed in the artificial intelligence (AI) venture scene: buzzwords and hype cloud people’s judgment, making it difficult to see real progress. The industry needs to take on much-needed reforms towards real-world autonomous systems in the following three areas. 1 Rethink metrics As more autonomous machines are deployed in the real world, conventional metrics such as speed, cycle time, or success rate can no longer represent the full picture. We need to measure the reliability of the system under uncertainties with robustness metrics such as the average number of human interventions. We need more tools and industry standards to evaluate overall system performance across a wide range of scenarios because real life, unlike a controlled environment, is unpredictable. If a delivery robot can reach a max speed of 4 MPH but cannot complete a single delivery without human support, the robot is not creating much value for its users. DevOps emerged a few years ago to shorten the development cycle and continuously deliver high-quality so ware. In comparison with so ware engineering, AI or machine learning (ML) is much less mature. Eighty-seven percent of ML projects never go into production. However, recently we’ve started to see MLOps or AIOps appearing more and more. This marks a crucial transition om AI/ML research to actual products that are used and tested every day. It requires a significant change in mindset to focus on quality assurance instead of state-of-the-art ML models. I’m not saying we can’t have both at the same time, but to date, we’ve seen much more emphasis on the latter. 2 Redesign error handling and communication The recent shutdown of Starsky Robotics reminds us that we are still years away om fully autonomous solutions. That doesn’t mean robotics cannot bring immediate value to humans. Even if humans need to handle edge cases 15% of the time, that still means companies can reduce significant labor and integration costs. However, AI companies currently tend to spend much more resources on building autonomous systems and much less time thinking about error handling and seamless hand-offs between machines and humans. We need a better way of handling and communicating errors, especially for ML products because ML is more probabilistic and less transparent. Therefore, showing the confidence level of model predictions or aming your predictions as suggestions instead of decisions are ways to gain trust with users.

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The Robot Report We need to categorize errors into different levels, design different protocols accordingly, and prioritize minimizing fatal errors that stop the system and require human intervention. If fatal errors occur and the system isnâ&#x20AC;&#x2122;t working anymore, can we respond quickly and troubleshoot remotely? The most difficult part is to identi the â&#x20AC;&#x153;unknown unknowns,â&#x20AC;? errors that systems cannot detect. Therefore, itâ&#x20AC;&#x2122;s also crucial to have two-way communication and allow users to flag errors or choose to activate the previously agreed fallback plan. 3 Redefine human-machine interaction The novel coronavirus forces companies to more rapidly adopt automation and shi to the cloud. As fewer people control a larger number of robots, do we have the right tools and technologies to pass all the relevant information to that decision-maker promptly? Are there

enough sensors on each robot to provide a full picture? Today, we rely on tactile input like computers or tablets to control robots. Are these still the best interfaces as the amount of information soars and response time remains short? Should we reconsider human-machine interfaces that go beyond tactile, for example, voice, VR/AR or brain-machine interface? We also need to decide who should be in control. As machines get smarter, should we always make the final call? For example, who should be controlling an autonomous robotaxi? The car itself? The human safety driver? Someone who monitors a fleet of robotaxis remotely? The passengers? Under what situation? Or should it be a co-decision with weighted judgment by both humans and machines? Whatâ&#x20AC;&#x2122;s the

The Ventilator Project

By Steve Crowe â&#x20AC;˘ Editor â&#x20AC;˘ The Robot Report

The COVID-19 pandemic has highlighted extreme shortages of medical supplies, including personal protective equipment for healthcare workers and ventilators for COVID-19 patients. The lack of ventilators is most critical for patients hit hardest by COVID-19 â&#x20AC;&#x201C; typically people 60-plus years of age and anyone with underlying medical conditions. To combat this shortage, companies have partnered to ramp up production of ventilators, including two Boston-based robotics startups at MassRobotics. Alex Frost, Founder of FloraBot, and Tyler Mantel, Founder of Watertower Robotics, started The Ventilator Project, a non-profit looking to develop a low-cost ventilator specifically for COVID-19 patients. One ventilator costs about $40,000, according to estimates. Mantel told The Robot Report his team is rapidly prototyping a ventilator that will cost between $1,000-$2,000. â&#x20AC;&#x153;The best analogy I can come up with is cars,â&#x20AC;? Mantel said. â&#x20AC;&#x153;RollsRoyce has some amazing cars. You feel like youâ&#x20AC;&#x2122;re on a cloud when you drive one because you never feel the road. But you can also get a car for far less money that gets you to where you need to go. The ventilators currently on the market are designed for any type of patient. Weâ&#x20AC;&#x2122;re building a ventilator specifically for COVID-19 patients. Think of it as a stripped-down, bare-bones version of what major companies produce.â&#x20AC;? The Ventilator Project is consulting with a group of doctors on the ventilator design. Mantel said the ventilator will be submitted to the Food and Drug Administration under the Emergency Approval Process. If and when approved, The Ventilator Project hopes to get production 90

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ethical implication? Can the interface support multi-step co-decision making? Ultimately, how do we design humancentered AI to make sure autonomous machines make our lives better, not worse? How do we automate the right use cases to augment humans? How do we build a hybrid team that delivers better outcomes and allows humans and machines to learn om each other? There are still a lot of questions that we need to answer. And the current pandemic is pushing us to answer them more quickly so that would-be autonomous systems can deliver on their promise. If the makers of these systems can focus on the three areas Iâ&#x20AC;&#x2122;ve outlined above, theyâ&#x20AC;&#x2122;ll be better positioned to reach key conclusions more quickly. And that will ensure weâ&#x20AC;&#x2122;re heading in the right direction. RR

www.therobotreport.com

up and running in 30 days and produce 1,000 ventilators within the first month. â&#x20AC;&#x153;A er that, weâ&#x20AC;&#x2122;ll ramp up production to help fill the anticipated shortage of 600,000 ventilators worldwide. Weâ&#x20AC;&#x2122;re working on contracts with major manufacturers in the medical device space to use their under-utilized facilities to pump out ventilators.â&#x20AC;? MassRobotics donated any unused space in its 40,000-square-foot-facility to The Ventilator Project. Developing hardware requires physical space, of course. This can be tricky due to the physical distancing recommendations currently in place. Mantel said The Ventilator Project team is following all the recommendations for physical distancing. As is currently the case for many companies across the world, things have slowed down for Watertower Robotics. Founded in 2017, the company built a robot that inspects water pipes. The goal is to reduce the 20% of water currently lost through deteriorating in astructure. The startup was one of three companies to win the Imagine H2Oâ&#x20AC;&#x2122;s Urban Water Challenge in Stockholm, Sweden. It won funding to deploy its robots in Vietnam. â&#x20AC;&#x153;For me, itâ&#x20AC;&#x2122;s the same mission Iâ&#x20AC;&#x2122;ve always had,â&#x20AC;? said Mantel. â&#x20AC;&#x153;I want to affect lives in a positive way using robotics. At Watertower Robotics, we find water for people. I get excited to do these things for the world.â&#x20AC;? THE ROBOT REPORT

4/9/20 3:18 PM

FHA-C Mini Actuator with Integrated Servo Drive

The Servo Drive is in the Actuator!

The FHA-C Mini Series is a family of extremely compact actuators that deliver high torque with exceptional accuracy and repeatability. As part of the FHA-C Mini family, an integrated servo drive version utilizing CANopen® communication is now available. This evolutionary product eliminates the need for an external drive and greatly improves wiring while retaining high-positional accuracy and torsional stiffness in a compact housing. • Actuator + Integrated Servo Drive utilizing CANopen communication • 24VDC Nominal +7-28VDC Supply Voltage Range • Single Cable with only 4 wires needed: CANH, CANL, +24VDC, 0VDC • Zero Backlash • Dual Absolute Encoders

• Panel Mount Connectors with 4 exit options • Output Sensing Encoder 14bit (16384 cpr) resolution • Input Sensing Encoder 15bit (32768 cpr) resolution • Control Modes Including Torque, Velocity, and Position Control, CSP, CSV, CST • Harmonic Drive HDL Software

42 Dunham Ridge, Beverly, MA 01915 | 800.921.3332 | www.HarmonicDrive.net Harmonic Drive is a registered trademark of Harmonic Drive LLC. CANopen is a registered trademark of CAN in Automation.

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The Robot Report

Robotics industry

responds to the

COVID-19 pandemic From disinfection to delivery and telepresence, robots extend healthcare capabilities. Eugene Demaitre • Senior Editor • The Robot Report

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THE ROBOT REPORT

4/9/20 3:21 PM

Disinfection robots can help with staffing shortages and in multiple environments. | UVD Robots

No technology or industry has escaped the effects of the COVID-19 pandemic. With hundreds of thousands of confirmed cases and tens of thousands of fatalities worldwide in 2020 so far, governments have closed borders, businesses have shuttered, and millions — even billions — of people have stayed in their homes in the hopes of controlling the spread of infection. At the same time, robotics developers and suppliers have risen to the challenge. They are offering systems to civil authorities and healthcare providers now keenly aware of staffing shortages, the need to limit human contact, and the ability of robots and drones to efficiently handle certain tasks. “Reducing the risk of person-to-person transmission is of the highest priority for government and health officials,” said Rocos Global Ltd. The Auckland, New Zealand-based company’s Rocos Robot Operations Platform is designed to enable developers and users to connect, monitor, and control fleets of robots. Rocos pointed out that “robots are no stranger in the healthcare system,” now being used in surgical procedures, dispensing medication, and transporting items within hospitals. While no one robot can do it all, there are robots that can help with informing the public, moving patients, and cleaning and disinfecting areas. Some of the challenges facing robotics startups that want to serve the healthcare market include central management of growing robotic fleets, providing the right levels of support, and improving collaboration among robots and with human staffers and patients, said Rocos. “China is becoming the largest testing ground to demonstrate how emerging technologies can be harnessed to improve epidemic management and minimize the economic impact of the coronavirus outbreak,” stated Venkata Naveen, a disruptive tech analyst at GlobalData. Some companies serving manufacturing and logistics have claimed that their robots are helping to deal with the novel coronavirus, but that’s indirect aid. Still, the crisis could expand public and industry awareness and acceptance of robotics. Here are some examples of robots that are attracting interest around the COVID-19 crisis.

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The Robot Report For instance, Hamilton Co. is offering its MagEEx STARlet and PCR Prep STARlet assay-ready workstations. It said it is prioritizing orders for testing products at its manufacturing sites in Reno, Nev., and Bonaduz, Switzerland. SRI Biosciences in Menlo Park, Calf., is using robots and AI in developing antiviral agents. The European Commission is offering small businesses €164 million ($178.16 million U.S.) in fast-track funding to develop treatment, testing, monitoring, and other technologies to help fight the COVID-19 pandemic.

The R80 ground robot sprays | XAG disinfectant in China. Disinfection robots ride to the rescue UVD Robots ApS is among the first providers of mobile robots that use ultraviolet light to disinfect hospital rooms. The Odense, Denmark-based company was already scaling up last year to meet global demand, said Per Juul Nielsen, CEO of UVD Robots. The subsidiary of Blue Ocean Robotics has received numerous orders for its disinfection robots from China and Brazil, among other countries. Los Angeles-based Dimer UVC’s GermFalcon is a cart that uses UV radiation to disinfect aircraft cabins. Shanghai-based TMiRob has deployed 30 disinfection robots across hospitals in Wuhan, China, the epicenter of the COVID-19 outbreak. Wilmington, Mass.-based Xenon Corp. provides UV-C lamps to Xenex Disinfection Systems. San Antonio, Texasbased Xenex’s robots are designed to reduce healthcare-associated infections in hospitals. It claimed that its LightStrike UV robot is already in use in 500 facilities in the U.S. More recently, Xenex has sent robots to Italy, which has been hit hard by the illness. In Taiyuan, China, local authorities have used a remote-controlled vehicle

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to spray disinfectant in residential areas in an attempt to limit the spread of the coronavirus. XAG has scaled up its use of ground robots with aerial drones, converting agricultural units into disinfectant sprayers. The company has deployed more than 2,600 drones in China, which is reportedly starting to recover. MTR Corp., the Hong Kong subway system, is using vaporized hydrogen peroxide (VHP) robots developed with Avalon Biomedical (Management) Ltd. to disinfect rail cars. “We plan to deploy a total of 20 VHP robots for train cleaning in depots and hope this helps to ensure the comfort of passengers’ journeys by providing ever greater health protection for our colleagues and our customers alike,” said Dr. Tony Lee, operations director at MTR. Autonomous vehicles have also been pressed into service. Idriverplus, which makes a street-sweeping robot, is also contributing to COVID-19 disinfection efforts. Automated testing scales up Testing hundreds of thousands of people for infection, as well as potential vaccines, is a monumental task aided by automated systems. www.therobotreport.com

Drones, robots search for symptoms, scofflaws Shenzhen MicroMultiCopter (MMC) has launched drones to remind people to wear masks, spray disinfectant, and manage traffic. Chinese officials are using aerial drones to keep residents indoors, according to social media posts. Drones could use thermal imaging to detect people with fevers, said Cameron Chell, CEO of Draganfly Inc. In fact, Guangzhou Gosuncn Robot Co. is providing police with patrol robots remotely controlled via 5G to detect people with fevers. Similarly, the California-based CaliBurger restaurant chain is using technologies including thermal imaging and facial recognition to screen entrants. Although sensors are not yet sensitive enough to detect viruses at a distance, artificial intelligence is being applied to analyze how the coronavirus is spreading to detect patterns, begin formulating vaccines, and draw lessons for future epidemics. Mobile robots help protect hospital personnel Hong Kong University of Science and Technology is testing a variety of mobile robots for infection control in collaboration with the government and local hospitals. It noted that the current pandemic requires truly global cooperation for innovative responses. Several hospitals in China are using robots to deliver food and medical supplies internally to limit people’s potential exposure to the new coronavirus, said Rocos. THE ROBOT REPORT

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Drones can monitor traffic and quarantines. | MMC

For example, Pudu Technology Inc.’s robots are autonomously delivering meals, and Qianxi Robotic Catering has donated robots to prepare food for medical workers in Wuhan. A hospital in Hangzhou, China, is using 16 “Little Peanut” robots from Keenon Robotics Co. to deliver food. Mobile robots can also remove trash. Some of China’s biggest tech companies have also gotten involved. Siasun Robot and Automation Co. has donated robots for collecting throat cultures, as well as adjustable beds, to hospitals in Shenyang. JD.com Inc. has also tested delivery robots in Wuhan. Although most social robots are designed to provide information than care, a new field hospital in Wuhan, China, uses a variety of systems, including CloudMinds’ 5G-enabled humanoid robots. Shenzhen, China-based Ubtech Robotics Inc. has modified its AIMBOT, ATRIS, and Cruzr service robots to measure people’s temperature. Orbbec, which makes 3D cameras, said its partners have joined efforts to slow COVID-19’s spread and to treat patients. They include delivery robot maker Keenon Robotics Co., disinfection provider EVA Robot, and guide robot supplier OrionStar. THE ROBOT REPORT

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Mobile manipulation and coronavirus Austin, Texas-based Diligent Robotics Inc. recently raised $10 million in Series A funding for its Moxi service robot. The mobile manipulator is more mature than other platforms, and we have yet to see the full market for robots to aid nurses and doctors. Zheng Gangtie, a professor at Tsinghua University in Beijing, built mobile manipulators to protect medical personnel in Beijing while attending to patients, but each one cost $73,000 to make. Hooman Somani has also placed a robot arm on a mobile base for its Ambulance Robot or AmbuBot. As with humanoid designs, these robots are still catching up to other material-handling systems.

Robot, drone deliveries help people avoid pandemic Baidu Inc. has partnered with Neolix to deliver food and supplies to Beijing Haidan Hospital with the Apollo autonomous vehicle. Baidu’s AI algorithms are also being used to track the spread of infection. Grocers, pharmacies, and restaurants have limited resources for fast and accurate order fulfillment, so robots are increasingly important in getting goods from warehouses and stores to trucks and customers. JD.com has used Level 4 autonomous vehicles for deliveries in Wuhan. Drone deliveries of medication aren’t yet commonplace, but companies such as Drone Delivery Canada Corp. (DDC) anticipate that they will be. “The company is in dialogue with governments at various ministries and levels emphasizing that the current situation is an ideal use case for our proven drone logistics solution to limit person-to-person contact; bring needed medical and pharmaceutical supplies to remote, rural, and suburban communities; transport blood samples to laboratories for testing; and deliver other relevant supplies needed for Canada to effectively manage the current situation,” stated Michael Zahra, president and CEO of DDC.

Service robots can provide information and check for fever. | Ubtech

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The Robot Report Aerial drones transport medicine and other supplies. | DDC

“With a global pandemic quickly on the rise, government officials will need to act quickly in search of a scalable solution that will help slow down the spread of coronavirus,” said Matthew Sweeny, founder and CEO of Flirtey. “Flirtey is uniquely positioned to provide drone delivery technology for pandemic management, because our technology can be utilized as a scalable, effective and low-risk means to significantly mitigating the virus’s threat.” Antwork Ltd., a Terra Drone group company, is already transporting medical supplies and laboratory samples between a hospital, a disease-control center, and a branch of Xinighang County People’s Hospital. Telepresence robots join the coronavirus fight Most telepresence robots were not designed with the coronavirus pandemic in mind, but wider use could help drop their prices. To keep patients from overwhelming hospitals, more physicians could turn to telemedicine. Alexandra Hospital in Singapore, which just started testing a BeamPro robot, plans to use it to see isolated patients suspected of being infected with the new coronavirus. Beijing Orion Star Technology Co. has partnered with Cheetah Mobile to provide robots for fixed-point delivery of medical supplies and remote consultation at Peking University Shougang Hospital, Beijing Haidian Hospital, Wuhan Vulcan Mountain Hospital, and Zhengzhou’s Xiaotangshan Hospital. Cheetah Mobile is an investor in the service robot company. “Since the outbreak of COVID-19, we have launched the anti-epidemic products in hospitals in the hope that they can alleviate the tension resulted

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from insufficient medical personnel as well as cross-infections,” stated Fu Sheng, CEO and chairman of Cheetah Mobile. OrionStar’s robots can also follow human instructions to collect, store, and transmit photos, video, and data, including body temperature measured by a no-contact infrared thermometer. The hospitals can disinfect the robots as needed, and informational models are being programmed with general epidemiological data, said a company spokeswoman. In addition, China Mobile and CloudMinds have donated 5G-enabled robots to a Shanghai medical facility to aid medical staffers. The hospitality industry is also using telepresence robots in response to health concerns. In Everett, Wash., doctors used an InTouch Health robot to remotely communicate with a patient. Zorabots is offering its telepresence robots to Belgian nursing homes, where vulnerable populations are limiting contact with family members in response to COVID-19. Israel-based Robotemi is also offering its Temi personal robot in South Korea to help reduce exposure to COVID-19. Although robotics competitions have been canceled or postponed, robotics can be helpful for telepresence and distance learning. For instance, children in New Rochelle, N.Y., another community hard hit by the virus, have also been using the Temi robot. www.therobotreport.com

Dallas-based RoboKind, which makes the Milo humanoid robot, is offering its robots4STEM Avatar Version software for free to students whose elementary and middle schools are closed. The virtual coding class follows computer science standards set by the International Society of Technology. Even if the pandemic eases soon, it’s likely that healthcare providers, consumers, and businesses will be more comfortable with robots of all kinds and more interested in using them. “The IMF has predicted global declines in the next two quarters, but we see the market for robotics picking up again,” Nikhil Kaitwade, senior research manager at Future Market Insights, told The Robot Report. RR

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The Robot Report

How robotic guidance

can improve neurosurgery outcomes Cranial robotic guidance platform provides real-time visualization, feedback and robotically-assisted movement to allow surgeons to accurately align with surgical plans. Keith Shaw • Senior Editor • The Robot Report

Phoenix Children’s Hospital recently became the first health system in the U.S. to deploy Medtronic’s Stealth Autoguide platform, which robotically assists neurosurgeons for more accurate positioning of instruments during procedures.

Medtronic’s Stealth Autoguide platform robotically assists neurosurgeons for more accurate positioning of instruments. 98

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The cranial robotic guidance platform provides realtime visualization, feedback and robotically-assisted movement to allow surgeons to accurately align with surgical plans. The system integrates with Medtronic’s StealthStation surgical navigation system and Midas Rex surgical drill technology to improve workflow efficiency in an operating room. The system can assist surgeons with placement of biopsy needles, the placement of stereo electroencephalography (stereo EEG or sEEG) anchor bolts to enable placement of depth electrodes, and support for laser ablation. At Phoenix Children’s, P. David Adelson, division chief of neurosurgery and director of the Barrow Neurological Institute (BNI), has performed at least two procedures (an sEEG procedure and laser ablation) with the new system on patients with epilepsy. The Robot Report spoke with Dr. Adelson about the hospital’s interest in the system and the benefits for surgeons using the robotic guidance system.

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The Robot Report

Besides improving instrument position during procedures, Phoenix Children’s Hospital said surgical robots help decrease length of stay in the hospital, time in the operating room, and exposure to anesthesia. Credit: Medtronic

Q How did you first get interested in the possibility of robots being used in neurosurgery? Dr. Adelson: Over the last few years, there’s been a number of new entries into neurosurgical robots. Throughout the U.S., we’ve seen increasing robotic technology for a lot of different aspects of healthcare and surgery. But with regards to neurosurgical robots, particularly cranial, there were a number of excellent technologies that were very interesting. The big issue for me was how easy would it be to integrate these into our present workflow. If you have to add new software for guidance, or new software that changes what you do or how you do it, then obviously there’s an extensive relearning and a high learning curve.

Q How did you narrow it down to selecting the Medtronic system? Dr. Adelson: Number one was the size, because it married into the technology that we already were employing – the Stealth Navigation System, as well as some other technologies in which we would be using the new robotic device. We had worked with Medtronic in the past on a number of different technologies, including the image guidance system and the laser ablation technology. This seemed to marry very well with that. The robot is also

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markedly smaller than its competitors, and so much easier to integrate into the operating room as an assistive device. Second, it increased our efficiency of doing these procedures. When we were researching the different technologies, I was being sold on the fact that we could do an operative plan in eight to 12 minutes. I was already doing these in eight to 12 minutes, so I didn’t see what was going to be the added benefit with this significant investment. But the Medtronic one clearly led to increased efficiency – for us it has actually cut the time in half. Lastly is the accuracy – I felt very comfortable using their present technology getting 0.2 to 0.5 millimeters of accuracy. With a frame-based system you could get to 0 to 0.2mm. So this robotic device gives us that type of accuracy without having to use a frame. A frameless approach saves time, saves anesthesia for the patient, and ultimately gives us the same accuracy.

Q How important is accuracy in terms of some of these procedures? From a layman’s perspective, is there really that big a difference between 0.3 and 0.5 millimeters? Dr. Adelson: That’s a great question. I guess if it’s your brain, you’d want it as close as it can be, but it’s not as simple as that. In many situations it’s not as www.therobotreport.com

important, but in certain situations it’s very important. If we have only a three-millimeter lesion that’s deep in the brain that we have to navigate across segments, then accuracy is very important to avoid blood vessels, to avoid particular tracks in the brain, and to try to get to deep locations in a safe way. In that case, the accuracy is quite useful.

Q For pediatric patients, is accuracy a bigger deal, because of the body type of a child versus an adult? Dr. Adelson: We always make a joke that children are not small adults, and I think that’s very true. Some of the lesions and types of problems that we’re using this robot for are quite different. For example, for epilepsy if they have a hypothalamic hamartoma, sometimes these lesions are only three millimeters in diameter. The accuracy and targeting for these are very important – we don’t see these types of lesions in adults. So robotic technology is useful in certain pathologies that are unique for children. I’m sure there will be unique pathologies that the robot will be used in adults as well. It was really a privilege and truly enjoyable to work with Medtronic to roll this out for children, because children often don’t get first out-of-box technologies. Often it’s done in adults, and then OK, the kids get kind of the layover – so I think this was wonderful for Medtronic to work with us to roll it out with us. THE ROBOT REPORT

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Q What reaction do you get om either patients or parents when you tell them about the robotic system? Dr. Adelson: A question came up with a family that asked, “Is the robot going to do the surgery?” and I said, “No, that’s not how it works.” The two patient families were on board, very interested in the technology as I explained how we were going to be using it.

Q What were your thoughts om the two procedures you’ve done? Dr. Adelson: The first one was a stereo EEG where we placed 10 electrodes, and that’s how I knew we could cut the time. As I said earlier, I was a little skeptical because I could already do this in eight to 12 minutes. We were doing them in four to five minutes [with the robot]. So that decreased anesthesia time for that child, and decreased operating room time. When you’ve got that many operative plans, the robot increasing your efficiency that way clearly saved us at least a half hour. [In the second case], we were marrying the image guidance system with the robotic technology and laser ablation in order to treat a young woman with intractable epilepsy. We used it with two probes, and all of them have gone where we needed them to go, which has been fantastic.

Q Does the extra time now allow you to do additional procedures, or is it more of a scheduling factor where you can schedule procedures faster than what you could have done before? Dr. Adelson: The hospital would like to know that I’m scheduling more surgeries – that would be fantastic (laughs). But for us, it’s about cutting down the time that patients are exposed to anesthesia, especially young children. They wake up easier if they’re not under anesthesia as long. Overall, we like to think that decreased length of stay in the hospital and decreased time in the operating room is better for health care, economics, and those kinds of things. RR

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Blood-drawing robot shows promising results

A team led by Rutgers University researchers developed a robot that draws and tests blood more efficiently than humans. Steve Crowe • Editor • The Robot Report

The first human clinical trials of a blood sampling and testing robot showed promising results for both patients and healthcare workers, reported Rutgers University. The trials found that an automated blood-drawing device developed over the past six years by a Rutgers-led team performed as well or better than human clinicians. The device provides quick results and would allow healthcare professionals to spend more time treating patients in hospitals and other settings, said the researchers. The results were comparable to or exceeded clinical standards, with an overall success rate of 87% for the 31 participants whose blood was drawn. For the 25 people whose veins were easy to access, the success rate was 97%.

The device combines high precision robotics with 2D ultrasound imaging to automatically guide an attached needle. Credit: Rutgers University

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Solving a costly problem Venipuncture, which involves inserting a needle into a vein to get a blood sample or perform intravenous (IV) therapy, is the world’s most common clinical procedure, with more than 1.4 billion performed yearly in the U.S. But clinicians fail in 27% of patients without visible veins, 40% of patients without palpable veins, and 60% of emaciated patients, according to previous studies. Repeated failures to start an IV line boost the likelihood of phlebitis, thrombosis, and infections, and they may require targeting large veins in the body or arteries – at much www.therobotreport.com

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The Robot Report To improve the system, researchers intend to add a third degree of freedom to auto-align the needle trajectory path and analyze how machine learning models can make rapid needle position corrections. Credit: Rutgers University

for patients, but it can also be modified to draw blood in rodents, a procedure which is extremely important for drug testing in animals in the pharmaceutical and biotech industries.”

greater cost and risk. As a result, venipuncture is among the leading causes of injury to patients and clinicians, said the New Jersey-based university. Moreover, problems with accessing veins can increase procedure time by up to an hour, requires more staff, and costs more than $4 billion a year in the U.S, according to estimates. System breakdown The device combines high-precision robotics with 2D ultrasound imaging to automatically guide an attached needle. The device is composed of three main components: • A 2-DOF robotic manipulator containing an electromagnetic needle loader and needle tip force sensor • A 2D short-axis view ultrasound probe • A host processor An integrated module that handles samples and a centrifuge-based blood analyzer could be used at bedsides and in ambulances, emergency rooms, clinics, doctors’ offices, and hospitals. The researchers previously developed a venipuncture device for point-of-care blood analysis that featured a 9-degree-of-freedom (DOF) robotic system that used NIR imaging and computer vision processing to identify suitable vessels for cannulation and ultrasound imaging to guide the robotic needle insertion. However, its large size, lack of mobility, and large number of DOF make it difficult to implement in a number of clinical scenarios requiring rapid venous access.

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How the system works Once a suitable blood vessel is identified by the attending physician, the device is manually positioned over the chosen venipuncture site for ultrasound imaging. The device is then positioned over the arm so that the ultrasound probe is perpendicular with the imaged vessel. The blood vessel coordinates, retrieved from the ultrasound images, are then used by the device to compute the necessary kinematics for needle insertion so that the needle tip reaches the lumen center at the intersection of the ultrasound imaging plane. After successful insertion, the needle tip can be seen in the center of the vessel lumen. A yellow dashed ellipse highlights the vessel wall in the ultrasound image, where red and blue lines represent the vessel ellipse major and minor axes, respectively. Once successfully inserted, 5 mL of blood is drawn into a collection tube, after which the needle is retracted and dispensed. “Using volunteers, models and animals, our team showed that the device can accurately pinpoint blood vessels, improving success rates and procedure times compared with expert health care professionals, especially with difficultto-access blood vessels,” said Martin Yarmush, a researcher involved in the study. “Not only can the device be used www.therobotreport.com

Avoiding future complications In the future, the device could be used in procedures such as IV catheterization, central venous access, dialysis, and placing arterial lines. Next steps include refining the device to improve success rates in patients with difficult veins to access. For example, before the device can perform the needle insertion, the needle trajectory must be manually aligned and centered with the underlying blood vessel. This can become timeconsuming, prone to mistakes, and require the device to be fixed and steadied once it is aligned and centered with the vessel. To improve this, the researchers intend to add a third DOF to the device that will auto-align the needle trajectory path with the underlying vessel. The team will also investigate combining predictive machine learning models with the device kinematics to make rapid needle position corrections that would maximize the likelihood of a successful venipuncture. “A device like ours could help clinicians get blood samples quickly, safely and reliably, preventing unnecessary complications and pain in patients from multiple needle insertion attempts,” said lead author Josh Leipheimer, a biomedical engineering doctoral student in the Yarmush lab in the biomedical engineering department in the School of Engineering at Rutgers University–New Brunswick. RR THE ROBOT REPORT

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Diligent robotics designs to aid stressed moxi clinicians The startup was working on a mobile manipulator before the COVID-19 crisis and has seen interest continue to rise. Eugene Demaitre • Senior Editor • The Robot Report The COVID-19 pandemic has brought attention to the challenges that healthcare providers face every day, such as staffing shortages, physical strain, and the need to securely manage medications and laboratory samples. Robotics developers and suppliers have addressed some of these challenges, but a flexible and useful humanoid or service robot has been elusive. Diligent Robotics Inc. has launched Moxi, a mobile manipulator designed to aid hospital personnel. Andrea Thomaz and Vivian Chu co-founded the Austin, Texas-based company in 2017. They began testing the robot, which also has social intelligence capabilities, in four hospitals in 2018. “Our vision is to improve the way people think about their work by giving them more time to utilize their unique human skills and let iendly robot assistants efficiently take care of their chores,” stated

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The Moxi mobile service robot is designed to help hospital workers. | Diligent Robotics THE ROBOT REPORT

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| Raytheon

The Robot Report Thomaz, CEO of Diligent Robotics. The company raised $2.1 million in seed funding in 2018 and $10 million in Series A funding last month. It has also received Small Business Innovation Research grants om the National Science Foundation worth $725,000.

Moxi can relieve nurses and other clinical workers of some tedious tasks. | Diligent Robotics

Moxi is not designed for patient-facing tasks, but it can help with retrieving and bringing supplies to hospital rooms and nursing stations or delivering samples to laboratories.

Recognizing needs even before the coronavirus crisis Even before the current global health crisis, many nurses were forced to spend time on non-nursing activities, according to a study by the Institute of Medicine. More than 30% of hospitals reported that they could not find enough candidates to fill open clinical positions, and clinician turnover was almost 20%. Nursing burnout costs $9 billion for hospitals annually and $14 billion for the healthcare system overall, said the report. “There will be a shortage of 1.1 million registered nurses in the U.S. in 2022, and 9 million in 2030,” Thomaz said at an MIT event. “We wanted to solve the interesting problem of having service robots help people in semi-structured environments like hospitals.” “During our beta trials, we were focused on learning as much as we could about clinical workflows and opportunities for automation to make the biggest impact,” she told The Robot

Report. “We learned so much om all of the 125 nurses that Moxi had the privilege to work alongside during the trials. We’re now very excited to act on those learnings and roll out Moxi as a full-time hospital teammate that makes a real impact on workflows.” “As the current pandemic and circumstance [have] shown, the real heroes are our healthcare providers,” said Q Motiwala, partner at DNX Ventures and newly named board member for Diligent Robotics. “Diligent Robotics has built a hospital robot assistant, Moxi, to help solve one of healthcare provider’s biggest challenges — nursing shortages.” “Now more than ever, hospitals are under enormous stress, and the people bearing the most risk in this pandemic are the nurses and clinicians at the ontlines of patient care,” added Thomaz, who is an engineering professor at the University of Texas at Austin. “Our mission with Moxi has always been focused on relieving tasks om nurses, giving them more time to focus on patients, and today that mission has a newfound meaning and purpose.” Designing a clinician’s aid Moxi was built on a mobile base and navigation so ware based on the Robot Operating System om Fetch Robotics.

Moxi combines standard robotics components for mobile manipulation. | Diligent Robotics

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Vivian Chu (left) and Andrea Thomaz co-founded Diligent Robotics in 2017. | Diligent Robotics

It also includes a lidar sensor from Velodyne, a camera from Intel, an arm from Kinova, and a gripper from Robotiq. “Because of ramps and other technologies, hospitals are already robot-accessible,” explained Thomaz. “Doors proved to be the biggest architectural challenge. We work with hospital IT to enable Moxi to integrate with various software systems in the hospital.” Moxi’s torso and head can change in height, and it has a humanoid face for interacting with people. The goal was to have a form that is non-threatening but still useful for picking up dropped items, for example. Moxi is not designed for patient-facing tasks, but it can help with retrieving and bringing supplies to hospital rooms and nursing stations or delivering samples to laboratories. “Another hugely pleasant surprise during our beta trials was the overwhelmingly positive reaction to Moxi by patients and their families, along with the front-line staff working with Moxi,” said Thomaz, who spoke at the inaugural Healthcare Robotics Engineering Forum last year. “We are humbled to get the

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opportunity to focus on building a product designed to positively impact nursing and healthcare, and we felt very proud seeing such an immediately positive reception of Moxi across the board.” Diligent focuses on AI Diligent Robotics has 18 staffers and describes itself as an artificial intelligence company, with the goal of applying AI so that people can attend to high-value tasks such as caring for patients. The fifth version of Moxi uses machine learning for object recognition, grasping, and learning tasks in real time. Time named the robot one of the best inventions of 2019. “We build artificial intelligence that enables service robots to collaborate with people and adapt to dynamic human environments,” said Chu, cofounder and chief technology officer of Diligent Robotics. “Diligent Robotics is delivering a new class of hospital service robots by building a solution that can autonomously navigate a hospital to perform collaborative tasks with nursing staff.” The robot’s ability to autonomously

www.therobotreport.com

Moxi is available now The company plans to use its latest funding to continue developing both its hardware and software and for the product launch. “We fully expect that our product will continue to evolve as we roll out with our first set of strategic partner customers this year and gain further insights into ways to drive value for them,” said Thomaz. “Our focus initially is on delivery-support tasks that take nurses away from the patient floor, and we are continually honing Moxi’s dexterity to handle an even a wider variety of objects for materials-management tasks.” Moxi is available in a robotics-asa-service (RaaS) model, and Diligent is in talks with two of the top hospital networks in the U.S. “Cost is based on the customized utilization of each Moxi robot for every hospital’s particular needs,” noted Thomaz. Diligent Robotics said the latest funding will help it scale its system to a wider customer base as well as invest in product strategy and development in both hardware and software. Humanoid and service robots have faced both technical and marketing challenges. “We envision a future powered by robots that work seamlessly with human teams,” said Thomaz. “We are enabling our hospital customers to redesign workflows for their frontline teams, letting nurses make full use of their specialized skills and letting robots handle tedious fetching tasks and other routine work.” RR

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CGI Inc. Advanced Products for Robotics and Automation At CGI we serve a wide array of industries including medical, robotics, aerospace, defense, semiconductor, industrial automation, motion control, and many others. Our core business is manufacturing precision motion control solutions. CGI’s diverse customer base and wide range of applications have earned us a reputation for quality, reliability, and flexibility. One of the distinct competitive advantages we are able to provide our customers is an engineering team that is knowledgeable and easy to work with. CGI is certified to ISO9001 and ISO13485 quality management systems. In addition, we are FDA and AS9100 compliant. Our unique quality control environment is weaved into the fabric of our manufacturing facility. We work daily with customers who demand both precision and rapid turnarounds.

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THE ROBOT REPORT

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Schunk’s End Effector Kit is a perfect addition to KUKA’s KR3 Agilus Robot. The FGA MPG+ 32 KIT is a gripper for smaller components. It is a pneumatic 2 Finger Parallel gripper with smooth roller guides for maximum repeatability. This kit leaves you with 13 mm channels to connect a variety of different fingers to best fit your unique application. Its specifications include a 4 mm stroke per jaw, a closing force of up to 80 N, an opening force of 70 N, and an operating temperature up to 90°C. Digi-Key also carries an assortment of accessories for the FGA MPG-plus 32 such as finger kits, mounting kits, tools, and adapter plates.

Digi-Key Electronics 701 Brooks Ave S Thief River Falls, MN 56701 Phone: 1.800.344.4539 Web: www.digikey.com Email: sales@digikey.com

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Harmonic Drive FHA Actuator with Integrated Servo Drive Just Released: FHA mini actuator with an integrated servo drive utilizing CANopen® communication. Eliminating the need for an external servo drive, it features a single cable connection with only 4 wires needed: CANH, CANL, +24VDC, 0VDC. A single-turn 14bit (16384 cpr) gear output sensing encoder has been integrated along with a single-turn 15bit (32768 cpr) motor input sensing encoder providing a true absolute encoder that does not require a battery within 360° of rotation of the output. The FHA-C mini Series is a family of extremely compact actuators that deliver high torque with exceptional accuracy and repeatability.

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Harmonic Drive is a registered trademark of Harmonic Drive Systems

igus Low-cost, maintenance-free gantry robots drylin® gantry robots consist of various X, Y and Z linear actuators. They’re engineered to glide instead of roll, which ensures quiet and smooth operation, and are designed with self-lubricating components that are corrosion resistant and maintenance-free. drylin® gantry robots are also lightweight and cost up to 40 percent less than traditional gantries. Typical applications include pick and place, sorting, labeling, measurement, inspection automation, and repetitive material handling. igus® offers single-axis actuators as well as customized drylin® gantry robots based on customer-specific application and installation parameters. Choose from a variety of actuators, stroke lengths and accessories.

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Visit www.igus.com/info/gantry-robots for more information.

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THE ROBOT REPORT

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Robotics Robotics

maxon Drive Systems for Robotics Reliable, Powerful, Efficient A complete joint actuation unit. Includes a brushless DC motor, an internal high resolution encoder, planetary gearhead with absolute encoder and position controller with CAN and RS232 interface. Exoskeleton Joint Actuator • Compact Housing • Integrated Controller • Reduced Weight and Cost • For Use in Hip and Knee Exoskeletons maxon is your single source for motion solutions. When you choose

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New England Wire Technologies Advancing innovation for over 100 years Why accept a standard product for your custom application? NEWT is committed to being the premier manufacturer of choice for customers requiring specialty wire, cable and extruded tubing to meet existing and emerging worldwide markets. Our custom products and solutions are not only engineered to the exacting specifications of our customers, but designed to perform under the harsh conditions of today’s advanced manufacturing processes. Cables we specialize in are LITZ, multi-conductor cables, hybrid configurations, coaxial, twin axial, miniature and micro-miniature coaxial cables, ultra flexible, high flex life, low/high temperature cables, braids, and a variety of proprietary cable designs. Contact us today and let us help you dream beyond today’s technology and achieve the impossible.

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Engineering April 2020

A supplement of Design World

Fastening technology Covering assembly, design, training, welding... plus, what to expect at this yearâ&#x20AC;&#x2122;s Fastener Fair USA!

| AdobeStock.com

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EDITORIAL •• •• •

•• •• •

•• ••

Finding strength in community We’re in challenging times. Social distancing has become a way of life. Events and conferences are banned, borders are shut down, and several workplaces have temporarily closed or must work remotely. Companies deemed essential have implemented new safety precautions and limited staff. It’s a struggle that’s impacted nearly everyone worldwide and, at least currently, there’s no obvious end in sight. One thing that does seem certain, however: the fastener industry will pull through if history is any indication. Although a world health and economic crisis like this is unprecedented in this generation, the majority of companies in the fastener industry are familiar with challenges — and longevity. Take NBK, for example, a specialty manufacturer of mechanical components (including fasteners) with four centuries of experience. The company, which has a U.S. branch, first set up shop in Japan in 1560. One reason for its staying power: “We’re very much a problem-solving company,” shared Daniel Timm, customer service and inside sales representative with NBK America. He said the company continually looks for opportunities to provide for and support customers, even it means developing new products. At Fastener Engineering, we’ve been compiling company profiles and what’s stood out is the remarkable commitment this industry has for its customers and colleagues. While NBK’s history is unique, the majority of fastener companies have decades of experience and wisdom. Take Patrick Murphy, for example, VP of D.L.P. Coatings, Inc., a provider of painted fasteners. His father started the company in the 80s. The top lesson Murphy learned from his dad: “Treat others how you want to be treated,” he told us. “It’s simple but true.” Rosa Hearn, an industry veteran with more than 25 years of experience and current product manager for the Proferred Rivets line at Brighton-Best International, also believes kindness is key. She supports the fastener industry and her local community in several ways. She’s the chairman of the Fastener Industry Coalition and WIFI, or Women in the Fastener Industry. These are two organizations dedicated to providing resources and education to those in the industry (such support organizations are yet another reason the sector will manage these tough times). “It’s important to me to connect with others and share my career experiences, so others are aware of what’s possible,” said Hearn. She’s also on the advisory committee for an economic and workforce development program in California, where she teaches high school and college students about the fastener market. These company profiles, and others, are posted at fastenerenergineering.com and included in our e-newsletters (simply sign up on our website). If you’d like to share your company’s story with us, please email fasteners@wtwhmedia.com. We encourage you to continue supporting one another, even from a distance. There is strength in community.

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F a s t e n i n g

J o i n i n g

Mark your calendars:

This year’s Fastener Fair USA includes all industry segments

North America’s fastest-growing expo for the fastener industry, Fastener Fair USA, will host its third-annual trade show and conference at the Charlotte Convention Center in North Carolina. The event is now set for July 13 to 15, 2020. “We look forward to getting back to business and reconnecting the industry in Charlotte in July,” said Randy Field, group VP with Reed Exhibitions. The Fastener Fair was originally scheduled for May and postponed due to COVID-19. “Our number one priority is the health and safety of our exhibitors, attendees, industry partners, and staff,” said Field. This year’s event theme, “Holding Industry Together,” is a direct reflection of Fastener Fair USA’s mission to serve all industry segments relating to fasteners and fixings. This includes fastener manufacturing, master distributors,

This year’s theme for Fastener Fair USA is “Holding Industry Together,” which is intended to honor just how important and integral every sector of the fastener industry is today.

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This year’s Fastener Fair includes two days of on-the-floor exhibitions, including Industry Education Stage presentations on July 14 and 15.

equipment makers, tool and software providers, end-users, and more. “Supply chain, assembly, measurement, and other processes are becoming increasingly integrated into the fastener industry,” shares Bob Chiricosta, event manager for the Fastener Fair USA. “It’s extremely important to us that we offer a comprehensive display of industry innovation with highly relevant education and networking opportunities — all of this in one of the U.S.’ fastest-growing manufacturing regions.” The pre-show Fastener Fair USA includes an educational pre-show conference program, starting on July 13. Beginning with an opening keynote, the conference will then segment into three tracks: 1 Fasteners 101, presented by the Fastener Training Institute

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The opening day of the Fastener Fair USA’s Exhibit Hall on July 14 will include an evening welcome party at the NASCAR Hall of Fame from 6:30 to 8:30 p.m. The Welcome Party tickets cover entry to the NASCAR Hall of Fame with live music, food, and beverages.

Moving fasteners forward The team at Fastener Engineering is proud to partner with Fastener Fair USA as a media sponsor. This year, we’ll be hosting a panel, entitled “How to move fasteners to the front of the design cycle,” which focuses on the importance of considering fasteners earlier on in project planning. The panel will take place on Tuesday, July 14 from 1:45 to 2:20 p.m. on the show floor. We hope to see you there!

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2 Tom Reilly Training: Value-added Selling, presented by Paul Reilly in partnership with Mid-West Fasteners, a fastener manufacturer and supplier 3 Fasteners in the Smart Factory, presented by Fastener Fair USA As these tracks conclude, registrants with a Monday Conference Pass will have the opportunity to visit a nearby industrial manufacturing plant at Blum, Inc., a family-owned company that operates internationally. “By including a plant tour with the 2020 Fastener Fair, participants will experience the real-world impacts of the fasteners they produce, add value to, and distribute,” says Chiricosta.

Assured Splice Quality for Assured System Performance When engineered systems rely on the performance of every input and output, every wire and splice counts. That is why, from automatic self-calibration to real-time indication of splice quality, the Branson™ GMX-W1 Ultrasonic Wire Splicer assures repeatability in your assembly operations. Touchscreen programming, multiple welding modes, and anti-side-splicing design support error-free production, while real-time monitoring, data collection, and statistical analysis prove splice quality and assure traceability.

The main event To set the tone for the event, a 9 a.m. general session that’s titled, “Industry 4.0: Tap the Cloud and Ramp up Profits,” will be presented by Yannick Schilly, president and CEO of Altix Consulting, on July 14. Attendees can also expect two days of on-theexpo-floor, “Industry Education Stage” presentations on July 14 and 15. This will include more than a dozen panel presentations, with topics such as moving fasteners to the front of the design cycle, sharing ideas for import and export strategies, and understanding smart tools, 3D metal printing, and more. Additionally, an “Ask the Standards Experts” will take place on both days, starting at 10:15 a.m. with the Fastener Training Institute and Industrial Fasteners Institute, which provides a comprehensive online fastener data resource. Attendees can bring questions about fastening standards to Booth 1237. “By adding more industry content into the Fastener Fair mix of outstanding networking and business developments, this event will offer everything fastener professionals need to build business,” adds Chiricosta.

Learn more at: Emerson.com/Branson

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

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F a s t e n i n g

J o i n i n g

How offshore manufacturing

has affected local training initiatives John Wachman • Managing Director • Fastener Training Institute Before the 1970s, most fasteners were produced domestically by U.S. manufacturers. Typically, these companies employed field sales executives and engineers to work with distributors and end users on the proper fastener selection and installation. These workers were backed by factorybased product managers and application engineers. For example, one major supplier had 65 business development executives working throughout the country to support its customer base. Product support was also available for each component type, including bolts, sockets, screws, nuts, washers, and so on. Eventually, however, the majority of fastener production moved overseas. This was simply a matter of economics, which occurred relatively slowly at first and then the shift accelerated as emerging countries began developing more solid manufacturing facilities. Of course, it was unwise to begin with major aerospace or automobile parts, so smaller components (such as fasteners) provided an ideal manufacturing place to start. The overseas manufacturing trend continued and, even today, most commodity standard fasteners are imported. Although the U.S. has since revitalized its share of fastener manufacturers, most supply higher quality, engineered fasteners. Certainly, some standard fasteners are produced in America, but suppliers must fight to be competitive. Domestic producers continue to offer great product support, but they are typically lean and product support is limited by economics.

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Over the years, less local manufacturing has led to two challenges: 1 Knowledge drain. Overall, a lack of local experience and knowledge about the entire manufacturing process means there’s a “knowledge drain” in the industry. Compounding this concern are the efficiencies companies have employed over the last three decades to save costs. For the most part, this has meant doing more with fewer people. As with many companies worldwide, fastener resellers and end users also had to get lean. 2 Tribal knowledge. Several people in the industry are retiring but without an immediate successor

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Students from one of the Fastener Training Institute’s advanced courses. FTI provides training on fastener products, standards, and specifications for students of all levels and experience.

who has been in the industry and gained the experience necessary to properly take over the role. Now when people retire, those who step into their positions are lucky to have a few years of experience under their belt, never mind 20 or 30 years, which used to be the case. However, the passing on of tribal knowledge takes time. With a gap in talent, there’s a risk that the tribal or historical knowledge could be lost. The burden on these newly promoted folks to get up to speed is enormous. Why training matters Given these concerns, how can the industry support smaller producers and their staff with product information and training? The answer is training. Employees that specify, order, and install fasteners must have a good background in fasteners. The integrity, reliability, and safety of assembled products depend on an educated fastener supply chain. For example, fasteners do experience failures. However,

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The Fastener Training Institute’s (FTI) core purpose is to enhance fastener use, reliability, and safety by providing fastener product and technical training. FTI does so by providing beginning and advanced courses with hands-on training opportunities.

www.fastenerengineering.com

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it’s rarely the result of faulty components and more likely because the wrong fasteners were specified, or they were improperly installed. Proper training aims to prevent such occurrences. Here’s what to look for in a fastener training program:

• Covers fastener products,

• Ideally, offers beginner and advanced courses

• Hosted by recognized industry experts with years of experience Training that enhances the level of technical understanding and expertise of individuals in the industry is critical for a successful industry.

standards, and specifications

• Teaches proper fastener selection

•

and installation methods to prevent unnecessary faults and failures Provides a mix of online and hands-on programs

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

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F a s t e n i n g

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How to choose fasteners that maximize assembly life Christie L. Jones â&#x20AC;˘ Vice President / Director of Marketing SPIROL International Corporation, U.S.A.

Typically, fasteners are the smallest, least costly components used in an assembly. Perhaps, for this reason, they are rarely considered until the end of a projectâ&#x20AC;&#x2122;s design stage. However, fasteners provide a critical function by holding an entire application together. Unfortunately, as important as fasteners are, design engineers rarely receive formal training on the mechanics of fastening and joining. This is particularly concerning in certain safety-critical applications, such as with steering columns, brakes, airplane engines, and others. Adding to the challenge is the sheer volume of fasteners available today. An assembly can be held together in many ways, using a variety of types of bolts, rivets, screws, pins, and other fastening devices. Assembly methods fall into two broad categories: 1. Methods that use two components or two operational steps to stay in place 2. Methods where the components are self-retaining

A coiled pin flexes under a load to absorb shock and vibration.

The challenge for the majority of design engineers when selecting a method is cost and reliability. Ideally, the goal is to use the highest quality joint at the lowest manufacturing cost. 126

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Self-retaining pins For many applications, self-retaining pins provide the ideal solution and assembly method. However, choosing the correct pin for an application requires research. Technically, when a load is applied, something has to give: the pin, the hole, or an element of the assembly. A pin that’s too rigid typically causes the hole in which it is retained to elongate, eventually leading to assembly failure. However, a pin that’s too flexible will fatigue under dynamic loading. There are several types of pins, so choosing pins with the appropriate strength and flexibility for the application is critical. Solid and spring pins are two common types of self-retaining pins. Solid pins Solid pins come in many different forms, including dowel, knurled, and grooved pins. Generally, solid pins are strong and relatively inflexible. They’re unable to absorb shock and dynamic loads and, instead, transmit these forces to the mating components. Before choosing solid pins, it’s important to consider these

Coiled spring pins (left) and slotted spring pins (right). dynamic forces for an application. For example, there’s a common perception that solid pins are ideal for heavy-duty applications. This is typically false because of the pin’s inflexibility. Any force applied to a solid pin is transmitted directly to the hole wall (because it’s unable to flex and absorb the force). This causes the hole diameter to elongate (open up), resulting in reduced retention of the solid pin. Movement of the pin within the hole can also result from the elongation. In fact, an extremely small change in velocity can result in a large force on the pin (due to F = MV2). This could lead to a pin breaking because of the impact load. Additionally, depending on the severity of the elongation, the distance between the shear planes can widen to the point where the pin is no longer in shear but in bending, which decreases the strength of the pinned joint (and again, the pin may break).

A solid pin’s rigidity elongates the hole, which leads to premature failure of the pinned joint.

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www.fastenerengineering.com

Although using a softer solid pin material might reduce the host damage, it also reduces the pin’s strength. Alternatively, a heat-treated spring pin provides strength and its inherent flexibility can maximize assembly life in dynamic, heavy-duty applications. Spring pins There are two distinct types of spring pins: slotted and coiled spring pins. Both types share features, including flexibility and an ability to accommodate wider hole tolerances (particularly compared to solid pins). • Slotted pins offer flexibility during installation, which accommodates wider hole tolerance. In turn, this reduces manufacturing costs. However, compared to a coiled pin, slotted pins only flex at 180 degrees from the gap. This may lead to premature failure of a pin subject to dynamic loading. If the gap is closed after installation, the slotted pin essentially becomes a hollow inflexible tube. Then, the same issue occurs under dynamic loading (similar to solid pins), where the pin ends up transmitting the applied load onto the hole wall. This is a concern in applications with a soft host

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Interlocking does not allow for automatic feeding and installation of slotted pins.

material, such as aluminum or plastic. Additionally, it is extremely difficult to automatically feed and install slotted pins that do not have a controlled gap because they can interlock. The most appropriate applications for these types of pins are non-critical assemblies, manufactured out of mild to hardened steel, that are manually assembled. • Coiled pins were invented to address many of the disadvantages of using slotted pins. They offer design engineers greater strength and flexibility, including an ability to “customize” the pins balance

of strength and flexibility to the application. For example, light-duty pins are generally recommended for soft or brittle materials, medium (or standard) duty pins are typically used in mild steel and non-ferrous assemblies, and heavy-duty pins are ideal for use in hardened components. They’re also ideal when space limitations prevent the use of a larger diameter standard duty pin. Coiled pins are capable of absorbing shock and vibration after insertion, which means they provide a prolonged life in most assemblies. These components are also conducive for automatic feeding and installation. They can fasten multiple components together (such as to pin a gear and shaft) and be used as hinge, alignment, and stop pins. Typically, coiled pins are not recommended for use as cam followers (a type of roller designed to follow cam lobe profiles), or

where there’s a limited length of engagement for the pin. These applications are generally served best by a solid pin with retention features. As there are several ways to fasten assemblies, it’s important to take advantage of the application engineering services provided by fastener manufacturers. By partnering with industry experts, design engineers can be assured that their assembly will be equipped with a reliable and cost-effective solution for a safe, long-lasting application.

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

Under load, stress is concentrated at 180 degrees opposite of the gap in slotted pins.

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C o m p a n y

P r o f i l e

Why do bolts loosen?

Julie Pereyra • Sales Engineer • Nord-Lock Group

Depending on the application, bolt loosening can have profound consequences. One loose bolt can bring a whole production plant to a standstill and cost a company thousands. In other applications, loose bolts can pose a significant safety hazard. So, what are the bolt loosening reasons? Broadly speaking, there are two main causes: 1. Spontaneous loosening – shock, vibration, and dynamic load 2. Slackening – settlement, creep, and relaxation “The main causes and consequences of failure depend on the purpose of the bolted joints on the environment and usually on the industry,” says Georg Dinger, Siegenia-Aubi KG, who has extensively studied the causes and effects of self-loosening of bolts. “For example, the petrochemical industry is primarily concerned with corrosion problems, while fatigue and vibration loosening are usually of minor concern. On the other hand, the automotive industry would probably name self-loosening and corrosion as the sector’s two main problems. The primary concerns for the structural steel industry are joint slip and corrosion, but self-loosening and leakage are less typical. The aerospace industry would probably list fatigue first,” adds Dinger. Repeated relative displacements between the contact surfaces, which are under the influence of the shank torque and result from the thread pitch torque, can lead to a gradual rotation of the bolt or the nut. “This causes a bolt preload loss and, consequently, a loss of function in the bolt connection. The effect is well known, but prevention is usually performed experimentally only after the occurrence of self-loosening events,” he says.

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What is preload? Preload is a term with many meanings in engineering. For example, one is the tension (load) that’s created in a fastener when it’s

An ounce of prevention To prevent spontaneous bolt loosening, the slip between the joined parts needs to be eliminated or at least reduced to below critical levels. This can be achieved by increasing the axial tension or the friction between the clamped parts or decreasing the cyclic loading (for example, shock, vibration, or cyclic thermal loading). Another common method is to increase the friction between the bolt threads. Although there are several effective ways to do this, some have disadvantages to consider. For example, glue or adhesives can be an effective friction-based method but dried glue can be problematic when dissembling and removing a bolt. Furthermore, increasing the friction between threads would decrease the achievable preload at a specific torque level. Locking wire is a common method used in the aviation industry. Fatigue is permanent damage or deformation in the bolt and clamped parts. It’s caused by the loss of preload, resulting in an opening in the joint. Spontaneous Bolts are the fastener of choice in multiple industries and applications for the simple reason that they are easy to dismantle. However, this also makes them vulnerable to self-loosening and loss of preload.

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initially tightened. As the bolt stretches, the components between the bolt and the nut compress, thereby increasing the so-called clamp load until the end of the tightening process.

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Las V Company Profile

Washers are an often overlooked component in securing bolted joints. Certain types of washers use tension — rather than friction — to prevent unintended bolt loosening. loosening and slackening are the two basic mechanisms for the loss of preload. Essentially, spontaneous loosening or rotational self-loosening occurs when a bolt rotates loose because of shock, vibration, or dynamic loads. Even a slight rotation can be enough for a bolted joint to lose all of its preload. This is the most typical cause of bolt loosening. Slackening is caused by three mechanisms: • Settlement • Creep • Relaxation

“Settlement is critical when it happens due to dynamic loads. It is the permanent deformation of the clamped material when the joint is subjected to the increase of stress from dynamic working loads,” explains Harlen Seow, technical manager with the Nord-Lock Group. “Most parts of a bolted joint will revert to shape after being released if the stress in the parts have not gone beyond their yield strengths.” This means some materials in the contact surface, such as paint, will most likely deform permanently,” according to Seow.

Spontaneous loosening or rotational self-loosening occurs when a bolt rotates loose because of shock, vibration, or dynamic loads. 132

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Understanding why bolts loosen in certain applications is the first step to proper installation.

Creep is a permanent deformation that occurs because of the long-term exposure to high levels of stress below the yield strength of the materials in the joint. It’s more severe in hightemperature applications. Relaxation is when the microstructure in the materials of a joint restructure, converting existing elastic deformation to plastic deformation over time. Unlike settlement or creep, the clamp length does not change, which makes it more difficult to detect. “One way to measure preload loss is to measure bolt length after a period in operation and compare it to the bolt length immediately after tightening,” says Seow. “However, this will not detect relaxation, which makes it more problematic.” The key to avoiding fatigue is a good design, which has grown in importance in recent years because of the increased demands on many bolted joints and greater use of lightweight materials. It’s

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important to avoid solely focusing on the tensile capacity of bolts while overlooking other parameters — such as elasticity and stiffness, which can also be critical. “Correct joint design is the key to achieving a high-strength friction grip connection with a high preload level, and a high slip resistance over the entire lifetime,” says Dinger. “Up until now, the focus for design engineers has been on the failure with bolts breaking. Other failure mechanisms have become more and more important as performance is increased and the weight of the joints is decreased. The mechanisms of preload relaxation and self-loosening are more common in lightweight designs.” Depending on the bolt, the application, and the cause of preload loss, there are multiple options for designing more optimal bolted joints. “In cases where there’s thermal loading, the joint can be optimized by choosing materials with equal thermal expansion coefficient for the clamped parts,” says

www.fastenerengineering.com

Dinger. “To help minimize settlement and maintain a high preload during operation, you can reduce the roughness between contact surfaces. Measures such as fine hole diameters or toothed surfaces can help minimize relative displacement.” Overall, achieving the optimal bolted joint involves factoring in multiple variables and design options. “In general, a good bolted joint is made up of very elastic bolts and stiff clamp parts, and there are different ways of achieving this. One way of improving bolt elastically is to have a long clamp length. But if you have a flange, where the clamp length can’t be too long, you can change the design by using more but smaller bolts. So, instead of using five bolts, you can use 10 smaller bolts, which will create a more elastic joint,” says Seow.

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How ultrasonic metal welding technology bonds non-ferrous metals

Joe Stacy • National Sales Manager for Ultrasonic Metal Welding • Emerson Automation Solutions

For nearly 30 years, ultrasonic metal welding has offered manufacturers a uniquely reliable solution for joining a variety of soft, conductive non-ferrous metals ranging from copper, aluminum, and nickel, to lithium, brass, silver, and gold. The process is particularly useful for joining dissimilar combinations of materials in applications that use batteries, power-storage devices, wire harnesses and assemblies, electrical breakers and switches, consumer electronics and cell phones, and implantable medical devices. Unlike resistance and laser welding, ultrasonic metal welding bonds metals without melting them, so the process never creates intermetallic compounds or particulates, or causes corrosion. This low-energy, solid-state process bonds metals in several configurations — including thin foils or sheets to stranded wires and bus bars (up to 2 mm in thickness), producing connections with a high electrical conductance for maximum electrical efficiency. One of the technology’s most important applications involves transportation, where nearly all batteries used in electric vehicles rely on ultrasonic metal welding to join their smallest and most basic components. These include the thin nickel, copper, and alloy films used in anodes and the aluminum foils typically used in cathodes, as well as the anode and cathode tabs that bind their power-generating chemistries together. A variant of the process, ultrasonic metal splicing, ensures the integrity of wire harnesses and terminations essential to delivering electric power, sensor inputs, or control signals in a host of other applications, worldwide. 134

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Converting electrical energy into ultrasonic welding energy

Ultrasonic metal welding at work As seen in the Converting electrical energy into ultrasonic welding energy diagram, the power supply takes a standard electrical line voltage (typically 50 or 60 Hz) and converts it to the frequency required for metal welding (40 kHz for smaller or more delicate parts and 20 kHz for larger, thicker parts). The electrical energy is sent through an RF cable to the converter. The converter uses piezoelectric ceramics to convert the electrical energy to mechanical oscillations at the operating frequency of the power supply. These oscillations are either increased or decreased, depending on the configuration of the booster and horn. The proper degree of oscillation, known as amplitude, is typically determined by an applications engineer. Precise control of amplitude is essential for repeatable metal welding. The bonding is accomplished by using high-frequency vibration to the

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Ultrasonic metal splicing metallurgically bonds stranded non-ferrous wires using vibratory motion and pressure.

metals that are held under pressure, and applied by the actuator. The lower metal part is held stationary in a piece of tooling called an anvil, and the upper part is pressed against it while subject to the motion of an oscillating horn or “sonotrode.” The sonotrode extends horizontally from the power supply of the welder and is the source of the ultrasonic energy www.fastenerengineering.com

that creates the metal-to-metal bond. When the weld process begins, the upper part is oscillated by the horn, producing a shear force that “scrubs” surface oxidation and contaminants away and creates a smooth, metal-to-metal contact. As oscillation continues, the metal surfaces heat up, plasticize, and coApril 2020

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Fastening + Joining

Ultrasonic metal welding and splicing: The process benefits • • • • • • • •

Works with a wide range of non-ferrous materials Creates a permanent, metallurgical bond between dissimilar metals Requires no melting — there’s zero change to the chemistry or metallurgy of materials Joins highly conductive alloys — the reactivity of materials doesn’t matter Creates no intermetallic compounds, particulates, or corrosion-causing reactions Bonds thin, fragile metal films and structures Offers multiple methods of control, enabling process customization, repeatability, and SPC Provides a low-energy input (up to 30 times lower energy use than with fusion or resistance welding), and without consumables

•

Offers the lowest total cost per weld of any welding technology

mingle at their interface — and bond at the molecular level. The result is a continuous weld with a finely grained structure similar to the structure of cold-worked metals. The entire process is very rapid, with welds typically completed in a fraction of a second. Multiple methods for control In addition to its ability to bond non-ferrous metals without melting or damaging them, ultrasonic metal welding offers multiple methods of control, which can meet several production challenges. Ultrasonic welding can join 100 layers or more of thin copper or aluminum foils, simplifying the assembly of power-dense, multi-layer battery designs used in the newest electric vehicles.

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Among the most important of these control modes are:

• Weld energy control, which allows welding for a fixed length of time (time mode), to a particular finished weld height (height mode), or to a fixed level of energy input (energy mode). In energy mode, the ultrasonic metal welder automatically compensates, varying the duration of the weld to adapt to commonly occurring differences in the surface conditions (e.g. the degree of oxidation and contamination) of the metals being joined. www.fastenerengineering.com

• Weld amplitude control, which regulates the length of oscillation (amplitude) delivered to the weld zone of each joint, and uses the capabilities of the weld power supply, converter, and sonotrode and horn assembly. • Weld downforce control regulates the pressure applied to the joint being welded. Advances in automation for downforce control cut both ways, enabling the application of greater and lesser pressure to be applied with exceptional precision. One example is Branson GSX, an ultrasonic welder from Emerson that incorporates a new “featherlight” electromechanical actuation system, which measures downforce so precisely that it can repeatably initiate ultrasonic welding with a fraction of the downforce required by older equipment. Another new ultrasonic welding technique developed in Emerson’s Application Laboratory uses higher actuation pressure on stacked metal films so that a durable weld can be created more “gently,” using less total weld amplitude. DESIGN WORLD

4/13/20 4:16 PM

FOR

THE INDUSTRY, IN THE OF MANUFACTURING

After extensive internal and external consultation and monitoring of the COVID-19 pandemic, we have made the decision to postpone Fastener Fair USA to July 13-15, 2020 at the Charlotte Convention Center. Fastener Fair USA is the only exhibition in the U.S. dedicated to the full supply chain–distributors, mechanical and design engineers, purchasers, wholesalers, and End -Users/OEMS—spanning key vertical industries. The third annual Fastener Fair USA will be held in Charlotte, NC, putting the show in one of the biggest manufacturing hubs in North America. Visitors can expect a comprehensive display of industry innovation with highly relevant education and unmatched opportunities to connect with peers and industry experts.

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FASTENER FASTENER 138

Selecting the Optimal Washer Flat: Generally used for load disbursement Tab/Lock: Designed to effectively lock an assembly into place Finishing: Often found on consumer products Wave: For obtaining loads when the load is static or the working range is small Belleville: Delivers the highest load capacity of all the spring washers Fender: Distributes a load evenly across a large surface area Shim Stacks: Ideal for simple AND complex applications

Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377 (in the US & Canada)

bokers.com

Branson GMX-W1 Ultrasonic Wire Splicer from Emerson Blends Performance, Ergonomics The Branson GMX-W1 Ultrasonic Wire Splicer from Emerson delivers precise and repeatable splicing of non-ferrous wires for in-line or pig-tail configurations. The lightweight, compact design of the GMX-W1 splicer makes it ideal for use as a portable unit for wire harness in-line assembly boards. The user-friendly design of the GMX-W1 splicer features a 22” touchscreen HMI, whose touch-keyboard and drag-and-drop program editor make it simple to create, edit, and recall different production recipes for splices, sequences, and harnesses. The screen also accesses the unit’s multiple welding control modes and offers flexibility for configuring production- and quality- monitoring solutions. The actuator unit of the GMX-W1 splicer is also userfriendly with an illuminated weld area, and a patented vertical stacking feature in the welding head.

Emerson Automation Solutions www.Emerson.com/Branson

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www.fastenerengineering.com

DESIGN WORLD

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FASTENER FASTENER

HUNTING FOR THE RIGHT ADHESIVE FOR YOUR PROJECT? GLUESPEC HAS A KILLER SELECTION OF BONDING, JOINING & FASTENING MATERIALS Join the thousands of engineers already using Gluespec

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No More Loose Bolts with Nord-Lock Washers Nord-Lock created the original wedge-locking technology to secure bolted joints with tension instead of friction. The system is composed of a pair of lock washers with cams on one side and radial teeth on the other. Nord-Lock washers secure the fastener in a joint that cannot be loosened even when subjected to extreme vibration or dynamic loads. Our range includes steel construction washers, wheel nuts, combi bolt washers and custom solutions. Features: • Available for bolt sizes M3 - M130 • Available in 5 different materials - steel, stainless steel, 254 SMO®, INCONEL® / HASTELLOY® and C-276 INCONEL® 718 • Available with enlarged outer diameter (SP washers) • Reliable bolt securing system at high and low clamp loads

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Nord-Lock Group www.nord-lock.com 412-279-1149

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FASTENER

Pivot Point, Inc. The SLIC Pin™ from Pivot Point is a pin and cotter all-in-one. An excellent alternative to installing e-clips and secondary cotters, the patented SLIC Pin features a spring-loaded plunger which acts as an automatic cotter pin. SLIC installs faster and more consistently than two-piece combinations – increasing productivity, cutting labor costs, and reducing risk of mis-installation and accidental disengagement. Simply depress the plunger with your finger or a tool in order to remove the pin. Use our “removable” style plunger if removing through small gaps. SLIC Pins can be made in virtually any material and finish. Millions of SLIC Pins are installed every year across all industries. Contact Pivot Point for free samples and information.

Pivot Point, Inc. www.pivotpins.com PO Box 488 Hustisford, WI 53034 761 Industrial Lane Hustisford, WI 53034 800-222-2231

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DESIGN GUIDE LIBRARY Great content broken out by key technologies

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•• •• •

Selection

and customization of universal joints for optimized operation

Rita Nolan • Belden Universal

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In most cases, sourcing universal joints require some degree of customization. Joint selection is therefore most successful when all aspects of the application are discussed with the component manufacturer. Engineering and production teams can then specify the most appropriate product based on welldefined parameters. The OEM or end user should be involved at every design stage to ensure requirements are met. Consider operational and environmental factors: The nature of application — including operating speed, angle, torque and environmental conditions — must be properly assessed during the initial phase of joint selection. Certain types of universal joints are better suited for handling heavier loads … others excel on axes run at high speeds over longer periods of time. Applications with abrupt stops apply additional force to the component that also needs to be considered. The operating environment is another vital factor for joint selection. Dust or abrasives for example can lead to premature wear and component damage. If the joint is exposed to heat, chemicals or washdown fluids, corrosion and failure of the lubrication can lead to universal joint failure. In these instances, special materials and component protection are necessary. When to use single or double universal joints or drive shafts The main aspect for selecting the joint configuration is the type and extent of misalignment between the driving and driven shafts. Angular misalignment occurs when the driving and driven shafts are positioned at an angle to one another. Axial misalignment is the horizontal distance between the two shafts. Parallel misalignment is the parallel offset or movement between shafts. • Single joints can compensate for angular misalignments of up to 45° • In contrast, double joints and drive shafts can compensate for up to 90° angles — 45° per joint) or compensate for parallel misalignment. Drive shafts are essentially elongated double joints — suitable for compensating parallel and angular misalignments as well as overcoming greater axial misalignments. Typical drive shafts feature a telescoping expandable middle portion that also allows for easy replacement of the assembly. DESIGN WORLD

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Keeping universal joints fully lubricated can significantly prolong the component’s useful life. If prelubrication is not attainable, the joints can be fitted with lubricant-retaining boots that can prevent contaminants entering and damaging the bearing faces. Project requirements determine the type of lubricant or grease to be used. Specialty lubricants abound for medical, food, marine, and aerospace applications.

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Friction bearing versus low-friction bearing components The term friction bearing refers to the friction created between the moving components of the central connector during operation. The higher the friction, the more

Ball & Crossed Roller Linear Slides

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Drive shafts are essentially elongated double joints — suitable for compensating parallel and angular misalignments as well as overcoming high axial misalignments. stress and wear asserted onto the joint — in turn resulting in heat, premature wear, and loss of precision. Friction-bearing joints operate with significant friction between the pins and the block of the joint. They are suitable for many standard applications and can carry high loads at moderate bearing speeds. Lubrication can help reduce friction, heat generation, and wear — in the form of regular re-lubrication or oil-drips as well as grease-packed or oil-filled boot covers fitted to these joints to extend their expected life. Needle-bearing universal joints use roller bearings at the contact points between pins and yokes, which significantly lowers friction, heat, stress and wear on the moving components. As a result, needle-bearing joints can sustain higher operational speed and precision for extended periods of time. Needle-bearings can be packed with lubricants and sealed for the lifetime of the joint; a method requiring less space and lubrication than the addition of lubricant-retaining boots. For these qualities, needle-bearing joints are suitable

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Grace under pressure

877-2-KELLER kelleramerica.com

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This single universal joint from Belden Universal can compensate for angular misalignments up to 45˚. There are several important factors to consider when selecting the correct universal joints. Shown here is a double universal joint from Belden Universal.

for high-precision, high-speed applications, such as automation and robotics. Durability considerations include rpm, angle, and backlash The durability of a universal joint is largely determined by the transmitted torque, angle of operation, and the rotational speed (rpm) of the driven shaft. Any combination of high torque, angle, and rpm values will effectively increase stress on the joint. As the angle of operation increases, the U-joint pins oscillate in the bores in a greater magnitude — resulting in increased movement and wear between the bearing components. Excessive torque can cause the joint to break … and an excessive

This universal joint employs needle bearings to allow for use on highspeed axes.

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speed and angle at an acceptable torque may cause lubrication failure. That in turn leads to increased friction, heat generation, and wear. It is therefore crucial to identify typed of universal joint to avoid failures during operation. Technical data and calculations for specific torque and speed can also aid in the size and type selection of the universal joint. Information pertaining to the acceptable amount of torque and torsional backlash (also called play) for a given application should inform the design and manufacture of the universal joint employed on that axis. Materials and coatings Special applications often require carefully selected materials to deliver high strength, improved corrosion and wear-resistance or other desirable qualities. Alloy steel is typically the strongest and most widely used family of metals for universal joints. Alloy steel universal joints are capable of handling high-torque applications and can be further strengthened by hardening. 300-series stainless steel is commonly used in sterile, sanitary and corrosive environments. Specialty stainless steel may be necessary for extreme corrosion or

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This exploded view of a universal joint shows the pin-and-block assembly.

temperature resistance. Titanium, bronze, brass alloys, and nitrogen-strengthened materials can deliver additional improvements with regards to strength-toweight ratio, wear, or corrosion resistance. Product qualities can be further enhanced by applying special coatings, such as nickel, zinc, cadmium, MoS2, PTFE, black oxide and finishing methods such as anodizing, polishing and surface passivation. Mechanical quality, testing, and certifications Many customers’ quality requirements call for the highest standards in manufacturing — most commonly ISO9001 or AS9100 certifications. It is vital that the quality system is integrated into all aspects of the manufacturer’s operations, with materials and hardware sourced from suppliers complying with the same standards. For

new product development, the design concept can be further validated using backlash testing as well as dynamic and static life tests. DW Belden Universal beldenuniversal.com

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Linear actuators —

it’s electric

Manufacturers are making it easier to connect electric linear actuators to machines and systems, helping smooth the transition to the industrial IoT. Edited by Miles Budimir • Senior Editor

The job of motion, moving things big and small, falls to actuation devices. Tried and true methods such as hydraulic or pneumatic actuators or mechanical means like screws or belt drives still satisfy motion needs in many applications. Other devices such as electric actuators and linear motors have become viable as well. What’s more, with rapid advances in networking and communications, these actuators increasingly include functions that allow them to connect to and help implement IoT functionality. Manufacturers are creating IoT-ready electromechanical actuators with high force capability that can replace traditional hydraulic actuators in some applications. For example, Ewellix, formerly SKF Motion Technologies, has developed new actuators which deliver forces up to 82 kN and speeds of 1 m/sec, providing real-time, accurate information to improve machine productivity. What’s more, these newly designed actuators allow production lines to be upgraded without major modification of existing machine layouts. The new CASM-100 and LEMC actuators feature integrated force sensors within the body of the actuator to provide a 148

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precise measurement of the torque being delivered from the motor through the internal ball or roller screw, even when the actuator is stationary. The sensor also acts as a temperature-monitoring device that activates an alarm if the actuator is at risk of overheating. This configuration provides operational information in real-time, which can be communicated to higher-level control systems. As a result, it’s possible to improve overall performance and productivity, with greater safety. DESIGN WORLD

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Damien Ehry, Global Business Support Manager at Ewellix, talks about why this is an important development. “Both types of actuators are available in multiple combinations covering a wide range of applications which makes them particularly popular with manufacturers and design engineers. Increased accuracy, flexibility, high performance and reliability of these actuators all adds up to improved productivity and lower maintenance costs for our customers compared with traditional hydraulic systems.” “The built-in sensors improve on this further,” adds Ehry. “Accurate measurements can highlight how space and energy savings can be achieved through downsizing attachments. This leads to an overall cost reduction of the production line, while still delivering safer manufacturing processes.” A further advantage of having the Ewellix IoT-ready actuators with sensors is that when converting from a hydraulic system to an electro-mechanical one, it’s easier to specify the correct sized actuator for the job. By using a prototype to replace one of the actuators before installing across DESIGN WORLD

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the entire production line, manufacturers looking to switch to an electro-mechanical process can potentially benefit from even more cost, space and weight savings. Electric actuators can also simplify the setup of linear motion axes. Case in point; Festo now sells a Simplified Motion Series of electric drives that combines the simplicity of pneumatics with the benefits of electric automation. These new electric drives equipped with Digital I/O and IO-Link enable a range of operational and productivity benefits and deliver intelligent industrial IoT communication. The actuators in the series are built for simple motion between two mechanical end positions. The drives offer optimized motion characteristics, including gentle cushioning, while advancing and retracting into the end positions and pressing and clamping functionality. Units in the initial release include toothed belt axis, spindle and toothed belt axis, mini slide, electric cylinder, and rotary drive. The drives are plug-and-play for fast startup needing no additional software or specific know-how. The parameters for advancing and retracting speed, as www.designworldonline.com

Electric drives equipped with Digital I/O and IO-Link from Festo enable a range of operational and productivity benefits and deliver intelligent industrial IoT communication.

Manufacturers are creating IoT-ready electromechanical actuators with high force capability that can replace traditional hydraulic actuators in some applications.

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New CASM-100 and LEMC actuators from Ewellix feature integrated force sensors within the body of the actuator, simplifying IoT connectivity.

Electro-hydraulic linear actuators for mobile applications An electro-hydraulic actuator series from Thomson Industries has the

strength of hydraulic cylinders but without their complex external assemblies or extensive

ďŹ&#x201A;uid handling requirements. Thomson Warner Linear H-Track actuators move loads of up to 4,800 lb from a compact mounting envelope.

The actuators are ideal for space-constrained applications requiring high load handling and shock resistance, such as snowplow blade H-Track actuators from Thomson deliver up to 4,800 lb (21,350 N) of force with travel speeds to 4 in./sec.

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control, agricultural plows and sprayer booms, mower deck lifts, and UTV dump boxes.

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well as pressing and clamping force, are set directly on the drive. End position, cushioning path, and manual operation are also set on the drive. Each drive in the series is controlled via Digital I/O. End position feedback, which is similar to feedback from a standard proximity sensor, provides information about the completion of the motion task. IO-Link enables remote control, parameter copy, backup function, and read functions for process parameters. “For those machines and lab instrumentation where compressed air for pneumatics is simply not feasible, the Simplified Motion Series provides a cost effective, easy to apply, and well-featured electric solution,” said Sandro Quintero, Product Manager of Electric Automation at Festo. Simplifying sensor integration On the sensor side of things, companies are making it easier to integrate sensors with other components such as actuators and controllers. For instance, Balluff’s new absolute magnetic linear encoders with Siemens Drive-Cliq interface are designed to smoothly and seamlessly integrate into Siemens motion controller environments. Plug-and-play installation makes incorporating them into the drive system easy with the controller automatically detecting the sensor and its basic settings. Its automatic status monitoring continuously checks the measurement quality, detecting any mechanical position shift during operation. These two Siemens certified versions — BML085L and BML08MH —join a family of absolute magnetic encoders that deliver absolute accuracy of position when end-of-travel is required. They provide 1 µm position resolution and a stroke length of up to 48 m. They also feature system accuracy of +/- 12 µm and high read distance of 1.3 mm. The BML08MH version also features an input for a temperature sensor, so that data can also pass through to the controller. DW

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Balluff’s new absolute magnetic linear encoders with Siemens Drive-Cliq interface are designed to smoothly and seamlessly integrate with Siemens motion controllers.

Ewellix www.ewellix.com Festo www.festo.us Balluff www.balluff.com Thomson Linear www.thomsonlinear.com

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

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Mechanism using geometric design constraints Use the power of geometric constraints within parametric CAD software to turbocharge development of synthesizing mechanisms. Dr. Jody Muelaner, PhD CEng, MIMechE â&#x20AC;˘ Muelaner Engineering Ltd Many CAD programs provide tools for analyzing and refining mechanisms. However, these assume that you already have an initial design. Classic graphical methods of synthesizing mechanisms provide methods of determining link lengths and joint positions to produce a particular motion. These methods can be turbocharged using the power of geometric constraints within parametric CAD software. Taking this approach, it is also often possible to synthesise a mechanism to meet a particular design intent using a first-principles approach, without any knowledge of the traditional graphical methods. Whether adapting traditional graphical methods or taking a first principles approach, mechanism synthesis within CAD software uses the built-in geometric constraint solver. This is the tool at the heart of the sketching functionality within any parametric CAD program such as SolidWorks, CATIA or Inventor. When you draw a line, set it to be perpendicular, equal length and so forth, and then watch it snap into position, a geometric constraint

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Fig.1: In this example of a 4-bar linkage, the four links are conventionally labelled according to where the force is applied. Ground link refers to the fixed point in which stationary joints are fixed. Driver refers to that link that experiences and applied force so that it rotates about the ground link. It is also known as the input link or, for certain types of linkage, the crank. Output link is the link that rotates about a fixed point on the ground due to forces transferred through the other links. Coupler is the linkage that connects the moving ends of the driver and output links.

solver is performing the calculations to determine its position in the background. Fundamentally, this involves solving a set of simultaneous equations. Creative use of sketching tools can, therefore, provide a highly intuitive way of leveraging the powerful mathematical solvers to determine the precise link lengths joint positions required for a mechanism to move through some specified positions or orientations. The generic methodology used to synthesize any mechanism, using the geometric constrain solver, is the same regardless of whether it is applied to traditional graphical methods or a first principles approach. It involves the following steps:

1 Sketch a link in a number of positions or orientations describing the required motion 2 Sketch an approximate mechanism at each of these positions, with the unknown joint positions and link lengths unconstrained. 3 Set the grounded joints to be coincident for each position. 4 Set the link lengths to be equal for each position. 5 Allow the geometric constraint solver to determine link lengths and grounded joint positions which satisfy these constraints. 6 Constrain any remaining unconstrained degrees of freedom in the model to create an optimal mechanism.

Fig.2: Free movement is not always the aim of mechanism design. One example is a shelf that locks in its open position. When the shelf is lowered it reaches a toggle position so that it cannot be lifted back up again. When force is applied, in the shelfâ&#x20AC;&#x2122;s open position, the force is transferred through the coupler into the output link with a zero-transmission angle because the coupler and output link are in line with each other. April 2020 www.designworldonline.com 154

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Fundamental theory of mechanism design Most mechanism design involves rigid body kinematics, with the assumption that each link is a rigid body that cannot bend. In three-dimensional space, a rigid body has 6 degrees of freedom (DOF): translation in x, y, and z; and rotation about each one of these axes. However, most of the time mechanisms are designed in 2D, even apparently 3D mechanisms are often simply combination of these planar 2D mechanisms. In this case, the motion of each link is constrained to a single plane and has 3 DOF: translation in x and y; and rotation in the plane of motion. If a 4-bar planar linkage, which is made up of four rigid bodies, had no joints joining the links together it would have 12 DOF, but this would not be a mechanism, it would simply be a collection of parts. When links are connected together by joints a mechanism is formed. There are three types of kinematic joint possible for a 2D planar mechanism, these are a pin joint, a full sliding joint which acts like a piston, or a half slider which acts like a pin in the slot. A pin joint removes 2-DOF (both translations), full slider also removes 2-DOF (a translation and a rotation), and half slider removes 1-DOF (a translation). Because mechanism synthesis is not concerned with the motion of the whole mechanism through space, one link is considered to be grounded, and acts as a reference frame about which motion takes place, it therefore has no degrees

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of freedom. Gruebler’s equation gives the degrees of freedom for a mechanism: DOF=3(LΩ1)Ω2(JP+JFS )ΩJHS where L is the number of links (including ground), JP is the number of pin joints, JFS is the number of full sliding joints JHS is the number of half sliding joints. Most mechanisms require one degree of freedom, constraining motion to a single dimension moving backwards and forwards along a known path. If structure has exactly zero degrees of freedom then it is known as a truss, while structures with negative degrees of freedom can be seen to be statically indeterminate or preloaded. Gruebler’s equation can provide a useful check for complex mechanisms that it is not entirely reliable as Gruebler’s paradox can result in certain mechanisms having more degrees of freedom than the equation suggests. Types of mechanism synthesis Mechanism synthesis is often categorized according to its aims into: • Path generation moves a single point through a prescribed path. • Motion generation moves a line through a number of prescribed positions. • Function generation attempts to map an input function to an output function. This is something of a catchall for any problem which isn’t a simple path or motion generation. Transmission angles and toggles Transmission angles are a way of quantifying how freely a mechanism can move and whether it will lock, or ‘toggle’ into a particular position. The transmission angle gives the angle between two links, one of which is applying force to the other through a joint which connects them. If the force applied by the first link acts in the direction that the joined point on the second link is travelling, then all of the force is applied to moving the second leg. If the force acts perpendicular to the direction of possible motion then there will be no component of force to produce a motion and the mechanism will lock. Although this provides a first principles explanation, transmission angle is not defined quite like this.

In a 4-bar linkage the four links are conventionally labelled according to where the force is applied:

• Ground link: The fixed point of reference to which stationary joints are fixed. • Driver: The link to which force is applied, causing it to rotate about the ground link. Also known as the input link or, for certain types of linkage, the crank

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• Output link: The other link which rotates about a fixed point on the ground, due to forces transferred through the other links. • Coupler: The linkage which connects the moving ends of the driver and output links. In this case the transmission angle is defined as the acute angle between the coupler and the output link. A transmission angle of 90 degrees means that all of the force transferred by the coupler is applied as a moment to rotate the output link about the ground link. When the transmission angle is zero, all of the force is transferred directly through the grounded joint at the other end of the output link, there is no resulting moment to cause movement of the output link and the mechanism does not move. This is called a toggle position.

Fig. 3: Here is an example of synthesizing a mechanism using geometric constraint-based sketching. This compact mechanism can produce a motion path 100 mm long with a radius of approximately 10 m using a 4-bar linkage. The first step is to sketch the 4-bar linkage mechanism in three approximate positions, each constrained to a point on the motion path, which may conveniently be located in another reference sketch. For simplicity the midpoint of the floating link has been used as the coupler point in this example. Each of the three moving linkages is then constrained so that it is of equal length in each position.

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If free movement is required, small transmission angles should be avoided. The minimum value for a particular mechanism will depend on the force being applied, frictional forces and accelerations. Generally, transmission angles below 30 degrees should be avoided. Free movement is not always the aim of mechanism design. Often, mechanisms are deliberately designed to lock, or toggle, in a particular position. For example, a shelf which locks in its open position, such as the tailgate of a truck. When the shelf is lowered it reaches a toggle position so that it cannot be lifted back up again, as shown below. When force is applied to the tailgate, in its open position, the force is transferred through the coupler into the output link with a zero-transmission angle because the coupler and output link are in line with each other. The tailgate will be closed if a force is applied to one of the aligned links. If the force is applied to the upper link, as shown below, the coupler acts with a transmission angle of 45 degrees, allowing the tailgate to close. When using geometric constraint-based sketching within CAD software, constraints can be added to limit or define transmission angles at specified positions. CAD based mechanism design The process of synthesizing a mechanism using geometric constraint based sketching is best understood with a simple example. Consider the design of a compact mechanism to produce a motion path 100 mm long with a radius of approximately 10 m. This can be achieved using a 4-bar linkage. The first step is to sketch the 4-bar linkage mechanism in three approximate positions, each constrained to a point on the motion path, which may conveniently be located in another reference sketch. The point on the ‘floating link’ which actually follows the motion path is known as the ‘coupler point.’ For simplicity the midpoint of the floating link has been used as the coupler point in this example. For more complex motions the coupler point may be easily offset from the axis of the floating link by creating a triangle instead of a single line to represent the floating link. If you do this just make sure to use make each side of the triangle the same length in each position. Each of the three moving linkages is then constrained so that it is of equal length in each position. By simply adding equal to constraints, the CAD software has automatically generated a mechanism that will pass through the defined positions. The sketch is not fully constrained at this stage. Different link lengths or joint positions could be used to satisfy the constraints. It therefore makes sense to add additional dimensions to constrain the mechanism in a way that fits the design intent. Since the aim was for a compact mechanism, the link lengths are important. It is also intended to produce a motion and so small transmission angles should be avoided. The fully defined mechanism synthesis sketch is shown below.

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Fig. 4: By simply adding equal constraints, the CAD software has automatically generated a mechanism that will pass through the defined positions. The sketch is not fully constrained at this stage. Different link lengths or joint positions could be used to satisfy the constraints. It therefore makes sense to add additional dimensions to constrain the mechanism in a way that fits the design intent.

It is important to validate the mechanism. In a separate sketch the mechanism is sketched again, using the same ground joint positions and link lengths but without constraining it to any point on the motion path. This can then be dragged through the range of motion to validate that it functions as intended.

This is only a simple example but with some thought, the method can be applied to solve complex mechanism synthesis problems involving both planar and 3D mechanisms. DW

Fig. 5: To validate the mechanism, sketch the mechanism again, using the same ground joint positions and link lengths but without constraining it to any point on the motion path. This can then be dragged through the range of motion to validate that it functions as intended.

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Next steps in fluid power connections

Reduced effort, high value for automating hydraulic systems

Theobald Herrmann | Product Management / Hydraulic Valves | Bosch Rexroth AG

The introduction of fieldbus technology in the 1980s was the starting point for horizontal connection of decentralized actuators within machinery. Serial wiring led to a considerable reduction in cabling and opened new possibilities for modularization in mechanical engineering. Fieldbuses — as well as most current real-time Ethernet protocols — are manufacturerspecific, proprietary systems. The protocols have been developed by control system manufacturers and focus on communication between own electric control systems and selected peripherals.

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For actuators, sensors and other third-party equipment, either their manufacturers or system integrators are required to provide suitable interfaces in hardware and software for the respective fieldbus. This is very complex as device profiles and software have to be created in the respective PLC for every individual fieldbus and control system of each manufacturer. Possibilities for hydraulic connection Integration of hydraulics in modern automation systems can be realized in different ways. Numerous existing machine concepts apply on-board electronics for control of hydraulic valves. Exchange of digital information is restricted and only possible if the respective device is connected to a superior

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control system via individual wiring. But increasingly, this state-of-the-art in technology no longer meets the requirements of end users. The alternative is using valves with integrated fieldbus connection. These, however, require extensive wiring — as well as integration into the control system and the respective fieldbus protocol by means of dedicated software. Both require considerable effort that is too high, particularly for price-sensitive applications. Thanks to IO-Link, machine manufacturer and system integrators are enabled to integrate for example proportional hydraulic series valves and sensors into digital communication structures with very little engineering effort. With its simple communication structure, IO-Link has low hardware requirements.

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Additionally, the standardized M12 connection technology enables simple and cost-efficient connection of hydraulic valves in the field. This way, components with analog control are transformed into communicating and flexible actuators and sensors. A look at IO-Link The manufacturer-independent IOLink — according to the IEC 61131-9 — standardizes connection technology for actuators, sensors and other equipment. It also provides a digital communication protocol for data exchange between control systems and devices, regardless of the fieldbus. Fieldbus technology is not replaced but extended. Parallel communication enables machine manufacturers’ use of IO-Link with all

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protocols and integration of IO-Linkcompatible devices into various concepts without additional effort. IO-Link is currently already supported by roughly 130 device manufacturers and other companies in the field of technology. IO-Link Masters are offered by about 40 manufacturers and the standard is supported by nine manufacturers of control systems. IO-Link devices are in the product range of almost 60 manufacturers of sensors, actuators and other peripherals. Rexroth, for example, now also offers hydraulic proportional valves and pressure sensors with respective technology. Function and performance of these proportional valves are identical to series valves. However, they also offer all options for bi-directional communication via IO-Link. This way, the hydraulics can be

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Serial wiring led to a considerable reduction in cabling and opened new possibilities for modularization in mechanical engineering. be integrated seamlessly into connected structures. What’s more, parameters can be changed and operating states changed by the control system during running operation. IO-Link system set-up A full IO-Link system consists of one centralized or decentralized IO-LINK Master, one or more IO-Link devices as well as unshielded 3 or 5-conductor standard cables with M12 connectors. Project planning and parameterization of the IO-Link Master can be realized in the control system hardware or an optional engineering tool. The point-to-point connections between IO devices and the automation system are established by the IO-Link Master. It serves as the interface to the superior control system. IO-Link Masters are offered by approximately 50 manufacturers for connection of one IO device per port. The selection includes options for the IP20 control cabinet as well as decentralized modules with protection class IP65/67 for installation at machinery or systems. Particularly in large-scale systems, the amount of cabling is considerably reduced. For decentralized IO-Link Masters, the user organization of IO-Link has defined M12 plug-in connectors with three or five conductors. The 5-pole version “Class B” port is used for devices with increased current consumption like hydraulic valves.

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Figure 1. IO-Link integrates hydraulic valves and sensors with analog control in any type of automation structures and establishes bi-directional digital communication.

by interchangeable options with IO-Link connection for direct communication with actuators and sensors.

The 3-pole version “Class A” port provides an energy supply of up to 200 mA, which is sufficient for most sensors. In contrast to analog controls, unshielded cables are sufficient for fault-free communication over a cable length of up to 20 meters. IO-Link standardizes connection technology for all actuators and sensors and eliminates numerous sources of errors during the installation of systems. Otherwise complicated and expensive cable dimensioning with individual wiring and shielding is no longer required. In addition, the logistic effort is reduced thanks to application of uniform M12 cables for sensors and actuators. Rapid commissioning per software Every IO-Link device features an electronic device description, referred to as IO Device Description (IODD). It provides standardized important information: • device data • text description • identification, process and diagnosis data • communication properties • device parameters with value range and default value. • image of the device, and • logo of the manufacturer

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automatic recognition of the device by the IO-Link Master for immediate parameterization. Another automatic feature is that device descriptions are included in the system documentation. For project integration of the IO-Link Master in overall automation, commissioning personnel use the engineering tools of the respective PLC manufacturer. The IO-Link Master is selected from the device portfolio and added to overall automation. Depending on the control system manufacturer, all blocks for communication are available in a library for free. Via IO-Link to Industry 4.0 IO-Link enables access to device data either directly from the control system or remotely via networks from any location. Particularly important for future-oriented concepts: Already today, IO-Link offers type and instance data of Industry 4.0 devices according to the definition of the German “Plattform Industrie 4.0” initiative. In this way, hydraulic actuators meet all conditions for future requirements of Industry 4.0 applications. Additionally, this approach is well-suited for subsequent connection of existing machinery and systems with low effort. Users replace installed proportional valves and sensors www.designworldonline.com

Diagnosis functions for increased availability The diagnosis functions of IO-Link devices enable new maintenance concepts and considerably reduce repair times. Now, possible call-up of device information in parallel to the process forms the basis for condition-oriented and predictive maintenance concepts. In this respect, proportional valves report whether they are functional as well as errors such as under- or over-voltage and electronic temperatures exceeding a set admissible value. In addition, the valve and sensor status are displayed for transparent error analysis. An integrated operating hour indicator enables calculation of the residual life cycle for maintenance and decision-making on further use of the valve. In case of faults, IO-Link accelerates diagnosis, thanks to remote access for maintenance specialists to identify the type and location of any errors. Precise localization without personal presence at the system alone considerably reduces reaction times. If necessary, the maintenance technician opens the IODD file of the respective device in the control system. Now, components do not need to be disassembled to decipher hardly readable labels and manufacturers and types no longer need to be looked for in system documentations. Thanks to the electronic name plate, all this information can now be accessed with just one mouse click to initiate the respective order without delay. IO-Link follows the plug-and-play principle. Replaced devices are recognized by the IO-Link Master according to their IODD file and the respective parameters are automatically transferred without any April 2020

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Figure 2. Ready for the future: IO-Link provides defined type and instance data and turns series valves into Industry 4.0 components.

actions in the software. This way, even less experienced technicians are enabled to replace components without problems to considerably reduce system downtimes. Concluding thoughts The open IO-Link standard establishes continuous communication with sensors and actuators irrespective of the used fieldbus. Now, even hydraulic proportional valves can be intelligently, easily and costeffectively, integrated in bi-directional digital communication. This simplifies commissioning in hardware and software and enables flexible adjustment of hydraulic valves for varying production processes. Increased requirements for flexible machinery and systems are now in compliance. Extended diagnosis information enables condition-oriented and predictive maintenance concepts and standstill and maintenance times are reduced. This increases the availability of machinery. In addition, IO-Link enables future-proof integration of hydraulic valves into connected structures as Industry 4.0 components with all their related features. DW

Bosch Rexroth www.boschrexroth.com

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Edge automation improves productivity

Shortages of skilled labor can be addressed by investments in automation at the edge.

Fig. 4 - Edge controllers allow OEMs to provide capability as a service by providing extensive remote connectivity and visibility.

| All images - figures courtesy of Emerson

Vibhoosh Gupta • Emerson Worldwide unemployment has been at a 50-year low in many countries across the globe, and many machine builder original equipment manufacturers (OEMs) and their customers are finding it difficult to attract and retain skilled labor. For example, Emerson surveys show 48% of their customers have a talent gap for the important task of gathering, consolidating, and acting upon the disparate data produced by automation systems. A dramatic increase in labor productivity is required to address this and other issues, driving automation investment trends and initiatives across the globe. 164

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Fig. 1 - Automation system architectures are evolving to incorporate smart devices in parallel with traditional real-time control systems.

These initiatives are often labeled as the industrial internet of things (IIoT) in the Americas and Industrie 4.0 in Europe, with both characterized by integration of more intelligent online devices, beyond those needed for basic real-time control. Emerson surveys show an awareness of this need, with more than 70% of industrial companies judging it critical to have an IIoT strategy in place by 2021. The goal is to reduce risk while increasing efficiency through digitization, with edge computing often used for decentralized data analysis. Even countries thought to have vast

supplies of labor, such as China, are experiencing shortages of skilled labor, driving investment initiatives to automate and digitize manual operations. These investments will add to the already large and constantly growing store of data, with surveys showing only five percent of industrial automation data is currently used to improve operations. Here’s a look at how edge control can be used to improve automation system architectures and productivity in industrial plants and facilities, often through better use of data.

Fig. 2 - An edge device supports many different industrial automation protocols, and it can also analyze data locally.

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Edge gateways, devices, and controllers Figure 1 depicts a modern automation system architecture. The bottom left of the diagram shows a traditional control system with sensor, actuator, and other field device data supplied to a real-time control system. This type of system can provide data to an edge component, enabling analytical insights. The bottom right of the diagram shows how other sensors, actuators, and field devices—usually of the smart variety—can supply data directly to an edge component, bypassing the real-time control system, with the edge component using this information to provide analytical insights. Smart devices are connected to edge components through digital data links, allowing these devices to supply extended information in addition to the process variable, such as status and diagnostics. Edge components can be one of three types, described here in order of increasing cost and functionality. An edge gateway simply collects data from field devices and real-time controllers, such as programmable logic controllers (PLCs), and forwards it to other systems for analysis. Although it only performs data collection and forwarding, these tasks require the capability to connect to many different types of field devices, controllers, and systems through a range of industrial digital protocols. An edge device (Figure 2) provides all of the functionality of an edge gateway and adds processing and configurability capabilities, making it possible to collect and analyze data locally. An edge controller (Figure 3) provides all of the general-purpose computing functionality of an edge device, and it adds a real-time controller to execute deterministic control and logic operations. The embedded edge device can be used to optimize real-time control based on edge analytics and secure, real-time, access to outside information. Connectivity to a range of field devices is provided through an edge controller’s

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Fig. 3 - An edge controller provides real-time control, along with analytics and optimization.

support of industry standard fieldbus protocols. Multiple Ethernet and USB ports are independently assigned to either the real-time controller section or the edge device section, providing physically separate and secure communications. Communication between the two sections of the edge controller are through OPC UA to maintain cybersecurity by separating real-time control from other functions. Separation extends to the operating systems, making it possible to reboot the Linux platform without affecting real-time control. Resolving issues faster by improving collaboration When a machine provided by an OEM to an end user experiences problems, finger pointing often results due to poor availability of operating information. For example, the OEM often believes the end user is operating the machine improperly, while the end user thinks the machine is not performing per specifications. For one packaging machine OEM, the solution was adding new field devices to their machines in the form of pressure, flow, and vacuum sensors; fan motor

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vibration sensors; differential pressure filter sensors; and position sensors. Each of these sensors was connected to the edge controller. Data from these sensors was not used to directly affect machine control, but it was instrumental for improving the local operator interface for the end user’s operators and providing data to the OEM’s cloud, from where it could be securely accessed by the OEM. The OEM and end user both have near real-time access to the same data, enabling collaborative problem solving. This improved visibility into the machine’s operation allows the OEM to deliver early diagnosis of problems before they escalate, reducing downtime and maintenance expenses. The end user can use this additional data to initiate procedural and tuning changes to machine operation, increasing throughput and improving quality. Providing capability as a service Many OEMs offer support for the machines they sell for a predefined period of time. While this arrangement works well in many cases, in other instances end users may prefer a higher level of service, along www.designworldonline.com

with lower upfront capital expenditures. To address these and similar situations, some OEM machine builders provide capability as a service to end users, with payments contingent upon machine availability or uptime (Figure 4). The OEM thus assumes a very high degree of responsibility for machine operation, requiring a corresponding high degree of visibility into machine operations. Edge controllers are a good fit for OEMs providing machines as a service because they combine reliable real-time control along with analytics at the edge and other functions. Virtually every aspect of machine operation can be monitored remotely, with the capability to make changes and adjustments as required to maintain uptime. Upgrades to improve performance can be performed remotely, saving time and travel cost. Edge controllers enable new renewable energy solutions Hydropower operations use turbine machinery for producing renewable energy from flowing water. Global demand for energy is expected to increase 50% between 2018 and 2050, and much of this DESIGN WORLD

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Fig. 5 - Hydropower microgenerators are typically installed in manmade water flows, such as irrigation ditches.

demand will be met by renewables as they are expected to become the leading source of energy by 2050. Unlike wind and solar, the cost to install additional renewable hydropower production capacity has not been falling recently. This is largely due to two factors. First, most of the best sites for developing traditional large-scale hydropower stations already have been developed, so increased capital investments are required to develop less-desirable generation sites Second, increasing concerns about environmental impacts of proposed new sites are driving up costs as more exotic mitigation schemes must be employed. To remain competitive with wind and solar power, an emerging trend in hydropower is the installation of microgenerators with outputs as low as 10 kW, as opposed to the hundreds of kW produced by traditional hydropower installations. Hundreds of microgenerators can add up to significant amounts of power, equal to a large hydropower installation. Importantly, these microgenerators are typically installed in existing canals, irrigation ditches, and other manmade water flows, drastically reducing environmental impact concerns (Figure 5). Because their power output is so low, hundreds or even thousands of sites must

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be developed, and then operated and maintained remotely to provide power economically. Edge controllers enable these types of applications as they can provide the required real-time control along with analytics at the edge and secure remote connectivity, all in one compact package. Analytics at the edge makes it possible to derive the insights necessary for moving maintenance from reactive to predictive. This dramatically increases labor productivity, enabling a single technician to efficiently maintain scores of sites, and keeping costs low. An edge controller can capture sequence of events and other data from many microgenerators, and then send this information to the cloud for further analysis. Results across a fleet can be used to not only detect developing problems, but to also improve performance by increasing power output for a given level of water flow. Shortages of skilled labor can be remedied in part by increases in productivity, which can be achieved by intelligent investments in automation. Edge components can be deployed in one of two ways to meet this need. For new installations, as in the hydropower microgenerator example, an edge controller can provide real-time control, analytics and optimization, and secure remote connectivity—all in one compact www.designworldonline.com

system. This is a much more efficient approach than using multiple components for control and other functions because these traditional approaches require integration between components, additional cabinet space, and added expense. For existing installations—as in the machine builder example—an edge gateway, device, or controller can be installed alongside a real-time controller. This edge component can collect data from new field devices and from the existing real-time controller, and then securely communicate this data to other platforms, often cloud-based, for remote monitoring and analysis. If the edge component is an edge device or an edge controller, then analytics, optimization, and other functions can be performed right at the edge, with results transmitted to end users via existing local networks or the cloud. In either case, labor productivity improves, allowing OEM machine builders and their customers to make better use of personnel while improving operations. DW Emerson | emerson.com

About the Author Vibhoosh Gupta is a portfolio leader for Emerson’s machine automation solutions business unit and manages its portfolio of automation system, operator interface, industrial PC, and Industrial IoT software and hardware products for industrial automation.

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

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When to use

pillow block bearings and why

Edited by Mike Santora

Design engineers specify pillow blocks when bearings need to be supported outside of a machine enclosure. Typical applications include conveyors, overhanging fans and blowers, or long line shafts. Here, we take a closer look at when to choose pillow block bearings and other key details. The use of pillow block bearings is spread across many different industry applications. This component’s abundant presence is due to ease of installation, a full and expanding range of configurations, a varying level of unitized assemblies, and a relatively low-cost design when compared to bearing system designs using integrated housings. Typically, pillow block bearings are insert bearings consisting of a one-piece housing encasing a sealed deep groove ball bearing.

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Selecting pillow block bearings is an easy decision for applications that allow for the bearings to be located in exterior locations away from the equipment working action, such as ball mills, chippers, conveyors, or general shaft support applications, while allowing easy access for temperature sensors, lubrication, and replacement or repair. If a bearing position is required to support an application that does not allow easy access or one that may become trapped between several pieces of equipment, such as a gear drive and a drive pulley in a conveyor system, there are options for housings using split bearings and seals to allow installation without fully disassembling the equipment. There

There are pillow blocks with various bearing types, including single-row ball bearings, multiple-row ball bearings, tapered roller bearings, spherical roller bearings, cylindrical roller bearings, self-aligning bearing assemblies, bushings or even custom units incorporating both radial and thrust bearing assemblies to support varying load conditions.

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are pillow block bearings for various lubrication options, including grease, oil bath, or even oil circulation. There are pillow blocks with numerous bearing types, including single-row ball bearings, multiple-row ball bearings, tapered roller bearings, spherical roller bearings, cylindrical roller bearings, self-aligning bearing assemblies, bushings, or even custom units incorporating both radial and thrust bearing assemblies to support varying load conditions. There are also pillow blocks with cast iron housings, cast steel housings, stainless steel housings, polymer housings, and even custom housings machined from billet or produced from plate and weldment processes.

option for review for any application requiring a packaged unit incorporating a bearing, locking mechanism, seals, and lubrication options.

There are pillow blocks with single seals, although many offer several options for secondary sealing. There are pillow blocks with locking mechanisms to support roughly finished shafts, while there are some with locking mechanisms that require precisely finished shaft geometry. There are metric pillow blocks, imperial pillow blocks, and in some cases, a combination of both dimensional series is required. There are countless applications where a pillow block is the most cost-effective, robust, all-in-one bearing system that provides myriad configuration options to fit a given set of parameters. This makes a pillow block bearing the number one

as demanding on the bearing. Consequently, pillow block bearings are seen in light load, low-speed applications. This is not to say pillow block bearing applications don’t encounter difficult conditions — harsh environments can present significant challenges to these housed units. For example, rust and corrosion can be costly in food and beverage plants, with problems ranging from frequent bearing replacements to the threat of a contamination event. At a minimum, corroded bearings are unsightly and a continuous source of concern. Some housed units, like Timken’s Corrosion-Resistant Poly-Round Housed Units have been designed to withstand wet, humid environments, and areas of

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Pillow block application conditions Pillow block bearing units are often sealed and pre-greased at the factory. Sealing and lubrication for the bearing units are application-specific. Some are designed to be maintenance-free, depending on the application operating conditions. With their sphered outer ring interface, they can handle some initial misalignment, but do not allow for axial displacement. Overall, most pillow block bearing units are designed for less complex applications —motion systems that are not

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Corrosion-resistant housed units can provide superior performance in harsh environments compared to standard mounted bearings. | Timken

a food plant where washdown and sanitation are especially aggressive. Mounted bearings like these are constructed from highly corrosion-resistant materials, use engineered polymer inserts, and do not require relubrication, making them a good fit for HACCP positions associated with rust and grease leakage. Bearings like these can help reduce maintenance time while meeting increasingly stringent regulatory requirements. It should also be noted that many of these types of applications also need self-aligning bearing solutions. It’s common for some form of self-aligning (either stationary or rotating) capability included in housed bearing units. Self-aligning bearings are used when bearings are likely to need to account for misalignment between the shaft and housing. A common scenario is when we expect the housing centerline to be at a slightly different centerline compared with the shaft. Split pillow blocks Split pillow blocks are versatile mounted assemblies designed for specific applications. Split pillow blocks accommodate a range of shaft sizes and higher loads. They are usually manufactured with heavy cast-iron housings and have higher flexibility and more sealing and lubrication options.

SAW • Accommodates a higher capacity SDAF • Used in applications that involve heavy or shock loads. • Used in steel mills, mineral processing plants, and other environments.

Soft pillow blocks also help meet unusual clearance or tolerance requirements; machine-based ends have a flat surface for jacking screws. This bearing is commonly found in rolling mills, pulp and paper mills, conveyors, and many other applications. DW Timken | timken.com

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

Split pillow blocks basics: • Are also made cast-steel or ductile iron • Horizontally split housing • Three styles of split pillow block bearings SAF • SAF features a combination of five bearing types, four sealing options, and two mounting methods.

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Product World Industrial microdrive Yaskawa America yaskawa.com/GA500 The GA500 Industrial Microdrive provides high reliability with its design delivering a minimum of 10 years of continuous operation. It meets RoHS2, providing a sustainable and environmentally friendly drive. Its TUV safety rating allows users to meet the most stringent safety ratings for their machine and provides a long mission time for the life of their equipment. The GA500 also provides users a wide range of flexibility. The drive is rated up to 40 HP and can be applied to 240 VAC singlephase, 240 VAC three-phase, or 480 VAC three-phase incoming power. For users that use DC as their power source, the drive is [UL] rated to accept DC as its primary power source. The GA500 can operate a variety of motors, which include induction, permanent magnet (SPM and IPM), and synchronous reluctance (SynRM).

Single-phase motor starter CARLO GAVAZZI GavazziOnline.com The HDMS Series is a single-phase motor soft-starter. It's a suitable solution for systems used in areas with weak power grids. Its unique design and control algorithm eliminates the need for a traditional start capacitor, effectively increasing reliability. This same control strategy allows the HDMS to easily start Capacitor Start / Capacitor Run (CSCR) motors, and in the case of Permanent Split Capacitor (PSC) motors, virtually eliminate the starting current. This product offers as much as 70% current reduction when compared to Direct On-Line (DOL) starters, which makes the HDMS a good choice for applications such as heat pumps, submersible pumps, or other scroll compressor loads connected to generators or electrical inverters. Features include Near Field Communication (NFC), Modbus communication, and ease of use as the HDMS does not require any user settings or adjustments.

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

Low-pulsation liquid diaphragm pump KNF KNFusa.com The FP 150 further expands KNF’s line of low pulsation liquid diaphragm pumps. This line of products combines the pulsation level previously only achieved by gear pumps with advantages of diaphragm pump technology — self- priming, safe to run dry, and long service life. Pulsation at the nominal flow rate for the new, smaller, FP 150 is less than 150 mbar directly at the pump outlet. Peak-to-peak pulsation levels far below this are achievable, depending on system materials, configuration, running speed, and other damping methods. The pump delivers up to 1.5 L/min of liquid at back pressure up to 29 psig (2 barg), with complete linear control of flow between ~10% and 100% of the nominal flow rate (0.2 – 1.5 L/min). Pump flow is fully stable with fluid viscosities ranging between 1 and 150 cSt. The pump can also handle viscosities up to 500 cSt with some flow rate reduction.

Motor control relays and intrinsically safe relays AutomationDirect automationdirect.com/relays ProSense motor control relays perform specific protective functions for motors or motor components to ensure proper and more efficient operation. Intrinsically safe relays provide safe control of loads within hazardous locations. Phase monitor relays protect against premature equipment failure caused by faults on 3-phase systems. Phase monitor relays provide protection against phase loss, phase reversal, phase unbalance, undervoltage, and overvoltage. These 10A-rated relays, with LED indicator(s), are compatible with Wye or Delta systems and are available in a range of voltage inputs. Alternating relays are used in special applications where the optimization of load usage is required by equalizing the run time of two loads. These 120 VAC 10A-rated relays are available in SPDT or DPDT configurations; an onboard switch selects alternating or single-load operation.

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Ad Index ABB Motors & Mechanical ................ 9 Aggressive Hydraulics .................. 167 Allied Electronics ................ Cover, 2,3 AllMotion ................................................. 4 Altech Corporation ....................... 16,17 Automation24, Inc. .............................. 11 AutomationDirect ...............IFC, Insert Bansbach Easylift .............................33 Bird Precision ......................................34 Bison Gear and Engineering .........30 Bodine Electric Company ...............26 Canfield Connector ......................... 162 Carlyle Johnson .................................20 CGI Inc. .................................................. 27 Chieftek Precision ............................... 6 Clippard ................................................ BC Del-tron ............................................... 144 Diamond Wire Spring Company ...34 Digi-Key .................................................. 13 Dura-Bar ................................................ 51 Eagle Stainless Tube .......................45 ebm-papst Inc. ..................................... 5 Elesa USA .............................................19 Fabco-Air, Inc. ...................................... 31 Fairlane Products ..............................29

SALES

FAULHABER MICROMO ................. IBC Fotofab ........................................... Insert IKO International, Inc. .......................35 Interpower .............................................14 Keller America ................................... 145 Keystone Electronics Corp. ........7,171 MW Industries - Servometer .........52 NB Corporation ..................................25 OKW .......................................................157 Pave Technology ...............................39 PBC Linear ..........................................42 PHOENIX CONTACT USA, INC. .....48 Questex .............................................. 165 R+W America .......................................50 Robotics Summit Expo ................... 86 ROLEC .................................................... 15 Rotor Clip ............................................ 155 Smalley Steel Ring ............................47 Sorbothane ..........................................41 The Lee Company ........................... 163 Tormach .............................................. 160 Trim-Lok ................................................. 21 Ultra Motion ........................................147 Whittet-Higgins .................................. 37 Zero-Max, Inc. .........................................1

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Publisher Mike Emich

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Bearing Tips Supplement

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Quality Bearings & Components ................56

Aerospace & Defense Tips Supplement Aurora Bearing Company ............. 66 Bunting Magnetics .......................... 66 Cadence .............................................. 69 CS Hyde Company ............................67 J.W. Winco, Inc. ................................... 72 LEMO USA .......................................... 68 maxon ....................................................63 MW Industries - Atlantic Spring ... 75

New England Wire Technologies & New England Tubing Technologies .................................. 77 Renishaw ..............................................70 Stock Drive Products/Sterling Instrument ........................................... 72 The Lee Company ............................. 73

The Robot Report AMETEK Haydon Kerk Pittman ................. 101 Brother Gearmotors ......................... 99 CGI Inc. .................................................. 103 Digi-Key .................................................. 97

Follow the whole team on twitter @DesignWorld Harmonic Drive ................................... 91 igus ......................................................... 109 maxon ..................................................... 105 New England Wire Technologies & New England Tubing Technologies ................................. 111

Fastener Engineering Supplement Boker's Inc. ..........................125 Emerson ..............................120 Gluespec.com ....................121 Nord-Lock, Inc. ...................127 Pivot Point Inc. ..................124 Fastener Fair ......................137 Spirol .....................................132

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Drive Systems, evolved A complete FAULHABER Drive System is more than the sum of its components. Experience FAULHABERâ&#x20AC;&#x2122;s principle of perfectly optimized parameters and interfaces for improved performance. More at: faulhaber.com/evolved/en

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