DESIGN WORLD AUGUST 2016 by WTWH Media LLC

www.designworldonline.com August 2016

INSIDE: MOTION CONTROL: Minimizing stepper vibration with affordable technology PAGE 58

LINEAR MOTION: Encoders help linear motion stages reach higher levels of accuracy and performance PAGE 64

CONTROLLERS: Select the right machine controller for your application PAGE 72

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Pulley bushings upgrade

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I n s i g ht s What can you do with your creativity? Engineers often get a bad rap as geeks who’d rather sit in front of a computer than interacting with others in a social setting. But we have a lot of creativity that is not always fully used in the workplace. When we find other outlets for our inventiveness, the rewards can be really rewarding. Jennifer and Ivan Owen are inspirations to me. I heard Jennifer speak about her and her husband’s work at NatureWorks’ Innovation Takes Root Conference in Orlando (innovationtakesroot.com), and it was a brilliant example of engineering changing the world in a small but positive way. Ivan, who I’d call a creative genius, fashioned a functional—but bizarre–metal hand as part of a steampunk costume several years ago. When he shared a video of it on YouTube, he received an email from a South African carpenter named Richard who had lost his fingers in an accident. Could Ivan help design him a hand with fingers, so he could work again? The cost for even one prosthetic finger was $10,000. The two men began a relationship across 10,000 miles trying to figure out a solution and design a prototype using myriad materials: paper towel rolls, PVC pipe, leather rivets, surgical tape, even some of Ivan’s kids’ toys. Jennifer had been blogging about the progress, and this soon led to parents asking her if they could also help make hands for their children. What Ivan and Richard developed was shrunk down and they successfully made a hand for a 5-yearold boy, Liam, also in South Africa. He realized that children would quickly outgrow these simple prosthetic hands, so Ivan reached out to Makerbot, which donated two 3D printers. Ivan taught himself to code and design, and perfected the hand.

Here’s the kicker: At this point, they realized that if there was one child like Liam in the world, there were thousands. Instead of patenting the design they had come up with, they decided it was too big to keep to themselves. They put it online—open source, public domain. So anyone, anywhere could make one for any child. And the kindness blossomed. After Makerbot shared one of their videos, a university professor noticed that in the comments section, people with 3D printers were saying that they were willing to print hands for others. They started a Google+ group where all the people that wanted to volunteer could collaborate and ask questions and get help from each other,” Jennifer said. “We started with approximately 150 people in 2013. As of today it is over 8,000 people worldwide who are collaborating and helping create these devices.” These designs are basic hands with a grasping motion. They are nowhere near as robust as a traditional prosthetic, but they can be made for $30-50, versus $3,000-5,000 for traditional prosthetics. And kids outgrow these every six months to a year. And people got creative, Jennifer said. “There were LED light fingertips. There are laser-pointers to terrify the cat. Superhero hands. Star Wars hands. You name it, it’s out there.” I was touched by the selfless dedication shown by this young family, to take this new technology and use it to better our society. We should all strive to do more with the creativity that inspired us to become design engineers. I know so many engineers who graciously volunteer their time, be it at programs like FIRST or as math tutors in their city—and I hope that the Owens’ story inspires you to take stock in where you’re giving back and how you can best make a difference. If you’re interested in donating your time or resources to the Owens’ cause, please visit enablingthefuture.org. DW

Pa ul J. Heney - Editor ial D i re ctor pheney@wtw hme di a.com

On Twitter @ DW—Editor 4

Insights 8-16_Vs3.LL.indd 4

DESIGN WORLD

August 2016

8/1/16 12:35 PM

How To Keep Your Electronics Cool When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. There are several cooling options out there and it’s important to know the facts.

line up of coolers that are prone to bad behavior $$$$$$ $$$$$ $$$$ $$$ $$ $ ¢

These coolers are prone to failure in dirty, industrial environments when dust and dirt clogs the filter. • It takes almost a day to install • Vibration from machinery causes refrigerant leaks and component failures • Compressor life expectancy is typically 2.5 years of continuous operation • It requires a floor drain for the condensation • Average cost to replace a bad compressor is $750

Opening the panel door and aiming a fan at the circuit boards is a bad idea. • It is an OSHA violation that presents a shock hazard to personnel • The fan blows hot, humid, dirty air at the electronics • The cooling effect is minimal • It is likely to fail again since the environment is still hot

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These have serious limitations. On hot summer days when the temperatures of the room and inside of the enclosure are about equal, there’s not enough difference for exchange. • They fail when dust and dirt clogs the filter • The cooling capacity is limited due to ambient conditions

The “plastic box cooler” from a competitor uses an inaccurate mechanical thermostat that’s designed for liquids. Th is thermostat has a poor ability to react quickly to changes in air temperature. It costs up to 85% more to operate than EXAIR’s ETC Cabinet Cooler® System with the same SCFM rating and Btu/hr. output. • Electronics can overheat before it turns on • It runs far longer than necessary before shutting off • Increased cycle time wastes compressed air

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

Chinese fire drill over trade Many moons ago I encountered the first auto I’d ever seen that was manufactured in China. It sat in Detroit’s North American International Auto Show, the premier event for vehicle introductions in the U.S. My experience opening the driver-side door set the tone of that initial encounter: A loud and extended creeeeak came from the door hinges. So much for Chinese manufacturing prowess, I remember thinking. Little did I know that the Chinese were in the process of putting many U.S. manufacturing plants out of business. To get a sense of this well-chronicled trend, consider that analysts at the Manufacturing Alliance for Productivity and Innovation have pointed out that the U.S. exported only $74 billion in manufactured goods to China in 2013, while importing six times that amount of Chinese goods. MAPI policy analysts have also claimed this imbalance in trade “has been driven by China’s wanton violation of international rules related to its currency.”

But that’s not what economists writing for the National Bureau of Economic Research concluded when they tried to determine why there had been such a swift drop in U.S. manufacturing employment after about 2001. U.S. manufacturing employment stayed at about 18 million workers between 1965 and 2000 before plunging 18% from 2001 to 2007. The principal cause of the decline, claim economists Justin Pierce and Peter Schott, was the U.S. granting of Permanent Normal Trade Relations (PNTR) to China. The interesting thing about PNTR was that, contrary to popular reports, it didn’t change the amount of tariff applied to Chinese goods coming into the U.S. – these rates had been pretty low as far back as the 1980s. The big change was that PNTR eliminated the need to annually renew the tariff rates. The renewal process was uncertain and politically contentious, the economists say. PNTR status ended the possibility that Chinese import tariffs could suddenly spike. And the spike could be significant; in 1999 U.S. tariffs on trade with countries lacking normal trade relations averaged about 36% higher than on those having this benefit. Ending the chance for sudden hikes in Chinese import tariffs probably accounts for big declines in U.S. manufacturing employment, the economists say. One reason is that with uncertainty about tariffs gone,

manufacturers had more incentive to open plants in China and establish relationships with Chinese suppliers. Likewise, PNTR may have given Chinese producers more reason to invest in the U.S. market, squeezing U.S. producers. U.S. manufacturers responded with capital- or skill-intensive production technologies or less labor-intensive mixes of products. Indeed, skill intensity rose in U.S. industries most affected by PNTR – the workers they shed were predominately blue collar and middle class. A point to note about the two economists is that they have no political axe to grind on Chinese trade. They say inspiration for these ideas comes in part from models of investment under uncertainty, where firms are more likely to undertake irreversible investments if there is less ambiguity surrounding expected profits. They also point to circumstantial evidence that their model holds: After 2001, U.S. imports from China surged in the same industries that experienced the largest reductions in employment. So there you have several reasons why China was able to take away 18% of U.S. manufacturing jobs in a mere six years. It had little to do with currency manipulation and much to do with U.S. companies willing to show the Chinese how to make doors that don’t creak. DW

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

On Twitter @ DW—LeeTeschler

DESIGN WORLD

Lee Teschler Column 8-16_Vs1.indd 6

August 2016

8/1/16 12:36 PM

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Te c h n o lo gy Fo r wa rd

How to make a new technology palatable Back in the days when a programmable logic controller (PLC) was known as a programmable controller (PC), the vendors deliberately chose those words to keep the truth from factory floor personnel. The truth was the PC/ PLC was a computer, the first step in the shift to automate as many factory tasks as possible. Vendors had to use those labels because operators kept taking sledgehammers and destroying these devices. Factory personnel could see the future, and it did not include them.

Now, we have the Internet of Things (IoT). The stated purpose is that the IoT will help everyone run their factories, their businesses and even their homes and personal lives better, thanks to analyses of “Big Data.” An end goal of IoT is to automate as much manufacturing as possible. But I’m beginning to suspect that, like the labeling of computers as PLC, the IoT is a label to help us accept a potentially uncomfortable development. The IoT could really be part of the “on-ramp” for artificial intelligence (AI). In his latest book, The Inevitable, Understanding the 12 technologies that will shape our future, founding executive editor of Wired Kevin Kelly notes that AI is one of those 12 inevitable technologies. Many intelligent scientists and engineers continue to debate what AI is and whether mankind can really create it. Many feel AI could be the doom of humanity. But none of that is stopping the rush to try and develop AI. The beginnings of AI are already here, in the form of the internet, and any device that connects to it. IBM’s Watson computer, for example, is an AI that is really a cloud of servers. Google’s search engine is the beginning of an AI. So are Facebook’s algorithms. Kelly says that by 2026, Google’s main product will not be search but AI. According to Kelly, “Private investment in the AI sector has been expanding 70% a year on average for the past four years, a rate that is expected to continue.”

Kelly notes that part of the recent breakthroughs in AI “lie in the incredible avalanche of collected data about the world, which provides the schooling that AIs need.” Aha! The gathering of data from manufacturing operations has been going on for 30+ years. So why IoT? For all this and other data, which feeds the algorithms that teach AI systems how to function. Any networked device will contribute to the growth, development, and intelligence of AI. While you need algorithms to teach the AIs, you need lots of data to feed the algorithms. What better source of data than Big Data courtesy of the IoT? Artificial intelligence, or probably more accurately, artificial smartness, will be something you plug into, like electricity, claims Kelly. Researchers may never develop artificial consciousness, a more common conception of AI, but they will develop narrow, supersmart specialists. AIs may specialize in medicine, for example. They already specialize in chess. They may specialize in manufacturing, thanks to the IoT. The inevitability of AI may not be bad. Having access to something that stores and retrieves important information could free you to be even more creative and innovative. You may even be one of the engineers tasked with preventing AIs from spontaneously developing consciousness. But since we don’t know what consciousness is, we may not recognize it if it does spontaneously develop in these systems. Thanks to the IoT Trojan Horse, though, AI will be inevitable. DW

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

On Twitter @ DW—3Dprinting 8

DESIGN WORLD

Leslie Column (Technology Forward) 8-16 Vs2.LL.indd 8

August 2016

8/1/16 12:39 PM

CNC MACHINING PLASTICS ABS • ABS-Flame Retardant • Acetal 20% Glass Filled / Delrin 570 • Acetal Copolymer • Acetal Homopolymer / Delrin 150 • Acetal Static Dissipative / Tecaform SD • CPVC • HDPE • LDPE • Nylon 6 • Nylon 6/6 • Nylon 6/6 30% Glass Filled • PC • PC 20% Glass Filled • PEEK • PEI / Ultem 1000 • PEI 30% Glass Filled / Ultem 2300 • PET • PMMA / Acrylic • PP Copolymer • PP Homopolymer • PPE+PS / Noryl 265 • PPSU / Radel R 5500 • PS (HIPS) / Polystyrene • PSU / Polysulfone • PTFE / Teflon • PVC • UHMW •

• – Milled only

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SMALLEY WAVE SPRINGS: FORCE WITHOUT THE FOOTPRINT. REDUCE OPERATING HEIGHT BY UP TO 50% WITH THE SAME FORCE AND DEFLECTION AS COIL SPRINGS. Looking for a solution for tight spaces where a conventional coil spring simply doesn’t fit? Smalley wave springs deliver precision and high performance in diameters now* down to 0.165". What’s more, a smaller assembly size and less material used means cost savings with no compromise in performance. Let us customize the wave spring that meets your exact requirements.

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3/10/2016 9:40:50 AM 8/1/16 11:43 AM

» Gre e n En gine e r ing

n Paul J. Heney • Editorial Director

Five years of solar—and still going strong Plastic tubing manufacturer NewAge Industries is observing the fifth anniversary of its rooftop solar panel array and green power system. The array, consisting of more than 4,000 solar panels, generates one megawatt of electricity annually and is the sixth largest in the state of Pennsylvania. Why did the company take this step five years ago? Company leaders gave several reasons: Ken Baker, NewAge’s CEO, said, “It’s very satisfying to say that • Because it’s good for the environment. NewAge had already we make our products using renewable energy. The solar array taken many steps toward greening its carbon footprint— provides about half our annual electricity requirements, and replacing all windows, adding screens to dock doors for the additional power needed is purchased from green energy natural ventilation, upgrading its lighting, replacing providers. We’re pleased to be able to help the environment, manufacturing equipment motors with energy efficient support our community, and lower our dependency on fossil versions, properly recycling e-waste—but the solar array fuels.” project was its most ambitious to date. The manufacturer has continued its push toward greener • Because it was a goal to be a green company. Companies activities. It recently stopped providing Styrofoam cups and asks that take measurable steps toward environmental team members to use washable, company-provided ceramic mugs responsibility are respected, and those are the companies or environmentally friendly paper drinking cups. Team members customers want to do business with. also received aluminum water bottles, which they can refill with • To set an example. Being a leader in going green showed that spring water from the company’s water coolers located throughout the company cares about the environment and its the building. Carpooling is encouraged and practiced, and green community. The company also made it a point to use only cleaning products are used. Restrooms are equipped with motion U.S.-made components—solar panels, inverters, the racking sensors, so lights are on only when necessary. Team members system–to support American manufacturing. In fact, using even swap plants to literally green their work areas. DW American-made solar panels instead of Chinese-made panels cost the company an additional $150,000. • To save money. It is estimated that the solar panel system NewAge Industries Inc. will pay for itself in electricity bill savings in about four more years. newageindustries.com/green-initiatives.asp • To preserve this earth for future generations. www.designworldonline.com

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August 2016

DESIGN WORLD

8/1/16 12:45 PM

Austin

2 0 1 6

NI Week Recap accelerating innovation

Steve Meyers Flowserve demonstrates real IoT usefulness

Lisa Eitel Applications draw big crowds

Until recently the Industrial Internet of Things (IIoT) has mostly been a conversation about things as we hope they will be sometime in the future. The future is here now.

This year’s NI Week saw the announcement of several new products — including LabVIEW 2016, hardware-in-the-loop (HIL) test-system functions, and equipment for easier IC design — as well as stunning applications using the latest National Instruments software and hardware. Hewlett Packard Enterprise, XILINX, Intel, Flowserve, Murchison Widefield Array, Saab Aeronautics, and dozens of other innovative companies and research groups presented a host of real-world applications to demonstrate how engineers and scientists are harnessing the NI platform. One standout example is how Audi is using NI’s vector signal transceiver (VST) and FPGA programmable by LabVIEW to optimize radar sensors for better driver-assist and autonomous-vehicle function. Wide system bandwidth and software-designed instruments let Audi identify sensor problems early in the design phase — previously impossible to catch. So now the carmaker can simulate an array of driving scenarios to boost safety and reliability of this cutting-edge suite of automobile functions. At NI Week, National Instruments also confirmed rumors that it will move the conference dates next year. So mark your calendar, because NI Week 2017 will be held May 22 to 25 to beat the Texas summer heat. 12

DESIGN WORLD

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August 2016

www.designworldonline.com

Case in point: Flowserve demonstrated a new pump system fully instrumented to gather data about the process being controlled and about the performance of the pump itself. A temperature sensor monitors seal temperature, vibration monitors sense bearing vibration, the system keeps track of run time and operating conditions and all of these data streams are compared to the “normal” operating parameters of the pump. Efficiency can be calculated from input electricity to output water flow in a simple HMI screen that also displays estimated lead time to failure of the critical components of the system. The analytics can be displayed on a tablet as well as a laptop, and when used with a laptop camera, displays the live operating values of the process and the pump on top of the video image from the camera. So wait no longer, because we saw the future of the internet at this year’s NI Week.

8/3/16 10:06 AM

Lee Teschler Med tech gets a boost from instrumentation One of the more interesting displays on the floor at NI Week was a demonstration by Masters’ students from the University of Leeds in the UK. To fulfill their degree requirements, they devised a robot arm able to test a device that helps stroke patients rehabilitate their limbs. As therapy, the patient grabs the end of an articulated arm and tries to move it to match the movement of a centipede on a video screen. The articulated arm is calibrated to push back and provide resistance as a way of building up muscle tone. The Leeds students devised a servo-controlled mechanism that can be used to manipulate the articulated arm for testing purposes, as a check for reliability and operational parameters.

The students used LabVIEW, myRIO and Fuzzy Logic Toolkits, and more to create two design iterations. Their work started with an arm created with hobby servo motors and moved to a more sophisticated version with industrial dc motors — as well as feedback from industrial encoders and force sensors.

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Co nten t s |

August 2016 • vol 11 no 8

designworldonline.com

F E AT U R E S CONTROL 58 MOTION Minimizing stepper vibration with affordable technology

Because stepper motors run and then stop at each step angle, they deliver high-accuracy position control. But the way they incrementally advance causes vibration and noise. Now, some drivers use advanced electronics to track and control current into motors as a way to get smooth motion from two-phase microstepping setups.

78 MECHATRONICS The next generation of grinding One company is leveraging CAD, vision systems and robotics to make dramatic improvements in grinding large castings. The next generation of grinding will not look anything like the past.

82 3D CAD

Outsourcing CAD: The good and the bad Outsourcing CAD drafting and design can boost a company’s productivity, but firms looking to outsource should ask some questions and do their own research before moving CAD work out of the company.

64 Gaining a measurement edge LINEAR MOTION

Encoders help linear motion stages reach higher levels of accuracy and performance.

A supplement of Design World • August 2016

2 0 1 6

72 Select the right machine controller

outsourced 3D printing 90

Design mission ready devices and equipment faster,

Design mission ready

smarter, and under budget with 100

3D printing for when you

Optimization software

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Picking the right type of machine controller will minimize costs and complexity, while still providing the performance required for the application.

2 0 1 6

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ON THE COVER A Concentric Maxi Torque System offers zero backlash and very high clamping torques on a robotic testing station to diagnose subtle motor deficits caused by brain injuries. Courtesy Custom Machine and Tool Co. 2015

2015

2015 O N LIN E

revenue over $3 million

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Con te n ts Repeatability Accuracy Is Nothing Without

Specify The Position Sensors With True Precision

8. 2 01 6 28 D E PA R T M E N T S

T/TR family of absolute position sensors feature repeatability to 2µm. They are ideal for machine automation and control applications where precise repeatability and long life are requirements. These sensors offer a proven solution for applications with alignment errors. T/TR position sensors are available with a return spring too for use in auto-retraction systems.

04 Insights 06 Teschler on Topic Novotechnik’s T/TR family shares these key specs:

08 Technology Forward

• • • • •

1 1 Green Engineering

Repeatability to ±0.002 mm Stroke lengths from 10 to 150 mm Long life of >100 million movements Linearity to ±0.075% Plug or cable connection

For complete information on T/TR sensors visit www.novotechnik.com/ttr Novotechnik U.S., Inc. 155 Northboro Road • Southborough, MA 01772 Telephone: 508-485-2244 Fax: 508-485-2430

F R E E C ATA L O G & B R O C H U R E

WASHERS & STAMPINGS

20 Design For Industry 28 Design Notes 38 CAE Solutions 46 Sensor Notes 4 8 Internet of Things 1 4 4 Products 1 4 8 Ad Index

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military/aerospace

» Design for Industry

off-shore

Moving modules for Brazilian oil TUPI BV is a consortium composed of Petrobras Netherlands BV, the British Gas Group and Galp Energia S.A. Together, the consortium is working on the ongoing development of the Lula Alto field, located in the Santos Basin, Brazil. When they needed a loadout of the first set of four modules bound for the FPSO (Floating Production, Storage and Offloading) P66 vessel, they turned to Mammoet, a global service provider specializing in engineered heavy lifting and transport. Working towards a tight deadline with the P66 nearing completion, the consortium was looking for a partner to install the last four modules. The modules range in weight from slightly over 1,000 to 1,425 metric tons. They were built by BJCHI in Sattahip, Thailand and shipped by module carrier to Brazil for integration onto the hull of the FPSO. The load-out was the result of close cooperation between BJCHI and Mammoet Thailand. BJCHI provides manufacturing and installation services for its customers’ industrial plants. Building and delivering FPSO modules is a move into new territory for BJCHI, which is venturing into the oil and gas market for the first time. The Mammoet team had to manage the total logistics operation including chartering the module carrier MV Mega Trust to ship the modules to Brazil, complete naval engineering, weighing the modules and a load-out at the fabrication yard using 60 axle lines of Self Propelled Modular Transporters (SPMTs). SPMTs are hydraulically operated trailers with high lifting capacity. The wheels can be rotated 360º and, due to the modular nature of the trailers, the lifting capacity can be increased by adding more trailers to the configuration. The basic principle of an 20

DESIGN WORLD

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August 2016

SPMT is the fact that loads are transported above the wheels of the trailer and the small circumference allows for a low loading height. Each of these wheels is mounted on an oscillating axle. Each axle is mounted on a hydraulic “suspension,” obtaining the following: • The regular load distribution between the axles, whatever the road super elevation may be, over which the convoy is travelling. This load distribution is obtained by the intercommunication of the hydraulic cylinders, giving a constant pressure, whatever the suspension height may be. • The sustentation of the load is obtained hydraulically, following the support in three points on the ground. DW Mommoet mommoet.com

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machine tool/aerospace/military

off-shore

Your Global Automation Partner

A LOGO!MAT E-CART, built into the facility floor, transfers a floor sweeper. The E-CART is an electric conveyor system capable of operating itself within Industry 4.0 parameters.

Secure, waterproof connectors for subsea robots In environments where connectors and cables are exposed to high pressures and submerged in water for extended periods, secure and waterproof electrical connections are vital for ensuring that installations can be easily assembled, modified and maintained. This is especially true for remotely operated vehicles or ROVs. These subsea robots connect to ships with data and control cables, which allow for remote control of the vehicle. To ensure these connections, one of the largest manufacturers of ROVs tasked engineers at Bulgin to develop an environmentally sealed connector that combined quick and easy connectivity with long-term corrosion resistance. The Bulgin Tether Connector allows data, fiber optics and power signals to be sent to the ROV, said Mark Berry, Product Line Programme Manager for Bulgin.

The 316 stainless-steel design allows ROVs to operate at the high pressures and extreme temperatures found at depths of up to 7,000 m below sea level, Berry added. This is accomplished by using dynamic pressure balancing through free flow of dielectric oil from the surface to the connector. The ROV Tether Connector is a custom solution that provides a quick yet secure coupling and locking mechanism. It is engineered to prevent problems happening in the first instance, and helps to reduce cable termination time and potential downtime for subsea projects. It is rated for 5 KV and 32 A. DW

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energy

Microcontroller with core independent peripherals Todayâ&#x20AC;&#x2122;s embedded applications targeting the Internet of Things (IoT), consumer, industrial control, and motor control require flexible microcontrollers (MCUs) that consume less power, are more cost effective and have smaller form factors. The PIC32MM family of 32-bit PIC32 microcontrollers features core independent peripherals that offload the CPU for lower power and lower system design. It suits applications demanding low power and longer battery life, and has sleep modes down to 500 nA. It also suits applications with space constraints, given its 4 x 4 mm package options. The PIC32MM devices include core independent peripherals such as Configurable Logic Cells (CLC) and Multiple-output Capture Compare PWMs (MCCPs) which help enable sensorless BLDC motor control applications. DW Microchip Technology Inc. microchip.com

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material handling/conveying

Your Global Automation Partner

Automatically handle individual packages and layers without changing grippers Challenged to efficiently remove filled cardboard boxes weighing up to 44 lb and ranging from ~9.5 in. to 14 in. in length and ~8.5 in. to 9.5 in. in width from crates, place them on a roller conveyor, and, in reverse order, place cardboard packages in crates, FIPA developed a flexible, cost- and energy-efficient, and process-reliable vacuum gripping system capable of handling both individual cardboard boxes and whole layers of boxes without changing grippers or wasting vacuum flow and related energy costs, regardless of the position of the packages. The designers used a custom TC Series vacuum gripper mounted to a Z-axis to generate the vertical lift movement required to place the cardboard packages in a crate and vice versa. This approach can accurately pick packages from both crates and the roller conveyor despite the absence of an accurately defined position. Featuring custom integrated valves capable of turning off suction openings that don’t come into direct contact with a package, the gripper also conserves energy and mitigates operating costs. Designed to beat current system requirements to save on future operating expenses, this design can handle loads weighing up to 66 lb with surface areas up to ~9.5 in. by ~13 in. The TC Series maximum-life, minimum-maintenance vacuum grippers feature EPDM sealing foam for gentle product contact and optimum vacuum sealing, and integrated valves for closing suction openings and saving energy when not in use. Enabling fast and uniform vacuum distribution, TC Series vacuum grippers ensure short cycle times and high acceleration rates, and enable the automated handling of both individual packages and layers of packages without changing grippers to accommodate additional products, rigid products, or even those with uneven surfaces. Featuring a vacuum located inside of the vacuum tubing, the optional gripper box reduces gripping time and contains special valves with excellent suction power for fast evacuation or venting, and, for reduced sensitivity to dirt, large valve openings for maximum suction power. DW

WARNING Not suitable for repairing flimsy connectors (or your reputation).

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FIPA, Inc. fipa.com August 2016

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Call 1-800-544-7769 or visit info.turck.us/connectivity

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Âť Design for Industry

medical

Tactile sensors support next generation medical devices Extremely sensitive, thin, conformable tactile sensors will play a key role in the

One reason that capactive tactile pressure sensing is so well-suited for blood pressure measuring is that it can hadle the extremely low pressures that need to be measured.

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next generation of consumer wearable and clinical devices that measure blood pressure. While there are many methods to measure blood pressure, all but the most invasive, intra-arterial techniques suffer from deficiencies that can lead to inaccurate or inconsistent results. Even the standard blood pressure cuff used by healthcare practitioners has limitations, such as signal quality, errors in human interpretation and calculation methods that rely on indirect or algorithmic interpretations. The latest generation of thin, conformable tactile sensor arrays promises more precise, accurate measurement of pulse pressure waveform. These sensors will aid artery location and pressure measurement; and for consumer wearables will measure more than just heart rate. Alternative automatic methods for measuring arterial pressure typically use an inflatable cuff to restrict flow, then measure pressure oscillations in the cuff to estimate systolic and diastolic pressure using proprietary algorithms. Such methods are often packaged as home use devices, but can have inaccuracies on the order of 10 mmHg and are particularly inaccurate on obese or those with conditions resulting in an irregular pulse. Pulse oximeters monitor blood oxygen saturation and pulse rate, and can monitor blood pressure as well. These devices pass two wavelengths of light through the body to measure the changing absorbance information that is then used to infer blood pressure. While these options have merits, neither approach meets the accuracy and repeatability standards of the lead organizations such as the Association for the Advancement of Medical Instrumentation (AMMI) and British Society of Hypertension. Instead, a more direct measurement of the pulse waveform is gaining interest, one that enables ambulatory, non-invasive blood pressure measurement without cuffs by using advanced capacitive tactile sensing technology. With capacitive tactile sensors, blood pressure can be measured through sophisticated arrays that map the pressure above the artery. These arrays can range from a number of discrete measurements to a large, dense array of hundreds of elements. The sensors, in direct proximity to the artery, deliver a detailed pulse waveform that is used to determine blood pressure and pulse information, including www.designworldonline.com

8/1/16 1:09 PM

5 Your Global Automation Partner

Using capacitive tactile sensors, blood pressure can be measured using sophisticated arrays that map the pressure above the artery.

other parameters such as arterial hardening. One reason that capacitive tactile pressure sensing is well suited for this task is that it can handle the extremely low pressures to be measured; blood pressure is measured in millimeters of mercury (mmHg), with 0.5 mmHg equaling roughly 0.01 psi. In addition, tactile pressure sensors conform to the contours of the human body and other curved surfaces so they can be integrated into a variety of soft, flexible materials. “The key advantages of these sensors are the sensitivity, the small form factor, the conformable materials enabling seamless integration into wearable devices and the tactile array configuration,” says Dr. Jae Son of Pressure Profile Systems (PPS). “The sensors are directly measuring pressure, not trying to infer it by optical or electrical properties.” To build its tactile array sensors, PPS arranges the electrodes as orthogonal, overlapping strips. A distinct capacitor is formed at each point where the electrodes overlap. By selectively scanning a single row and column, the capacitance at that location, and thus the localized pressure, is measured. With this approach, a PPS tactile array can feature up to 8,192 integrated sensing elements while measuring pressures as low as 0.01 psi. According to Dr. Son, another promising application for capacitive tactile sensors is arterial line placement, a common, but

difficult, procedure performed in a clinical setting. An arterial line is a thin catheter inserted into an artery. It is most commonly used in intensive care medicine and anesthesia to monitor blood pressure continuously and to obtain samples for blood gas analysis. This type of intra-arterial measurement is more accurate than noninvasive alternatives. Locating the artery can prove difficult, even for trained clinicians. The mean diameter of the radial artery is only about 2.3 mm in adults. A weak pulse can make it even more difficult. The device uses PPS tactile sensor arrays in a conformable material worn over the clinician’s index and middle fingers. The PPS sensor identifies the location of the pulse, and indicates the location using LEDs and a needle guide to facilitate needle insertion. The device also protects the clinician’s fingers against needle-stick injuries. Today, the holy grail of blood pressure monitoring is for consumer wearables such as smartwatches and fitness bands. Currently, most are limited to measuring heart rate, but many are already developing next generation devices with wristbands capable of taking blood pressure, pulse and other key arterial measurements. DW

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WARNING

DESIGN WORLD

Call 1-800-544-7769 or visit info.turck.us/sensors

8/1/16 1:06 PM

» Design for Industry

off-highway

Safely wire multiple sensors in series Eden OSSD safety sensors let users wire multiple sensors in series to any standard safety relay without compromising the level of safety. The Eden OSSD safety sensor operates as an output signal-switching device (OSSD) for “stop” commands to prevent hazardous movements. OSSDs stop or interrupt machinery when entry or proximity is a hazard. They are electro-sensitive and typically respond to changes in an optical field on or near machinery. Consisting of two separate devices – Adam, for signal output, and Eva, for signal input – the Eden OSSD safety sensor is an interlocking device for gates, hatches and doors. It communicates with OSSD signals and can be connected to any safety module that handles them. “The Eden OSSD safety sensor is designed so that up to 30 sensors can be connected in series without reducing the achieved performance level,” Richard A. Gibson, product manager at ABB Jokab Safety Products, said. “By being available separately, it is possible to mix different models of the Adam and Eva units in the same safety circuit, providing flexibility in configuring multiple sensors for machine safety.” The Eden OSSD safety sensor uses no contacts and is neither magnetic nor mechanical. It uses solid-state technology with no moving parts, which eliminates the cost and potential danger of using mechanically keyed interlock safety switches and non-contact magnetic safety switches. The operation of Eden OSSD safety sensors maintains Performance Level (PL) e, Safety Category 4, in accordance with ISO/IEC 31010:2009 Risk Management – Risk Assessment Techniques. The Adam OSSD unit is available in four models: Adam OSSD- Info M12-8, with information output and inputs for cascade connection; Adam OSSD-Reset M12-8, with built-in monitored reset, indication lamp output and inputs for cascade 26

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

connection; Adam OSSD-Info M12-5, with information output; and Adam OSSD-Reset M12-5, with built-in monitored reset and indication lamp output. The Eva unit is available in two models: Eva General Code, which are all coded alike, and Eva Unique Code, which all have a different and unique code. The Eden OSSD safety sensor is IP69K rated and meets coding requirements pursuant to EN ISO 14119:2013 regarding manipulation protection. Other features include a unique integrated reset function, which allows for each sensor to have its own independent and illuminated reset function. Eden OSSD safety sensors also feature a diagnostic LED for both the device and system status, which will direct the operator to the appropriate door without individually cycling and testing each door to diagnose common system faults. DW

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» D e s i g n N o te s

Case Study: Yaskawa improves turnaround time and accuracy for reference lab Edited by: Mike Santora • Associate Editor

s ambient istant place ss a ry to ra A labo LaboratoMayo Medical e th to on s sorts specimen system, which ed sortation at m to tion au ta s ks rie tory wor n to a labora w do s en im pr spec essing ior specimen proc e lin am re st level to bspecialty ayo Clinic’s su M of e on in to testing tories. clinical labora

Yaskawa Yaskawa Motoman recently collaborated with Mayo Medical Laboratories, Rochester, Minn., to implement a state-of-the-industry specimen automation system. The laboratory handles tens of thousands of patient vials every day from more than 3,000 tests across the full spectrum of clinical laboratory subspecialties. Laboratory leadership wanted to continue to improve turn-around time from when specimens are received by Mayo Medical Laboratories internal operations to when the specimens arrive at the one of 60 clinical laboratories for testing. The operations team also wanted perfect accuracy when directing specimens through pre-analytic workflow. This obsession with accuracy is critical to patient care; according to industry research that analyzed errors in clinical laboratories, nearly 70% of mistakes happen in the pre-analytic phase — during sample collection, handling or processing.

DESIGN WORLD

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Deceleration & Vibration Technology:

Expect more than Automation Control! Motion Control Custom control of hand forces

The system use

s a series of specially design ed conveyor-bel ts to route specim ens to the corre ct specimen sorter for placement into tube racks designated for clinical specialty laboratories.

Several design challenges As the Mayo Medical Laboratories test volumes continue to increase, the staff needed robust automation to meet aggressive productivity goals. The previous automation line was limited to handling from 2,500 to 3,000 vials per hour and required a certain level of manual pre-sorting. While one-in-one-million quality defects is acceptable in some types of manufacturing, this level of inaccuracy is unacceptable for a patient care provider and commercial reference laboratory handling one million patient specimens every week. So Yaskawa engineers and a team from Mayo Medical Laboratories evaluated potential solutions for addressing the laboratory’s goals and then settled on a new installation in August

Vibration Control Isolate unwanted vibrations

2014. The solution included a large track-based system with six configurable Yaskawa AutoSorter 1200T output sorters. The new line also included six container scanning system (CSS) stations, which read specimen labels and link them to radiofrequency identification (RFID) tags on conveyor pucks. Once the CSS establishes the bond between specimen and tag, the station sends the specimen to the main conveyer and directs it to the proper destination. The automation system also determines the configuration of certain specimens before routing them to their sort targets. If the system identifies a specimen in an unsuitable container, the line routes the vial to a designated sort target for pour-off into a container.

The Mayo Med ical Laboratori es system utilizes

Design Notes 8-16_Vs6.indd 29

August 2016

DESIGN WORLD

Automation Control Optimum tuning for any design

by ACE

RFID-pucks to ro ute specimens to th e correct specim en sorter, where sp ecimens are plac ed in racks according to the laborato ry.

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Safety Products Protection for all machine designs under any condition

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8/1/16 1:24 PM

» D e si g n N o tes Mayo’s previo

As the new specimen automation system is processing patient specimens, the line can provide information to the laboratory information system concerning specimen history and status. This ensures specimen traceability, including target rack, column and row. Along with recording specimen location, the line reports and logs when an operator empties a drawer and scans a barcode on the rack to provide a contents manifest.

Capabilities of the new automation system “Laboratory personnel can place specimens right on the new line, and we can route 80% of all specimens through automation,” said Aaron Maixner, an operations manager for Mayo Medical Laboratories. “Prior to August 2014, only 60% of the daily volume was processed via automation.”

us automatio n line limited spec

Higher throughput is from the system’s ability to sort 6,000 specimens per hour, a 100% increase over the prior line’s speed. The line can also sort vials into 540 targets versus the previous system, which topped out at approximately 320 targets. Along with increased speed, the new line catches errors as it receives specimens, rather than further downstream which occasionally compounded delays and slowed production. According to Maixner, the laboratory hasn’t experienced any incorrect sorting since implementation of the new specimen automation system.

imen handling to 2,500 to 3,000 vials per hour an d required lab staff to carry out a m anual pre-sort. The la b also experienc ed errors in sorting specimens, whi ch, on occasion, th e legacy specim en automation syst em would send to the wrong labs .

Lab pe

rsonnel can plac e specimens right on the new line, and Mayo is able to route 75% of specimens by noon. Prior to August 2014, it to ok until 2 p.m. to sort 75% of th e total volume. High throughput is thanks to the system’s ability to sort 6,000 specimens per ho ur.

isting ith a tion system w a m to u a en specim with a large toman setup Yaskawa Mo x output system and si track-based orter 1200T skawa AutoS Ya e h T s. er rt so yriad lab le to meet m is configurab . requirements placed an ex

Engineers re

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» Desi gn Notes

The new Yask awa Motoman line

The new line can accurately identify when vials need to be poured off, too. Pour-offs, says the laboratory, take additional time. By increasing accuracy and speed, the laboratory’s new specimen automation system has optimized customer turnaround time. The improvements ultimately speed delivery of correct results for patients and physicians. DW

reports and logs when operators scan barcodes on the rack to provide a contents manifest.

WHAT DO YOU THINK?

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

Yaskawa www.yaskawa.com

1.800.933.4915 www.designworldonline.com

Design Notes 8-16_Vs6.indd 31

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8/1/16 1:25 PM

» D e s i g n N o tes

Using robotics to improve brain assessments

ed to oskeleton us A robotic ex atics m an limb kine analyze hum every be precise in must not only a but also allow minute detail, active, lab to perform person in the tions. real-world ac

Edited by: Mike Santora • Associate Editor

Clinicians have always had to rely on a patient’s behaviour and movement to diagnose a brain injury or track the impact of neurological diseases. Today, with advanced technology, clinician-scientists have a more precise window on brain function and they are driving new approaches to managing brain injuries and disease. BKIN Technologies is transforming the assessment of brain-injuries by putting robotic technology in the hands of neuroscientists and clinician scientists around the world. KINARM Labs were invented by Dr. Stephen Scott, a professor in the Department of Biomedical and Molecular Sciences and the Centre for Neuroscience Studies at Queen’s University in Canada. Over 15 years ago, he 32

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assembled a team of physicists, neuroscientists and machinists to design a robotic exoskeleton that could precisely move and monitor a person’s arm. Because of his understanding of the brain circuits involved in making healthy arm movements, he was able to create a proprietary suite of tests that allows him to provide a complete brain function assessment in a short period of time. “It enables researchers to create a ‘fingerprint’, if you will, of the patient’s unique neurological condition. Traditional testing methods, such as touching a finger to the nose or bouncing a ball, just don’t capture the complexity of brain processes necessary for everyday activities such as preparing dinner or driving a car,” says Scott. One of the major challenges facing Dr. Scott and his research and development team at Queen’s University was the complexity of the robotic system itself. A person either sits in a chair with robotic arms affixed (KINARM Exoskeleton Lab) or grasps on to two robotic manipulandums (KINARM End-Point Lab). The robotics are combined with an augmented reality system which creates a virtual environment where subjects perform tasks, such as directing a hand to a target, or interacting with an object in the environment. A robotic exoskeleton used to analyze human limb kinematics must not only be precise in every minute detail, but also allow a person in the lab to perform active, real-world actions. The key component that enables smooth, natural, non-jerky robotic movement is the slotless motor. This motor powers and drives the robot through a pulley and belt mechanism. The connection between the motor and the master pulley is therefore critical, requiring zero backlash and no slippage. The initial KINARM Lab design used a pulley that attached to the motor shaft using set-screws. However, the constant changing of motor direction during operation produces high shock loads on this motorpulley connection, which in the prototype KINARM Labs caused the set screws in the pulley to loosen, resulting in backlash, shaft damage and eventual system failure. A viable coupling solution had to be found. 34

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ue bushing tric Maxi Torq CMT’s Concen h backlash and hig system has zero w lo its th wi g s. Alon clamping torque d the an ing ion sit po se of profile design, ea its e to aft damage du elimination of sh tion ec nn co is th , fit k mechanical shrin RM NA choice for the KI system was the b. Exoskeleton La

After an extensive search, BKIN’s engineers connected with Custom Machine and Tool Co., Inc. (CMT) of Hanover, Massachusetts. They learned that CMT had designed and patented a more reliable connection system, the Concentric Maxi Torque bushing system, which offers zero backlash and high clamping torques. Along with the additional benefits of its low profile design, which allowed for direct coupling to the motor shaft, its ease of positioning and the elimination of shaft damage due to its mechanical shrink fit, this connection system was the choice for the KINARM Exoskeleton Lab.

Pulley and bushing are sold together as an assembly (it’s not something CMT would rework into an existing pulley). There is a mechanical shrink fit affected by using a setscrew, axial to the shaft, as a lever to force the tapered bushing into the matching taper in the hub. As the lever forces the two tapers together, the slot in the bushing is compressed, thus clamping the pulley to the shaft with a mechanical shrink fit. That same set screw is removed and used on the opposite hole, which acts as a jack, releasing the shrink fit and allowing for removal or repositioning. DW Custom Machine and Tool Co., Inc. www.cmtco.com

otic air with rob er sits in a ch th ei n so er b) p A oskeleton La d (KINARM Ex arms affixe ulandums robotic manip o tw to on are or grasps . The robotics d-Point Lab) stem sy y (KINARM En ted realit h an augmen it w d ne bi m he co ent w re rtual environm vi a s te ea cr ga which ch as directin orm tasks, su object an subjects perf h it ing w et, or interact hand to a targ ent. in the environm

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Design Notes 8-16_Vs6.indd 36

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» Desi gn Notes

Water jets use big data to cut hydraulic failures Edited by: Mike Santora • Associate Editor

AMC Jets has over 20 years’ experience using high-pressure water jet cutting technologies worldwide. A widespread issue in its field of operations is a reduction in hydraulic system pressure, which often leads to performance decay of the water pressure intensifier. To solve this problem AMC Jets went to Webtec, a hydraulic measurement and control manufacturer, to find a portable hydraulic monitoring and data capture approach. After specifying their exact requirements the AMC team came away with a hydraulic data-logging system that used the measurement and data capture of multiple sensors including flow, pressure, temperature, contamination and relative humidity of the oil all in one portable unit. After initial on-site training, the Webtec HPM hydraulic test kit allowed the AMC team to test and record each customer’s power unit performance during service visits. By using the HPMComm software supplied with the kit, the AMC team can analyze the thousands of data points they have built up. Furthermore, they can then over lay performance curves collected from

previous tests of the machine many months or years before to visually and graphically identify performance decay and schedule preventative maintenance. By combining this structured approach with the HPM hydraulic test kit, AMC has reduced hydraulic failures in their customers’ hydraulic systems and prevented potentially expensive downtime in their CNC water jet operations. DW Webtec www.webtec.com/us

lic hydrau c HPM to test e t m b a e e t e AMC The W h t unit d e allow ’ power test kit each customers visits. By

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» CA E S o lut i o n s

Predictive engineering analytics: Simcenter unifies, advances Siemens PLM’s simulation/test portfolio By Bruce Jenkins • President • Ora Research

One of Siemens PLM’s hallmarks is its track record of outstanding management of its acquisitions over many years. It consistently presents a compelling strategic rationale for the move, makes sensible, comprehensible commitments as to how it will operate and integrate the acquired business and its technologies—then follows through, robustly and on schedule. When Siemens announced its agreement to acquire LMS International in 2012, it said the acquisition would make it “the first product lifecycle management (PLM) software company to provide a closed-loop systems-driven product development solution.” Now, with its just-announced Simcenter portfolio, the company has taken possibly its single greatest step both to continue delivering on this vision and to further extend it.

Simcenter combines simulation and physical testing with intelligent reporting and data analytics to help produce digital twins that more accurately predict product performance throughout all stages of the product development process.

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» CAE S olut i ons

In addition to incorporating its most recent acquisitions—CFD leader CD-adapco, and the HEEDS design exploration technology from CD-adapco’s Red Cedar Technology subsidiary—Simcenter also introduces Simcenter 3D, a “next-generation 3D CAE solution built on the Siemens NX software platform and combining the capabilities of several solutions to cover a range of simulation disciplines and industry applications.” Beyond that, the company characterizes Simcenter as a “comprehensive portfolio of simulation software and test solutions to enable digital twins to drive innovation through all stages of product development” that “supports Siemens’ digitalization strategy and systems-driven product development.” The overarching message is that Simcenter “combines simulation and physical testing with intelligent reporting and data analytics to help produce digital twins that more accurately predict product performance throughout all stages of the product development process.”

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The digital twin What’s a digital twin? “A digital twin of your product,” says Siemens, is “a multi-fidelity model that reflects reality and continually evolves throughout the product lifecycle to accurately simulate performance from concept through actual use.” In this way, “Simcenter helps you go beyond simple verification to performance prediction by combining simulation, physical testing and data analytics to spot unforeseen trends.” More specifically, Simcenter is designed “to address these challenges and realize Siemens’ predictive engineering analytics vision by combining multiple technologies in simulation and test.” These include computational solid mechanics (CSM) and finite element analysis (FEA), computational fluid dynamics (CFD), multibody dynamics, controls, physical testing, visualization, multidisciplinary design exploration, and data analytics. These technologies are then managed in a PLM context, using Siemens’ Teamcenter software, to support the engineering and development of complex systems.

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Predictive engineering analytics Simcenter advances a concept that Siemens calls “predictive engineering analytics,” or PEA, in support of closed-loop, systems-driven product development. “Closed-loop, systems-driven product development involves deconstructing the design into separable elements, yet considering their intended interactions and controlling the global system behavior from the start,” the

August 2016

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» CA E Solu t i o n s

company explains. “Individual elements can be further developed as details become available.” The intent of this approach is to minimize risk and avoid latestage changes by enabling clear target or boundary setting for subsystems, and full understanding of the global system’s dynamic behavior throughout the development process. This process is traditionally supported by continuous verification and validation at the component and full-system level, limiting physical prototyping cycles. “PEA pushes this approach to the next level,” according to the company. “It includes all the tactics and tools that will help you predict product behavior in actual use. Deploying a PEA vision will help you develop a replica that remains synchronized with the actual product.” The goal of PEA, says Siemens, is to “bring revolutionary improvements that will make simulation a predictive driver of development. PEA achieves these

Simcenter advances a concept that Siemens calls “predictive engineering analytics,” or PEA, in support of closed-loop, systems-driven product development. objectives by introducing new technologies and providing a strong alignment between 1D simulation, 3D computer-aided engineering (CAE), controls development, design exploration, data analytics and physical testing. The latter is essential to reach the appropriate modeling realism and enables effective component and final prototype testing.” “Simcenter,” the company sums up, “enables PEA by bringing all disciplines together under one umbrella.” With the introduction of Simcenter, Siemens says it is “taking the next step forward in its digitalization strategy and predictive

engineering analytics vision, which foresees the transformation of design simulation and verification into an analytical tool critical to systems-driven product development.” DW Ora Research oraresearch.com

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Comsol Multiphysics 5.2a has a number of user-driven features and enhancements that focus on accuracy, usability, and productivity. From new solvers and methods, to application design and deployment tools, software version 5.2a expands the electrical, mechanical, fluid, and chemical design and optimization capabilities. Three new solvers deliver faster and more memory efficient computations. The smoothed aggregation algebraic multigrid (SA-AMG) solver handles linear elastic analysis, but is also applicable to other types of analyses. This solver is memory conservative, making it possible to run structural assemblies with millions of degrees of freedom on a standard desktop or laptop computer. The domain decomposition solver handles large multiphysics models. A new explicit solver based on the discontinuous Galerkin (DG) method for acoustics in the time-domain is available. Combining the discontinuous Galerkin method with the new absorbing layers in the time-domain results in memory efficiency. The complete suite of computational tools allows users to create apps for the benefit of colleagues and customers. With version 5.2a, app designers can build more dynamic apps where the appearance of the user interface can change during run time, centralize unit handling to better serve teams working across different countries, and include hyperlinks and videos. Apps can be deployed throughout organizations using the COMSOL Client for Windows or web browser by connecting to a COMSOL Server installation. Version 5.2a features include core technology to specialized boundary conditions and material libraries. For example, the tetrahedral meshing algorithm with an included quality optimization algorithm makes it easy to create coarse meshes to study complicated CAD geometries that feature thin parts. Visualizations include annotations with LaTeX formatting, improved table surface plots, VTK export, and new color tables.

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FE ATURE S INCLUDE: 1/ GEOMETRY AND MESH: The enhanced tetrahedral meshing algorithm creates coarse meshes for complicated CAD geometries that feature thin parts. An optimization algorithm built into the mesher is available for improving element quality, which may improve the accuracy of a solution and make it faster to converge. Interactive drawing for 2D geometries now features better coordinate display and snapping points. 2/ MATHEMATICAL MODELING TOOLS, STUDIES, AND VISUALIZATION: Three new solvers are introduced: the smoothed aggregation algebraic multigrid method (SA-AMG), the domain decomposition solver, and the discontinuous Galerkin (DG) method. Users can now save data and plots added to the Export node under Results in VTK format, making it possible to import COMSOL simulation results and meshes to 3rd party software. 3/ ELECTRICAL: The Ac/dc Module features a material model for magnetic hysteresis built-in called Jiles-Atherton. The lumped two-port network coupling is in the RF Module, allowing for lumped modeling to represent parts of a microwave circuit in a simplified way without having to model the details.

4/ MECHANICAL: The Structural Mechanics Module includes the adhesion and decohesion features, available as a subnode under the Contact feature. A Magnetostriction physics interface supports both linear and nonlinear magnetostriction. The nonlinear material modeling capabilities have been expanded with plasticity models, mixed isotropic and kinematic hardening, and large-strain viscoelasticity. 5/ FLUID: The CFD Module and Heat Transfer Module includes a feature that adds a gravity force and concurrently compensates for the hydrostatic pressure on boundaries. A linearized density option in Non-Isothermal Flow, a common simplification for natural convection flows, is available. 6/ CHEMICAL: Battery manufacturers and designers can model complex 3D assemblies in battery packs using the Single Particle Battery physic interface available in the Batteries & Fuel Cells Module. Additionally, a Reacting Flow Multiphysics physics interface is available. DW

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LVIT technology offers more flexibility for less cost Edited by: Paul J. Heney • Editorial Director

• Figure 1 LVITs, or Linear Variable Inductive Transducers, have been around for

• Figure 2

more than 30 years. They are relatively low cost, contactless position sensing devices that use eddy currents developed by an inductor in the surface of a conductive movable element—that is mechanically coupled to the moving object whose position is being measured. The common form of an LVIT uses a small diameter inductive probe surrounded by a conductive tube called a “spoiler.” Typical LVITs have full ranges from fractions of an inch to 30 or more inches. Modern electronics using microprocessors make possible outstanding performance, achieving linearity errors of less than ±0.15% of FSO and temperature coefficients of 50 ppm/°F, along with either analog or digital outputs. See Figure 1 for a cutaway view. LVITs are used in many factory automation applications, including packaging and material handling equipment, die platen position in plastic molding machines, roller positioning and web tension controls in paper mills or converting facilities, and robotic spray painting systems. Being contactless, the basic measurement

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mechanism of an LVIT does not wear out over time due to rapid cycling or dithering like a resistive device. LVITs also offer a much lower installed cost than that of most other contactless technologies. While Figure 1 shows a LVIT that is intended to be attached to the part it is measuring, LVITs can also be spring loaded, as shown in Figure 2. The natural question is: where does one use a spring-loaded LVIT sensor versus another spring-loaded technology such as an LVDT gage head? In fact, LVITs can be used in place of traditional gage heads primarily because, electrically, an LVIT offers the same resolution and repeatability and, mechanically, the same outer diameter and an external mounting

www.designworldonline.com

8/1/16 2:12 PM

thread, but with about half of the length of the gage head, making the stroke-to-length ratio of an LVIT substantially better. And all of these features come at a markedly lower cost. Why use a 9-in. long sensor to measure 1 in. of travel when the same performance can be achieved with a 4-in. long LVIT sensor? LVIT-based gaging applications in factory automation typically mirror those for traditional gage heads. When compared to LVDT pencil gaging probes, a spring-loaded LVIT can satisfy many of the same applications: automotive, medical and mil/ aero test stands, robotic arms, part placement, and shop-floor dimensional gaging applications. Pencil probes are typically selected for one of two reasons: resolution and repeatability, or size. Pencil probes are smaller (either 8 mm or 0.375 in. OD) than LVITs and have resolution and repeatability of 4 millionths of an inch. However, a pencil probe requires a separate LVDT signal conditioner, making the cost per channel typically double the cost of an LVIT. If an application does not require the specific features of a pencil probe, a spring-loaded LVIT is a much lower cost alternative. Some factory automation applications that have been solved by proximity sensors can be better satisfied with LVIT technology, which offers a proportional analog output, giving greater control flexibility than merely an NPN or PNP TTL switching signal. The spring-loaded LVIT shown in Figure 2 has an 18 mm thread on its housing, matching a thread commonly used by proximity sensor manufacturers. With an LVITâ&#x20AC;&#x2122;s short body length, the sensor can fit in places or mountings where there previously was a proximity probe. All LVIT products offered by Alliance Sensors Group feature the companyâ&#x20AC;&#x2122;s SenSet field programmable scaling, which allows a user to adjust for any mechanical variations after installation in the application simply by pushing a button or grounding a single connection. This reduces setup time and total cost of ownership. As a typical example, consider a 6-in. range LVIT being used to measure the position of a process valve stem that moves 5.5 in. By using SenSet to scale the output of the sensor after it has been installed, the full 4-20 mA output can be obtained over the 5.5 in. that the stem actually moves. DW Alliance Sensors Group

alliancesensors.com August 2016

Sensor Notes 8-16_Vs3.LL.indd 47

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I nter net of Things

By Dan Roberts • Senior Consultant • Cambashi

With the growth of embedded software and the Internet of Things (IoT), we’ve had much discussion about which industries these tools are used in. We have coined the term “Smart Industries” for those products that incorporate the IoT. Initially, we selected these Smart Industries by using the experience and knowledge of experts that understand which products contain significant amount of embedded code. However, as our observatory research becomes more sophisticated, we can use this tool to pinpoint these industries for us and thereby track the development of IoT-enabled products across industry sectors.

Software developers for embedded software The Employment Observatory shows the number of employees in particular occupations by industry and country. A quick look for software developers in manufacturing industries found that the US was way ahead of the other countries (see figure 1). The number of software developers in manufacturing ought to be an indication of the amount of embedded software development taking place. Although some manufacturing companies do some development of tools to run their business (for example, Tesla has developed its own ERP system), these are unusual. Most of the

Figure 1 The Employment Observatory chart shows the number of employees in particular occupations by industry and country. In manufacturing industries, the US was way ahead of the other countries.

DESIGN WORLD

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software developers in manufacturing companies are there to develop products or improve production processes. After the US, the next 5 countries all have more than 50,000 software developers: Germany, Russia, China, UK and Japan.

Which are the smart industries? What about the industries? Figure 2 shows the total number of software developers in manufacturing by 2-digit ISIC code (that’s the International Standard Industrial Classification, used by the UN). Unsurprisingly, the sector for manufacturing of computers and electronics employs the most software developers. Next up is manufacturing of other transport equipment. This sector includes aerospace, shipbuilding and train locomotive manufacture. Although aerospace is not the next biggest manufacturing sector worldwide, it is at the forefront of adding

Figure 2 Here is the total number of software developers in manufacturing by the 2-digit International Standard Industrial Classification (ISIC) code used by the UN.

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... .. embedded software components, for example, automatic pilots and navigation equipment. Locomotives are also heavily instrumented now and interface directly with track-side monitoring and signaling systems. Manufacturing of machinery is next. This is a large sector that is also keen to include smart capabilities. Much of the equipment is used by other manufacturers in their factories. Machinery manufacturers are adding sensors to track machine performance, alongside embedded software to process the resulting data. Fourth on the list is the automotive industry. If this chart tracked the number of engineers, automotive would be right behind other transport equipment, with almost as many engineers. But automotive employs less than half the number of software developers (despite Tesla’s ERP development efforts). However, the automotive industry has been adding embedded software into cars and trucks for some time.

Are they really smart? But are these industries really focusing on producing smart products, or are they just the largest sectors? If we look at the proportion of software developers compared to all employment, this should reveal the sectors that are truly implementing smart technologies (see figure 3). Again, computer and electronics manufacturing tops the list, with other transport a distant second. The industries in third and fourth are more interesting. Oil refineries make up the bulk of the third-place sector. Pharmaceutical manufacture is in fourth. These industries need to monitor their processes carefully. Refineries are concerned primarily with safety - although tracking what products are being 50

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Figure 3: Here are the manufacturing sectors implementing smart technology.

made is also important. Pharma companies are worried about traceability and meeting regulatory requirements. IoT helps these companies to monitor the sensors that are in place, to enable tracking, safety and ensure optimum maintenance scheduling. To give some more detail on that top sector, here is the data broken down by sub-industry: This shows quite nicely that the manufacture of computers and peripherals (printers and so on) have a high proportion of software developers. This may be because many of these manufacturers ship custom software pre-loaded on their products. Indeed, this may not really be what we think of as embedded software at all, since it’s probably installed on regular computers. However, we should also not forget things like printer interfaces, which will require a significant amount of embedded software. The instrumentation sectors—optical instruments, medical devices and control equipment—all have significant proportions of

software developers. These are what we think of as the smart industries. Manufacture of communications equipment includes phones, as well as routers, switches and broadcast equipment for radio and TV. Smart phones are in this sector and can be thought of in much the same way as computers. The other communication equipment comes with embedded software to help manage and monitor the systems. Again, these are smart industries.

Where are they? The US has by far the most software developers in manufacturing, but are all of the smartest industries in the US? There are a lot of individual data points to consider here - 57 countries by 22 industries is 1254 data points. The chart (figure 5) is deliberately small, so that you can see the pattern. The data displayed are the proportion of employees that are software developers. The countries are ranked from left to right in increasing order of overall manufacturing software developer

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... .. proportion. The manufacturing industries are ranked from bottom to top in increasing order of software developer proportion. The highestranked country/sectors should therefore appear in the top right. The blue squares are the top 2%, orange is the next 2%, yellow the third 2%. The white squares represent the remaining 94%. Most of the blue squares appear in the top row—manufacturing of computer, electronic and optical products. However, a few stand out. Most surprising is that Israel is the top-ranked country for proportion of software developers. In Israel, as well as computer manufacturing, manufacturing of other transport equipment and coke and refined petroleum products make the top 2%. In Switzerland, computer and electronics manufacturing does not make the top 2%, but manufacturing of electrical equipment does. In the US, manufacturing of other transport equipment makes the top 2%. In the Netherlands, manufacturing of basic metals makes the top 2%. This is despite the sector not making even the top 6% in any other country. Some other stand-out sectors are manufacturing of electrical equipment in Croatia and Qatar, which both make the top 4% and manufacturing of chemicals in Israel, Norway and Denmark which makes the top 6%.

Figure 4: Here is the data from Figure 3 broken down by sub-industry. The manufacture of computers and peripherals has a high proportion of software developers.

Surprising omissions are France and Italy, which do not have any sectors in the top 6% and the automotive industry, which has no countries in the top 6%.

Conclusions If the chart in figure 5 had used total number of software developers, rather than proportion of employment, then it would have looked different. So vendors targeting smart industries must take into account the total employment as well as the relative level of ‘smartness.’ However, the proportions help

us to spot the industries that are focusing on adding embedded software to their products or production processes. If you’re selling IoT development tools, there are three things to ensure: • Sell in the US (figure 1). • Target computer and electronics manufacturers (as per figure 4). • Watch out for hot spots - highlighted in figure 5. DW Cambashi www.cambashi.com

Figure 5: This chart shows the pattern of the proportion of employees that are software developers by country. The countries are ranked from left to right in increasing order of overall manufacturing software developer proportion. The manufacturing industries are ranked from bottom to top in increasing order of software developer proportion. The highest-ranked country/sectors should therefore appear in the top right.

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Global reach with a personal touch.

Wireless I/O modules The series of 2.4G WISE-4000 IoT Wireless I/O modules is for gathering data from remote or difficult to wire locations. These modules feature RS-485 ports, analog, and digital signal models. These wireless Ethernet I/O modules can be used without the need of a gateway to provide information. With integrated digital input and RS-485 in the same module, the WISE-4051 provides a flexible combination of I/O to acquire digital signal and data from Modbus/RTU slave devices. The RS-485 port can also support data log functions from Modbus/ RTU slave devices with time stamp, preventing data loss compared to traditional transparent Ethernet COM ports (virtual COM of serial device server). The WISE-4051 can automatically push data to the cloud. Its data logger can send time stamped information to a Dropbox account, or a private cloud depending on the configuration, and it can also buffer a devices’ data so that in the event of network failure, no data are lost before they are sent to the administrator. The private server function allows the modules to push data to specific web server by the RESTful web service and MQTT protocol with WebAccess. The helps reduce the effort of acquiring big data. DW

 Partnership & collaboration  Solution provider  Family operation

The five WISE-4000 modules are: 1. WISE-4051 eight channel digit input IoT wireless I/O module with 1 RS-485 port. 2. WISE-4012 four channel universal input, two channel digital output Wireless I/O module. 3. WISE-4050 four channel digital input, four channel digital output wireless I/O module. 4. WISE-4060 four channel digital input, four channel relay output wireless I/O module. 5. WISE-4012E six channel input/output wireless I/O module with WebAccess. Advantech advantech.com

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... Ethernet spanner for multiple ........ ...... .... ..Ethernet protocols on one network

The TBEN-L Ethernet spanner is a protocol converter for applications dealing with multiple protocols on the same network. It uses multiprotocol technology and serves as an easy way to link multiple Ethernet networks togetherâ&#x20AC;&#x201D;even networks that speak different protocols. Its master-to-master data exchange allows PLCs to exchange data easily. The device allows isolated networks to pass data between them (up to 256 bytes), even if the networks are on different Ethernet subnets or using different protocols such as Modbus TCP, PROFINET or EtherNet/IP. Additionally, by using the isolated Ethernet network, the TBEN Ethernet spanner can setup a NAT (Network Address Translation) router for up to 5 IP addresses. The devices also include an embedded webserver for a streamlined setup and configuration process. The TBEN-L spanner offers 16 digital inputs that are available to both networks and allows data transfer speeds of up to 100 megabits per second. Additionally, the spanner comes in a glass-fiber reinforced housing with fully potted electronics and offers a IP65, IP67, or IP69K rated housing. DW Turck turck.com 54

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I nternet of Things

N E WS :

Industry focused and solution driven.

Get more visibility into plant operations

 Food & beverage

The Brilliant Manufacturing Suite module, Plant Pulse Optimizer, enables manufacturers to run their plant on up-to-date production, inventory, quality and product delivery information rather than intuition for the purpose of continuous process improvement. Plant Pulse Optimizer delivers broad visibility to all plant personnel quickly and improves operational execution by coordinating isolated activities. This program provides a Panoramic view of all production activity for all factory personnel through real-time, multi-shift based KPIs (machinematerial-labor-product intelligence) as scorecards. The module provides insights focused on production analytics to organize manufacturing data into a structure to provide information on inventory, yield and achievement of production plans. The module is also device and back-end agnostic, which allows it to be connected to both GE and non-GE manufacturing operations systems. Plant Pulse Optimizer is an out-of-the-box system that requires minimal configuration. The “card”-based views aid in execution for various roles within the plant, with associated drill down cards to allow quick identification of bottlenecks at the operation level. DW

 Metal & steel  Mobile automation  Construction & agriculture  Warehousing & logistics  Assembly & handling

GE Digital www.ge.com/digital

WHAT DO YOU THINK?

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

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qp-designworld-full-page-ad-1115.indd 1 3D Systems 12-15_MPF.indd 56

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I nternet of Things

N EWS: ........................................ .............................. ...................... ................. Precise, ............ ......... Predictive analytics for ...... reliable .... .. digital twins products for

the world’s applications.

The Simcenter portfolio is a suite of simulation software and test products. It combines simulation and physical testing with intelligent reporting and data analytics to help produce digital twins that more accurately predict product performance throughout all stages of the product development process. Within this portfolio is a next generation 3D CAE program built on the Siemens’ NX software platform, combining the capabilities of several programs to cover a range of simulation disciplines and industry applications. It includes computational solid mechanics (CSM) and finite element analysis (FEA), computational fluid dynamics (CFD), multibody dynamics, controls, physical testing, visualization, multidisciplinary design exploration, and data analytics. These technologies are then managed in a PLM context, using Siemens’ Teamcenter software. Within Simcenter, the applications will also leverage the Industrial Internet of Things (IIoT) through the integration of sensor-based data with high-fidelity, physics-based simulations, allowing manufacturers to build and maintain digital twins of their products and to keep them in-sync with the physical product in use. DW

 Distance measurement  Motor feedback  Quality & error-proofing  Heavy duty & harsh environments

Siemens Digital Factory Division , Siemens AG www.siemens.com/plm

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Minimizing stepper vibration with

affordable technology Kazuki Into • Circuit Development Manager • Oriental Motor USA Corp.

This is the board-mounting version of Oriental Motor’s CVD driver. It has right-angle connectors. The driver monitors phase currents individually to improve current control, so it tracks five different currents separately — or in the case of a two-phase driver, four different currents. 58

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M o t i o n

C o n t r o l

Because stepper motors run and then stop at each step angle, they deliver high-accuracy position control. But the way they incrementally advance causes vibration and noise. Now, some drivers use advanced electronics to track and control current into motors as a way to achieve smooth motion from two-phase microstepping setups.

Stepper motors should operate over all speed ranges without vibration. But real-world steppers vibrate when running at low, middle and high speeds with what’s called rotation vibration. That’s because rotor speed varies between each move to a main step angle. Suppressing rotation vibration at all these speeds is a challenge, but some setups use microstepping of the stepper motor as the first line of defense. Remember that microstepping is a control technology that divides the basic step angle of a motor by controlling current flow through the motor windings. Reducing the step angle effectively minimizes speed variation when moving one step forward, which helps minimize vibration and motor buzzing. Unfortunately, microstepping is often insufficient to mitigate all vibration. So, one newer approach to suppress vibration is current control. Here, in addition to microstepping, a microprocessor tracks and controls individual phase currents with advanced algorithms. As we’ll explore, this design also leverages the fact that precisely controlling current running through motor windings can make the motor run more smoothly.

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M o t i o n

C o n t r o l

This is the plate-mounting version of Oriental Motor’s CVD driver. It has parallel connectors. The driver comes as as a standalone product or packaged with a compatible stepper motor.

New stepper option put in context Consider five-phase stepper-motor technology. One advantage of such setups is that circuits can use an all-phase current-detecting method that simultaneously monitors currents from all five cables into the motor. This traditional method of tracking motor input only needs one detecting circuit, so the circuit is simple. But this method can’t detect backflow current that never goes through the sensing circuit. Because of this, current control can become unstable, necessitating extra driver features to fully mitigate vibration. Conﬁguration of power ampliﬁer New vibration-suppression drivers track individual current phases to control current. They detect the five different Two-phase H bridge currents separately — or in versions of the Two-phase PWM B-Phase H Bridge A-Phase H Bridge Pause A driver for two-phase vibration-suppression, B four different current controls. Here, D E Voltage directive the driver has a microprocessor running A (Two-phase AC) B advanced algorithms programmed to D maximize torque with current correction. E Current feedback (Two-phase AC)

This is the configuration of the power amplifier in the driver for a two-phase stepper motor.

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Maximize output with motor’s electromagnetic profile Remember that motor output torque is proportional to input current when the Two-phase stepper motor latter is below rated current. But consider what happens when current goes higher. Here, the driver applies to the windings a current that comes to exceed rated current, due to the magnetic saturation phenomenon caused by armature reaction of the magnetic flux. It is then that the relationship of the current and torque gradually strays from its proportionality.

So to increase a motor’s output torque, motion designs must effectively use this range of nonproportional motor response. New vibration-suppression drivers apply the individual-phase current detecting method with microprocessor technology running advanced algorithms. These setups pair advanced microstepping with functions to get smooth microstepping at all speeds. In addition, some vibration-suppression drivers offer advanced microstepping functions. Case in point: One proprietary option for smooth driving enables good low-vibration operation from a microstepping driver with the flick of a dip switch on the driver circuit board. The smooth-drive function automatically controls the motor’s microstep drive operation at the same travel and speed as in full-step mode, without making the operator change speed settings of the driver’s pulse input. So the function eliminates the need to increase pulses to the driver. Consider how most microstepping drivers offer resolution to 0.007° or 51,200 microsteps per revolution. In contrast, vibration-suppression stepper drivers that take the form of two-phase bipolar drivers automatically microstep 0.0008° or up to 2,048 steps per full 1.8° step of the motor. With the smoothdriving feature enabled, the drivers significantly improve overall

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Torque

Ideal characteristics

C o n t r o l

M o t i o n

Distortion of current-torque characteristics

As current becomes higher, that applied to the windings exceeds rated current (defined by magnetic saturation caused by armature reaction of the magnetic flux). Then the relationship of current and torque gradually becomes non-proportional. Getting the most from stepper motors requires that designs work around this behavior.

Actual characteristics

Comparison of 3,200 P/R and 1.8˚ motors

Correcting sinusoidal current into motor Another way to smooth motor output is to minimize torque ripple, which is the fluctuation of output torque when changing excitation phases. Here, some algorithms correct sinusoidal current into the motor. If the relationship of the motor current and generated torque were a linear form, torque ripple wouldn’t arise from current changes at each phase to a sinusoidal wave. However, the relationship of the motor current and generated torque is not linear. Therefore, torque distortion arises when changing current at each phase of the sinusoidal wave. This happens when current is high — and that in turn causes vibration. So dealing with high output torque and low vibration at the same time requires an additional control. To solve this issue, some vibration-suppression stepper drivers appropriately correct the phase of the sinusoidal current supplied to the motor, known as phase control — or properly switch the electrical phases at critical times. These switching times are based on the most common characteristics found in stepper motors. As these characteristics are unique from motor to motor, such drivers use proprietary phase control technology for specific motor sizes and input currents to get ideal performance. The program does this by matching rated motor current to driver current. In other words, it matches the maximum current value of the motor to maximum of the driver — for example, a 2.8-A motor to a 2.8A driver. This phase control corrects the distortion of current-torque characteristics, so it concurrently mitigates low vibration and maintains high output torque. This in turn improves stop-position accuracy. Activating phase correction dramatically reduces peak vibration values. The optimized level of phase correction depends on the motor’s magnetic properties, so the correction value is best set to cater to specific motor-driver combinations. That’s why vibration mitigation with this method depends so heavily on well-paired motors and drivers. DW

Oriental Motor USA Corp. www.orientalmotor.com

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1.0 CVD233-K/ PKP246D23A Conventional 1.8° driver-motor

0.8 0.6 0.4 0.2 0

100

200

300

400

500

600

Speed (revolutions/min.)

The 3,200 P/R is a 0.1125˚ per-step motor. A CVD vibration-suppression two-phase bipolar stepper driver (running a proprietary Smooth Drive algorithm) automatically microsteps up to 0.0008° or 2,048 steps per full 1.8° motor step. In this way, Smooth Drive significantly improves performance at all speeds, and not just lower speed ranges — drastically reducing vibration that can cause step errors.

Improvement of rotation vibration with phase correction Vibration component voltage — Vp-p

performance across all speed ranges, not just at slower speeds — drastically reducing vibration that can cause step errors. This gives design engineers a wider design window of motor speed with a set level of performance.

Vibration component voltage Vp-p (V)

Current

0.3

Correction not activated Correction activated

0.2

0.1

100

150

Speed (revolutions/min.)

This is just one example of how controls address vibration. This plot shows phase correction with a CVD228-K and PKP266D28AA two-phase motor and bipolar driver package from Oriental Motor. Notice how activating phase correction dramatically decreases the peak vibration value.

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L i n e a r

M ot i o n

Gaining a measurement edge

Encoders help linear motion stages reach higher levels of accuracy and performance Edited by Miles Budimir

Application demands of modern motion systems are pushing the envelope for greater accuracy and finer resolution. Case in point; laboratory equipment with demands for high accuracy positioning of test samples, such as in microscopes. When it comes to measuring position, linear encoders are among the best choices. Linear encoders monitor linear movement and provide position feedback in the form of electrical signals. Common sensing schemes include optical and magnetic technologies. Thorlabs, a U.K.-based company that designs and manufactures an array of photonics equipment, recently selected encoders from Renishaw for a number of its linear stages used in laboratory test equipment. Thorlabs subjected Renishawâ&#x20AC;&#x2122;s TONiC encoders to a number of tests in direct competition with other optical encoder brands. The TONiC series outperformed the competition in every test and was selected to equip both the Thorlabs DDS600 600 mm long travel stage and the MLS203 microscope stage.

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The measurement principle of the TONiC encoder system from Renishaw is optically based. Design features such as filtering optics to support good signal stability and substrate materials optimized to minimize errors from thermal effects improve performance in high accuracy applications.

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L i n e a r

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Linear encoders Optical encoders use a light source and a photo-detector to determine position, but their use of light makes them sensitive to dirt and debris, which can disrupt the signal. The performance of optical encoders is highly influenced by the gap between the sensor and the scale, which must be properly set and maintained to ensure that signal integrity is not compromised and that measurement accuracy is not negatively impacted. This means that mounting must be done carefully, and shocks and vibrations should be avoided. The real benefit of using a linear encoder is a marked improvement in quality of the final process or output, whether cutting, dispensing, or positioning. Laboratory automation is a perfect example. Many linear motion systems in laboratory equipment use

stepper motors for lower cost, but need position feedback to avoid damage to the machine or loss of expensive test samples. In Thorlabs’ case, the Renishaw linear encoders met the design specifications for high-performance motion control. For instance, the company’s DDS600 low-profile stage requires high-speed translation with high positional accuracy and is designed for surface mapping and characterization applications where there’s a need to move a camera or probe at constant velocity while simultaneously capturing data. And the company’s MLS203 X-Y scanning stages are dropin replacements for the manual stages found on select microscopes, providing motorized X-Y positioning of microscopy samples. The MLS203 is compatible with inverted and upright microscopes from Nikon, Olympus and Zeiss. Optional adaptor brackets allow integration with other microscopes, optical tables and custom-built applications.

Higher performance Measuring 800 mm (L) x 130 mm (W) x 50 mm (H), the DDS600 stage consists of a platform mounted onto a linear axis and driven by a linear dc synchronous motor. Linear motors eliminate the need for mechanical couplings, allow backlashfree operation of the motion stage and enable highly repetitive operations that would otherwise cause wear in a traditional motorized lead-screw. Thorlabs required high-quality velocity feedback to commutate the linear motor and meet the demanding metrology requirements of a high accuracy scientific motion stage. A compact high-performance encoder readhead was specified to integrate with low-profile motion stages without sacrificing stage rigidity, as is common when removing material to accommodate larger package sizes. Thorlabs carried out a failure mode analysis on the DDS600 design that highlighted the encoder signal cable as one of a few theoretical potential points of failure. Renishaw technical support shared data that provided information on cable lifetime expectations, which were subsequently evaluated independently by Thorlabs under soak test conditions to verify the failure mode assessment. These test results showed that Renishaw’s hi-flex

The TONiC encoder system from Renishaw features the RGSZ tape scale, a gold-plated steel ribbon that helps significantly reduce thermal errors.

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Haydon Kerk® Linear Actuators...

SOLUTIONS IN MOTION High performance, precision linear motion technology Size 17 43 mm2 (1.7-in)2 Double Stack external, non-captive, captive hybrid linear actuator stepper motors

25000 Series G4, can-stack captive, non-captive, external linear actuator steppers 25 mm (1.0-in) diameter

Size 34 87 mm2 (3.4-in)2 captive hybrid linear actuator stepper motor. Non-captive and external linear also available.

Size 17 - 43 mm2 (1.7-in)2 non-captive hybrid linear actuator with programmable IDEA™ stepper motor drive Size 8 21 mm2 (0.8-in)2 captive hybrid linear actuator stepper motor. Also available in Single and Double Stack, non-captive and external linear.

Haydon Kerk Motion Solutions hybrid and can-stack linear actuators continue to offer equipment designers new motion control solutions that provide unmatched performance-to-size ratios, patented technologies and thousands of configuration options, and a vast experience in customized solutions. HYBRID actuators are available in six sizes from Size 8: 21 mm2 (0.8 -in.) to Size 34: 87 mm2 (3.4-in.) – capable of delivering up to 500 pounds (2224 N) of force. Travels per step range from .001524 mm (.00006-in) to .127 mm (.005-in), with micro stepping capability for even finer resolution. An integrated, programmable IDEA™ Drive is also available for Size 17 hybrids. The G4 Series represents the industry’s most robust and most powerful CAN-STACK linear actuators. The G4 Series offers diameters of 20 mm (.79-in), 26 mm (1-in), and 36 mm (1.4-in). The can-stack product line also includes motors with diameters of 15 mm (0.59-in), 20 mm (.79-in) , 26 mm (1-in), 36 mm (1.4-in) and Ø 46 mm (1.8-in), available with captive, non-captive or external linear lead-screws. Haydon Kerk Motion Solutions continues to be an innovative motion control technology company with a global network of people, facilities and services dedicated to engineering and manufacturing the world’s most advanced linear motion solutions. For more information: www.HaydonKerk.com > Linear Actuators

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L i n e a r

M ot i o n

MLS203 x-y scanning stages from Thorlabs feature a minimum 100-nm step size and a maximum speed of 0.25 m/sec.

encoder cables perform between 60 and 80% above the specified lifetime, giving Thorlabs the confidence to accurately predict product service life. The DDS600 stage features a light aluminum construction to minimize the inertia of moving parts and high-rigidity recirculating bearings to increase load bearing capacity and lower maintenance costs. The scale of a typical encoder, attached in some way to the machine structure, is the basis for measurement performance of the system. In general, the scale and supporting substrate are made from different materials, which results in a thermal displacement mismatch due to differing values for the coefficient of thermal expansion (CTE). Although aluminum has a significant CTE compared with other materials, such as granite, its extremely high thermal conductivity minimizes the build-up of thermal gradients within the stage structure and allows effective real-time thermal error compensation. Thorlabs selected Renishaw’s TONiC readhead, which measures 10 mm (H) x 35 mm (L) x 13.5 mm (W), with 5 nm resolution. It’s combined with the RGSZ self-adhesive tape scale, which is essentially a gold-plated steel ribbon of 6 mm x 0.1 mm cross-section, and significantly reduces thermal errors while satisfying other performance criteria. RGSZ is mastered to the axis substrate with epoxy-fastened end clamps and expands precisely with 68

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“Optical encoders use a light source and a photo-detector to determine position, but their use of light makes them sensitive to dirt and debris, which can disrupt the signal.”

it, ensuring the elimination of hysteresis for completely predictable metrology, as well as easy installation without the need for fixing holes. Differential movement between the scale and substrate is effectively zero, even with significant temperature fluctuations. With Renishaw’s TONiC encoder system, the DDS600 stage performance made possible a minimum 100 nm stepsize, ±0.25 μm bi-directional repeatability and a maximum speed of 0.4 m/sec. For the design process for the MLS203 X-Y fast scanning stage, Thorlabs used in-house testing to evaluate encoder performance. When choosing an appropriate position feedback system to be deployed within the MLS203, a potential concern was the risk of sample spillage and the effect this would have on position control. The dirt immunity performance of a number of competing encoder products was evaluated by the application of isopropyl alcohol, as a liquid contaminant, and common salt, in place of debris,

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Mechatronics Enabled

™

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For applications small to x-large...

Bring mechanical design and electronic motion control together with an optimized solution.

PBC Linear’s full range of linear slides and actuators are easily integrated for a completely automated mechatronics solution. See all Mechatronics Enabled motion systems at www.pbclinear.com

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L i n e a r

M ot i o n

I’ll carry that for you! with precise straight line accuracy

Del-Tron’s

Ball & Crossed Roller Linear Slides carry loads up to 779 lbs! These light weight slides offer engineers and designers the flexibility to choose the right linear slide technology for their application. Manufactured in the USA, our ball and crossed roller slides offer several levels of precision ranging from a straight line accuracy of 0.0005” per inch of travel in our standard precision slides to 0.0000040” per inch of travel in our high precision slides. Available with inch or metric holes and hole locations these factory preloaded, low friction slides are ready for installation right out of the box!

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to the encoder scales. Testing showed that Renishaw’s TONiC encoder system outperformed competing encoder products. This qualitative result allowed Thorlabs to determine that the TONiC encoder would not be susceptible to performance degradation as a result of contamination. The MLS203 X-Y fast scanning stage is equipped with a 20 nm version of the TONiC RGSZ encoder system on both X and Y axes of 110 mm and 75 mm, respectively. The MLS203 measures just 260 mm (L) x 230 mm (W) x 31 mm (H) and uses the same linear motor technology as the DDS600. In addition to criteria outlined for the linear stage, calibration is an essential operation that completes readhead set-up during final installation, with the optimum incremental and reference mark settings stored in the readhead’s non-volatile memory. Integral LEDs on TONiC’s readhead and interface allow optimum set-up and system diagnosis that further simplify installation during manufacture and servicing with particular benefit for multi-axis machines. Similar to DDS600 stage performance, the MLS203 stage features a minimum 100 nm stepsize, ±0.25 μm bi-directional repeatability, ±0.25 μm homing accuracy and a maximum speed of 0.25 m/sec. DW Renishaw www.renishaw.com Thorlabs www.thorlabs.com

Precision Linear Motion Required. Del-Tron Preferred. • Accuracy ranging from 0.0005”/” to 0.0000040”/” of travel. • Low friction straight-line design reduces the coefficient of friction to 0.003.

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C o n t r o l l e r s

Select the right

machine controller for your application

Picking the right type of machine controller will minimize costs

and complexity, while still providing the performance required for the application. Don Pham â&#x20AC;˘ Product Manager â&#x20AC;˘ IDEC 72

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Many different controller options are available for machine automation, giving you the opportunity to select a controller closely matched to the application. All those choices can cause confusion. The Controller Comparison Table lists some of the leading characteristics of each type of controller to help guide your selection. Let’s start with a class of controller often used in simple applications due to its low cost, small form factor and ease of implementation. Educated relays Relay-based controllers were very basic when first introduced and only suitable for use in place of a few relays and timers. But now, the capabilities of these smart relays are approaching those of micro PLCs, making them a good choice for control of simple machines. These expanded capabilities have led to increased demand with more than a million units purchased per year and an annual projected growth rate of 6%. Most smart relays come with an integral front panel alphanumeric display (Figure 1), and some also feature an optional external text display panel. Typically, both displays show the same information, with the external display used when the base unit is mounted inside a control enclosure and thus not visible during normal operation. Although most smart relays can be programmed through their display, it’s more common to use PC-based programming software, which is usually supplied free of charge with the relay. Once programmed, at least some of the smart relay’s settings, such as alarm settings and other values, can typically be modified with its display. Newer smart relays have an Ethernet port in addition to a serial or proprietary communication protocol port. This Ethernet port can be used for connection to the PC for initial programming, and then for connection to other devices once programming is complete. These other devices might include the external text display panel, other smart relays or an Ethernet switch. Some newer smart relays have built-in web server capability, allowing web pages to be programmed and stored in the unit for remote access with any web browser. This feature connects the smart relay to

Figure 2. Newer micro PLCs are approaching the capabilities of older model PACs, putting pressure on PACs to add new features and capabilities. All images courtesy of IDEC. www.designworldonline.com

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Combo Controllers Specialty controllers include combo, motion and hydraulic controllers. Combo PLC+HMI controllers combine the operator interface, controller and I/O into one unit (Figure 3). When compared to a separate controller and operator interface, combo units cut costs, reduce required footprint and simplify integration. Costs are reduced because upfront purchase price is less, there are fewer components to install and wire, and there are fewer components to stock. Integration is easier because there’s no need to establish a connection between the controller and the operator interface device. Although combo units traditionally weren’t as powerful as PLCs or PACs, their capabilities have expanded over the past few years to include analog I/O and control, Ethernet connectivity and web server functionality. Motion controllers are a good fit for machines with lots of motion functions, but with few other real-time control requirements. Although these units excel primarily at motion control, many also include I/O and logic capability to control a limited number of discrete and analog inputs and outputs. Although many PLCs, most PACs and all IPCs can perform motion control, using a dedicated motion controller can simplify programming, startup and maintenance. Another type of specialty controller is dedicated to hydraulic systems, making them the right choice to control hydraulic machines. As engineers like to say, given enough time and budget virtually any controller can be programmed to accomplish any task, including control of a complex hydraulic system. But, using a controller dedicated to this specific function provides the best tool for the job, reducing design and programming time and costs, and simplifying startup. Like motion controllers, most hydraulic controllers contain logic and additional I/O for control of other points in addition to hydraulic systems. Expanding options to include specialty units such as combo PLCs+HMIs, motion controllers and hydraulic controllers gives designers increased flexibility, allowing them to match machine requirements more closely to controller capabilities.

C o n t r o l l e r s the world through the internet, useful for remote access. Some suppliers are also writing smartphone apps to enable communications with their smart relays with Apple and Android phones, which greatly increases speed and ease of remote access. Ladder logic or function block are the programming languages of choice, which makes it easy to write efficient programs for simple operations. Internal program storage is limited, so operations can’t be overly complex. Smart relay I/O used to be strictly discrete, but analog I/O is now becoming available on some newer units. With respect to maximum allowable I/O, IDEC’s FL1F SmartRelay can handle up to 60 I/O with its base unit and expansion model. These 60 I/O consist of a maximum of 24 discrete inputs, 20 discrete outputs, 8 analog inputs and 8 analog outputs. When this amount of I/O isn’t sufficient, or when other features are required such as a graphic display or more sophisticated control, the next step up is a PLC or a PAC. Is it a PLC or a PAC? Programmable logic controllers (PLCs) and programmable automation controllers (PACs) are the main engines driving machine control worldwide, and with good reason. Starting with the introduction of the PLC as a relay replacement in the 1960s, these controllers have grown to dominate the machine control market. Annual purchases exceed 8 million units with a growth rate of about 7%. Although there is no clear line defining the difference between a PLC and PAC, in general PACs add more capabilities than PLCs, particularly for control of very complex systems. PACs can handle advanced motion control, incorporate vision systems and perform advanced control of analog loops—a set of tasks that might unduly burden a PLC.

Figure 1. Smart relays are typically supplied with an integral display, and often with an external display mimicking the same information.

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Figure 3. Combining the operator interface and the PLC into one unit is an attractive option for many OEMs building simple machines and looking to keep costs down.

These controllers run the range from micro PLCs with about 32 built-in I/O points, to full-featured PACs capable of handling tens of thousands of I/O. For example, the Micro PLC pictured in Figure 2 can handle up to 520 I/O total, and 126 of these I/O points can be analog. Although this controller is labeled as a Micro PLC, it approaches PAC power in many respects including execution speed and program memory. Multiple operator interface options can be used for PLCs and PACs. The first is

the supplier’s operator interface graphics terminal, often connected to the controller with a proprietary interface. The second is an embedded HMI, which consists of thirdparty HMI software running on some type of embedded platform. The third is a PC-based HMI. PLCs and PACs are programmed using PC-based software, and any changes to the program typically require a PC. The programming PC typically connects to the

PLC or PAC through an Ethernet port. Although the program usually can’t be changed without a PC, many parameters can be adjusted with the operator interface device such as setpoints and alarm values. When the operator interface device is a PC-based HMI, the PC can also be used for programming. PLCs and PACs are capable of controlling almost any machine, and many now have built-in PID and motion control. Copious

Controller Comparison Table Characteristics

Smart Relay

PLCs/PACs

Industrial PCs

Maximum I/O Footprint Local Expansion Capability

About 60 Smallest

10,000 plus Depends on I/O quantity

n/a

Medium to High

High

Remote Expansion Capability

n/a

Medium to High

High

Programming Languages

Ladder, some function blocks

Multiple – ladder, structured text, function block, etc.

Same as PLC/PAC, plus all common PC programming languages

Programming Software Cost

Free to low

Medium to High

High

Hardware Cost

Low

Medium to High

High

Program Memory

Low

High

Ease of Use

Easy

Medium

Most Complex

Flexibility

Low

High

Very High

Connectivity to other systems

One comm port and protocol

Multiple communication ports and protocols

Virtually unlimited

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on-board memory allows real-time and highspeed control of many I/O points and control loops, even for sophisticated applications like multi-axis motion control. I/O can range up to tens of thousands of points, and can include many types of local and remote I/O modules. Very high-speed applications can be addressed with special I/O modules with quick scan times, and high-resolution modules are available when precision is required. Remote I/O modules are often available in machine mount versions, with no cabinet mounting required. Networking options are numerous, with almost all PLCs and PACs equipped with multiple Ethernet ports and support for various Ethernet protocols. Communications with these ports can typically be programmed in scripting languages, which are much more powerful and easier to use than ladder logic for these types of tasks. Speaking of programming, many of these controllers support the IEC 61131 suite of languages that includes ladder diagram, function block diagram, structured text, instruction list and sequential function chart. Even with all these options, some applications demand even more performance, making an industrial PC the best fit. PC performance Industrial PCs (IPCs) are at the top of heap in terms of machine control, combining the power and connectivity of a PC with the ruggedness of a PLC. As one would expect, costs are correspondingly high, making these controllers economical only for the most demanding applications. Many modern industrial PCs now come in rack-mount versions, giving them an appearance and form factor similar to a PLC or PAC. IPC I/O also looks similar, with local rack mount and remote options, easily expandable to tens of thousands of I/O points. IPCs are the most open of all controllers, so adding almost any type of I/O is possible, often through the addition of a plug-in card to handle a particular protocol. And because IPCs are so open, connectivity is easy, with the ability to connect to virtually any type of HMI, controller, vision system 76

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or upper-level computing platform such as a database, ERP system or a manufacturing execution system. Like PCs, IPCs can be configured as virtual machines, meaning they can host multiple operating systems simultaneously. For example, a real-time operating system could be used for control, a Windows operating system for running an HMI, and a third operating system for a dedicated task such as machine vision. In terms of programming languages, expect an IPC to accommodate all the IEC 61131 languages, as well as PC-based languages like C++ and Virtual Basic. Because so many different languages can be used, the cost of IPC programming software is typically quite high. Program and data storage memory can be expanded as required, allowing both execution of large real-time control programs and storage of manufacturing data. There are also many options for storing data including internal disk drives, CDs and jump drives. One way to get more bang for the buck with an IPC is to combine control with HMI functionality. When this is done, all thatâ&#x20AC;&#x2122;s needed to create a powerful graphical interface is an industrial monitor. This concept is also trickling down to more applications in the form of combo PLC+HMI units, as discussed in the Combo Controllers sidebar. Your three main options for machine control are smart relays, PLCs/PACs and IPCs. Each option has its place, and making the right choice will help keep costs and complexity down while providing the required level of performance for your specific application. DW

Personal CNC Prototyping - Product Design - R&D - Engineering Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line. To read more about this story, and to see what others are doing with their PCNC mills, visit www.tormach.com/design. PCNC 1100 Series 3

Titanium bone screws and surgical spinal implants manufactured by Eisertech LLC.

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M e c h a t r o n i c s

The next generation

of grinding One company is leveraging CAD, vision systems and robotics to make dramatic improvements in grinding large castings. The next generation of grinding will not look anything like the past.

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Steve Meyer â&#x20AC;˘ Contributing Editor

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Traditional machining and grinding processes have been around for a long time. Historians

record that one of the earliest known lathes was operating around 1483. Machines that cut metal in complex shapes were the foundation of the industrial revolution, and for that matter, all of modern manufacturing. Computer Numerical Control (CNC) has been in use since the 1950s. A lot of effort goes into the making of metal parts, and a lot of effort is expended to make parts more efficiently. 3D printing of metal parts is the beginning of the next generation of part making, but for now it is only cost effective in complex designs. In engineering school, undergraduate mechanical engineers are taught graphics in order to document and communicate part design. The process requires that we think about a part as if it were inside a glass cube and imagine the edges, holes and features of the partâ&#x20AC;&#x2122;s shape as they would appear on the 2D surfaces of the cube. Complex parts often require a great deal of detail in order to capture all of the information needed to produce the desired part. Combustion engine blocks are a great example of this complexity. Computer Aided Design (CAD) has been around since the 1970sâ&#x20AC;&#x201D;at first, as very expensive workstations that allowed designers to work in 2D and 3D without pencil and paper. In the 1990s, lower cost programs on desktop systems replaced the workstation. 3D solid modeling software became integrated with machining when editors for CNC part programming became available extensions of the software. Much of the lead time and the cost associated with starting up a new part were reduced, which changed industry forever. All of these tools and training are based on Cartesian (perpendicular) orientation as the standard means of visualizing and processing parts. Machine tools are organized the same way, using three linear, perpendicular axes to mill, bore, drill or tap a part. 5-axis machining centers are more flexible adding 2 rotary axes to the 3 Cartesian, but this is a lot more expensive and doesnâ&#x20AC;&#x2122;t solve all problems. As the part size increases, the forces necessary to support the machine tool goes up arithmetically. The result is that machining centers for parts like engine blocks end up costing millions of dollars.

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M e c h a t r o n i c s

Robotic grinding goes well beyond 5-axis machining by adding the flexibility of being able to operate inside the part with relative freedom.

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In complex parts, several different machines may be necessary to perform all of the processes required. Conventional manufacturing procedures require time consuming setups from one machine to another, which presents the potential for catastrophic error. The further along a part goes in the process, the more cost the scrap part represents. In addition, multiple machine tools contribute to extremely high parts cost. So the ideal solution to grinding large, complex castings would be a machine that can process the part in a single work cell using a single part setup. Which is exactly what Chris and Randy Sutton decided to create at their engineering firm Sutton Engineering Technologies (SET) in Alabaster, Ala. The Sutton brothers and their team of engineers have decades of experience between them, and a vision to solve production problems with solutions that work better. Sutton Engineering has successfully integrated a Kuka Titan series robot with a 40 hp spindle motor as the end effector. This formidable looking combination creates a giant robotic grinding tool. The robot has 6 axes of motion, with a nearly 12-ft reach, enabling a large work envelope with amazing dexterity. In addition to the robot’s size, it has a payload capability of 1,650 pounds giving it the heft to carry the massive 40-hp spindle motor for grinding, and the ability to generate enough force at the end of the spindle to do some serious material removal.

The main event—grinding metal One of the major limitations in any grinding environment is the speed at which material can be removed. This is a function of material hardness and the cross section, or volume of the material to be removed. High speed spindle motors are used to improve the material removal by simply speeding things up, typically at speeds of 10,000 to 40,000 rpm. However, unwanted variations in the amount of material removed can show up in the grinding process. Traditional grinding is the result of a grinding tool engaging a workpiece. This is generally done as an open-loop positioning function in a machine. If the grinding is done with a CNC, there are tool wear compensation features to insure accuracy, but it is still strictly a positioning process—and errors can occur. The missing ingredient is measuring the force at the end of the grinding tool. The SET robotic grinder integrates a strain device between the robot arm and the spindle motor and grinding wheel. The sensor measures the force between the grinding wheel, robot and workpiece in real time. This creates a closed loop around the grinding process, which can be monitored and regulated by the system controller. When the robot removes material from the work piece and reaches a section that requires multiple grind passes, the strain device detects push back, which is also reflected in the robot’s positioning system. By recording the “out of position” state, the robot can come back and do a second pass in the affected area and eliminate the high spot. The SET process has been tested and is producing precise, repeatable parts on the shop floor. A Danfoss VLT drive is used to control the induction spindle motor at speeds up to 12,000 rpm. The VFD is able to do speed and torque regulation with sufficient dynamic response to optimize the grinding process. The drive is even able to perform spindle orient cycles to 1/32-in. of rotary position, so that the robot can pick up one of several grinding wheels required for the range of grinding processes. Single setup with automated homing One of the most difficult aspects of grinding complex metal castings is orienting the part and creating a home position reference for the machine tool. The SET robotic grinding center handles this problem in a unique way.

8/1/16 3:49 PM

M e c h a t r o n i c s

Parts ready for grinding are clamped down to a large rotary table that can index like a loader/unloader, giving the robot access to the 2 or 4 parts at a time, depending on size. The parts are fixtured in mirror imageâ&#x20AC;&#x201D; this simplifies programming of the robotâ&#x20AC;&#x2122;s grinding path. Multiple parts in the work cell also helps ensure high operating effectiveness, so that productivity is maximized. The work cell includes an operator station where production part numbers can be searched and selected from a list by the operator. After a part number is selected, the vision system scans the part and compares it to a 3D reference image that is on file in the system controller. This step verifies that the correct part is present in the work cell. The vision system also scans for prominent features like casting sprues and vents to determine where the part is and what its orientation is. Using this input, the robot does a multiple point touch-off cycle to provide absolute verification of the part position. This unique combination of hardware and software features makes the robotic grinding work cell repeatable, reliable and highly efficient at grinding complex parts. Initial demonstrations have shown 300% improvement in cycle times with no scrap. Other features Currently, there are two, 10-ft diameter tables for parts supported by a third table that can index work in and out of the robotâ&#x20AC;&#x2122;s work envelope. All three tables are independently controlled by closed-loop hydraulic actua-

tors. The work tables support up to four parts weighing as much as 3,750 lb each. The main table has considerable extra capacity and will support up to 15,000 lb of work. The table system rests on multiple hydraulic cylinders so that it is level and evenly supported. Robotic grinding goes well beyond 5-axis machining by adding the flexibility of being able to operate inside the part with relative freedom. Cleanup of the interior surfaces of a casting is relatively easy since the robot can reach inside from either side. The SET Robotic Grinding Center combines CAD, CAM, vision, load cell, spindle drive and robot into an elegant, high productivity work cell that solves many application problems. The economic benefit of the new solution has gained the attention of several large companies that have expressed interest in testing the system for their own unique requirements. DW Sutton Engineering Technologies setincorporated.com Danfoss North America danfoss.us

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3 D C AD

Outsourcing CAD:

The Good and the Bad

Outsourcing CAD drafting and design can boost a companyâ&#x20AC;&#x2122;s productivity, but firms looking to outsource should ask some questions and do their own research before moving CAD work out of the company. Jean Thilmany â&#x20AC;˘ Contributing Editor

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Thanks to technological advances, more companies are outsourcing work, according to a recent Deloitte Global Outsourcing and Insourcing Survey. Engineering companies are certainly part of that trend. Today, engineers and CAD drafters can take advantage of CAD in the cloud, which offers access from anywhere and allows users to receive and work with up-to-the-second information. Also, engineers can now pass designs and ask for feedback through sharing sites like Dropbox or product lifecycle management systems. The nature of the systems themselves allows CAD work to be more readily outsourced—or done by in-house temporary workers—than other engineering jobs, says Sandesh Joshi, president and co-founder of Indovance, which provides CAD outsourcing services. Engineering companies can also buy licenses that give them access to CAD software on a short-term basis. These types of agreements include the Desktop licenses from Autodesk and similar-type license from Solid Edge and other CAD companies. It’s tools like those, including online forum software, that lead at least one expert to believe mechanical engineers themselves will be able to act as free agents in the not-too-distant future, moving from one company to another when a project ends. But before that happens, outsourcing the simpler aspects of CAD drafting and design remains a big part of many engineering company’s business plan, Joshi says. Indovance, of Cary, N.C., has seen its business revenues grow by 50% in 2014 and again in 2015. Joshi, expects that trajectory to continue, with his firm forecasting a 50 to 60% revenue growth in 2016. So what’s driving the trend toward outsourcing CAD work? Joshi has an easy answer. “The growth in CAD outsourcing is a direct result of the recession of a few years back, which changed the mindset and opened people up to different ways of doing business,” he says. “Teams are leaner and productivity is measured more closely now.” CAD projects are the most outsourced jobs at engineering and manufacturing companies today, he says. “Companies have reinvented their business model to focus on what they do best and contract out everything else,” he adds. “Our clients are

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3 D CA D

focused on building core teams, that’s been the trend since after the recession.” Mark Jakiela, a professor of mechanical design at Washington University in St. Louis, says that engineering firms could cut costs even further by hiring temporary, or freelance, engineers to work on single company projects. When the project ends, the company could compile an entirely new staff of freelancers (or keep some of the best performers) for the next job. Freelancers could have more employment opportunities, as they could work on nationwide, even international, projects from home, Jakiela says. Meanwhile engineering companies would pay fewer costs in long-term benefits, employee perks, and office space. The researchers at Washington University are investigating the best type of software for freelance engineers and the companies they’d freelance to. The researchers studied how engineers at large equipment manufacturers worked together on product development. Those studies lead them to think freelance mechanical engineers would work best together through what they call web-based user communities. They’ve determined forum-based software—in which a poster begins a conversation about a project and others involved with the project respond—would best meet user and company needs, Jakiela says. Now they’re looking at the specifics of how such a forum needs to function, he adds. 84

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“The real value is in the process,” Jakiela says. “The software itself is not radically new.” Until freelance engineers become commonplace, most companies that need extra help look to offload some of their organizations’ simpler CAD work, says Charlie Seymour, president of the Raleigh, N.C.-based CAD Designs Inc. Temporary CAD workers boost engineering companies’ productivity, he says. He advocates calling upon temporary workers from a local or nationwide agency, like his own, which places skilled CAD designers and drafters across the nation. Companies who use contract CAD workers onsite at their U.S. locations must comply with federal rules for temporary workers, he adds. Engineering companies need to have an agreement with the temporary worker that outlines benefits they’ll receive and compares them to the benefits permanent workers receive, Seymour says. “Temporary workers should feel just as valued as their permanent counterparts, or else productivity is stalled,” he says. The worldwide availability of popular CAD tools, mean, however, that outsourced CAD projects needn’t be done within the United States, Joshi says. Outsourcing companies like Indovance can purchase the needed CAD software and train users. Also, engineering design software is flexible enough for use across time zones and project type. Indovance has carried out

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projects in the mechanical and civil engineering industries as well as for architects and graphics providers, Joshi says. Indovance’s more than 120 contractors have a four-year engineering degree, mostly from universities in India, and contractors often speak English, he adds. “Our clients leverage us to do the front-end project manufacturing or design work and that’s attractive to the end customer,” he says. “That’s where we can boost our client’s productivity.” For example, an oil-industry client sends its inhouse engineering team onsite to determine project requirements, as initial designs and concepts are difficult to work out remotely, Joshi says. “But once those initial parameters are figured out, then a lot of the work will be back-office and that’s a great candidate for us to be involved in,” he says. Of course outsourcing isn’t without its cautions. Rebekah Campbell, chief executive of Posse, which makes an app that stores users favorite or “totry” restaurants, shops, and travel locations, wrote in the New York Times in March 2014 about her own experience with outsourcing app developers. “I started with an idea for an app but lacked the knowledge or money to hire my own developers, so I outsourced,” she wrote in an article titled “What I Learned (the Hard Way) About Outsourcing.” First, she went with a local company that did some development work in house and outsourced other aspects of it to India. “I never spoke to the Indian team, which had no clue about the business problem the app was intended to solve; they simply received instructions from guys who didn’t really care about my project. The result was a buggy product that crashed constantly,” she wrote. After raising her first round of financing, Campbell hired two in-house engineers and a team in India. She hired the U.S. engineers for around $100,000 a year each, while the total for six full-time engineers in India was $180,000 a year. The local engineers spent significant time writing specs for the India team; still the returned code was filled with mistakes, she wrote. Eventually, Campbell found success with outsourcing software development to the Philippines after overseeing hiring herself. The 2014 Deloitte study found that, like Campbell, companies “consider locations that have a reputation for high service quality and lower cultural barriers. Countries with an educated technological workforce, language capabilities, stable currency, and 86

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In In In I

3D C AD stable technology infrastructure are potential candidates for offshoring.” India does match that description, says Joshi, who received his bachelor’s degree in mechanical engineering from the Indian Institute of Technology Bombay in Mumbai, India, before moving to the United States, where he received a master’s degree in engineering with a focus on CAD from North Carolina State University. Because he’s from India, yet has lived in the United States, he’s in a good spot to hire his contractors in India, check out their background and experience, and understand U.S. company needs, he says. His company also maintains the same team across an engineering company’s projects. “For remote outsourcing to work well it’s important to have the same team working on projects one after the other,” he says. “It’s important to go through the handshake

between the companies, so it’s more like a partnership.” In fact, Joshi views his staff members as a “virtual extension of the client team.” And that means his clients dictate how its engineers choose to pass CAD files back and forth. Usually, that means adapting to how the client team has exchanged files in the past, or will exchange files on this project. The usual exchange methods include Dropbox, virtual private network (VPN), file transfer protocol (FTP), or product lifecycle management (PLM) systems. If the client does have a PLM system in place and opens it to include Indovance contractors, that’s the method Joshi’s staff members use. Often, the client or Indovance itself will provide a quick training session on the system. “From a security and privacy point of view, we want to stay within the client’s server systems rather than bringing client

data on our central server,” he says. Companies that perform CAD projects for engineering firms want more work from those firms. So they’ll do the job correctly—meeting specs and keeping all information private, Joshi says. But ultimately, the decision to outsource CAD drafting and design work—or to bring in temporary CAD workers—depends on the nature of the engineering company’s business, the project itself, and its past experiences with outsourcing, he adds. Engineers may or may not be free agents in the future. For his part, Joshi is sure companies will still be outsourcing some of their CAD design and drafting projects in that future. Even many engineering companies have rebounded after the recent recession. The outsourcing trend isn’t going away anytime soon, he says. “It just helps their bottom line and their productivity too much for them to turn away from it,” he says. DW

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INJECTION MOLDING Material Selector

THERMOPLASTIC ABS (Acrylonitrile Butadiene Styrene) ABS/PC (Acrylonitrile Butadiene Styrene / Polycarbonate) ETPU (Engineered Thermosplastic Polyurethane) HDPE (High-Density Polyethelene) LCP (Liquid Crystal Polymer) LDPE (Low-Density Polyethylene) LLDPE (Linear Low Density Polyethylene) PA (Nylon) PBT (Polybutylene Terephthalate) PC (Polycarbonate) PC/PBT (Polycarbonate / Polybutylene Terephthalate) PEEK (Polyetheretherketone) PEI (Polyether Imide) PET (Thermoplastic Polyester Resin) PETG (Copolyester) PMMA (Acrylic) POM (Acetal) PP (Polypropylene) PPE/PS (Polyphenylene Ether / High-Impact Polystyrene) PPS (Polyphenylene Sulfide) PS (High Impact Polystyrene) PSU (Polysulfone) SB (Styrene Butadiene) TPE/TPV (Thermoplastic Elastomer / Thermoplastic Vulcanizate) TPU (Thermoplastic Polyurethane Elastomer)

MATERIAL PROPERTIES Tensile Strength 1,200–4,000 psi

Heat Deflection 130 ft-lb/in2

130-190º

Impact Strength

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A supplement of Design World â&#x20AC;˘ August 2016

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and 3D printing deliver

subtractive and additive

custom off-road bikes

manufacturing

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Outsourcing options

for 3D printing

You donâ&#x20AC;&#x2122;t have to own a 3D printer to obtain prototypes or finished parts. The 3D printing service industry is vibrant, with interesting innovations to help you make your parts fast.

Leslie Langnau â&#x20AC;˘ Managing Editor

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A d d i t i v e

M a n u f a c t u r i n g

Most service bureaus are local, small shops that handle your prototypes relatively quickly. Today, they have competition. The major vendors of 3D printing / additive manufacturing (3DP/AM) equipment have moved into the service arena. On top of that, you have small innovators exploring distributed 3D printing service approaches moving in. All of which means you have more choices for obtaining prototypes, or handling low volume production needs. Several factors promote this direction in the 3D printing industry. But this recent emphasis on providing 3D printing services does not mean that vendors are experiencing slow sales of their additive manufacturing machines. Far from it. According to Wohlers Report 2016, 62 vendors produced and sold additive manufacturing systems valued at $5000 or more in 2015. Of those companies, 15 had sales of 100 systems each, while the remaining companies sold a bit less than that. For AM vendors, adding a part prototyping or manufacturing service component to their capabilities makes financial sense. As noted in Wohlers Report 2016, the worldwide AM services market was estimated at $2.8 billion in 2015. It has grown over the years. In 2012, it grew by 36.4%. In 2013, it was 26.3% and in 2014, it was 38.9%. A key factor in users turning to AM services is cost. On average, new product developers (of any product) may spend 10 to 15% of the cost of a product on design and prototyping. The remaining cost of a product, 90 to 95%, goes to the production of that product. Additive manufacturing can lower that production cost, whether you own a machine or outsource to a service provider. Here are a few of the new business models in this part of the 3D printing industry.

» For Confederate Motors, its

collaboration with 3D Systems On Demand Manufacturing, Quickparts, has given the bespoke motorcycle company the ability to turn even its most wildly imaginative designs into physical reality.

3D Hubs 3D Hubs is one of the newer service providers using a distributed manufacturing model. It works with individuals who own their own 3D printers and have excess time or capacity to accommodate orders. 3D Hubs helps these individual entrepreneurs find customers. Members of the 3D Hubs network “rent out” time on their 3D printers to customers. A customer uploads the files to be 3D printed, selects a local 3D print Hub August 2016

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Additive Manufacturing

quoting engine. It analyzes 3D CAD data (based on volume and geometry), then it produces an instant, custom quote in the process and quantity you specify. It supports native CAD data from CATIA, SolidWorks, Pro/ ENGINEER, as well as industry standard formats such as Parasolid, ACIS, IGES, STEP, and STL.

» 3D Hubs uses a distributed manufacturing model to deliver prototypes and finished

parts to users. It works with individuals who own their own 3D printers and have excess time or capacity to accommodate orders.

member, and receives or picks up their finished order within a matter of hours or days. For the individual Hub member, it can be a lucrative opportunity. One provider with 3D Hubs is Ara Boghosian, a mechanical engineer with 23 years of product design and manufacturing experience. He has nine desktop 3D printers. Through referrals from 3D Hubs, he has enough capacity to make a six figure living out of 3D printing prototypes for others. His customers range from experienced hardware developers, engineers, and designers to first time users and students; customers that need complex products that can be produced on a limited scale. Last year, Boghosian completed over 500 customer orders and produced an estimated 10,000 products.

3D Systems 3D Systems bought Quickparts around 2009 as a way of offering prototyping services. Quickparts offers 3D design-to-manufacturing services, and is suited to unique, low and high-volume custom-designed parts. Similar to other service providers, it offers an instant online quoting system and experts to help you tweak your design for 3D printing. Quickparts works with a global network of facilities to handle user prototypes and final parts. QuickQuote is Quickparts patented geometric analysis and instant

C.Ideas Founded in 1998, CIDEAS is a fullservice, additive manufacturing and 3D printing center. It has more than 30 in-house machines covering stereolithography, selective laser sintering, Fused Deposition Modeling, PolyJet, Carbon’s CLIP, urethane casting, and offers part finishing. Mike Littrell, president and founder, helped develop the company’s TrueQuote program, a comprehensive and interactive quote engine that helps you determine the best orientation, support usage and material choices. The goal was to speed up the quotation process and take advantage of recent developments in additive manufacturing. You can get a quote in as little as a few seconds, depending on the part and other choices you

» Proto Labs quickly quotes a job based

on the 3D CAD file. The quote is often returned within a few hours, including detailed information on the potential manufacturing issues and suggested solutions when available.

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Additive Manufacturing make. Perhaps one of the more important features of this visualization system is the ability to see how part orientation affects build time as well as cost. In some cases, you can see a $3000 shift in cost by simply re-orienting the build. You can also see the effect of support structures in the part, and make alterations as needed. Manual quotes and uploads are also available thru this system. Littrell is also a recipient of the Additive Manufacturing Users Group’s prestigious Dino award.

Fast Radius Fast Radius has taken a unique approach to providing fast 3D printed prototyping. It is part of a collaboration between SAP SE and UPS. SAP SE and UPS are attempting to transform 3D printing services into seamless, on-demand manufacturing from order through manufacturing and delivery. The collaboration will integrate supply chain solutions from SAP with UPS’s additive industrial manufacturing and logistics network. The tools of SAP and UPS will help you calculate the costs in real time, including tax calculations, shipping costs, bill of materials, and so forth. This capability will enable real-time decisions on the optimal supply chain path for every parts order. UPS end-of-runway manufacturing can get most orders sent in by 6:00 P.M. manufactured and delivered anywhere in the United States by the next morning. Users will track their order from their SAP software system. Fast Radius is an industrial manufacturer with capabilities in cutting edge 3D plastic and metal printing technologies, CNC machining and rapid injection molding. Its Fast Radius On-Demand Production Platform delivers fast quotes. This manufacturer delivers nearly unlimited manufacturing capacity and capability for quick-turn part production to customers from all industries.

Lighter, Stronger Parts without the Learning Curve

Easy to use topology optimization and analysis software for early-stage design.

 Learn more at solidThinking.com/DW

Company

August 2016

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Additive Manufacturing

Stratasys Manufacturing Direct is a full prototyping/ manufacturing provider. Services include PolyJet, Laser Sintering, Stereolithography, and CNC machining among others.

Plus, it is co-located with UPS hubs in the US and external manufacturing partners. Customers will visit the Fast Radius website (formerly CloudDDM) to place their 3D printing orders, which will be directed to the optimal manufacturing or The UPS Store location based on speed, geography, and the product quality the customer requires. Orders can be shipped as early as same day. While participating The UPS Store locations are all in the U.S., companies globally could use the network and place orders. “Fast Radius continues to enhance its production platform and globally expand its manufacturing capabilities in 3D printing (plastics and metals), CNC machining and rapid injection molding,” said Rick Smith, co-founder and CEO of Fast Radius. “With this distributed, ondemand manufacturing network, UPS customers will be able to get their products to market faster and more cost-effectively because parts can 94

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be produced exactly in the quantity they need and when they need them. The potential of on-demand manufacturing is here today.”

Fictiv Fictiv is the latest additive manufacturing service provider. Founded in San Francisco by two brothers, Dale and Nate Evans, Fictiv gives small businesses and enterprises access to fast prototyping technology. The founders’ concept is to use a network of vendors with 3D printing

and CNC machines in a distributed manufacturing arrangement. With this arrangement, users can have finished prototypes in a few days or hours; specifically Fictiv provides 3D printed prototypes delivered in 24 hours, and CNC machined parts in 3 days. Fictiv offers the following additive manufacturing prototyping technologies: FDM, SLA, SLS, and PolyJet. For CNC machining, it offers milling and turning. Rasheq Zarif, Senior Manager, Business Innovation at Mercedes-

» SmartQuote is Studio Fathom’s specialized online platform that provides quick and easy access to 3D printing services for prototyping and low volume production.

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Additive Manufacturing Benz Research & Development North America, Inc., is a customer of Fictive. Noted Zarif, “Access to a variety of high quality prototype parts early in the development process enabled us to test our hardware designs to create intelligent and great performing features. Fictiv gave us the insight and quality we expected and need to prototype new parts quickly.” Noted Abe Fetterman, CTO at Nomiku, another Fictiv customer, “Fictiv dramatically reduced our iteration time by getting us high quality prints within days, with no extra time spent on our end preparing parts for a print, setting up a printer, or cleaning and finishing parts. Fast turnaround and less hands-on time meant our time could be spent where it was needed most: designing our product.” Fictiv automates the prototyping process by optimizing machine capacity to support faster, ondemand fabrication of parts. Once customers upload their design files, the platform intelligently identifies available machine capacity and sends the parts to pre-vetted, trusted fabricators in Fictiv’s network. This distributed approach supports local manufacturing ecosystems by helping quality vendors fill excess capacity. As the manufacturing industry shifts toward more localized models, Fictiv is building the infrastructure needed to allow for a distributed, agile manufacturing economy. “The US was once the center of manufacturing in the world,” says Nate Evans, co-founder, Fictiv. “Today the country is still filled with some of the best manufacturing

minds and expertise globally. However, many of these shops have been left behind without the needed technology and tools to compete against larger, centralized manufacturers. Fictiv is building a technology infrastructure to allow engineers and designers better access these experts, while catalyzing local economies to spur growth.”

Proto Labs Proto Labs has offered fast prototyping services since 1999. At first, most prototyping involved CNC machining and injection molding. In 2014, the company acquired FineLine Prototyping Inc., a provider of additive manufacturing services, which enabled Proto Labs to add this technology to its repertoire. Thus, the company now offers stereolithography, selective laser sintering and direct metal laser sintering services for parts targeted at medical, aerospace, computer/ electronics, consumer products and industrial machinery industries. Proto Labs quickly quotes a job based on the 3D CAD file. The quote is often returned within a few hours, including detailed information on the potential manufacturing issues and suggested solutions when available. Stratasys Manufacturing Direct Stratasys Manufacturing Direct is the result of combining the acquisitions of Solid Concepts and Harvest Technologies with Stratasys’ own RedEye prototyping service. Stratasys Manufacturing Direct is a full prototyping/manufacturing provider, offering services that include PolyJet, Laser Sintering, Stereolithography, Direct Metal Laser

Sintering, Fused Deposition Modeling, as well as CNC machining, urethane casting, tooling and molding and finishing and assembly. This company has eight manufacturing facilities located throughout the United States.

Studio Fathom Studio Fathom offers a range of 3D printing services, including advanced manufacturing services. 3D printing machines include Stratasys 3D printers, both PolyJet- and FDM-based additive manufacturing systems. Thus, users can submit designs for 3D printing as well as for injection molding (steel / aluminum / 3D printed), RTV / silicone molding / cast urethane, CNC machining, part assembly, and model finishing. SmartQuote is the company’s specialized online platform that provides quick and easy access to 3D printing services for prototyping and low volume production. n MPF 3D Hubs 3dhubs.com 3D Systems 3dsystems.com C.Ideas www.buildparts.com Fast Radius fastradius.com Fictiv www.fictiv.com Proto Labs www.protolabs.com Stratasys Manufacturing Direct www.stratasysdirect.com Studio Fathom studiofathom.com

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3D printing for when you have no time Edited by: Leslie Langnau â&#x20AC;˘ Managing Editor

Management and customers always want you to develop products faster. The automotive industry, for example, continues to tighten product development timelines and compress design time in the supplier network. One technology that helps you deal with shorter design and production time is 3D printing/additive manufacturing. At Delphi, Jerry Rhinehart, manager of additive manufacturing development, has been working with additive manufacturing technologies for more than 20 years. His teamâ&#x20AC;&#x2122;s day-to-day operations focus on prototyping a range of parts including electrical connectors, grommets and housings. Rhinehart was first introduced to Carbon3D, a developer of unique 3D printing systems, in April, 2015. He and his team have been working with the M1 printer to develop functional prototypes, run true part validation testing and explore new opportunities for the production of final, end-use parts.

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Âť Delphi uses the Carbon3D CLIP process because of the materials it uses. The materials provide more mechanical properties for the needed functions than materials used in other manufacturing methods. Delphi is currently using the M1 on a project to install a batch of connectors and other electrical components into a 25-car fleet for road and validation tests.

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www.makepartsfast.com

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» Many 3D printing technologies are

unsuitable for printing electrical connectors.

Even though these parts are complex, intricate

and require product design details to account

for primary and secondary locking mechanisms,

it’s the needed detail that can trip up some

printing. The Carbon3D CLIP process can

deliver the detail and a smooth surface.

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Rhinehart and his team have realized the potential impact of the CLIP technology and Carbon3D’s ground breaking materials. ”We’re excited to expand our work with the M1 to functional prototyping, something we haven’t been able to do until now, and to explore new manufacturing opportunities as a whole,” said Rhinehart. “It’s all about the materials and mechanical properties that we can achieve with Carbon3D’s technology. Traditional materials only provided about 50% of the mechanical properties we need to produce functional and final parts. We’re currently using the M1 on a project to install a batch of

connectors and other electrical components into a 25-car fleet for road and validation tests.” Previously, to address the economics of part production, Delphi used technologies like injection molding to deliver parts at scale. But the cost and time of tooling development limited part production to mass-production only. Rhinehart believes that Carbon3D’s 3d printer will allow Delphi to access new markets for low and medium volume manufacturing runs. Rhinehart’s team can leverage CLIP to produce end-use parts, which gives product designers and

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engineers opportunities to explore the products they develop. “Engineers can start to re-design parts from the ground up without being constrained by the design rules associated with traditional manufacturing technologies. They can consider lighter weight parts using internal mesh structures, single assembly parts that will better address sealing needs and reduce overall complexity of product assembly, and ultimately decrease part and product failure modes because of this new design freedom,” explained Rhinehart. Since receiving the M1 machine in the Fall of 2015, Delphi has worked to produce and validate a number of parts using an array of Carbon3D engineering materials including EPU for grommets to protect wiring, FPU to shield parts during product assembly and RPU for an array of electrical connectors. Electrical connectors are particularly interesting because they are complex, intricate parts that require product design details to account for primary and secondary locking mechanisms and specific engagement and disengagement retention forces. Part accuracy to account for these details has not been possible with conventional 3D printing technologies due to the harsh, layered nature of the processes, which result in jagged edges on the part and inconsistent performance. The resolution and gentleness of Carbon3D’s CLIP process makes it possible to develop isotropic parts with smooth surface finishes, allowing product designers to address the necessary retention forces and

“Delphi is currently using the M1 on a project to install a batch of connectors and other electrical components into a 25-car fleet for road and validation tests.” engagement mechanism for these parts. Traditional manufacturing technologies for such parts have been a time intensive process. Traditionally fabricated electrical connectors require a wait time of 6-12 weeks for a prototype injection-molding tool to be created. If the resulting parts produced then need to be redesigned or changed, the team would need to wait an additional four weeks for tooling revisions. The flexibility to quickly produce functional parts using the M1 has enabled Delphi to address their customers’ tight product development timelines and more successfully address material needs through functional testing and material validation. n MPF Carbon3D carbon3d.com

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

August 2016

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Optimization software

and 3D printing deliver custom off road bikes

Edited by: Leslie Langnau â&#x20AC;¢ Managing Editor

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M a n u f a c t u r i n g

For Robot Bike Company (RBC), the goal is to “create the best bike frames possible.” The challenge will be to build and tailor the bike to an individual’s weight, height, and riding style, all within acceptable delivery times and manufacturing costs. How do the founders plan to do this? They are turning to additive manufacturing (AM) technologies to create these high-end mountain bikes. Although the team at RBC had considerable experience in additive manufacturing and developing products and systems for the aerospace industry, it required multiple partnerships with industry experts to turn its ambition into a workable business. The team approached: • HiETA Technologies, a specialist in design and engineering solutions for additive manufacturing technologies • Renishaw, a leading developer of additive manufacturing machinery, • and Altair ProductDesign. The engineers here were given the role of ensuring that the bike took full advantage of the flexibility that additive manufacturing offers. In recent years, there have been several interesting examples where 3D printing or additive manufacturing was used in the bike industry, but to date the manufacturing method has been limited to technology demonstrations or short-run manufacturing rather than a practical way of delivering commercial products to market. RBC’s goal for the project was to design and manufacture a fully customizable product that could be sold online to the public. To deliver a lightweight, high stiffness bike, the RBC frame was to be created from carbon fiber. The carbon fiber tubes, as well as the bike’s other components and systems were to be joined with additively manufactured titanium ‘nodes’ made based on the specifications of individual riders (height, weight, riding style, and so on). Altair ProductDesign’s engineering team designed these

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Additive Manufacturing

joints, which included the head tube, seat post, and chain stay lugs. The goal for these parts was to ensure they were as lightweight as possible, yet still able to withstand the forces of downhill mountain bike riding. Plus, they had to be produced with additive manufacturing.

Âť Before and after comparisons of brackets.

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Maximizing material layout The first task for the engineers at Altair ProductDesign was to perform optimization studies on each of the nodes to find a material efficient design that met the required performance characteristics and could be sized for different ridersâ&#x20AC;&#x2122; specifications. The engineers used solidThinking Inspire. The technology allowed the team to quickly take the existing designs into the virtual environment and apply a variety of loading data that the bike frame would be required to withstand during use. The data were then used to develop a new geometry layout that maximized material layout efficiency while still achieving all performance targets. Throughout this process, the design iterations were optimized for the additive manufacturing (AM) process, which included determining the ideal print angle and placement of the supporting structure to avoid the component collapsing during manufacturing. This process was conducted in conjunction with HiETA Technologies. In addition to designing weight efficient components, Altair engineers also looked for opportunities to simplify the frame design to lower the cost of production. One such example was the chain stay lug, which was originally a three-piece assembly of two symmetric titanium components and an interlinking carbon fiber tube. Using solidThinkingâ&#x20AC;&#x2122;s Inspire for optimization, and Evolve for final part refinement, the team built in the additive manufacturing requirements from HiETA Technologies. The lug was designed as a single component, optimized for mass, performance, and manufacturing cost. This optimization work delivered designs engineered for mass for the additively manufactured titanium frame nodes. The new material layout created innovative, organic looking designs

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» Design space and

loading conditions in solidThinking Inspire.

Bottom picture. Optimized material layout based on solidThinking Inspire.

targeted for AM. Weight was reduced where possible and part count was cut to minimize manufacturing complexity and cost. RBC’s customizable mountain bike is a ground-breaking entry to the market. Altair ProductDesign’s involvement and usage of solidThinking Inspire and Evolve contributed to an extremely lightweight and stiff frame which, with HiETA Technologies and Renishaw, can be taken into production. “Working with Altair ProductDesign has helped us create a minimum weight, maximum performance bike that really takes advantage of additive manufacturing,” said Ed Haythornthwaite, Founder, RBC. “Altair’s experience in designing for AM optimization technologies, have been extremely valuable. We would not have such a lightweight and stiff bike frame without their involvement.” n MPF Altair altair.com

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Get to market fast with subtractive and additive manufacturing and

Many additive manufacturing service providers are broadening their range of services to include CNC machining as well as additive printing. The combination not only delivers prototypes fast, it tackles complex design challenges. Madelynn Martiniere â&#x20AC;˘ Director of Community â&#x20AC;˘ Fictiv

To get to market fast, Hykso engineers used 3D printing and CNC machining to prototype wearable wrist sensors for boxing and mixed martial arts. These sensor wearable devices can count punches, measure speed and striking intensity and recognize the type of punch being thrown to help fighters train more effectively.

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A d d i t i v e

For mixed martial arts fighters, speed is a huge advantage in the octagon. Speed is also a competitive driver in any design situation; for start-ups, it helps them compete against large enterprises by being first to market. Hykso is a small company developing a set of wearable wrist sensors for boxing and mixed martial arts. Backed by tech accelerator Y Combinator, the company develops sensor wearable devices that can count punches, measure speed and striking intensity and recognize the type of punch being thrown to help fighters train more effectively. Having pre-sold more than $350,000 worth of units, Hykso was under a tight development schedule to deliver 2,000 pre-sold units of their first product. The engineers needed to prototype designs as quickly as possible, so they partnered with Fictiv as the manufacturing partner first for 3D printed parts and later as CNC machined prototypes. Fictiv is an additive manufacturing service provider that uses a network of vendors with 3D printing and CNC machines in a distributed manufacturing arrangement. “When we started to get into really high detail for the smallest parts, that’s where Fictiv came in,” shares Patrick Chandler, Co-Founder of Hykso. Weighing in at just 0.3 ounces (8.5 g), the sensors are lightweight and small - measuring 1.5 in. (38.1 mm), by 0.75 in. (19.05 mm). The first prototype enclosures were printed in VeroWhite. That’s when Hykso engineers learned that Fictiv also offers CNC service and was able to deliver machined parts in 3 days. CNC prototype parts served as a logical next step to test for flaws in material choice, structural strength and tune the Bluetooth antenna before moving to production. However, the prototype was a challenge because it required small and detailed parts for CNC machining in ABS and

Polycarbonate, with mating features that need a 0.003 in. endmill. “We were looking to get the material as close to production specs as possible (injection molded ABS) and in researching local CNC shops, they mostly specialized in metal and hadn’t work with such small plastic features,” says Chandler. “But with Fictiv’s CNC capabilities, we were able to prototype the component more rapidly than with injection molding.” “I thought I wouldn’t be able to CNC the part, and we would be set back by weeks. If we wanted to get the part injection molded, that would be 29 days to build the tool, and then another week or so to check it and iterate on the design. It would be over a month before we’d know what it was actually going to look like,” adds Chandler. Instead, Hykso was able to get the components CNC machined and quickly turned around, shaving 39 days off their production schedule. “Fictiv made it possible for us to run multiple processes in parallel—as we’re building the injection molding tool now, we’re also tuning the Bluetooth antenna to make sure it works perfectly in the final product.” With the CNC prototypes, Patrick was also able to spot small interferences, test ease of assembly and assist in conversations with their overseas manufacturer. n MPF

Hykso engineers learned that Fictiv, an additive manufacturing service provider, also offers CNC service with delivery of machined parts in as few as 3 days. The CNC prototype parts were used to test for flaws in material choice, structural strength and tune the Bluetooth antenna before moving to production. The CNC had to be able to machine in ABS and Polycarbonate materials, with mating features.

The first prototype enclosures were printed in VeroWhite.

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The complete sensor.

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A u g u s t

2 0 1 6

Design mission ready devices and equipment faster, smarter, and under budget with

Image: shutterstock.com

TiPS from leading suppliers

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Aerospace/Defense

Lubricants play critical role in

space applications Satellites must operate around the clock in a harsh and

extreme environment. While they seem to glide gracefully through space, reaction wheels inside are constantly spinning at high speed to provide small but precise adjustments for the position and altitude. Essentially, the reaction wheel is a flywheel, where torque is applied to a single axis of the satellite causing it to react by rotating. Keeping the bearings in the reaction wheel spinning— and a billion dollar satellite in operation—is a thin layer of lubricant. Once launched, there is no way to change the oil in a satellite after a million miles, so all mechanisms must be “Lube for Life.” This extreme lubrication challenge can be solved by using a multiply-alkylated cyclopentane (MAC) base oil. This unique oil, developed specifically for outer space, offers low volatility, good lubricity and long life. The MAC oil is only the start of a long process that Nye Lubricants of Fairhaven, Mass. goes through to produce an aerospace lubricant. First, additives for the oil must be tested. Then, the lubricant is formulated in an ISO rated clean room by specially gowned technicians, followed by a multi-step ultrafiltration process. Next, the aerospace lubricant must pass a gauntlet of application related tests. For example, wear protection is confirmed by using a SRV test rig. This test, which incorporates oscillation, friction and wear,

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determines if the lubricant will provide the proper film strength over the life of the mission by testing the grease between two oscillating metal surfaces. Data obtained in this test includes wear scar diameters and coefficient of friction. Under Vacuum is another application test performed at Nye. Samples are tested to measure for any volatile contamination that might escape from the lubricant. This test is critical to ensure that the optics for reconnaissance satellites will not fog by condensables from the lubricant. In addition to volatile contamination, the company also controls the solid particle contamination in the lubricant. To ensure the cleanliness, a sample is inspected under a 200x microscope to confirm that no large hard particles are present. Particles in the lubricant would cause vibration in the bearing, followed by wear and

premature failure. Other tests the aerospace lubricants must pass include apparent viscosity, oil separation, wettability, FTIR and density. Having passed all the specifications, the lubricant is ready for the ride of its life aboard a communication satellite the size of a school bus, or on a new-generation, toaster sized CubeSat satellite. Nye Lubricants www.nyelubricants.com

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Power and feedback connector

Aerospace/Defense

• Overall housing length 160 mm • Front flange 45 mm wide • Max Height 115 mm

Brake location and brake connector

The custom Parker motor

designed for a new jet’s flap power drive unit.

Motor winding and rotor location (38 mm wide)

Aerospace regulations

can prove challenging for successful design projects Edited by: Paul J. Heney • Editorial Director

There’s a rough rule of thumb that’s widely observed in aircraft system design and development: It usually takes at least five years to go from the original concept of a new system to the point at which the FAA issues a Type Certificate, so that an actual aircraft containing the system can be sold to a customer. Bringing a new system to market takes both a broad range of engineering skills and the ability to coordinate the work of multiple groups simultaneously. A project that involved multiple divisions of one manufacturer, Parker Hannifin Corp., illustrates the staggering complexity of these types of projects. The company was approached by a well-known maker of 110

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commercial and executive jets for assistance in developing a new flap control system, including the flap power drive unit (PDU), for its new business jet. Among other functions, flaps are used to increase the lift of an aircraft wing at a given airspeed, lower the minimum speed at which the aircraft can be flown safely, and increase the angle of descent for landing. “From the onset of this project, various divisions were responsible for everything between the flap select lever in the pilot’s hand to the actuators that actually move the flaps, including the flex shafts, position-sensing

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maxon EC motor Brushless, dynamic, compact.

maxon drives in autopilots.

When it really matters. Our drive systems are also used in the airline industry. You'll find them, for instance, in modern autopilots, where they enable the thrust lever to be properly positioned according to flight parameters.

The maxon product range is built on an extensive modular system, encompassing: brushless and brushed DC motors with the ironless maxon winding, planetary, spur and special gearheads, feedback devices and control electronics.

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Aerospace/Defense devices, and control electronics,” said Ted McKay, one of the principal engineers involved in the project. During the development of the overall flap control system, virtually any change to other components of the system had to be evaluated and tested in terms of how it would affect the performance of the motor under development. At the heart of the new system was a custom resolver-commutated, inverter-driven brushless dc

“From the onset of this project, various divisions were responsible for everything between the flap select lever in the pilot’s hand to the actuators that actually move the flaps, including the flex shafts, position-sensing devices, and control electronics.”

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motor with an integral solenoid-operated poweroff parking brake. The system included two of these motors to power the main wing trailing-edge flaps through a speed summing differential. A large pool of engineering talent was drawn upon to design and verify the new flap control system—including three engineers just for the motor, a power transmission specialist, three engineers for the balance of the flap power drive unit, a quality engineering team, and a separate verification team to design test equipment and handle testing. Jeff Nazzaro, a product manager for Parker Hannifin gearheads and servo motors, outlined the earliest steps of the motor development process. “After we evaluated the customer’s operating requirements, our magnetic design engineers performed a Finite Element Analysis that helped them customize the size, shape, and materials used in the motor’s magnets. We also looked at very basic things like the gauge of the copper wire used and the number of turns of wire and the lamination material. Although in some ways it could just be considered a standard servomotor, it’s optimized for this precise application,” Nazzaro said. The design of the motor also had to take into consideration the voltage drops and delays associated with the wires and switches that control the flow of power to the rotating magnetic field. The job of designing and building the new motor to meet the aircraft manufacturer’s requirements presented Parker’s Electromechanical and Drives Div. in New Ulm, Minn., with a number of engineering challenges. For example, it had to provide the required torque at a very high speed to deliver sufficient power output. After many months of design and development, experimentation, negotiation with other design teams within Parker and with the customer, and “iron bird” testing, each motor provides a maximum speed of 17,000 rpm at 6 in.-lb of torque. This performance needed only 24 Vdc to the motor, and current requirements of no more than 60 amps. This maximum speed falls far outside the capabilities of the company’s standard, off-the-shelf motors, the fastest of which are capable of maximum speeds of just 7,000 rpm. Many challenges involved the extreme environments in which the motor needed to perform flawlessly, such as in ambient temperatures ranging from -65° to 158° F and under a range of loads, both in flight and on the ground. It also had to meet all commercial aerospace environmental conditions related to electromagnetic interference (EMI) with other nearby components, vibration, duty cycle, and so on.

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“At -65° F at 35,000 feet, oil turns to sludge. At the other end of the spectrum, it can be 120°F on the tarmac in Riyadh with the mechanic constantly operating the flaps to try to track down the source of a noise,” said McKay. “The motor we design has to handle both ends of that—we have to have produce enough torque to keep operating at very low temperatures and it can’t overheat over the most aggressive thermal cycles.” The high efficiency required of this motor made an inherently low cogging torque design essential. “Our maximum motor output torque requirement was so close to the motor starting requirement that any cogging torque actually would have robbed it of torque needed to get it moving,” said Nazzaro. “New Ulm went to enormous effort to create a motor that didn’t cog.”

Efficiency was also critical because of the relatively low level of power provided by the plane’s internal generation system. The level of power available from the aircraft to drive the motor was just 28 V, 50 A per RTCA DO-160, making high efficiency doubly critical. Possibly the biggest challenge the design team faced was creating a powerful motor that could fit into the tight confines of the motor enclosure. For everyone involved in the PDU motor project, the final motor design represented an important learning experience that they’ve been able to apply to subsequent motor design challenges. AD Parker Hannifin Corp. www.parker.com

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Linear Slides and Cam Roller Linear Guide Rail System Components

Rod Ends and Spherical Bearings designed and manufactured to Aurora's exacting standards for quality and durability. Registered and Certified to ISO-9001 and AS9100. From economy commercial to aerospace approved, we've got it all !

See Us at the IMTS Show, Booth N-6589 J.W. Winco, Inc. offers high quality, heavy duty linear slides and telescopic linear slides, along with cam roller linear guide rail systems components, suitable for every application. Explore our full line at www.jwwinco.com or contact us with your requirements. 2815 S. Calhoun Road New Berlin, WI 53151 Phone: 800-877-8351 Fax: 800-472-0670 Sales@jwwinco.com

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Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538

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Aerospace/Defense

Digital signal conditioner

adapts to measuring conditions

More and more industries and manufacturers are requiring sensors for condition monitoring in their machines or processes. New digital signal conditioner technology is available that simplifies the use of eddy current (inductive) displacement sensors for high precision/high reliability applications. The technology is the best option for monitoring movement, position, vibration, alignment, or deflection, especially where parts operate in high temperatures or within environmental contaminants. Unlike previous versions that required circuit modifications and manual calibration to match the required target, sensor, cable length, and range, the new digital signal conditioners configure themselves in a matter of minutes. In addition, the technology works with a variety of sensors. Many sensor options are available for machine condition monitoring, including inductive technology, linear variable differential transformers (LVDTs), laser triangulation, capacitive, and ultrasonic systemsâ&#x20AC;&#x201D;as well as air gauging, Hall effect, and optical systems. Each technology has distinct advantages and disadvantages, depending on the application.

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Eddy current sensors are generally more insensitive to environmental contaminants than other options. They operate on the principle of impedance variation caused by eddy currents induced in a conductive target by a sensor coil. The sensor coil is excited by a high frequency oscillator, which generates an electromagnetic field that couples with the target. Signal conditioning electronics sense impedance variation as the gap between sensor and target changes and translates it into a usable displacement signal. This technology provides extremely high (submicro inch) resolution.

www.designworldonline.com

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Eddy current sensors can “see through” nonconductive materials, making these sensors useful in such applications as paint, rubber, and paper thickness. They can also be a good option for operation over a variety of temperatures and environments, including dust, oil, gas, diesel fuel, liquid oxygen, and rocket fuel. Inductive technology is used for many high performance sensor applications, especially those needing higher frequency responses in challenging environments and temperatures. They allow operators to monitor a machine and determine when it has to be taken offline for maintenance. Conversely, the sensor may indicate that the machine is running well, so maintenance is not yet required. If, for example, the machine in question is a critical pump operating in an inaccessible location, precise information on machine condition can be important to a company’s bottom line. High precision inductive sensors can also monitor or control the quality of a process. The sensors provide a real time control signal to the machine or a display to the operators so they can adjust machine performance. Previous signal conditioner technology required hardware or software configuration to accommodate different sensors, target materials, cable lengths, and range. This was more costly, not to mention time consuming to set up. New digital signal processors, including digiVIT, simplify the use of eddy current sensors for high performance applications. Calibration is performed by menu options and push buttons

on the front panel, as opposed to adjustment of analog potentiometers. Reconfiguration, if required, can be performed in a matter of minutes. A highly linear output signal is achieved internally using digital linearization techniques. Temperature compensation of the output signal, desirable to minimize measurement temperature effects, is performed by the internal microprocessor and can be easily set up by the user, in many cases in-situ. The digiVIT signal conditioner also includes user programmable functions, including: • • • •

Relay set points for indication of out of tolerance conditions or process control Digital low pass filtering to improve resolution Adjustable sensor sample rate Quick 2-point adjustment instead of full calibration when replacing broken sensors

Some customer examples include: Metal stamping process—In this metal stamping process, the customer’s feed stock must be checked for straightness and flatness. The metal type was changed several times a day. Eddy current technology was ideal for the oily machine environment, but required recalibration to each different type of metal, which was too timeconsuming. With the digiVIT, recalibration took a matter of minutes, making the measurement practical. Manufacturer with many large assembly machines—For this customer, monthly sensor calibration was required for quality control purposes. The sensors were located far from the signal conditioner making calibration of analog sensors difficult and time consuming. Replacing the analog systems with a digiVIT signal conditioner required only a 2-point calibration adjustment, reducing calibration time significantly. Paper thickness measuring application combining the digiVIT with a laser—This customer performed a special calibration over a limited range to optimize resolution. Digital filtering and in-situ temperature compensation were enabled to further improve performance. The digiVIT proved very easy for the customer to implement. Kaman Precision Products www.kamansensors.com

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Makers of unmanned vehicles are leaning on technology to field drones that can fly longer with fewer worries about maintenance.

Reliability concerns drive UAV propulsion technologies Leland Teschler • Executive Editor

Eyeball the radio-controlled model planes at your local hobby store and you’ll likely see some of the same components now found on the unmanned aerial vehicles used in missions over Afghanistan. But check out the price tags. Super-hot engines for model planes typically run in the $400 to $1,000 range. Similar engines for UAVs used on military and government agency missions can run $5,000 or more. Is it a case of gouging Uncle Sam? Nah. It’s true that some early small UAVs borrowed much of their technology from the hobby world. However, there’s a problem with repurposing hobby technology for more critical applications: Cost, not reliability, is generally the first consideration for consumer products. As UAV applications have become more strategic, and their payloads 116

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more expensive, suppliers have developed components and propulsion systems that emphasize durability. To see how hobby components become more rugged, consider the UAV engines produced by HFE International in Tucson, Ariz. HFE takes consumer-grade engines made by Desert Aircraft, also in Tucson, and modifies them for use in critical applications as run by the military and government agencies. The key component in the durability equation is a special electronic fuel injector, explains HFE CEO Thomas West. “A hobby engine might only work a couple of hundred hours

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Military and research agencies use the SeaHunter from Griffon Aerospace in Madison, Ala., for training, test, data collection, and system development. The UAV is powered by two DA150 electronic fuel-injected engines from HFE International. Each of these 150-cc boxer-style engines put out 9.9 kW and let the SeaHunter have a max take-off weight in the 250-300 lb range while also offering up to 2 kW of on-board electrical power for power-dependent payloads. The use of electronic fuel injection and special fuel pumps lets these engines work reliably at 10,000 ft.

reliably. The main problem is the carburetor. Smaller engines are more difficult to tune because of the smaller dimensions of the needles and orifices and because they tend to vibrate more than larger engines,” says West. Hobby engines also tend to have more trouble at higher altitudes. “If you are not good at tuning a hobby engine you will get a ceiling of only about 5,000 ft. And if you rely on a human operator you will get a lot of variability in how long the engine lasts. Tune it too lean and the rings and pistons wear out prematurely. If it’s too rich the bearings wear and soot builds up in the head,” West says. It turns out that the addition of a special fuel system and fuel injection goes a long way toward curing the ills of low ceilings and premature engine wear. “Fuel vapor pressure is a problem at really high altitudes,” says West. “Gas put in the tank at sea level is prone to vapor lock at

20,000 ft because the liquid gas is trying to change into a vapor at the low pressure up there. You can end up with air in the fuel pump, and most pumps stop working when that happens. High-dollar fuel systems come with pumps that can withstand the potential for vapor lock. They generally use a slow-moving piston pump that compresses the vapor back into a liquid. The engine runs lean but at least it will keep going.”

Engine technologies HFE builds its engines on a twocylinder boxer-style block. But aviation experts say that for the near future, no one propulsion technology will dominate in UAVs. Different internal combustion engine (ICE) technologies have different strengths and weaknesses that depend on factors such as the UAV speed, altitude, and weight. For example, it looks as though electric motors and www.designworldonline.com

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Wankel engines from UAV Engines Ltd. have flown since 1986 in drones that include the Textron Systems AAI Shadow. Wankels can be air or liquid-cooled. Those that power drones typically are in the 4 to 100-hp range. These fourstroke engines can exhibit power-toweight ratios of about 1.7 hp/lb.

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Jet engines like these examples from JetCat Germany can be found in drones, but only when thereâ&#x20AC;&#x2122;s a need for speed that out-weighs the fact that such engines burn through a lot of fuel quickly. The record for the longest hoverboard

batteries will be confined to powering only small UAVs for the near future. The problem is that even high-energy lithium batteries have much less energy density than conventional airplane fuel. (Rechargeable lithium-ion batteries typically come in the 0.9 to 2.63 MJ/L range. Ordinary gasoline is about 34.2 MJ/L.) Conversely, small ICEs tend to be inefficient, so comparably sized electric motors have an advantage in some kinds of UAV missions. For example, 400-W electric motors from Aveox Inc. for use in RC models sport efficiencies up to about 88%. Automotive gasoline engines are about 30% efficient or less; the smaller cylinder engines as found in UAVs are even less so. Similarly, large gas turbines can exceed 55% thermal efficiency, but turbine engines tend to be too inefficient for applications below about 200 kW -- when idling, they are less efficient than ICEs in cars. So they are only found in bigger drones and in those that demand fast flight. Experts say ICE technologies that include two and fourstroke cylinder engines, Wankels, and diesel technology are seeing advances that make them good candidates for some kinds of UAV applications. Two-stroke diesels have long been applied in marine vehicles, rail engines, and trucks. They are possibilities for large UAVs because they have a good powerto-weight ratio and are relatively efficient. Challenges include reliability, weight, operation at high altitudes, and cost. In these areas, UAV engines are expected to benefit

flight was set with a hoverboard powered by four P400pro engines, according to a JetCat spokesperson. The P400 develops 397 N of thrust at max speed while sucking in 1,300 ml/min of jet fuel. It weighs in at about 8 lb. The protrusion on the front of the engine (left) is a generator. The slightly larger P550-pro generates 550 N of thrust and weighs 10.8 lb.

The DA 120 EFI (electronic fuel injected) engine from HFE International is an example of a hobby engine that has been re-engineered for use in more serious applications. The base block is from Desert Aircraft to which HFE adds electronic fuel injection and fuel pumps that provide more reliable operation, particularly at high altitudes. This re-engineered 121-cc engine puts out 8.7 kW (11.7 hp).

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Aerospace/Defense

The HQ-60 by Latitude Engineering in Tucson, Ariz. is a hybrid quad rotor that lifts off from the ground like a helicopter then transitions to flight as a conventional plane. Designed for 12 to 24-hr missions, it carries payloads ranging from 8 to 12 lb. Power comes from a DA 70 electronic fuel-injected engine from HFE International. This 70-cc engine puts out 4.5 kW (6 hp) and is built on a base engine from Desert Aircraft that is frequently used for hobby planes. To make an engine that is reliable enough for more serious applications, HFE adds fuel injection and a special fuel pump able to work well at high altitudes.

from advances in automotive engine technology. For example, automakers that include Mazda, Honda, and VW now make diesels with aluminum cylinder blocks as a means of reducing weight. This approach has only become practical recently because the high cylinder compression pressures and heat that characterize diesel combustion are problematic for aluminum. Manufacturers overcome this difficulty using wet cylinder architectures with cylinder liners made of high quality iron. The liners are in the bottom and top of the block. The middle external walls directly exposed to water passages. Advanced aluminum alloy cylinder heads are capable of withstanding the pressures diesel fuel creates because the size is small enough to withstand it. But the vibration associated with the impulse torque during combustion can be severe, and this issue is still an area of research. Wankel rotary engines are widely used in drones because they are inherently balanced. They also generally weigh less than piston engines of comparable power and are known for a high power-to-weight ratio, as high as 120

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1.7 hp/lb. Wankels are four-stroke engines. Compared to four-stroke reciprocating piston engines, the Wankel has higher volumetric efficiency. Its power strokes quasioverlap so the engine tends to run smoothly. However, Wankels spin at high rates so require reduction drives when turning most propellers. Wankels in UAVs typically are in the 4 to 100 hp range. Durability is one research area for these powerplants. For example, Wankel engine maker UAV Engines Ltd. says that its engines typically need minor maintenance after about 50 hrs and a more major workover after about 200 hrs. But, says Len Louthan – a Wankel engine expert involved in applying Wankel diesel engines to military electrical power generation applications – UAV makers are looking for Wankels able to run for about 1,000 hrs before needing serious maintenance. Louthan also says military UAV users would like to see Wankels, as well as other kinds of ICEs, run on JP-8 jet fuel. But that goal is

problematic on a variety of levels. One difficulty: JP-8 is basically kerosene. It has less lubricity than diesel fuel. So diesel durability tends to suffer when running JP-8. And conventional Otto-cycle engines have their own set of issues when they try to run JP8. “It can be difficult to atomize the fuel sufficiently to get it into a vapor that can combust,” says HFE International’s Tom West. “Because it is basically kerosene, it is just tough to get JP-8 to vaporize.” So it looks as though the use of heavy aviation fuels in UAVs will remain a topic of research for some time to come. AD

References HFE International www.hfeinternational.com UAV Engines Ltd. http://www.uavenginesltd.co.uk/

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Aurora Bearing Company 3 Piece Metric Rod Ends.... ideal for high loads or high vibration levels Metric rod end bearings built to DIN ISO 12240-1 ( formerly DIN 648 ) schedule K typically are made with inner races or inner rings made of brass, bronze or copper. For many low demand applications, these bearings have proven to give satisfactory service. However, in applications with high loads and/or high vibration levels, they can quickly develop excess clearance do to the deformation of the softer race material. They are typically manufactured with low carbon steel bodies, with limited high strength options. For applications with high loads or high frequency reversing loads, parts in this type of configuration can give less than desired performance. Aurora Bearing Company offers 3 different series of parts to address these shortcomings. The Aurora MM-M and MW-M series parts are made with a low carbon steel raceway. This construction offers ball/race durability greater than brass race parts, with a load capacity comparable to the more common configurations. For applications with vibratory loads, where the body strength or load capacity is not an issue, but severe demands are placed on the bearing itself, the Aurora KM-M and KW-M series offer a heat treated alloy steel raceway around the alloy steel ball in a low carbon steel body.

Aurora Bearing Company 901 Aucutt Rd. Montgomery, Il. 60538 www.aurorabearing.com

Concerning the most demanding applications , those that see high loads and vibratory conditions, the AM-M and AW-M series feature the heat treated raceway bearing construction combined with a heat treated alloy steel body. Combining the standard feature of a one piece steel raceway, the MM/MW-M and AM/AW-M series are also offered with Aurora's exclusive AT series PTFE liner for the optimum in self lubricating/ long life service.

Tel: 630-859-2030 Fax: 630-859-0971

Eagle Stainless Tube & Fabrication Inc. Eagle Stainless Tube & Fabrication Inc. is the leading supplier of ultra high precision, cut-to-length, stainless steel tubing and bar for medical, electronic, semiconductor industrial, and aerospace applications. ISO 13485, ISO 9001 & AS 9100 certifications have reinforced Eagle’s commitment to each and every customer to provide the ultimate in quality, service and reliability. • • • • • • •

Tubing - Hypodermic, Fractional, Metric and Pipe Bar Stock Custom Sizes and Shapes Custom Fabrication Precision Cut-to-length Laser Welding & Cutting CNC and more!

At Eagle we welcome the opportunity to share our expertise in developing product concepts and helping you solve your engineering problems.

Eagle Stainless Tube & Fabrication Inc. 10 Discovery Way Franklin, MA 02038 E-mail: eagle @eagletube.com www.eagletube.com Tel: 1-800-528-8650 Fax: 508-520-1954

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M I C R O H Y D R AU L I C S.

MACRO

CAPABILITIES. REDUCING THE SIZE AND WEIGHT

O F F L U I D C ON TRO L . Designing hydraulic systems to perform flawlessly under less-than-ideal conditions is hard enough. But factor in the need to keep components as small and light as possible, and you’ve got a real challenge. Fortunately, you’ve got a real solution. The Lee Company. For more than 65 years, we’ve been engineering stateof-the-art microhydraulic components with diameters as small as 0.10 in. and weighing as little as 0.1g, but able to withstand pressures up to 8,000 psi. And because everyone of our designs originates out of an application need, and is scrutinized with 100% testing and inspection, we’re found in just about every mission-critical fluid control challenge you could imagine – from miles above the earth in satellite positioning systems, to miles below in downhole drilling. Plus many applications in between. If you require precise fluid control, and absolute reliability, go with the experts. Contact The Lee Company.

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Harmonic Drive Ultra-flat, Zero-Backlash Gear Units

The CSF-2UP gear unit is the newest model in the CSF mini-series product line. These new zero-backlash gear units have an ultra-flat configuration and feature a large cross-roller bearing with high-moment stiffness. Harmonic Drive® gear units are comprised of a zerobacklash gear integrated with a housing and precision output bearing. These new models are very lightweight and extremely flat. Utilizing a large cross-roller bearing at the output flange allows direct mounting of the load without the need for any additional support, enabling compact robot designs. These bearings have excellent axial and radial run-out characteristics and provide high load capacity as well as high-moment stiffness to achieve precise, repeatable positioning of the robot arm. The CSF-2UP mini gearheads are ideally suited for robotic joints, wheel drives or manipulators requiring an ultra-compact solution.

Harmonic Drive LLC 247 Lynnfield Street Peabody, MA 01960 www.harmonicdrive.net Toll Free: 800-921-3332 Tel: 978-532-1800 Fax: 978-532-9406

J.W. Winco, Inc. Achieve torque-free, rapid clamping and releasing with J.W. Winco, Inc.’s clamping levers with eccentrical cam. These RoHScompliant, ergonomically designed components are designed to insure movement cannot exceed maximum clamping position. They are offered in inch and metric sizes, fixed or adjustable, tapped or stud types, in steel or stainless steel, and can obtain forces up to 1800 lbs. of force. Handles are steel, stainless steel, or zinc die cast with plastic coated, abrasion-proof epoxy resin finish. Applications for these components include workholding, quick change applications on the factory floor, and adjustable elements of equipment such as camera apparatus and medical devices. www.jwwinco.com/products/section11/index. html#cam-units-and-cam-levers

J.W. Winco, Inc. 2815 S. Calhoun Road New Berlin, WI 53151 800-877-8351 www.jwwinco.com sales@jwwinco.com

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Master Bond Inc. One Component Epoxy Adhesive Has Ultra Low Thermal Resistance and Meets NASA Low Outgassing Specifications Master Bond Supreme 18TC is a single component epoxy adhesive that contains a blend of special thermally conductive fillers. This smooth paste system can be applied in bond lines as thin as 10-15 microns. It offers an exceptionally low thermal resistance of 5-7 x 10-6 K•m2/W and a thermal conductivity of 22-25 BTU•in/ft2•hr•°F [3.17-3.61 W/(m·K)]. Supreme 18TC passes NASA low outgassing tests and offers outstanding heat transfer capabilities. Supreme 18TC maintains high bond strength properties over the wide temperature range of 4K to +400°F. It bonds well to a wide variety of substrates including metals, composites, ceramics and plastics. This compound offers a tensile lap shear strength of 2,200-2,400 psi, a tensile strength of 6,000-7,000 psi, a t-peel strength of 5-10 pli and a compressive strength of 22,000-24,000 psi. Supreme 18TC features a low shrinkage upon curing, a low CTE and a high degree of dimensional stability. It can be used in applications in the aerospace, electronic, optical, specialty OEM and cryogenic industries.

MASTER BOND INC. 154 Hobart Street Hackensack, NJ 07601-3922 main@masterbond.com Tel: +1-201-343-8983 Fax: +1-201-343-2132

maxon precision motors, inc. Research mission: Actuators for rovers, satellites and spacecraft. Motors for Aerospace applications differ greatly from standard motors. They have to with-stand greater temperatures and vibrations, have a longer life span and have to be very reliable. There are more than 30 maxon DC motors in Opportunity, NASA’s Mars rover. These are drives that were specifically optimized for use in the 8 mbar of CO2 Martian atmosphere. After more than 11 years and 42 kilometers traveled throughout planet Mars, the drives are still performing as required. maxon motors are reliable, efficient and proven to withstand the harsh environments in space. This is why the European Space Agency (ESA) has selected maxon for their next Mars mission with the ExoMars rover. maxon is found in satellites, on the ISS and in space labs that explore far-away worlds. The knowledge gained during all these missions benefits our customers down here on Earth.

Learn more about the maxon solutions and visit www.maxonmotorusa.com

maxon precision motors, inc. 101 Waldron Road Fall River, MA 02720 Tel: 508-677-0520

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The Lee Company Miniature Solenoid Valve Sets New Standards The Lee Company’s new 250 Series Solenoid Valve sets a new standard in reducing space, weight and power consumption. Designed for 28 volt systems, this 2 position, 3-way miniature piloting solenoid valve features Lee’s field proven Piloting Solenoid coil, as well as Lee’s unique and patented MultiSeal technology. The one-piece MultiSeal provides reliable sealing both axially and radially, minimizing the size of the hydraulic interface. It’s omni-directional design allows porting flexibility without the need for O-Rings or anti-Extrusion Rings. This new 250 Series Solenoid Valve is available in both single and dual coil, as well as normally open and normally closed models. The single coil valve weighs only 0.14 pounds and consumes just 7.8 watts at 28 Vdc.

The Lee Company 2 Pettipaug Road P.O. Box 424 Westbrook, CT 06498 inquiry@theleeco.com www.theleeco.com Tel: 860-399-6281 Fax: 860-399-2270

Servometer & BellowsTech Electrodeposited and Edge Welded Metal Bellows Servometer has pioneered the manufacture of electrodeposited miniature metal bellows, bellows assemblies, contact springs, flexible shaft couplings and structurally rigid electroforms. Our unique, patented electrodeposition process has led Servometer to become the leading supplier of miniature metal bellows manufactured by this method. Our custom designed, miniature metal bellows can be made as small as .020 inch (0.5 mm) in diameter and still retain full sensitivity and flexibility. They offer superb performance in applications such as metallic hermetic seals, volume compensators, pressure and temperature sensors and flexible connectors. BellowsTech is an industry leader in the development of metal bellows using edge welded bellows technology. Offering a wide array of alloys and over 90 standard dimensional configurations, our high strength, high cycle, leak-tight edge welded metal bellows provide the most flex in the smallest amount of space of any bellows technology on the market by reaching a 90% stroke length. Sizes from less than half an inch to over two feet in diameter are offered. With end-piece machining capability, customization is simple. As one united team; BellowsTech and Servometer have a synergistic relationship to offer customers solutions. The technologies complement each other in size, compatibility, pressure and temperature limitations without sacrificing performance. The cross-over of engineering talent adds value and experience to ensure customers employ the right technology for their applications.

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501 Little Fall Rd. Cedar Grove, NJ 07009-1291 www.servometer.com sales@servometer.com Tel: 973-785-4630 Fax: 973-785-0756

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Permanent Precision, Excellent Backlash Stability • Harmonic Drive® or Harmonic Planetary® gearheads • Zero backlash and low backlash versions • Ratios: 3:1 - 160:1 • Peak Torque: 3.9 N•m - 3940 N•m • Sizes: 40mm - 230mm • Output Conﬁgurations: Hollow Shaft, Flange, Keyed Shaft

247 Lynnfield Street, Peabody, MA • 800.921.3332 www.HarmonicDriveGearhead.com Harmonic Drive, Harmonic Planetary and Quick Connect are registered trademarks of Harmonic Drive LLC.

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PROMESS Electro-Mechanical Assembly Press If you need to push, pull, position, monitor and control every aspect of your assembly process, Promess has the solution for you; The Electro-Mechanical Assembly Press (EMAP) System. The Promess EMAP System combines our servo-controlled ball screw press technology with our multiaxis motion control system to provide a high precision, closed loop press system. The EMAP is a fully electric, programmable motion controlled ball screw press with integrated motion control and monitoring. Promess offers 33 different Electro-Mechanical Assembly Servo Presses with capacities ranging from less than an ounce to over 200,000 pounds to fit any application. The Promess Electro-Mechanical Assembly Servo Press offers you the most competitive, accurate, and efficient solution to any assembly requirement. The EMAP brings you the ability to literally clone your original assembly, and then forces the system to duplicate â&#x20AC;&#x201C; very precisely â&#x20AC;&#x201C; all ongoing production. If, for some reason, the system cannot reproduce it, a fault condition will tell you that you have made a component outside the desired parameters. Promess would like to invite you to our Process Development Center. The PDC is available to help you develop your processes and confirm the Promess technology that is best suited for your application. The Process Development Center gives you access to: Electric Press Work Stations with capabilities ranging from 0.2kN-300kN, Torque stations ranging from 1Nm-600Nm, andthe REMAP (Rotational Electro-Mechanical Assembly Presses) which combine rotational and linear motion in one machine.

Promess Inc. promess@promessinc.com www.promessinc.com Tel: 810-229-9334

DieQua offers more gearboxes Are You Selecting The Right Technology?

For Power Transmission

Whether your application is for precise motion control or for general power transmission, there are several gear technologies that can do the job. But which one does it best? Only DieQua offers the widest range of gearmotors, speed reducers and servo gearheads along with the experience and expertise to help you select the optimal solution to satisfy your needs.

Worm Reducers

Helical Gearmotors

Spiral Bevel Gearboxes

For Motion Control

If you are using gearboxes, you should be talking to DieQua!

Planetary Gearheads

www.diequa.com half page horizontal ad.indd 1

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Servo Worm Gearheads

Precision Cycloidals

630-980-1133 August 2016

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MPC

SYNCHRONOUS SPROCKETS

Direct drop-in for the most popular tooth profile

• Available from stock from over 30 Martin locations throughout North America • MTOs in days not weeks: » QD bushed » MST® bushed » Finished bore

» Stainless steel » Aluminum » And more...

• Over 350 MPC® SKUs on the shelf • Stocked in TB and Minimum Plain Bore • Compatible with all leading Curvilinear Belts

Martin's MPC® Sprockets are manufactured in various sizes, dimensions and capacities to

meet a variety of industrial requirements. These include a wide range of loads, speeds, and demanding applications such as blowers, conveyors, pumps and mixers.

martinsprocket.com • 817 258 3000 MartinSprockett_PTGuide4-16.indd 129

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Design mission ready devices and equipment faster, smarter, and under budget with TiPS from leading suppliers

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IMTS 2016

hits the Windy City Mike Santora • Associate Editor To say the Association For Manufacturing Technology (AMT) is preparing for another big IMTS event this year would be an industrial-level understatement. Eighty-nine years after the first show, IMTS 2016 remains a huge industrial manufacturing technology event. This year, AMT states that 2,000 exhibitors and an estimated 125,000 visitors are expected to flock to Chicago’s McCormick Place Sept. 12-17, 2016 for the event. IMTS 2016 will also include five co-located shows that will allow attendees to gather news on the latest product advances while gaining insights into where manufacturing technology is heading.

Heidenhain will showcase its brand new QUADRA-CHEK 3000 digital readout, Heidenhain encoders (including RCN 6000 angle encoder and LC 100 linear scale), and TNC control/capabilities. ETEL’s TMB+ torque motors, as well as the well-known ACU-RITE MILLPWRG2 CNC control with enhanced features will also be shown. QUADRA-CHEK 3000 – HEIDENHAIN’s sleek new QUADRA-CHEK 3000 evaluation electronics box measures 2-D geometrical features quickly and easily, using technology that, up to this point, has only been available on PC systems. ETEL’s TMB+ Torque Motors – This newest line of ETEL’s next generation direct drive torque motors improves upon the TMB series with even greater material quality, new size additions (62 sizes up from 50), higher force density and more winding options. These motors can achieve peak torque values up to 44,000 Nm.

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Siemens is just one of many companies showcasing new technology. At IMTS 2016 Siemens will present a new concept for work process efficiency surrounding the Sinumerik 840D sl CNC control in the form of Smart Operation. Job shops will benefit particularly from the use of Smart Operation, as it allows all kinds of work at the machine tool to be performed with greater flexibility and speed and helps boost productivity. The new concept encompasses aspects such as job preparation, IT networking, improved usability with touch operation and the use of mobile devices to perform monitoring and control functions. In short, Smart Operation significantly simplifies the integration of machines into the production process. Smart Operation does not require support by IT specialists and can be implemented independently by machine operators — meaning that companies can implement the individual functions using minimal financial and organizational resources.

Delcam, an Autodesk company since 2014, will be at IMTS 2016 to show its recent developments in automation for 5Axis machining, intelligent manufacturing systems and inspection. New CAM software algorithms in PowerMILL have made programming 5-axis mills easier, including digitally verifying the code for safety once programmed. PowerMILL can undertake complete verification of a project for machine-tool issues such as collisions, rather than having to undertake verification of each individual toolpath in turn. Comprehensive verification is performed, including ensuring that the machine tool is capable of running the proposed strategy, as well as checking for both machine-tool and tooling collisions, during cutting moves and for all leads and links, including machine-tool movements as tool changes are executed.

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The conference aims to connect attendees with industry experts to provide the newest technical information available. IMTS attendees will: • Gain insight into improving production and operations • Learn from professionals with solutions to manufacturing challenges • Network with peers and more Areas of focus for the The IMTS Conference program will include these five topics: Process Innovations, Alternative Manufacturing, Plant Operations, Automation and Quality. Additionally, attendees can view a complete range of manufacturing technology options during the event. The show will contain several technology specific pavilions to help direct attendees to the focus areas of their choice. The pavilions include: Tooling & Workholding Pavilion, the EDM Pavilion and the Additive Manufacturing Pavilion. AMT suggests that anyone connected with the manufacturing field will benefit from the event yet it may be of specific interest to: • Executives building a business • Decision makers involved in manufacturing equipment purchases • Engineers who identify equipment needs • Plant superintendent who will set it up • Operators who use the equipment and know it better than anyone else • All staff members and suppliers you count on for new ideas AMT President Douglas Woods explains the value as such: “IMTS showcases the most current manufacturing solutions while embracing emerging technologies. Spending three days at the show enables business leaders to look into the future and envision what might be possible. If the history of IMTS has taught us anything, it’s that tomorrow’s most successful manufacturers are also the most forward-thinking.” IMTS 2016 www.imts.com

Thousands of cables, tested for millions of cycles in the igus® lab. 100% guaranteed for up to 36 months of continuous-flex performance. Chainflex® works... or your money back!

www.igus.com/chainflex IMTS Supplement Feature 8-16_Vs5.LL.indd 134

The Kurt DoveLock dovetail 5-Axis vise line is expanded with a new reverse model and smaller foot print model. DoveLock provides up to 4,000 lb of precision clamping force. The DoveLock dovetail holding feature requires only 1/8-in. of material height to hold the part. All DoveLock 5 axis vises are manufactured from 4140 steel. Kurt’s IMTS 2016 exhibit also will include an expanded small machine table workholding lineup ranging in size from a 5.00-in. length up to a 15.500-in. length vise. 134

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Visitthe theFesto Festobooth boothfor fordetails detailsabout aboutthe theVUVG VUVG Visit standalonevalve valvegiveaway! giveaway! standalone Visit the Festo booth for details about the VUVG

Visit the Festo booth for details about the VUVG standalonevalve valvegiveaway! giveaway! standalone

Festoisisa aleading leadingglobal globalmanufacturer manufacturerofofpneumatic pneumaticand andelectromechanical electromechanicalsystems, systems,components, components,and andcontrols controlsfor forprocess process Festo controland andfactory factoryautomation automationsolutions. solutions. control

Formore more information: Call: Call: 1-800-Go-Festo 1-800-Go-Festo 1-800-463-3786 1-800-463-3786 www.festo.us www.festo.us For Festo isinformation: a leading global manufacturer of pneumatic and electromechanical systems, components, and controls for process

Festo is a leading global manufacturer of pneumatic and electromechanical systems, components, and controls for process controland andfactory factoryautomation automationsolutions. solutions. control

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Formore moreinformation: information: Call: Call: 1-800-Go-Festo 1-800-Go-Festo 1-800-463-3786 1-800-463-3786 For

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Dynatect Ad – “Protect Your Assets” Design World 1/2 Island: 4-5/8 x 7-7/8

Prima Power Laserdyne’s new LASERDYNE 606D multi-axis laser processing system has two completely independent work stations in a single structure. The 606D consists of four main components: two 6-axis motion systems, an integral Class 1 enclosure with dual automated doors, two S94P laser process controls for motion and laser coordination, and two fiber lasers. Users can expect incresed throughput while using the same laser power. The two work stations have an X-Y-Z speed of 2000-in./min (50 m/min), 2 g acceleration, and bi-directional accuracy of 0.0008-in. (20 µm).

PROTECT YOUR ASSETS Protect your people, machinery and your bottom line. Dynatect offers a large array of industry-proven protection solutions. From standard to custom-designed products, Dynatect can help safeguard your assets. • Machine Door Actuators • Walk-on Pit Covers • Custom Roll-up Doors

• Cable & Hose Carriers • Bellows & Way Covers • Precision Ball Screws

Learn more at: Dynatect.com/IMTS2016 Visit us at Booth NC-300

McCormick Place • Chicago September 12 - 17

The ÖLFLEX VFD 2XL symmetrical motor and drive cable from Lapp is rated for voltages as high as 2kV and is suitable for high horsepower applications. This large gauge cable offers three symmetrical grounds and features a helical copper tape shield and meets many key approvals. Robust, oil- and UV-resistant, it delivers a minimum bend radius of 15 x cable diameter.

Formerly A&A Manufacturing

FOR MORE INFORMATION: 800-298-2066 sales@dynatect.com dynatect.com

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Go-To Products

for Machine Tools, Transfer Lines and Automation Customers have trusted Schneeberger guideways with integrated linear encoders for over 25 years. Now including Monorail with Absolute scale (IP68) and Minirail with 0.1um incremental scale. Visit us at IMTS 2016 Booth E-4871 (East Bldg) Sept. 12-17, 2016 Mention this ad at our booth to be included in our daily drawing.

Precision ground rack grades Q4 - Q11 and sizes M2 - M16. Segment lengths up to 3m reduce assembly time!

SCHNEEBERGER, INC 44 6th Road | Woburn, MA 01801 Info-usa@schneeberger.com

www.schneeberger.com

800-854-6333

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IMTS 2016 IMTS 2016

igus®, Inc. 7 Guidelines to continuous-flex cable design 1. Strain-relieving center element A high-quality, high tensile strength center protects twisted conductors from falling into the center of the cable. 2. Conductor structure A combination of conductor strand diameter, pitch-length, and pitch direction achieves the best service life and performance, even in the most demanding applications. 3. Conductor insulation Insulation materials within the cable must be resistant to adhering to one another and support the individual conductor wires. 4. Cable Core A bundled conductor design enables pulling and compressive forces to balance and cancel out torsional forces on the cable. 5. Inner jacket An extruded inner jacket ensure sufficient guidance of insulated conductors, and maintains the integrity of the cable core. 6. Shield design An optimized braid angle prevents the shield strands from breaking over the linear axis and increases torsional stability. 7. Outer jacket A dynamic cable’s jacket must resist abrasion and chemicals, while providing flexible support.

igus®, Inc. Phone: 1-800-521-2747 E-mail: sales@igus.com www.igus.com

IMTS Booth E-4521

SCHUNK The World’s Smallest and Strongest Clamping System - VERO-S NSE Mini For the production of small precision components, SCHUNK has expanded its line of modules for efficient workpiece clamping. With a height of only 20 mm, the VERO-S NSE mini pneumatic quick-change module is extremely thin, making it ideal for retrofitting existing machines to achieve full utilization of the machine area and direct clamping of small workpieces. A patented dual stroke actuation concept ensures extremely high clamping performance of the module, and the standard integrated turbo function of the NSE mini achieves significant pull-in forces of up to 1,500 N. It is self-locking and designed for form-fit clamping with large contact areas between the clamping slides and the pins to minimize the surface compression in its clamped state, therefore reducing wear on the modules. In addition, the low-maintenance, fully sealed modules are completely protected against chips, dust, and coolant.

Phone: 919-572-2705 info@us.schunk.com www.us.schunk.com

IMTS Booth W-2000

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Schunk 211 Kitty Hawk Drive Morrisville, NC 27540

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Automation for a Changing World

High Performance / Standard Compact Drive MH300 / MS300 Series Compact. Reliable. Capable. Global AC Drive and Power Quality technology solution provider offering reliable products that are unmatched in value for cost, functionality and efficiency. Delta has unveiled its new MH300 high performance and MS300 standard compact AC motor Drives for Micro VFD applications up to 30 HP. Delivering high speed operations with induction and permanent magnet motors, including up to 2,000 Hz for spindle applications the M300 Series is feature-rich with intelligent PLC functions, safety features and network connectivity. www.delta-americas.com/iaM300 2016 IMTS | September 12-17, Booth E-4338 McCormick Place | Chicago, IL

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IMTS 2016 IMTS 2016

DYNATECT (Formerly A&A Mfg)

5 Common Machine Protection Problems and Solutions That Impact Your Bottom Line The lack of dynamic protection may result in lost uptime, reduced efficiency, increased injuries, or more contamination. Whether your initiative is Lean, workplace safety, quality, or throughput – equipment protection can be part of the answer. Here are some common problems and solutions to consider: 1. It works for a while, then stops - Keep build-up from dirt and liquid spray away from rods, spline shafts or sensors 2. When the chips are down, so is the machine - Keep heavy chips and dropped tools from damaging expensive machine ways 3. We could produce more, but lose time walking around pits - Keep open machine pits covered with a walk-on surface designed to roll up and out of the way (machine or motor driven, or manually operated) 4. Reduction in lost-time injuries has leveled out, but our goal hasn’t - Add protective guarding to reduce unintentional contact with pinch points or moving parts 5. It’s loud, and the dust gets into everything - Reduce noise and trap dust from machining of carbon fiber, wood & other materials

IMTS Booth NC-300

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Dynatect Manufacturing, Inc. Contact: Jessica Mallinus Email: jessica.mallinus@dynatect.com Phone: 800-298-2066 Fax: 262-786-3280 www.dynatect.com

Proto Labs Rapid Overmolding at the Speed of 3D Printing Proto Labs is launching the latest addition to its service offerings at IMTS this year: overmolding for rapid prototyping and low-volume production. Overmolding is suitable for prototyping, bridge tooling, pilot runs and ondemand, end-use parts for applications that include vibration dampening, improved grip and added impact resistance. Rapid overmolding allows you to prototype with engineering-grade materials in the same turnaround time as 3D printing: • Parts ship in 15 days or less • Molds start at $4,990 • Production quantities range from 25 to 10,000+ parts Get a quote at protolabs.com Proto Labs, Inc. 5540 Pioneer Creek Drive Maple Plain, MN 55359 Phone: 877-479-3680 www.protolabs.com

IMTS Booth N-72

140

Regardless of the shape, the travel, or the environment—Dynatect can provide dynamic bellows and covers for your application. Don’t get caught off guard! Protect your people, equipment and your bottom line. Dynatect® (formerly A&A Manufacturing) offers a large selection of industry-proven protection solutions to help safeguard your assets. Visit Dynatect at IMTS (Booth NC-300) in the North C Hall, where you’ll find an entire exhibit hall dedicated to safety and environmental solutions and machine components.

August 2016

www.designworldonline.com

8/2/16 10:10 AM

ÂŠ 2016 SCHUNK INTEC, Inc

Visit Us Sept 12-17

Booth W-2000

www.us.schunk.com/vero-s

More than 500 possible combinations for your reliable workholding.

High tech from a family-owned company

Positioning and clamping in one step. Production possible parallel to set-up outside of the machine. The quick-change pallet system VERO-S offers the precise interface for the biggest clamping technology toolkit.

0.005 mm

Repeat accuracy

quick-change pallet system

Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding. www.us.schunk.com/Lehmann

Schunk 8-16.indd 141

Combination with system

Combination with chuck

Combination with system

8/1/16 5:20 PM

IMTS 2016 IMTS 2016

DELTA Integrated Automation Solutions for Industrial Machinery Delta is a major provider of Industrial Automation product technology, and a key contributor to the global advancement of smart production. With key competencies in design, manufacturing, and service/solutions - new technology is developed with higher levels of integration within a wide portfolio of automation products. These include: VFD, Servo, HMI, PLC, Motion Control, Temperature Control, Industrial Ethernet, Network Conversion, Power Quality, Power Supply, Energy Management, Sensor, Actuator, and Robotic products. Well rooted in the USA since 1982, the Industrial Automation Business Group of Delta Products Corporation is dedicated to customer satisfaction in the America’s region, and long-term sustainability of the Delta brand. Come to the IMTS booth E4338 with your “Delta Passport” and tour the “Integrated Automation Solutions for Industrial Machinery” demonstration units. See first-hand how Delta’s complete line of product technology is used in advanced machine automation, spindle control, and robotic cell to produce smart manufacturing system solutions. Delta Products Corporation Email: CustomerService.ia@deltaww.com Phone: 919-767-3813

IMTS Booth E-4338

www.delta-americas.com/ia

FESTO The VUVS by Festo is the new generation in standalone valves. With high flow rates and low cost, the VUVS is a powerhouse valve that offers great value, and will improve your productivity. This valve comes in both NPT and Metric sizes, is easily assembled, and is also available as an electrically or pneumatically actuated valve, making the VUVS Solenoid Valve perfect for a broad range of applications. It is perfect for a broad range of applications. We invite you to try the VUVS Solenoid Valve for yourself. Stop by our booth to register to receive a complimentary VUVS Valve.

IMTS Booth E-5066

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FESTO Phone: 1-800-993-3786 www.festo.us

August 2016

www.designworldonline.com

8/24/16 9:45 AM

IMTS 2016

SCHNEEBERGER AMS Absolute linear encoder integrated Monorail guideways deliver 0.1 micron resolution. Customers have trusted Schneeberger for over 25 years for its application experience and success with integrated linear scales on ball and roller profiled guideways. Nobody else comes close. Scan head is designed to fit all guideway sizes, minimizes spare parts, and easily disassembled and exchanged by any plant or field technician. Weld-sealed cover strip protects the magnetic scale and electronics are hermetically sealed to IP68 allowing operation in the harshest environments, even submerged in coolant. No air purge required.

SCHNEEBERGER integrated AMS Absolute linear encoders save assembly space and time. Align rail and scale in one step. Certified for use with controllers; Fanuc, Siemens (including DRIVE-CLIQ*), SSI, Mitsubishi, and more. Call today for more information or application support. 800-854-6333 781-271-0140 Info-usa@schneeberger.com www.schneeberger.com

IMTS Booth E-4871

Schneeberger Linear Technology Email: info-usa@schneeberger.com Phone: 800-854-6333 781-271-0140 www.schneeberger.com

Registration is open for IMTS 2016 & Conferences

w w w. i m t s . c o m

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Prod uc t World Conveyor fits in tight spots Dorner dornerconveyors.com The 2200 LPZ / Z-Frame Conveyor comes with one or two pivot points, and features a low profile to fit under machinery or any other tight places. The 2200 LPZ’s sleek, narrow profile means it can be positioned under machinery where other conveyors won’t fit. It is suitable for part removal and product handling in packaging, metalworking, automation, medical, pharmaceutical and other general manufacturing applications. The pivot points on the conveyor add flexibility as it can be configured in either Z-frame, horizontal-to-incline and nose-over positions. Performance specifications include: handling loads up to 80 lb (36 kg), belt speeds up to 250 fpm (76 m/min), and belt width ranges of 1.75 in. (44 mm) to 24-in. (610 mm).

Luminescence sensors detect the invisible

Helical gearboxes added to IronHorse line

Pepperl+Fuchs pepperl-fuchs.us

AutomationDirect automationdirect.com/helical-gearboxes

DK50-UV Luminescence Sensors from

The IronHorse line of motor products includes helical gearboxes with

Pepperl+Fuchs provide an easy way to complete

C-face and TC-face inputs, and inline outputs. They are available in

tasks such as error checking, sorting,

five frame sizes from 56C up to 254/6TC with six nominal ratios of 5:1

measuring, and positioning

to 60:1. Manufactured in an ISO9001-certified plant, the gearboxes

materials that blend into a

are constructed of FC-20 cast iron one-piece housings, and feature

background or are invisible.

a carbon steel shaft protected with shaft sleeves, as well as heat-

DK50-UV features a graphical,

treated and ground high-strength steel gears.

user-friendly 8-segment LED display. This display indicates luminescent signal strength, uses an output mode toggle for quick adjustments, and comes with an integral timer that allows slower controllers to react to sensor output.

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Easily expandable stepper module KEB America KEBAmerica.com The C6 I/O EtherCAT Stepper module offers an expandable remote I/O system with snap in modules and communicates through an EtherCAT backbone. Used as a remote terminal, this stepper module actuates a stepper or brushless dc motor with incremental encoder. It features five digital inputs to be used with limit stops, reference switch or similar signals. A digital output is also available for a holding brake or similar device. The drive module is compliant to the CiA 402 standard and allows the following drive modes: stepper motor (open or closed loop mode), brushless dc motor, profile position, velocity and more.

Pneumatic pinchvalves reduce contamination risk Bimba www.bimba.com/pinchvalve The Model 600 series pneumatic pinch valve is comprised of three models (603, 604 and 606) that will support tubing outer diameters up to 0.375-in., 60 psi media pressures and hardness ratings up to Shore 70 material.

RapidTurn makes lather out of CNC Mill

Units are panel-mount ready, with easy tube loading and change-out head-designed slot features. They will be available in

Tormach tormach.com

single-acting, normally-open, closed, or double-acting formats. All units weigh less than a pound.

The RapidTurn is a 5C CNC chucker lathe attachment for use with the PCNC 1100 or PCNC 770 mills. RapidTurn runs on the PathPilot CNC machine control system. This device provides real CNC lathe functionality without taking up shop floor-space. It also has a manual index plate with a locking pin. Parts can be securely positioned in 15° increments for secondary work with the PCNC’s primary spindle. www.designworldonline.com

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Prod uc t World Encoder for vector motor control Leine & Linde leinelinde.com This bearing-less encoder is for high horsepower electric motor applications using vector control.Â The MRI 2850 encoder can be used as a motion feedback system in applications such as large rotating machinery typically found in the construction, pulp & paper, oil & gas, wind and marine industries.

Designed for mounting on a NEMA standard 8.5 in. C-face, the sensor

technology provides compliant tolerances. One or two independent read-heads can be provided, each with any resolution between 1 and 16383PPR. The IP67-protected read-heads include power and status LEDs so proper mounting and operation can be visually determined at any time.

HMI/operator interface

Nanosilica filled, dual cure adhesive Master Bond masterbond.com/products/dual-curing-adhesive-systems

Omega Engineering, Inc. omega.com The NS Series touch screen HMIs have built-in Ethernet communications, alarming/recipe/ data logging capabilities, and live video input/ display capabilities. By allowing direct resetting of faults, these HMIs save time and effort in troubleshooting and quickly return lines to production. The NS Series has flexible data access to a variety of devices. It enables operators to reach the devices on the network including special I/O units, intelligent devices, and PLCs.

UV22DC80 is a one component, low viscosity, nanosilica filled epoxy based system for bonding, sealing and coating with the ability to cure under UV light and with heat. It is optically clear with a refractive index of 1.52 and passes NASA low outgassing testing per ASTM E595. It is a competent electrical insulator and features a volume resistivity exceeding 1014 ohm-cm. These properties make this compound suited for high tech applications in aerospace, optical, optoelectronics and related industries. It bonds to a variety of substrates, including metals, glass, ceramics and many plastics. UV22DC80 is a high strength product featuring a tensile strength of 6,0008,000 psi. This system also resists chemicals such as acids, bases, fuels and solvents.

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

High concentricity couplings Miki Pulley www.mikipulley-us.com Miki Pulley SFD couplings are rigid, metal disc couplings featuring zero backlash, high torsional stiffness and high concentricity. Handling system speeds up to 20,000 RPM, they maintain concentricity within 0.001 TIR.

Offset couplings for constant speed at connections

The SFD couplings feature self-centering, single bolt clamping at both coupling ends. RoHS compliant, they are available in three models in bore sizes ranging from 6.00 to 22 mm. Transmittable torque for these sizes range from 2.2 Nm to 25 Nm.

Zero-Max www.zero-max.com Schmidt Offset Couplings from Zero-Max provide constant speed at both ends of the coupling connection and accurate machine registration. They are available for shaft displacements of 0.156 to 17.29-in. and torque capacities from 55 to 459,000 inch-pounds. These couplings are also available with zero-maintenance bearings which eliminate lubrication and system downtime.

Belt-drive actuator for harsh environments

High-performance synthetic gear oils

Tolomatic www.tolomatic.com

Klüber Lubrication klueber.com

The MXB electric belt-drive

Klübersynth GEM 4 N are high-performance

actuators include a solid bearing

gear and multi-purpose oils based on

load-carrying design for harsh

polyalphaolefin that protect against wear

environments. The trapezoidal

and resist micropitting, foaming, and

solid bearing provides a rigid

residue formation. They lubricate plain and

system capable of operating in

rolling bearings, toothed couplings, chains,

environments that roller bearings would not withstand. With loads

guideways, joints, spindles and pumps.

up to 520 lb (235 kg), speeds up to 100 in./sec (2.54 m/sec) and

Klübersynth GEM 4 N provides good thermal

strokes up to 230-in. (5.8 m), the actuator is a suitable solution

stability, high load-carrying capacity, and low

for light to moderate-loading applications requiring high duty cycle

friction values that improve the reliability of

and high speeds over long strokes. The actuator can withstand

major components.

light washdown. www.designworldonline.com

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A d In dex 3D Systems ................................................56 ACE Controls ................................................ 29 All Motion ....................................................... 4 Allied Electronics .....................................3,43 Altech Corporation ...................................... 17 AMETEK PMC ............................................... 19 AMETEK DFS ................................................ 33 AutomationDirect ..............Cover,IFC,Gatefold AutomationDirect ......................................... 1 Baldor Electric Co. ...................................... 35 Baumer LTD ......................................53,55,57 Bishop Wisecarver ..................................... 63 Bison Gear & Engineering Corp................ IBC BOKER’S Inc. ............................................... 16 Canfield Connector ..................................... 37 Cicoil ............................................................ 51 Clippard Instrument Laboratory, Inc. ....... BC COMSOL ....................................................... 41 CS Hyde .......................................................42 Del-Tron Precision, Inc. ...............................70 DIEQUA Corporation ..................................128 Digi-Key Electronics ................................... 15 Dorner Mfg. Corp. ........................................86 DSM Somos ................................................. 85 Dunkermotoren, part of Ametek .............. 61

SALES

EXAIR Corporation ........................................ 5 Freudenberg Sealing Techologies ............. 71 Haydon Kerk ............................................... 67 Helical Products Company .......................... 7 ICOMold ........................................................ 87 IKO International, Inc. .................................. 2 Martin Sprocket ........................................ 129 Master Bond ................................................49 NBK America LLC ........................................ 47 Novotechnik ................................................ 16 PBC Linear ................................................... 69 PHD Inc. .......................................................34 Pilz Automation Safety ..............................40 Proto Labs ..................................................... 9 Red Lion Controls .......................................39 Ringfeder Corp. ...........................................44 Setco ............................................................ 76 SMAC Moving Actuators ............................. 18 Smalley Steel Ring Company .................... 10 Stego USA ....................................................49 Thomas ........................................................ 45 Tormach ....................................................... 77 TRIM-LOK, Inc. ............................................. 31 Turck-USA .......................................... 21,23,25 Whittet-Higgins Co. ..................................... 27

Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference Michelle Flando mflando@wtwhmedia.com 440.670.4772 @mflando Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029 David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Tom Lazar tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM Publisher Mike Emich memich@wtwhmedia.com 508.446.1823 @wtwh_memich Managing Director Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty EVP Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

M ake Par t s Fast Su ppleme n t

Proto Labs ..................................88 Solid Thinking ............................93

A supplement of Design World • August 2016

Imaginative design with

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Maxon Motors ............................111 Promess Inc. .............................125 Servometer & BellowsTech ......119 The Lee Company ......................122

Aurora Bearing Co. .....................113 Eagle Stainless ..........................106 Harmonic Drive ..........................127 J.W. Winco, Inc. ..........................113 Master Bond ...............................112

CONNECT WITH US!

I M TS Su pplement

Delta Products Corp. ..................139 Dynatect .....................................136 igus, Inc. .....................................134 FESTO ..........................................135 Proto Labs ..................................130 Schneeberger .............................137 SCHUNK ......................................141

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