DESIGN WORLD AUGUST 2019

www.designworldonline.com

August 2019

inside: MOTION CONTROL: 6 common mistakes to avoid

when specifying and using step motors

p. 102

LINEAR MOTION: Sensors report down to

the wire

p. 108

3D CAD: CAD and AI: making

design better, faster, and easier

p. 112

Transport System rethinks linear drive technology to boost machine building page 18

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Technology has shifted many former engineering functions to software or electronics over the past couple of decades, and that trend shows few signs of slowing. Let’s take mobile hydraulics as an example. In my career, I’ve met a lot hydraulics people — from system designers to founders of component manufacturers — who started off as teenagers either on the farm, working on equipment, or in the driveway, working on their car. These kinds of mechanical lessons often proved invaluable in their later movement into engineering design.

But today’s modern agricultural equipment users have been grumbling about some aspects of progress the last few years. Outlets as varied as WIRED magazine, Forbes and The Guardian have all covered the “right to repair” issue (which also extends to consumer electronics and other items). Some farmers are fighting back against the trend for OEMs to require all repairs to be done only by authorized repair shops or technicians.

Greg Downs, Senior Principal Engineer, Zoomlion Heavy Industry NA Inc., spoke with me about this issue at this Spring’s Fluid Power Technology Conference in Milwaukee, and he noted that when he was growing up, he used to work on cars a lot himself.

“We’d build an engine and we didn’t have to have a PhD to do it — but you can’t do that anymore. The reason is because they have cars that are more reliable and a better quality. You give up simplicity for the complexity, because they are better performing, more efficient,” he said.

“Several years ago, I was talking to a farmer about his combine harvester,” Downs said. “He explained how he could work on it during his harvest, when the machines had a lot of belts and chains and mechanical drives. But I told him that he’d been asking for much higher productivity, more speed, bigger grain tanks, longer seasons. All of these things mean more efficiency. So, you give up some of that ease of maintenance for systems that are much more complex but also simplified; your software diagnoses issues. In order to get the higher production, the higher efficiencies — that’s what you give up. The days of being a shadetree mechanic, going out and changing out things is becoming less and less.”

Some engineers who learned mechanics the old-fashioned way might not be able to handle all the new changes. The truth is that today, we need experts to fix things — that means engineers comfortable with electronics and sensors and software in addition to the mechanics. And really, this is just one more lesson that adapting to change might be the best lesson we can learn early on in our careers. DW

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August 2019 www.designworldonline.com DESIGN WORLD

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Teschler on Topic Tariff tango? A reminder why

domestic manufacturing matters The recent round of tariffs on $300 billion-worth of imports from China rocked markets because it will mostly target popular consumer products such as cellphones, laptops, apparel, and toys. Unfortunately, the politics of tariffs can obscure the rationale underlying tariff wars: the need for a strong domestic manufacturing base. To really understand that rationale, it is good to consult a non-political source.

A few years ago, MIT professor Suzanne Doris Berger penned How We Compete, summarizing the results of a five-year study by the MIT Industrial Performance Center. The study looked over 500 international companies to figure out what business practices are succeeding today.

Berger says there is no question Chinese imports led to a drop in U.S. manufacturing jobs. Chinese imports accounted for about 33% of manufacturing job declines between 1990 and 2000 and 55% between 2000 and 2007. And the deck is stacked against entrepreneurs with ideas for new manufacturing companies but no money. Venture capital is strongly concentrated in IT and telecom where firms can scale up relatively quickly, Berger says. VC investors are less likely to invest in areas where it takes longer to develop

products. As one CEO in the study put it, “The VC model does not work for manufacturing companies. VCs cannot make any money on something that costs $100 million and takes at least 10 years to build.”

It’s also evident that companies are more likely to lose their technological edge when they develop technology in the U.S. but chose to manufacture it elsewhere. The process by which technology scales from pilot to commercial production creates opportunities for learning by building, says Berger. When the learning takes place outside the U.S., it is likely to lead to innovations outside the U.S. as well.

Berger says the phenomenon manifested itself in the R&D trajectories of U.S. optoelectronics firms, some of which moved production overseas.

Within a few years, the technological paths of those remaining in the U.S. diverged from those that had moved offshore. New optoelectronics technologies that integrated functions on a single IC flourished only in the firms staying in the U.S. Those that had moved production were generally stuck optimizing the discrete chips of the previous generation.

Though high-tech manufacturing gets headlines, medium-low-tech manufacturing firms account for almost eight times more value added in production. Berger likens them to the weight-bearing foundations of the U.S. economy. It turns out that many

of these manufacturing firms are integral to U.S. innovation, but not in ways that can be measured in terms of patents and high-profile products.

Instead, superior performance seems to come from collocation, Berger says. Proximity to other firms and suppliers helps innovators handle problems that take special skill sets, unfamiliar equipment, and different kinds of experience. She explains that being across the street from suppliers was critical during the early years of manufacturing companies as they moved their ideas toward prototypes and into pilot production.

Specific instances illustrate these effects. An example is the contrast between Raleigh-Durham and Greenville, N.C. Both places host pharmaceutical companies. But Raleigh-Durham also hosts related industries such as medical devices and is the home of universities and community colleges with research programs. With these additional resources nearby, Berger thinks it’s no surprise that Raleigh-Durham employment growth in pharmaceutical industries far outstrips that of Greenville.

And that is the goal of adding tariffs to imports. The complementary activities that can produce high rates of growth and job creation can only happen if those activities take place here. That’s something to keep in mind if you find yourself paying a little more for your next cellphone. DW

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

6

August 2019 www.designworldonline.com

Lee Teschler Column 8-19_V1.indd 6

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Technology Forward

What is the key to better design?

What’s the “next big thing” to boost productivity and innovation in design? A couple of the more recent innovations were additive manufacturing and generative design.

These technologies have had some success at boosting innovation, but perhaps not as much as expected.

So, what’s next on the horizon?

Perhaps AI?

Well, according to a recent independent research study, “The State of Product Development & Hardware Design 2019,” (released

by Onshape) it’s not some new hardware or software. The next big thing is actually two things — better communication and better version control — more procedural processes than technology.

At least 850 executives, engineering managers, product designers, project managers, sales technical engineers, CAD administrators, and quality assurance engineers from companies of all sizes, using the most widely adopted professional design and manufacturing tools, identified these areas as the next ones needing improvement in the design field.

According to the study, 89% of respondents said they want earlier and better communication between members of their extended design team. Respondents want to address miscommunication, insufficient communication between internal teams or with external partners, and missed opportunities to get design feedback from contributors who could have game-changing ideas.

For version control, 86% of respondents said they need to reduce errors from working on the wrong version of a design or receiving important information too late. These preventable data management issues often result in costly manufacturing mistakes, and ultimately, a slower time to market.

An interesting comment in the report was, “89% of respondents say they want the ability to monitor their product design team’s progress

anytime without having meetings, sending emails, or making phone calls. As in other industries, executives at manufacturing companies want real-time information and actionable data.”

“Engineers, managers and executives say they are still wasting too much time in the product development process,” says Onshape co-founder David Corcoran, “Whether it was expressed as reducing mistakes, poor communication, inadequate visibility, too many meetings, time wasted working on the wrong data, getting important information too late, or time spent on IT and other soulcrushing overhead, the single biggest problem is process complexity and inefficiency.”

For some, it might be surprising to see that additive manufacturing or other recent technologies are not viewed as the key to faster time to market. Better team communication, visibility, and data management clearly can improve the design process. But will they be the key to better product design, or a potential problem as that moment to moment monitoring, that realtime information need potentially overwhelms the design process? DW

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

8

August 2019 www.designworldonline.com

Tech Forward 8-19_Vs2.LL.indd 8

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Paul J. Heney

Precision engineering and sustainable energy

The European Society for Precision Engineering and Nanotechnology (euspen) announced a workshop focused on the role of precision engineering in stimulating innovation in solar, wind, and oceanic renewable energy and energy storage technologies. The workshop will be held October 9-10, 2019 at the University of Strathclyde in the U.K.

Sustainable energy strategies center around cleaner methods offshore including in-situ manufacturing of ever larger of producing energy through the use of solar, wind, and oceanic elements; to energy storage systems from batteries to energy technologies, and energy storage considerations — the hydro power systems. cost of which have decreased in recent years due to government For sustainable wind technology, the specific focus will support policies and investor confidence as the sustainable energy be on the design and manufacture of actuators, gearing market expands exponentially. and controls, blades and materials, and towers. The hot The role of precision engineering in the sustainable energy topics that will be covered when looking at solar energy sector will stimulate the advancement of various technologies will be concentrating solar power (CSP) and photovoltaics, needed to gain industrial competitiveness, and this euspen and for oceanic energy wave, tidal, off-shore wind, and workshop will bring together professionals from academia, industry, automated aquaculture and mineral harvesting will be and government to share experiences concerning the use of considered. precision engineering principles to help develop new ideas and Obviously of critical importance when looking at any manufacturing systems to reduce production and ownership costs energy solution is the topic of storage, and so hydro, in sustainable energy solutions. flywheel, battery, and thermal (including geothermal) All new and innovative technologies in these sectors will storage technologies will also be central to the Workshop. require the design and manufacture of extremely accurate, robust, For more information, visit www.euspen.eu, or contact and decisive mechanical components. The workshop will look Dishi Phillips, Business Development Manager at euspen at at automated precision production of components and systems +44 (0)1234 754023 or e.dishi-phillips@euspen.eu. DW ranging from manufacture of solar cells and panels to their installation and maintenance; to ever larger wind turbines on and

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August 2019 www.designworldonline.com

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4/5/2019 8:29:34 AMAM 7/30/19 11:03

Contents 8 • 2019

•

vol 14 no8

•

designworldonline.com

A supplement of Design World August 2019

printing’s benefits for prototyping 46

102 102 _MOTION CONTROL

112 _3D CAD

6 Common mistakes to avoid when specifying and using step motors

CAD and AI making design better, faster, and easier

The mistakes outlined here have been corrected countless times by thousands of step-motor users around the world. Avoiding these mistakes by following the solutions should help to make your next application a successful one.

108 _LINEAR MOTION Sensors report down to the wire

When it comes to measuring position in linear systems, draw-wire sensors are still a simple, durable, and low- cost option.

50 Better post processing will aid additive manufacturing acceptance

54 Preparing to switch from traditional to additive manufacturing

COVER_MPF 8-19_FINAL.indd 45

8/5/19 7:56 AM

45-57

A Supplement to Design World - August 2019 www.designworldonline.com

AI has the potential to allow engineers to design products faster than before while meeting design specifications, sometimes in new and unique ways.

Myomo Scales up Production, Training for Upper-Body Mobility Device page 76

INSIDE: • Exoskeleton Developers Must Keep Refining Capabilities, Cost, Says maxon Manager .....60 • Industrial Exoskeletons Gain Capabilities, Expand Into New Uses ....................................66 • Why Engineers Should Attend the Healthcare Robotics Engineering Forum .........................72 • Sarcos Robotics Readies Guardian Alpha for Industrial Use ..............................................82 • Robotic Hand Uses Machine Learning to Detect Wearer’s Intent ....................................90

118 _MECHANICAL

ROBOT REPORT COVER_8-19_FINAL2.indd 58

Choosing the right coupling for robust crane and hoist applications

8/5/19 10:32 AM

58-101

For cranes and hoists, a key components is the coupling. Without the right coupling, your crane or hoist may not function properly, causing your manufacturing process to grind to a halt.

ON THE COVER

The EtherCat enabled eXtended Transport System delivers efficient integration for motion control applications in many industries. | Beckhoff Automation

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

2019

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12

August 2019 www.designworldonline.com

CONTENTS 8-19_Vs3.LL.indd 12

DESIGN WORLD

8/6/19 9:06 AM

FEATURED MANUFACTURERS

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Machine Tool Components

8.19

• contents departments 04 Insights

Spring Plungers

06 Teschler on Topic 08 Technology Forward 10 Green Engineering 16 MC2 School

Clamps

18 Design For Industry 28 Design Notes 36 Internet of Things

Workholding Grippers

40 Connector Notes 123 Product World

Fixturing Accessories

128 Ad Index

Rollers & Bumpers

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catalog online! www.fixtureworks.net 888.794.8687 CONTENTS 8-19_second page_Vs2.LL.indd 14

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14

August 2019

DESIGN WORLD

8/5/19 10:15 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

WEB DEV / DIGITAL OPERATIONS

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

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek Videographer Graham Smith gsmith@wtwhmedia.com DIGITAL MARKETING

VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia Digital Marketing Manager Amanda Fourlaris afourlaris@wtwhmedia.com @wtwh_amanda

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Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

Senior, Digital Marketing Strategist Mike Ulanski mulanski@wtwhmedia.com @wtwh_mike

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Events Manager Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen Event Exhibitor & Speaker Manager Michelle Flando mflando@wtwhmedia.com Event Marketing Coordinator Christina Lograsso clograsso@wtwhmedia.com @wtwh_christina PRODUCTION SERVICES

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August 2019

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8/6/19 1:22 PM

w w w. d e s i g nw o r l d o n l i n e . c o m / M C 2

Lisa Eitel

T

Conveyor for discrete material transport

Today’s conveyors are sophisticated designs at the core of myriad automated operations. Consider synchronous conveyors — those that index workpieces from workstation to workstation — as well as asynchronous conveyors that advance workpieces or products in independent transport tasks. Synchronous-conveyor installations run along fixed paths at set speeds ... often quick and automated arrangements. The slowest tasks tend to define overall cycle rate. In contrast, asynchronous conveyors service one or just a few workpieces or products at a time over flexible paths to any number of destinations or staging areas. Usually these conveyors are setup to optimize use of automated machinery and minimize manual workers’ waiting for new product to assemble or otherwise service.

Synchronous conveyors are common for the packaging of bottles, boxes, and bags that ride directly on the conveyor strand. Guides on the conveyor sides and friction pads keep discrete items from sliding or going off course.

Contrast this with features often (though not always) more typical of asynchronous conveyors. Some designs have discrete products sit in carriers or pallets that go through standardized lift, diversion, rotation, and rerouting stations. Units such as pallets in these setups often sport datatags for workstation sensors to read. Such connectivity for data collection lets the whole installation more intelligently route products — even letting plant end-users produce or otherwise transport multiple items via one centralized conveyor network.

In fact, general motion components as well as dedicated conveyor designs are spurring new levels of material-transport flexibility only recently thought impossible. That’s especially true in the proliferating designs of AS/ RS installations as well as self-contained vertical transfer units. The latter might make use of spiraled elevators or (increasingly common) elevator units that employ linear actuators for pushing, hoisting, and workpiece (or product or bin) unloading operations. Some variations even employ linear guides on

Educational installment brought to you by:

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August 2019 www.designworldonline.com

Motion Control Classroom_8-19_Vs2.LE.indd 16

the hoists to steady loads within the elevator cage — especially where the products being lifted are of standard size or collected in bins or pallets.

Elsewhere on asynchronous conveyors, motion lifts (usually in the form of pneumatics) can temporarily raise pallets holding workpieces just a bit above the conveyor below; work is then done on the product while the conveyor is protected from damage. Next the workpiece is lowered back onto the conveyor to continue. Alternatively, other relatively new conveyor designs omit such motion lifts and include structural reinforcements to allow assembly and other tasks to occur right on the conveyor surface.

In the conveyor installment of Design World’s MC2 we’ve written and collected more than a dozen references that detail these and other material-handling types; compare conveyor drive modes, controls, and PT components; and describe how to size subsystems during conveyor design.

References include: Basics of conveyors Chain on edge conveyors Power and free overhead conveyors: Where do they excel?

Chain-driven live roller versus belt and over-under conveyors Pitch: What is it in the context of conveyors?

What are precision-link conveyors? Summary of one type of transfer system What are pallet conveyors? (Not to be confused with pallet-moving conveyors) Access this and other MC2 installments at designworldonline.com/MC2.

DESIGN WORLD

8/5/19 8:44 AM

Production Downtime Doesn’t Stop the Clock. Failure to Deliver Does!

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Low productivity and yield, combined with high energy consumption could be symptoms of an inefficient fluid system design. HYDAC accumulators store hydraulic energy for use at peak requirements, reducing overall power consumption, dampening shock and vibration, and stabilizing your production. Turn productivity into profit!

Production downtime due to unavailable parts is frustrating and costly. Longer and longer lead times on your needed components is a symptom you may be at risk. HYDAC industrial valves are available right now with lead times in weeks, not months.

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Design for Industry Material Handling

Transport System rethinks linear drive

technology to boost machine building

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The EtherCAT-enabled eXtended Transport System (XTS) combines the advantages of proven rotary and linear drive principles into a modular platform. With its compact and flexible design, the mechatronic system can reduce machine footprint up to 50%. Â XTS contains all functions necessary to support efficient integration for motion control applications in many industries. With attached mechanical guide rails, XTS motor modules feature directly integrated power electronics, EtherCAT communication and position measurement. An unlimited number of wireless XTS movers can be controlled

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The eXtended Transport System (XTS) from Beckhoff suits applications with continuous product flow and offers competitive advantages in terms of energy efficiency and machine footprint reductions.

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SEAL and

DELIVER

with high dynamics at up to 4 m/s on customizable paths. By harnessing the flexibility and scalability of EtherCAT, PC-based control and TwinCAT 3 automation software, XTS enables flexible mass production down to lot size 1 for the smart factories of today.

Movers can accelerate, brake, position and synchronize themselves on the fly with automatic collision avoidance provided by TwinCAT 3 software.

They can take up absolute positions and positions relative to each other; they can group themselves and accumulate; they can create clamping forces in motion, drive through curves and along straights, recover energy through regenerative braking and use both the return and outward paths for transport purposes.

This linear motor principle unlocks new possibilities in drive technology: linear motor characteristics with unlimited movers on an endless path low machine footprint and power requirements simple implementation of complex handling and transport tasks low project engineering and assembly expenditure

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Don’t Get Caught In a Labyrinth of Bad Seals

Simple XTS motor modules form a complete unit with the movers and guide rails. The desired geometries, lengths and radii are determined by the number and type of the components selected, with various options for 22.5-, 45- and 180-degree modules to enable circle, clothoid and S-curve designs as well as open straight segments. Motor modules contain electromagnetic coils and all other active functions necessary for operation. The only further requirements are a power supply and EtherCAT connection. Motor modules contain no moving parts and are thus not susceptible to wear.

Our Patented Centrifugal Pressure Seals: ✓ Keep lubricants in and contaminants out ✓ Reduce down time ✓ Support horizontal and vertical applications ✓ Prevent friction and overheating with a non-contact design ✓ Create a dynamic pressurized barrier ✓ Support extremely low-viscosity fluids

A modular mechatronic solution, the eXtended Transport System (XTS) features customizable movers, guide rails and motor modules, with flexible, dynamic control via EtherCAT and TwinCAT 3 automation software.

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Design for Industry Material Handling The XTS movers contain magnetic plates that, together with the coils in the motor modules, generate propulsive forces. Movers absorb the attractive forces of the magnets on both sides and compensate for them. As a result, the rollers, composed of particularly lowwear plastic, can move at high speeds with acceleration greater than 100 m/ s2. A mechanically robust encoder flag communicates mover position to the motor modules.

The system is well-suited to highspeed material handling:

High Performance, Aluminum, Flexible Chain Conveyors

• optimize irregular product flows to constant intervals and speeds • clamp and move products • pick up, transport and discharge products • manipulate products: lift out, close, rotate, screw on caps • process products one at a time or in parallel in groups • integrate with robotics in real-time via EtherCAT DW

Helix

Beckhoff Automation www.beckhoffautomation.com

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• Flexible design fits in tight spaces and reduces conveyor footprint

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Change the way you look at pressure measurement

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Design for Industry M a c h i n e To o l

System prevents machine tool

spindle crashes

Dante Payva • Milling Product Manager at GF Machining Solutions

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Nobody wants to hear the words that a machine tool crashed. When clamped tools, such as a drill or a milling cutter, collide with a workpiece, the resulting impact force is often tremendous. Such force can damage or completely destroy a cutting spindle or even worse, the machine itself. Just one spindle crash, for instance, can easily accrue to more than $30,000 in repairs in addition to production losses.

Shops must have a way to protect their machine tool investments.

The Machine & Spindle Protection (MSP) system works in all directions.

During operation, the MSP allows the machine spindle to deflect when the force acting on the cutting tool during a collision reaches a strength that would damage the spindle bearing in the event of another surge. With this deflection of the spindle, the machine axis drives have the distance required to initiate an automatic emergency braking system.

The length of the braking distance depends on the speed of travel and is limited by the clearance gained. With the MSP mode active, feed rates up to 12 m/min (472 in./min) will still ensure machine braking without damage, regardless of direction. This feed rate does not limit general machining operations because usual cutting feeds are slower in most materials.

To simply run the machine within the safe MSP limits, for example when running a program for the first time,

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When the Machine & Spindle Protection (MSP) system is active, feed rates up to 12 m/min (472 in./min) will still ensure machine braking without damage, regardless of direction.

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operators would use the M-function M304. It restricts the rapid feed of the axes to a safe braking speed to prevent damage at feeds of 12 m/min in X, Y, Z and A to 2,250°/min. or C to 3,150°/min.

After the MSP successfully runs through the process, it is disengaged with a M305 command, allowing the machine to run back up to maximum feeds.

The mechanical safety features of the GF’s MSP system are always active even when a machine runs faster than 12 m/ min and can minimize the effect of a collision. The system doesn’t wear and is maintenance-free. Machine spindles are not be damaged during a collision with a tool cutter or tool holder with the activated M304 function.

Once a collision does occur and MSP has responded, its benefit continues.

The machine can be recovered from the event by reviewing cutters, tool holders and other associated components TL Design World V1.pdf

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for need of replacement. Afterwards, it is recommended to run a standard automatic calibration routine to relocate the machine and program’s starting location points.

A MSP-protected machine tool is back up and running at its original precision in roughly 10 minutes after a collision.

No other crash protection system in the industry can deliver such fast turnaround times. Other crash protection systems, once activated, have to be serviced and replaced themselves, which translates into substantial downtime and repair costs. DW

GF Machining Solutions

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Design for Industry Medical

Compact electronic Slide bolt offers door and

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latch status monitoring

In medical dispensaries, designs often need safe and secure latching.

This compact electronic slide bolt simplifies the upgrade from mechanical to electromechanical latching. The EM-05 4 Series Slide Bolt integrates an electronic lock with latch bolt position sensing and door sensing, allowing for simple monitoring of door and latch status.

The electronic slide bolt is energy efficient and requires no power draw to maintain its retracted or extended position. With its compact size, the lightweight bolt can be installed in tight spaces and is adaptable to various mounting requirements. Simple to install and operate, the 4 Series uses a springloaded, gear motor-driven mechanism for a secure and reliable alternative to solenoid solutions in high-volume dispensing and storing applications.

STANDARD

 The EM-05 4 Series Slide Bolt offers a simple, cost-effective upgrade to electromechanical access control that offers more energy efficiency and reliability than traditional solenoid solutions. With integrated latch bolt position sensing and door sensing, the 4 Series allows simple monitoring of door and latch status for added security. DW Â

Southco, Inc. | www.southco.com

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Two in One: See how AS-Interface lets you put standard and safety signals on the same cable

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IDEC touchscreens are redefining Human Machine Interaction.

Featuring up to 800 cd/m2 brightness, 1024 x 768 pixel high resolution display and over 100,000 hours of backlight life, they’re the brightest, longest-lasting displays on the market. Built for endurance and reliable operation even in the toughest environments, these high-performance HMIs have an exceptionally wide operating temperature range -20°C to +60°C and are IP66F, IP67F and Type 4X, 12, 13 and Class I Division 2 rated.

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Design for Industry Safety

Sensors ensure machine tools and systems operate safely and efficiently Michael Scalet • Industry Management Machine Tools • Leuze electronic GmbH + Co. KG

O

One of the primary tasks of sensors today is to link processes together. The

Safety@work products optimize the collaboration between man and machine: sensor and control systems, like those of the RSL 400 safety laser scanner, can be integrated

RSL 400 safety laser scanner

intelligently into the processes performed by machines and safeguard these machines reliably and securely. At the same time, the processes are structured efficiently and cost-effectively.

The prerequisite for processing work pieces in complex machining centers with precision is having the right tool available for each work step. In addition to checking whether the tool is present and identifying it, the drill or milling cutter must also be monitored for tool breakage. Inductive switches or camera-based code readers clearly identify whether the correct tool is mounted for the respective processing step. Focused laser photoelectric sensors can – thanks to their very small light spot – reliably check whether even the smallest drills or milling cutters are intact.

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Safety and high quality measurement data output in one device

Increased level of automation Industrial robots, which can perform a large number of swivel and gripping movements in a short period of time, are often used for automated loading and unloading of machine tools. Their movement zones must be reliably protected against access over a large area. Before a robot picks up a part, the part must be uniquely identified to ensure that the correct processing step is carried out. This can be done using the DCR 200i camera-based code reader.

The DCR 200i is a reader used to detect and identify Data Matrix codes. The fast imager, integrated high-performance LED illumination, as well as high resolution in combination with a high depth of field guarantee reliable decoding, even with fast processes and high object speeds.

Safety-related monitoring of machines and systems Safety laser scanners such as the RSL 400 are used for the safety related monitoring of areas in and around machines and systems. A maximum operating range, robust operation and simple handling are crucial here. The simultaneous monitoring of four protective fields means the working area can be split up and the speed safely reduced.

In future, an important aspect, in addition to the automated loading and unloading of machine tools, will be the linking together of multiple machine tools in combination with automated production processes. This includes, for example, storage systems that optimize

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material flow, but also a variety of transport equipment such as linear gantries, pallet handling systems and conveyor systems, which all increase the level of automation considerably. For the safeguarding of large access points, safety laser scanners with vertical alignment of the protective field are used, e.g. to detect vehicles and persons.

The RSL 400 safety laser scanner provides a solution for such applications.

Its operating range of 8.25 meters allows large areas to be monitored.

With two parallel protective fields and two integrated safety related switching outputs, only one RSL 400 safety laser scanner can also monitor two stations independently of one another.

A further option is safeguarding using multiple light beam safety devices. These devices provide a greater operating range and therefore an efficient solution for safeguarding access points over long distances of up to 70 meters – even “around the corner” solutions with multiple mirror columns are possible.

Intelligent products such as the MLD 500 safety light curtain have an integrated laser alignment aid for time-saving and cost-effective alignment. Simple configuration by means of wiring and integrated indicator lights for status display are possible, even over long distances.

In-house logistics with automated guided vehicles (AGVs) An AGV, which moves autonomously and flexibly in space, transports blanks

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into the working area of the robot or machine tool. On completion of the production process, the machined work pieces are collected again. The transportation path of the AGVs must be safeguarded with safety sensors which monitor the presence of persons and objects. An important consideration here is the flexible adaptation of the protective fields to the movement situation and the different loads. In the case of the triangulation principle, an AGV must be equipped with two different scanners. Unlike the contour navigation principle, just one scanner is needed for safeguarding and navigation.

This means that safeguarding and data capture for navigation requires one single safety laser scanner. In other words, the scanner simultaneously also provides the measurement data needed for navigation. In addition to that, the measurement values have an extremely high angular resolution and accuracy. This is important to precisely determine the position of the AGV. The RSL 400 safety laser scanner enables such a combined solution.

The safety laser scanner is available in various models. The extensive range of scanners includes nine functional variants – three of which with data output for AGV navigation. All variants are available for the four operating ranges of 3.0, 4.5, 6.25, and 8.25 meters. Models with PROFIsafe/PROFINET interfaces are also available. DW

Leuze electronic

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Design Notes

Continuous extrusion process helps upgrade modern fenders

Edited by Mike Santora • Associate Editor

Trim-Lok designed, developed, and patented its FENDER FLARE with a modern shape and design combining its Edge Trim for ease of installation and 3M Automotive Grade Bonded Tape system for added strength and security.

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Bus, RV, and truck body manufacturers currently use an old design and outdated Fender Flare around their wheel wells. This current part has a two-part manufacturing method, meaning that it is extruded as raw rubber and coiled onto plates. Those plates are then placed into an autoclave, which cures the part through high pressure and heat. The main benefit of this older manufacturing process is that the part cures in the shape required for end-user assembly. The challenge is that installation is cumbersome and costly; holes must be pre-drilled through the fender, drilling creates potential for rust and corrosion, and hardware such as plated or SS bolts, washers, and nuts are expensive. Often, the length of time for each fender flare installation is longer than desired and the look of the fender flare is outdated.

That is why Trim-Lok designed, developed, and patented its FENDER FLARE with a modern shape and design combining its Edge Trim for ease of installation and 3M Automotive Grade Bonded Tape system for added strength and security. The Fender Flare is manufactured from EPDM Dense Rubber using a continuous extrusion process, which is more efficient and cost-effective than autoclaving. Fender Flare can be coiled or cut in straight lengths for shipping and continues to have to the ability to install around the tightest radius without buckling. Lab testing shows that over 30 pounds of force per inch is needed to remove Fender Flare after installation.

Efficient installation without the need for pre-drilling, nuts, bolts, and costly fasteners, thus eliminates rust and corrosion potential — there are also labor savings from the reduced installation time. DW

A modern shape and design updates the look of buses, RV’s and truck bodies while eliminating rust and corrosion potential caused by drilling and bolting.

Trim-Lok | trimlok.com

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Design Notes

A coil’s worst enemy is heat.

Specifically, prolonged periods at excessive temperatures can cause the coil’s insulation to degrade. In general, heat can come from a variety of sources, including hightemperature fluids passing through the valve, the coil’s electrical energy, or simply the air surrounding the coil.

Enhanced thermal design improves life

of nuclear solenoid valves Edited by Mike Santora • Associate Editor

If you manage or design safety-related equipment for nuclear power plants, your solenoid valves may be approaching their qualified life limit. Qualified life is primarily driven by material degradation caused by radiation, thermal, and environmental exposures. One way to obtain a longer qualified life is to select solenoid valves with a new and improved thermal design for better heat dissipation. This design, which incorporates the coil into an epoxy-encapsulated solenoid assembly, not only lengthens the valve’s thermal life but also improves the solenoid’s electromagnetic properties—delivering the same maximum operating pressures at a lower coil wattage in most applications.

Improving traditional valve designs A coil’s worst enemy is heat. Specifically, prolonged periods at excessive temperatures can cause the coil’s insulation to degrade. In general, heat can come from a variety of sources, including high-temperature fluids passing through the valve, the coil’s electrical energy, or simply the air surrounding the coil. The

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

resulting internal temperature is what determines the coil’s required insulation class: Class B (130°C), Class F (155°C) or Class H (180°C).

Exceeding these ratings can cause the coil to open or burn out prematurely.

Traditional solenoid valves house the coil in a metallic enclosure.

This design, however, causes the air surrounding the coil to act as an insulator, preventing the heat from dissipating and raising the valve’s internal temperature. This type of enclosure ages your valve, reducing its qualified life.

Alternatives to the traditional solenoid valve design can overcome these thermal shortcomings. Emerson’s Nuclear Qualified (NP-G/H) 2-, 3- and 4-way solenoid valves integrate its RedHat II technology, which includes a one-piece, epoxy-encapsulated solenoid coil that improves valve performance and extends the component’s lifecycle.

The epoxy encapsulation serves as the enclosure with the magnetic frame molded into the coil. With this design, the coils and solenoids reduce thermal degradation by dissipating heat more effectively than traditional coils.

Along with reducing heat degradation, the RedHat II solenoid design also provides longer qualified life. Depending on the environmental conditions, typical NP series solenoid valves have a qualified life of 3
to 4 years. With their lower operating temperature, NP-G/H solenoid valves have a much longer qualified life — up to 8 to 12 years. Designed
as an upgraded drop-in replacement, NP- G/H solenoid valves also facilitate the plant’s EQ acceptance criteria — minimizing required documentation. Coil replacement is also easy.

Other solenoid valves require substantial disassembly, NP-G/H valves involve simply removing a high-shock clip and disconnecting the conduit to replace the coil.

NP-G/H direct-acting and pilot valves can suit the needs of a variety of nuclear applications, including pilot operators for control valves, pressurizing and venting cylinders, and the selection and diversion of instrument air. Additionally, these valves have the same fluid piping configuration, mounting brackets, EPDM and FKM elastomers, pressure rating, and flow rating as NP legacy valves.

The NP-G/H series solenoid valves can operate from 0 psi to the valve’s maximum-rated pressure. Most nuclear applications fall in the 80–115 psi range, but many NP-G/H valves can work over 115 psi and below 5 psi if necessary. To make replacing current nuclear valves easier, the NP-G/H series retains the same brass or stainlesssteel bodies and elastomeric and pressure vessel components as previous NP models. Many materials, including the elastomers, are designed to meet the harsh degradation effects found in nuclear applications. For example, EPDM rubber withstands high radiation levels, while Viton withstands lower radiation levels but higher temperatures.

These valves are also 100% inspected and functionally tested before shipment. DW

ASCO | www.Emerson.com/ASCO

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Design Notes

Smart sensor enhances material handling systems closed-loop control Edited by Mike Santora • Associate Editor

Most vehicles with lifting booms require the chassis platform to be level with the ground before the boom and load can be elevated above a certain point or rotated around its base axis. This helps ensure the safety of the operator and payload.

Mobile equipment manufacturers are always striving to get the most out of their machines without overburdening the system with costly and complex mechanics. Performance expectations are not only shaping machine needs but also safety requirements. Consequently, this has driven many engineers to design closedloop systems featuring electronic sensors as feedback devices.

Manufacturers of lifting equipment such as truck-mounted cranes or telehandlers, are all striving to provide operators with a safe work environment while maintaining the integrity of the lifting function. The choices for detecting or measuring tilting/leveling conditions are vast. They range from purely mechanical devices: tilt gauges and bubble levels for simple visual indication to basic electronic sensors offering discrete tilt switch points. While these options are typically cost-effective, they offer little to no feedback for safety or performance.

Design engineers are increasingly relying on sophisticated sensor technology for fast and accurate feedback and diagnostics during operation. Today’s systems require something more — electronic inclinometers that offer continuous monitoring of angular position in relation to calibrated reference planes either horizontal or vertical.

The latter can best be accomplished with Parker’s Universal Tilt Sensor (UTS).

The UTS is a MEMS technology tilt sensor designed for configurability making. It is suitable for a range of mobile applications. The UTS communicates via SAE J1939

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protocol providing reliable angular information from either two or three axes. The patented 3-point setup and low-profile housing offer ease of installation, reduced build time, and maximized installation possibilities. Since some applications require a balance of speed and accuracy, the UTS also offers tunable filter settings to adjust the output response on command. Three factory variations are available: X, Y-axis +/- 10 deg; X,Y-axis +/- 90 deg; and X,Y, Z-axis +/- 90 deg.

Most vehicles with lifting booms require the chassis platform to be level with the ground before the boom and load can be elevated above a certain point or rotated around its base axis.

This configuration helps ensure the safety of the operator and payload. A chassis mounted UTS can continuously monitor changes in inclination during the deployment of the stabilizing actuators (outriggers and jacks) to feed the control system real-time information throughout the leveling process. This feedback can ensure a uniform lift, even on the most challenging terrain. While a system using the UTS for auto-level can be made simple as a one-touch function, it can also offer continuous monitoring of the

chassis as different loads and mechanical movement adjust the center of mass of the platform. The continuous feed of information can provide real-time feedback on out-of-level conditions alerting the control system and operator of potentially danger inclination.

In cases where the chassis has an overextended wheelbase, as with a ladder engine or multi-axle crane trucks, two UTS sensors could be used — one in the fore and one in the aft part of the chassis. By monitoring the pitch and roll condition of the chassis in two locations simultaneously, a machine can use the UTS output to prevent excessive twisting along its longitudinal axis of the platform frame thus preventing costly repairs to the machine.

This is just one of many ways the UTS can be used in a closed-loop system to achieve optimum performance and peak safety on mobile platforms. It has been built to operate in the most demanding marketplaces including agriculture, construction, material handling, and more. DW

Parker Hannifin | parker.com

Quality Fast— Because Every Day is Critical Since every day is critical in a medical setting, it’s crucial to design and use quality hospital-grade products. Made in the U.S.A., Interpower® can make hospital-grade power cords and cord sets to your specifications and have them to you fast with a 1-week U.S. manufacturing lead-time on non-stock Interpower products.

The UTS, manufactured by Parker’s Electronic Controls Division, is a MEMS technology tilt sensor designed for configurability. It is suitable for a range of mobile applications. The UTS communicates via SAE J1939 protocol provide fast and reliable angular information from either two or three axes.

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Design Notes

Seals designed to improve medical

device performance Edited by Mike Santora • Associate Editor

PCTI designed a polymer seal to meet the skin grafting and wound debridement device’s high rotary speeds of 10,000+ rpm.

Insulin pumps, oxygen compressors, and surgical drills are included among hundreds of life-supporting machines manufactured by the medical device market. Each device is composed of highly-engineered seals and sealing components that are critical to its performance.

In an oxygen compressor, for example, low-friction reciprocating motion piston seals support the machine’s continuous operation. Unreliable sealing components in an oxygen flow device can compromise its performance and be life-threatening to the end-user. Consequently, seal design and materials are an important part of the design process.

As we consult with medical device manufacturers about sourcing seals for their unique applications, three common challenges surface. First, FDA-compliant materials are required. These parameters ensure that seals and sealing materials in medical devices are suitable for their planned use, which often involves contact with the human body. It also enables full traceability of materials and manufacturing processes for operator and patient safety.

Second, medical devices require seals designed for the extreme heat of autoclaving. In an autoclave steam sterilization environment, every part and component within a piece of equipment is subjected to temperatures ranging from 250 to 375 °F. This may occur for an extended period over the life of the device based on the time required to clean it properly. For reliable device performance, a careful approach to selecting seals designed to withstand the rigors of autoclaving is recommended.

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The third, and possibly one of the most complex challenges medical device manufacturers face, is the market’s limited pool of seal suppliers with the technical knowledge to develop FDA-compliant solutions. Devices are becoming more advanced, must operate for longer cycles than ever before, and must be able to process various fluids at high speeds, temperatures, and pressures. Additionally, many devices are portable, requiring expertise in designing seals that enhance the longevity and reliability of battery-powered equipment.

High-speed medical devices, such as surgical drills and cutting instruments, operate with rotary motion that requires dynamic sealing solutions. This operating environment is also characterized by high temperatures. PTFE-based materials are typically used in a dynamic sealing environment while ethylene propylene diene monomer (EPDM) may be used on the static side of the seal. EPDM can be acquired as FDA-compliant and is hightemperature tolerant, which is suitable for autoclaving.

The mating components of a highspeed device also play an essential role in sealability. By working with a seal supplier that can provide full applications engineering support, manufacturers benefit from the development of equipment designed with the best operating conditions for the seal. For

example, in manufacturing a shaft for a rotary component, the process can be enhanced when the engineering envelope expands beyond seal design. If the interaction of the seal with all relative equipment and components are properly evaluated, solutions to make the entire device work better become much clearer.

This was the case for a manufacturer of skin grafting and wound debridement devices that are being used in surgery across the U.S. Surgical procedures involving skin grafting and wound debridement for a burn patient can be very complex and lengthy. By designing more advanced surgical devices, it can help improve the outcome and recovery of a burn patient; that’s why Exsurco Medical, Inc. began designing an air-powered medical device that allows precision skin grafts and exciosion for surgical patients.

During the device development process, the manufacturer encountered a sealing challenge. A solution was needed to handle extremely high temperatures generated from continuous rotary speeds at 10,000+ rpm. This affects the interface between the seal and its dynamic surface. The focus was to create a lowwear solution with the ability to dissipate localized heat where the seal contacted the shaft. The composition of a seal’s surface contact design is important to manage how it handles heat derived

from speed and friction.

The solution also had to be designed to eliminate trapping contaminants under the seal, in the motor, or any of the device’s electronics for complete autoclaving. This called for a seal without spring energizers because of the risks associated with contaminants getting caught between the spring and the seal.

Exsurco partnered with Polymer Concepts Technologies, Inc. to conduct a thorough assessment of the sealing needs for the skin grafting device and how the seals interact with mating components. This resulted in the design and development of a PTFE lip seal that features a proprietary processing method for enhanced performance as temperatures rise. Success was achieved through an indepth understanding of the application, full collaboration between the two parties, and appropriate selection of design and materials.

Seals can provide peak performance to life-saving devices. The applications engineering experience is critical in proper design, development, and manufacture of precise devices to create, not only a manufacturable item, but one that is sustainable. “Thinking outside the box” is important in any design and development situation and teaming up with a supplier to find the answers “inside the box” can make all the difference. DW

Polymer Concepts Technologies www.polymerconcepts.com

Exsurco partnered with Polymer Concepts Technologies to conduct an assessment of the sealing needs for the skin grafting device and how the seals interact with mating components. This resulted in the design and development of a PTFE lip seal that features a proprietary processing method for enhanced performance as temperatures rise.

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Internet of Things

Forecasters predict a $20 B digital twin market by 2025

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Digital twins play a major role in the adoption of IoT and IIoT. Thus, forecasters, such as Global Market Insights Inc., are forecasting the growth of this market to reach more than $20 billion by 2025.

Digital twin applications can be found in manufacturing, automotive, and healthcare industries. Digital twins enable real-time and predictive analytics, and help in cost and time savings. For example, in the aviation sector, GE helps client companies understand airline routes and dynamically optimize maintenance schedules of jet engines, and maintenance shop availability with the help of its digital twin Predix platform.

The growth of digital twins is driven by a rising demand for less asset downtime, optimizing process time, reducing time-to-market, and improving operational efficiency. The process support and service application are anticipated to exhibit a growth at a CAGR of more than 30% between 2019 and 2025. This application includes inventory management services and supply chain management services. Digital twins in these application help organizations reduce inventory up to a considerable percentage to free up the working capital from unnecessary inventory buffers. They also help reduce inventory carrying costs and increased customer service performance.

The healthcare sector is anticipated to hold a significant market share in the digital twin market. The digital twin offers real-time monitoring and analytics with machine learning and helps to streamline operations and processes in hospitals, improving customer experience. For instance, a single MRI scanner produces an average of 800,000 log messages, which reflects how a system works technically. The proactive remote monitoring services with the digital twin of MRI scanner will help to track and analyze these log messages for early warning signs of impending technical issues.

The manufacturing sector is expected to secure a market share of more than 25% in digital twin market by 2025. This growth is attributed to the growth of the manufacturing sector after Industry 4.0 and the emergence of automation systems in the manufacturing sector to rapidly increase production capacities. According to the World Bank, manufacturing globally contributed to 16% of the total economic value in 2016. This steady growth of the sector is expected to further fuel the demand for digital twins to streamline and optimize the manufacturing process flows.

The Asia Pacific digital twin market is projected to register a growth with a CAGR of around 30% between 2019 and 2025. The growing adoption of the IoT and IIoT due to increasing internet penetration coupled with the proliferation of smartphones is fueling the market. The presence of prominent automotive players in the countries including Japan, South Korea, and India is contributing to the digital twin market growth.

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Additionally, this growth can be attributed to the rapidly evolving e-commerce ecosystem along with heavy investments from venture capitalists to leverage the growing demand for the online market. In 2017-2018, the retail shrinkage percentage of sales in the Asia Pacific region was estimated at around 1.75%, amounting to nearly USD 24 billion. To tackle the growing concerns related to inventory shrinkage, the uptake of digital twin in the region is expected to grow consistently over the forecast timeline.

The companies operating in the digital twin market are focusing on technological innovations, strategic acquisitions, and mergers to strengthen their market position and acquire new customers. For instance, in May 2019, Bentley Systems acquired Keynetix, a UK-based provider of cloudbased software for capturing, modeling, visualizing, and sharing geotechnical data to build subsurface digital twins. These models of underground assets and environments for infrastructure projects will be easily monitored in real-time.

Some of the key players operating in the digital twin market are ABB Group, Ansys Inc., Autodesk Inc., Dassault Systèmes, General Electric, IBM Corporation, Microsoft Corporation, Oracle Corporation, Robert Bosch GmbH, SAP SE, Siemens AG, and Wipro Limited. DW

Global Market Insights Inc. www.gminsights.com

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The Pocket Portal has an RS-485/power port, input/ output port, browser interface, and provides limited control with Modbus RTU write capability (up to 115.2 kbaud) and 3 Vdc discrete output logic. Unmonitored devices can be IoT connected and become monitored quickly with Modbus RTU, 4 digital and 2 analog inputs.

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Internet of Things

Voith adds IIoT functionality to torque limiting couplings with Dtect

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Voith now offers Dtect — an intelligent monitoring system that provides real-time data of driveline performance and coupling status. With Dtect operators can take actions to prevent potential problems and avoid unplanned downtime. By supporting better decision making, Dtect also increases productivity and significantly lowers production and maintenance costs.

Dtect enables comprehensive monitoring of a driveline’s torque limiting couplings. It was specifically designed to work with couplings, such as Voith’s SmartSet, which serve to prevent machine damage in high-value rotating equipment. It is also possible to upgrade existing couplings with this intelligent system.

Slippage monitoring for maximized uptime: Through continuous measurement of the slip angle, Dtect accurately identifies and monitors coupling slippage caused by high torque peaks in a driveline. This lets operators take action if necessary — for example, by adjusting the load of the driveline or by performing a controlled shutdown. That lets operators get increased uptime, reduced maintenance, and lower spare-parts cost.

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Data analysis ensures optimum performance: Dtect continuously collects driveline performance data that can be analyzed to ensure maximum productivity. It uses an updated quadruple sensor setup that increases the sensing range without affecting the resolution of the expanded measurement. By analyzing the slip behavior of the coupling, the operator can evaluate if the system is running at full capacity and, if not, adjust the parameters accordingly. Further, proactive coupling maintenance can be performed to avoid costly downtime.

Simultaneous monitoring through a single interface: Dtect now makes it possible to monitor multiple couplings at the same time. It assesses each coupling individually and communicates the multiple data streams to the common interface. In this way, Dtect allows for simultaneous monitoring of all connected drivelines.

Operators benefit from comprehensive, real-time status information provided by one central system.

Easy integration for platform-independent data monitoring: Equipped with Modbus TCP/IP communications, Dtect is easily integrated into established process information networks. Given its high flexibility, the system can be adopted with ease to other communication standards to fit a wide range of requirements.

HMI touch panel for outstanding ease-of-use: Dtect can be fitted with an integrated HMI touch panel. It offers the highest usability, better control and status information at a glance. With visual warning indicators, the system assists operators in making decisions and taking the necessary actions in any given situation. DW

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Connector Notes

Partnerships ensure the future of Single Pair Ethernet

Edited by Mary Gannon • Senior Editor

Harting’s ix Industrial connector

H

Harting Technology Group is continuing to develop and enhance its partnerships with other connector

manufacturers as it works to develop, standardize products and market a connection technology system for Single Pair Ethernet (SPE). All relevant standardization committees have now opted for the HARTING design of an SPE mating face.

For the protocol, this is IEEE802.3, and for cabling it is ISO/IEC JTC 1/SC 25 and TIA 42.

The latest udpate, 802.3cg 10Base-T1, for distances up to 1 km, will be released in 2019. SPE allows for a single open, scalable Ethernetbased network within the automation system. This significantly reduces complexity, costs and enables going beyond existing borders.

At Hannover Messe this past April, the company revealed further updates to its partnership with Hirose Electric Co. Ltd. The two companies partnered in the autumn of 2016 when they jointly launched the ix Industrial interface on the market.

The two companies are inviting others to partner up in order to drive Single Pair Ethernet as the infrastructure solution for the fast growing IIoT market. The latter consists of offering a practicable portfolio of connectors, sockets, cables and cable sets on the component side. Both are working to successfully position the entire technology in user groups.

“In addition to establishing a uniform mating face, the standardization of all other aspects is actively being pursued and is seen as the basis for a comprehensive SPE ecosystem,” said Ralf Klein, Managing Director Harting Electronics.

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The goal of this alliance is a consistent and reliable Single Pair Ethernet infrastructure that brings the IIoT to life. Whether in transportation, robotics, energy or classical industrial automation, T1 Industrial from Hirose and Harting gives users a comprehensive infrastructure to take a successful step on the way to the Internet of Things.

At Hannover Messe, Harting revealed the first IP20 interface consisting of a plug connector and angled printed circuit board socket.

Single Pair Ethernet helps to ensure fast Ethernet speeds of 10/100Mbps, which requires two-wire pair cabling; Gigabit Ethernet requires four wire pairs.

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181015

The new Single Pair Ethernet is now pushing a technology into the market that can transmit these TCP/IP-based data streams via just one pair of wires.

Harting also announced at Hannover a new partnership with TE Connectivity, which will co-develop products for the future SPE infrastructure as a cooperation partner.

The two companies are inviting others to partner up to drive Single Pair Ethernet as the infrastructure solution for the fast growing IIoT market. “Single Pair Ethernet is the technology on which we will build the road to the future success of the IIoT,” said Eric Leijtens, Global Product Manager Industrial Communication, TE Connectivity.

“With the new interconnection standard IEC 63171-6, we have an outstanding opportunity to reap the full

Harting’s IP20 interface consisting of a plug connector and angled printed circuit board socket

potential of the Industrial Internet of Things,” added Frank Welzel, Director Global Product Management, Harting Electronics. DW

The Harting Technology Group harting.com HIROSE Electric | hirose.com TE Connectivity | te.com

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Connector Notes

The importance of insulation for safe, failure-free operation of VFDs Edited by Mary Gannon • Senior Editor

Test shows heat propagating into the cable

T

To address the latest developments in frequency-controlled motors,

variable-frequency drives (VFDs) show a clear trend: more compact design with the same or higher power with extremely high switching accuracy of the frequency converters.

As a result, in the future the user must not only pay attention to the right number of conductors and AWG size combinations, but also to the electrical characteristics of the motor or servo cables. For that reason, igus has been developing and testing materials made of high-performance polymers for years.

Cable theory describes an electric cable as an electrical quadrupole, comprised of inductance, capacitance, resistance and dissipation factor. Every electric cable has a certain inductance, capacitance and ohmic resistance depending on its structure and the materials used. The purely ohmic resistance in an industrial environment depends mainly on the conductivity of the conductor material (usually copper), its AWG size and length, while the capacitive values are strongly dependent on the insulating material.

Thus, two identical cables with identical conductor structures of the same length and AWG size with different insulation materials have completely different capacitive specifications.

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Connector Notes

Proper insulation material for capacitance Although the insulating material plays a fundamental role in capacitance, many power, motor and servo cables are still being made on the market with PVC insulation. This material has many good specifications: it is cost-effective and easy to process, but also has an extremely high dielectric constant. A higher dielectric constant will increase the capacitive effects, therefore requiring more energy to charge and discharge the cable. This ultimately leads to higher losses and higher switching inaccuracies of the overall system.

In short, the higher dielectric constant of PVC has a greater capacitive effect than materials with a lower dielectric constant. The cost savings gained by using PVC insulated cables are lost on problems created with power cables from a drive to the motor.

Safe and reliable cables for high-frequency drives

Today’s generation of VFDs change their speed by changing the frequency of the drive voltage. If a high capacitance cable is used in this control system, a significant amount of energy is lost for the capacitance of the cable alone. This can lead in the worst case to unwanted reflections and voltage overlaps.

Hence the growing need for lowcapacitive insulation materials. For more

than 15 years, igus has been offering materials made of high-performance polymers for all of its chainflex motor and servo cables used in the energy chain.

These polymers have a lower dielectric constant with a high electrical resistance.

The goal is to offer customers a cable that is tested to withstand continuous movement inside an energy chain and provide power from a VFD to the motor safe and efficiently.

Smaller motors require a new electrical supply Maximum current carrying capacity of an electric cable is defined by the permissible maximum conductor temperature (usually marked on the cable) at a given ambient temperature.

Depending on the insulation material used, this can range for PVC from 70° – 80°C and 90°C for TPE materials.

The data for the cable temperature is calculated independent of the connector used to terminate the cable.

Old generation motors were usually larger than today’s with the same power level, so the metallic round connectors used were relatively large. As a result, both the motors and connectors served as heat sinks.

Today, users are demanding ever smaller, more compact, and more powerful motors. Drive manufacturers are already coping with this demand by modifying many of the structural

Replacement circuit diagram for a cable element of a two-wire cable of length dx. For a required length, L’ = Inductance, R’ = Resistance, G’ = Dissipation factor and C’ = Capacitance are used for simplicity.

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components of the motor including smaller connectors.

The trend is moving from larger motors, metallic round size M23 or larger connectors, toward smaller motors with M18 or M16 round connectors with additional plastic housing insulation. Due to their small size, the motors get hotter when they run at the same power level as their predecessors. This means that a significant amount of waste heat is driven directly into the first 3-4 ft of the cable.

The large metallic connectors of the past would help to absorb this heat, but these new motors use the connecting power/servo cable to absorb more heat.

Although there are no consequences for the motor and the connected components in the short term, serious problems may be the outcome in the long term. If the insulation material of the cable does not withstand the elevated temperatures in the long term, short circuits can occur inside the cable and in the vicinity of the connectors, which in the worst case can lead to fires. It is therefore important for cable manufacturers to respond to market developments with new insulation materials that can withstand the current requirements.

Insulation material for the latest servomotors To prevent damage to the compact motors, igus now offers a new insulation material for its chainflex motor and servo cables. This new insulation was qualified after five years of testing in the igus laboratory and extensive practical tests.

It has a low capacitance and withstands the increased thermal requirements of the latest generations of motors.

The igus range of cables undergoes extensive testing under real conditions in the company’s 30,000 ft2 test laboratory.

For example, the servo cable CF29 was also tested with the new insulation material. In test number 5034, the cable with a bend radius of 5.4 x d withstood more than 45 million strokes inside an energy chain. DW

igus | igus.com DESIGN WORLD

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A supplement of Design World August 2019

printing’s benefits for prototyping 46 50 Better post processing will aid additive manufacturing acceptance

COVER_MPF 8-19_FINAL.indd 45

54 Preparing to switch from traditional to additive manufacturing

8/5/19 7:56 AM

A d d i t i v e

T e c h n o l o g y

PolyJet 3D printing’s

benefits for prototyping By using PolyJet features like full color, graphic textures and multiple materials, designers, engineers and product development teams can create prototypes that accurately simulate end-product look and feel.

Matt Stenoien • Product Manager • Stratasys Direct Manufacturing

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With pressure to get to market quickly, product designers and development teams must make fast and accurate decisions during the early stages of design and testing. Rapid prototyping is a key component for design verification, and 3D printing offers the fastest method for prototyping. While the 3D printing industry offers several fast technologies, PolyJet technology is one of the more impactful, popular methods for prototyping.

The PolyJet process begins with your design in Below is a breakdown of PolyJet as a solution rapid the form of 3D CAD data. The system’s printhead prototyping, and how it can benefit designers and both jets and cures photopolymer material nearly engineers during product development. simultaneously, cross-section by cross-section, with Speed ultraviolet (UV) light. The machine adds support 3D printing has historically been used as a rapid structures using specially formulated material to prototyping method because of the simplicity of the support free-floating features. After each crossprocess -- a 3D design is uploaded into a computer section, the build platform lowers, and the process and the printer uses that data to build the design layer repeats until the full part is formed. With the 3D by layer. The design is in an engineer’s hands usually printer’s ability to produce parts rapidly and in that same day. This contrasts sharply with the longprecise detail, PolyJet is an excellent technology for lead times and set up costs associated with other quick delivery of accurate and cosmetic prototypes prototyping methods such as molding and machining and concept models. The technology produces parts operations. with fine layers as thin as 27 microns (0.00106 in.), Build speed is largely determined by part size and intricate details, and in full color. resolution. Even so, PolyJet continues to be one of the

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fastest 3D printing technologies in the market. The technology can build multiple parts in a matter of hours, enabling product development teams to receive imperative feedback, revise, and reiterate within days. PolyJet is most efficient for small, detailed parts. Designs within a 5 to 6-in. cubed area leverage the speed, surface finish, detail and low price point of PolyJet.

PolyJet can deliver a minimum feature size of 0.012 in. and layer thicknesses as thin as 27 microns (thinner than human hair). Because the 3D printing process doesn’t use heat to fuse layers together, warping and shrinking are not a concern.

A designer can take advantage of the technology’s build features to create finely detailed prototypes unburdened by the constraints of traditional manufacturing.

Geometric freedom 3D printing gives you freedom to design.

Traditional design for manufacturability rules don’t apply because the technology can build complex geometries with cavities, undercuts, overhangs and more.

What may have been an impossible design to machine is now feasible. You have the freedom to let function and performance be the main drivers of design, rather than cost, time or the limitations of traditional manufacturing methods.

Full color One of the biggest challenges designers face when prototyping is meeting the seemingly contrasting needs for an accurate, aesthetic model that is also delivered quickly. In addition to being fast, PolyJet technology produces cosmetic parts in full color.

PolyJet offers a full range of CMYKW color options – 360,000. Graphics and pictures can be incorporated via images that further the visual complexity that

DESIGN WORLD

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www.makepartsfast.com

A gearshift prototype 3D printed on a PolyJet system in multiple materials and colors. | Courtesy of Stratasys Direct Manufacturing

August 2019

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Additive Technology

The Stratasys J750 PolyJet system is one of the fastest 3D printers in market. | Courtesy of Stratasys Direct Manufacturing

can be achieved, like wood grain or bricked surfaces. Designers can add transparencies to their models to display interiors, simulate glass or other seethrough elements. Companies can reduce time to market by enabling graphic designers to integrate product images in marketing materials and ensure that packaging and displays work seamlessly with end products well before the design goes into actual production.

The models can be nearly indistinguishable from the end product,

A cosmetic packaging prototype 3D printed with PolyJet technology in multiple colors. | Courtesy of Stratasys Direct Manufacturing

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mimicking the final part’s look and feel for concept reviews and promotional uses. The PolyJet parts are built with the desired visual aesthetic quickly without the need for additional finishing.

Color can be incorporated with two file formats, depending on the desired color and characteristics of the part.

With STL files, color and transparency are determined by RGB color code assigned to each unique shell. In VRML format, color can be applied to each face or individual triangles of the geometry or with a texture (graphic) file. Texture mapping, also known as UV mapping, is the process of adding an image or graphics to 3D geometry. Color information is stored in a 2D image file (.png, .jpg, .tiff), which is related to the coordinates of the mesh.

Through the high-resolution of PolyJet technology, prototypes and concept models can accurately mimic the final product as soon as it comes off the 3D printer without post-processing.

Multiple materials Material versatility is another significant benefit of PolyJet for rapid prototyping.

PolyJet materials like Digital ABS Plus simulate engineering-grade plastics that

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may be used in the final product. The Agilus30 family of PolyJet materials, for example, simulate thermoplastic elastomers with flexible, rubber-like qualities. Glass-like clear materials further enhance the range of visual capabilities available with PolyJet. Multiple material types can be used in conjunction to support a range of visual, tactile and functional simulation for advanced prototypes and concept models. Incorporating rubber surrounds, overmolds, buttons, knobs, grips, gaskets and boot and hose assemblies can increase the realism of a prototype used for stakeholder feedback or for marketing materials.

PolyJet materials offer the versatility to allow team members to see, touch, feel, test, analyze and use prototypes as they would the final product. These prototypes are tested or used in trials to gauge their success and enable rapid iterations. By using the benefits of PolyJet like full color, graphic textures and multiple materials, designers, engineers and product development teams can create unparalleled prototypes that accurately simulate endproduct look and feel.

Ultimately, PolyJet prototypes give designers a thorough understanding of products earlier in the development process, minimizing the risk that problems will go unnoticed. With fine feature details and little need for finishing, designers and engineers can be more confident in their work as they move forward in the product development life cycle. n DESIGN WORLD

8/5/19 11:29 AM

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A d d i t i v e

T e c h n o l o g y

Better post processing

will aid additive manufacturing acceptance Post processing, in one form or another, is inevitable with additive manufacturing (AM) technologies. But it is critical for serial production applications of AM in terms of the financial costs and the time it takes between a part leaving the AM system and becoming an end-use product.

There are ways to make post processing efficient.

U

Joseph Crabtree • CEO • Additive Manufacuring Technologies Ltd.

Undoubtedly there are many benefits associated with the use of additive manufacturing (AM) as a production technology.

On a pan-industrial basis, manufacturers exploit the fact that through the use of AM they can not only build complex parts, in one piece, that were previously impossible, but they can also build stronger, lighter weight parts, reduce material consumption, and benefit from assembly component consolidation across a range of applications. These advantages have all been well documented during the last 10-20 years as AM has emerged as a viable technology for prototyping and production, and are invariably seen as being enabled by the additive hardware that builds the parts. In reality, however, this is a partial picture, particularly for serial production applications of AM. AM hardware systems are just one part of an extensive ecosystem of technologies that enable AM, both pre- and post-build.

By focusing just on the AM build process, a fundamental part of the production process chain is often

overlooked, namely the post-processing steps once the part is out of the AM machine. Manufacturers using (or considering using) AM for serial production applications need to identify the appropriate additive process for their targeted application. From there the postprocessing requirements must be identified and focused on, otherwise the use of AM as a viable alternative to traditional manufacturing processes may end up being negated completely.

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Post-Processing for AM Post-processing is actually an umbrella term for a number of stages that AM parts may go through after they come out of the AM system and before they are fit for purpose. The term “post-processing” is often used interchangeably with “finishing,” which can be confusing. With many processes there are a series of essential post-processing steps that must be undertaken prior to the AM-produced part finishing stages. Thus “finishing” is actually a subset of post-processing, not a term that should be used interchangeably with post-processing.

Post-processing can include any or all of the following: • Excess material removal • Curing / heat treatment • Support removal • Machining • Surface finish processes (such as bead blasting) • Coloring • Inspection

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Post-processing is often the elephant in the room when it comes to AM as a production tool. For AM production applications, post-processing is a considerable element of the overall cost-per-part, and can be anything up to 60% of total cost depending on application. Support removal and other post-processing activities are often labor intensive, and therefore cost- and timeconsuming. In addition, there is often a necessity for post-processing to enhance final part characteristics, in terms of function or aesthetics.

This is why the issue of post-processing is so important when looking at the viability of AM for serial production, because it is often the area where the technology falls down as a competitive manufacturing technology. The post-processing conundrum must be confronted head on with an ecosystem approach to each individual application — from end to www.makepartsfast.com

The PostPro3D BLAST process can achieve consistent surface finish on non-line of sight organic lattice structures.

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Additive Technology end. This means joining the dots from product conception through to final product.

To a certain extent, post-processing can be cauterized by a focus on design for AM (DfAM) to reduce the necessary post-processing steps. Success here will depend on how well the designer understands the intricacies and capabilities of the AM process they are using, how to orientate the parts in the machine(s), and how to generate optimal support structures for build and removal. In general, post-processing requirements for a given application depend on the geometry of the component and how well it is designed for manufacturability using AM. For an industry that calls itself disruptive, manufacturers are still largely post-processing parts the same way they

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did 100 years ago, with the requirement of significant manual intervention. And it is this that is slowing the whole process chain down for production applications of AM. An innovative approach to post-processing There can be no argument about the increased number and improved nature of thermoplastic materials available for AM processes in recent years. Alongside these material developments, the AM systems that produce thermoplastic parts have also significantly improved in resolution, accuracy, repeatability and overall quality; they consistently meet industrial requirements for exacting prototyping and tooling.

Yet, the critical mass of production applications remain lower than they otherwise might be due to previously mentioned limitations placed on the overall process chain by the postprocessing phase. This is because powder-bed processes — which require significant powder handling and removal post build — also require infiltration operations, as well as finishing processes, particularly if aesthetics are important alongside the strength advantages that laser sintering offers.

If colored parts are required, then this is also applied at the finishing stages of post-processing.

With filament thermoplastic material processes, the nature of the AM process (no matter how refined) results in a stepping effect. The traditional post-processing steps required to eliminate these process-specific results are considerable, costly, and time consuming. However, an automated post-processing solution for smoothing high volumes of thermoplastic polymer parts to an injection molded surface quality would remove one of the biggest hurdles to the serial production process chain. Here, I am talking about parts 3D printed using Laser Sintering, Multi Jet Fusion, High Speed Sintering, and Fused Deposition Modeling processes for specific material types including

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The PostPro3D machine from Additive Manufacturing Technologies.

Polyamide/Nylon, flame retardant Nylon, glass filled Nylon, ULTEM, PMMA, TPU, and TPEs. One option, known as PostPro3D, includes a range of hardware that integrates new systems, software and virtual services. The system is built on the proprietary BLAST process.

Simplicity is the key. Post-build, 3D printed parts can be removed from the machine, loaded onto a rack, and placed into the PostPro3D post-processing chamber. The user then selects the appropriate program and the process starts and runs for 90-120 minutes, after which the parts can be removed, inspected, and fit for purpose.

During those 90 to 120 minutes, 3D printed parts are subjected to a physiochemical process that involves converting a proprietary but wholly safe solvent into vapor under precisely controlled vacuum and temperature conditions. The process refines the surface of each part for a perfectly smooth finish, equivalent to that of an injection molded part. Moreover, the process also seals and strengthens parts, essentially improving their mechanical properties— such as elongation at break — compared with how parts were when they came out of the 3D printer.

PostPro3D systems have been designed to connect through an IIoT network where data are analyzed in real-time. This allows for new insights on process performance, which can subsequently be shared amongst the global fleet of PostPro3D machines, and

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made available via software updates to continually upgrade performance, all while protecting individual IP. Moreover, this connectivity capability also allows for integration with other intelligent devices and workflow automation software across the production process chain.

All of this points to a continued need to work towards developing whole process chains that will help convince AM users, and potential AM users, that the transition to AM for an increasing number of production applications is worthwhile and not nearly as complex as it may have been, even a few years ago. It demands a unified approach — across the AM sector itself — to develop more capable and connected systems, while simplifying the overall process to provide economically viable, automated solutions.

Automated turnkey hardware for post-processing — such as the commercially available PostPro3D range — is certainly a step forward for the post-processing stage. However, there are still more steps to take, in terms of wholly connected, custom, end-to-end digital manufacturing systems. n Additive Manufacturing Technologies www.amtechnologies.com

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A d d i t i v e

T e c h n o l o g y

Preparing to switch from traditional to additive manufacturing How to overcome design-for-additive-manufacturing (DfAM) constraints that can be deterrents to mass production.

T

Benny Buller • founder and CEO • VELO3D

The manufacturing world’s mindset is shifting with the news of 3D-printed, certified-for-flight components and FDA-approved human joint replacements: additive manufacturing has shown signs it can produce end-use parts, but making metal additive manufacturing (AM) dependable enough for serial manufacturing remains an accomplishment of few companies.

Why is AM still falling short? After all it offers the promise of less tooling, shorter lead times, and fewer supply chain issues.

Not to mention the enticing vision of consolidating multiple parts, and even the magic of “innovative designs that can’t be manufactured any other way.” The short answer is, while the technology has dramatically advanced in recent years, there are still many less-visible technology issues to be overcome.

One of these is the complex reality of shifting production from conventional methods to AM. A manufacturer will encounter this as soon as they start redesigning an existing part to ready it for 3D printing. Beware—this introduces significant, additional risk because it adds a host of new variables.

For one thing, you’re not comparing apples to apples. When you test old versus new manufactured parts and you see a difference, is that because of the design changes you made or due to the manufacturing technology itself? Or maybe a little bit of both? And when you begin to see financial benefits from the switch, will you be able to separate the benefits of improved manufacturing technology versus design changes that reduced

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the cost? Maybe not all of those benefits are unique to AM—will you be able to fend off those people who are skeptical of your math?

Another point is that redesign might not even be a viable option for various reasons: • Does your business have the regulatory authorization to redesign the part (Design Authority)?

• Does your part have enough volume to justify a redesign and have you accurately captured all the design considerations that will make the part equivalent in operation to the original one?

• How many candidate-parts do you have and how much time will it take to redesign them in a way that truly makes an impact?

• What about the resources needed to validate your redesigns?

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Finally, there’s just the sheer level of complexity of AM technology, particularly when it involves metals.

Rey Chu, Co-founder of Phoenix, Analysis, and Design Technologies (PADT) says: “There are no guarantees of successful outcomes when printing with metals. There are so many variables coming together from the alloy, the machine architecture, the process parameters—they all compound into widespread complexity. Because of the nature of machine dependency, try getting the same result by printing the same part on a different machine requires significant effort in process development, validation and control ….it’s all hard.”

Is it possible to avoid or reduce this complexity?

Is full up redesign required for most parts? In fact, lots of parts can be converted to AM now. They haven’t been in the past because they didn’t fit the rules of DfAM so they were being fabricated another way. Parts like impellers, heat exchangers, blisks, and volutes are excellent examples that have traditionally been manufactured outside of AM because of their geometries—low overhangs, large inner diameters, untenable aspect ratios, and complicated internal channels that make postprocessing difficult or even impossible.

However recent developments in AM technology— most notably support-free manufacturing—are challenging the traditional mindset, providing high levels of quality control, and overcoming previous barriers such as those in the part-geometries above.

A little more about the implications of “support free” here: In AM, a self-supporting angle describes the feature’s angle relative to the build plate. The lower the angle, the less likely it is to support itself.

Each material will perform slightly differently, but the general rule of thumb has been to avoid designing a self-supporting feature that is less than 45 degrees. As you can see in the picture below, as the angle decreases, the feature’s downward-facing surface becomes rougher and eventually the part will fail if the angle is reduced too far.

Support-free AM overcomes what were previously thought of as written-in-stone laws of physics, allowing you to accelerate your move to 3D printing without having to adhere to all the old rules of DfAM.

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The 45-degree rule: angles below 45 degrees require support structures to ensure stability of the part during production. | Courtesy of Proto Labs

Overview of how Velo3d enables additive manufacturing without support structures. | Courtesy of VELO3D

Industrial metal parts manufactured with support-free AM overcome many of the traditional barriers of the past. | Courtesy of VELO3D

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Additive Technology As Robert Smith, COO of Optisys, a leading aerospace/defense antennasystem OEM, says, “I have been designing and printing with additive manufacturing for more than 15 years.

All that time, I’ve had to think about whether or not the machine tool can even access the support structures; if it can’t, then the design isn’t compatible with AM and it gets set aside. The ability to manufacture without consideration of support structures is transformative.”

Such a transformation will free you from being bogged down by outdated DfAM issues, allow your knowledge to mature as you carefully explore all the possibilities of AM, and enable applesto-apples comparisons of manufacturing methodologies. Now you can focus on those critical challenges mentioned before: qualification and quality control.

All of these questions need to be considered, particularly if you are setting up a manufacturing flow for missioncritical, metal-AM parts. Addressed properly they will enable faster part qualification and quality controlled production—and allow you to manage the move from conventional methods to AM in a way that will also fit your financial goals. n Velo3D | www.velo3D.com

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

It’s not a web page, it’s an industry information site Stay current with the latest additive manufacturing tips, resources, and news, visit makepartsfast.com and stay on Twitter, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the additive manufacturing community.

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A Supplement to Design World - August 2019 www.designworldonline.com

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INSIDE: • Exoskeleton Developers Must Keep Refining Capabilities, Cost, Says maxon Manager ......60 • Industrial Exoskeletons Gain Capabilities, Expand Into New Uses .....................................66 • Why Engineers Should Attend the Healthcare Robotics Engineering Forum ..........................72 • Sarcos Robotics Readies Guardian Alpha for Industrial Use ...............................................82 • Robotic Hand Uses Machine Learning to Detect Wearer’s Intent .....................................90

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The Robot Report

Exoskeleton Developers Must Keep Refining Capabilities, Cost, Says maxon Manager Company supports Cybathlon teams, works on Generation 2 of its joint actuator.

Eugene Demaitre • Senior Editor • The Robot Report

The story of exoskeletons is full of twists and turns, with promising technologies, challenging use cases, and a sometimes tortuous path to adoption. Robotics observers might be familiar with demonstrations on video or at conferences, but the developer story is rarely told.

The Robot Report recently got some insights from Otto Ineichen, business development manager

at maxon motor ag in Switzerland. Ineichen has experience as an applications engineer and a sales engineer, and he described the evolution of exoskeletons for healthcare and industrial uses.

How did maxon, which supplies high-precision drives for robots and other devices, become interested in exoskeletons?

maxon motors’ Ineichen

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Ineichen: A few years ago, we became more and more focused in the U.S. on exoskeletons.

We studied the growing market and saw exoskeletons for medical applications.

Maxon developed motors based on our standard parts. We have Generation 1, and we’re now working on Generation 2, to come next year.

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maxon is supporting teams for Cybathlon 2020. | maxon motor

The exoskeleton market will grow from 7,000 units and global hardware revenue of $192 million last year to 301,000 units and $5.8 billion in revenue by 2028, predicts ABI Research.

How does that compare with maxon’s expectations?

Ineichen: We design a dedicated drive for the companies building exoskeletons. Most companies on the market with electricdriven exoskeletons initially designed them for medical or military use.

The majority of the industrial applications are passive exoskeletons, which are driven by springs or gas, to support assembly work. These exoskeletons are for supporting lower limbs, like the knees or hips for lifting tasks, or for the upper limbs for overhead work.

We’ve seen lots of companies and universities around the world developing exoskeletons, some in New Zealand, some in Europe, and some in the U.S.

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maxon designed its exoskeleton actuator after studying the market. | maxon

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The Robot Report

New Zealandbased Rex Bionics used maxon motors in its exoskeleton for restoring the ability to walk. | maxon motor

We design precision motors for the companies building exoskeletons. Most companies in the exoskeleton market initially designed for medical or military use. — Ineichen

What was the initial reception of maxon’s motors for exoskeletons?

What else should exoskeleton designers be aware of?

Ineichen: Last year, we released our Exoskeleton Joint Actuator. A lot of universities used it for prototypes, and they liked it very much.

Based on their experience and feedback, we are able to provide more customized drives.

Ineichen: During the development stage, we thought that backlash would be important and then discovered that was not the case. This allowed us to work on a simpler design and put more effort into dynamic motion controls.

At maxon, we understand that customization is very important during the design concept. At our newly built manufacturing facility in the U.S., maxon engineering services assist with project design.

We’re also working with universities participating in Cybathlon 2020, a competition for people with physical disabilities using assistive technologies. maxon is a key sponsor of the event and is supporting teams with our drive systems, as well as our expertise in drive technology. (continues on page 65)

How is exoskeleton technology changing? We already know that battery weight and endurance are issues.

Ineichen: Based on what we’ve learned from the first users, exoskeleton developers need to continue trying to reduce the weight and to make it more dynamic. Most exoskeletons do not have the range of motion of the human body, but that is improving.

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The Robot Report (continued from page 62)

What have you learned about exoskeletons for healthcare?

What advice do you have for exoskeleton developers?

Ineichen: In the beginning, exoskeletons were mostly in hospitals and rehabilitation centers because of control and the price of the systems.

If engineers could reduce the weight and the size, that would make it easier for patients to use, and would help bring them into the home. In terms of efficiency, we already have highefficiency systems.

As for cost, a reduction from the current price of approximately $45,000 per exoskeleton is needed to make it more affordable -- the cost driver is based on quantity. Exoskeletons are currently low-volume; they could be less expensive if they were produced in higher volumes.

The biggest part of the costs is in the development, not the actuator. If vendors could sell more exoskeletons, that cost could be divided among more systems.

Ineichen: A good point is that they should go to the motor producer really early in the design process. If they do that, it’s much easier to integrate drives into the whole system.

Developers may have to change from a unique design, making it harder to do a final design. If they can use something existing, the development time is much shorter.

That said, maxon is known for working closely with its customer base.

We are strong in customization with design specifications in mind.

It’s important to know that our Generation 1 Exoskeleton Joint Actuator is a universal system. It has a lot of functions for testing and is a good starting point. The motor can be optimized so that developers can make quick progress. RR

Does maxon follow developments in soft robotics and exoskeletons?

Ineichen: We do work with some companies in this field. The application is much different from the exoskeleton for paraplegic patients.

In the medical field, it’s often used for people recovering from strokes. Soft exosuits can help support them in the recovery process.

In general, the user needs a basic muscle function for soft exosuits, and the suit just amplifies the force.

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

What do you think about increasing competition?

Ineichen: We’ve seen that there are other companies entering this field, and we expect them to come up with some good systems. maxon has been working on our designs and making them even better.

We feel that we have had a great head start on perfecting what is needed in the marketplace. Our Generation 2 system will showcase these new developments.

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The Robot Report

Industrial Exoskeletons

Gain Capabilities, Expand Into New Uses Wearable robots aid workers in industries beyond healthcare.

Eugene Demaitre and Dan Kara • The Robot Report

Although exoskeletons are best known for helping people with disabilities, limitations of weight, power, and cost have slowed adoption rates. In the meantime, enabling technologies have continued to advance, and industrial exoskeletons are providing developers experience in a variety of applications.

The majority of today’s $130 million wearable robotics market is for medical exoskeletons, but industrial exoskeletons are growing in number, as is the number of providers, reported Wintergreen Research Inc. Industrial exoskeletons augment human operators’ cognitive abilities with mechanical strength and endurance. They mirror the structure of human limbs, joints, and muscles while providing support and stabilization. They are similar to robots in enabling the precise performance of repetitive tasks.

For example, Hyundai Motor Group has been testing in a North American Kia factory its Hyundai Vest Exoskeleton (H-VEX), which is designed to reduce pressure on workers’ necks and backs. Its Hyundai Chairless Exoskeleton (H-CEX) assists sitting workers and is meant to relieve knee stress.

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Shared Enabling Technologies Advances in actuators, batteries, and advanced materials are increasing the functionality and reducing the cost of exoskeletons, resulting in more widespread adoption. The intersection between other areas of robotics and medical technologies is driving much of that innovation.

Industrial robots and medical devices share a need for more lightweight and capable systems. For example, Harmonic Drive’s lightweight, brushless FLA rotary actuators are useful for both types of systems. Levitate Technologies uses polymer bearings from igus in its unpowered exosuit.

In addition, maxon motor recently introduced a compact, low-weight Exoskeleton Drive joint actuation unit that consists of a brushless DC motor with inertia-optimized rotor and highresolution encoders.

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In return, the medical exoskeleton market will likely benefit from the spread of industrial exoskeletons, as affordability improves.

ReWalk Robotics’ announcement that Cigna Corp. will reimburse exoskeleton expenses for people with spinal cord injuries demonstrates the progress being made. Israel-based ReWalk also recently received approval from the U.S. Food and Drug Administration for its ReStore exoskeleton for stroke rehabilitation.

Fourier Intelligence Co. is developing its Fourier X2 open platform with affordability in mind.

“The new Fourier X2 is lighter, with better materials to make it more wearable,” said Zen Koh, deputy CEO of the Shanghai-based company. “The application can be used in research, education, different augmentation application purposes, and industrial use. www.designworldonline.com

Hyundai is using industrial exoskeletons to relieve worker stress. | Hyundai

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The Robot Report

Adoption and Testing Advances in industrial exoskeletons, as well as increasing familiarity with their potential on the part of businesses, is increasing testing and adoption. The Robotics-as-a-Service (RaaS) model, in which equipment is leased or rented rather than bought outright, is also helping to alleviate cost and risk concerns.

Industrial exoskeletons are finding early use cases in automotive manufacturing because of the repetitive, labor-intensive nature of the work.

Other applications include logistics, retail, and construction.

While both suppliers and early users are typically reluctant to discuss trials, some large international companies have openly shared their exoskeleton experiences, which have been mostly positive.

Hyundai: In 2018, Hyundai Motor Group began testing its Hyundai Vest Exoskeleton (H-VEX), which pressure on workers’ neck and back, at a North American Hyundai-KIA factory. This follows trials of the Hyundai Chairless Exoskeleton (H-CEX), a knee joint sustainability device that maintains the sitting position of workers. According to Hyundai, both the H-CEX and H-VEX systems are designed to reduce injuries and increase worker efficiency.

Ford purchased 75 EksoVest exoskeletons from Ekso Bionics to reduce workforce injuries. | Ford

Ford: Following a pilot program with exoskeleton maker Ekso Bionics, Ford last summer introduced 75 of Exo Bionics’ upper-body exoskeletons across 15 automotive plants worldwide. Ford stated that the exoskeletons, which assist employees performing overhead tasks, should reduce the number of repetitive motion injuries.

BMW: A BMW assembly plant in South Carolina is using Levitate Technologies’ AIRFRAME exoskeleton. The unpowered, upper-body exoskeletons are also being trialed at other BMW plants. Levitate representatives claimed that AIRFRAME can reduce exertion levels by up to 80% for tasks involving repetitive arm motion.

Providers by Exoskeleton Type As the nascent wearable robotics market grows, the number of exoskeleton providers is also growing. The diversity of currently available commercial exo-skeletons reflects the widely ranging backgrounds and core historical strengths of suppliers. They can be distinguished by their products’ design and intended use.

maxon motor’s Exoskeleton Drive.

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| maxon

Arms, upper and lower body: Exoskeletons come in many forms, including systems that attach at the hip and transmit weight to the floor such as Lockheed Martin’s FORTIS or Noonee’s Chairless Chair, which can lock in place and act as a seat. Others, such as StrongArm Technologies’ FLx ErgoSkeleton, are upper body systems, while still others assist hands in gripping, like Bioservo Technologies’ Ironhand.

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Powered and unpowered: Although most exoskeletons use batteries to power actuation and assistance, some rely on non-traditional sources such as elastic systems. Examples of powered exoskeletons include ATOUN’s Power Assist ARM, Innophys’ Muscle Suit, Cyberdyne’s HAL for Labor Support, RB3D’s HERCULE, Sarcos Robotics’ Guardian XO, and Noonee’s Chairless Chair.

In contrast to powered exoskeletons, unpowered or “passive” devices increase strength and provide stability through a combination of human-guided flexion/ extension and locking mechanisms.

Unpowered industrial exoskeletons include Ottobock’s Paexo, Levitate Technologies’ AIRFRAME, suitX’s MAX Exoskeleton Suit, StrongArm Technologies’ FLx ErgoSkeleton, Laevo’s Laevo, and Lockheed Martin’s Fortis.

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The Robot Report Sarcos Robotics Guardian XO industrial exoskeleton. | Sarcos Robotics

Rigid and soft: Rigid exoskeletons offer power and precision, but they can produce musculoskeletal stress due to their weight and unnatural or constrained movement. As a result, a number of companies are developing exoskeletons made of soft, lightweight, and compliant materials. The systems themselves are powered with soft muscle actuators, compressed air, or flexion/ extension mechanisms. Examples include Bioservo Technologies’ Ironhand and Daiya Industry’s Power Assist Glove.

Organizations such as Harvard University and Seismic, which are developing soft exoskeletons for military or consumer applications, respectively, are likely to target the industrial sector at some point.

International Interest in Industrial Exoskeletons In addition to increasing lifting capacity and minimizing physical stress, another

demand driver for industrial exoskeletons is an aging labor pool and a shortage of qualified replacements.

Global demand for industrial exoskeletons is already strong. ABI Research has stated that the total addressable market for industrial exoskeletons exceeds 2.6 million units and that shipments will grow from 7,000 units in 2018 to 301,000 by 2028, with revenue of $5.8 billion by 2028.

Early this year, Ekso Bionics Inc. signed a $100 million joint-venture agreement with investors in China to build manufacturing facilities there and expand its marketing efforts. The company previously sold 75 EksoVest industrial exoskeletons to Ford for use in two plants in Dearborn, Mich.

It was the largest adoption of industrial exoskeletons to date.

In March, German Bionic presented its IO cloud platform, which it said connects its third-generation Cray exoskeleton with networked manufacturing systems through

the Industrial Internet of Things (IIoT) and applies machine learning to controls for Industry 4.0.

German prosthetics maker Ottobock also plans to sell industrial exoskeletons.

Eighty percent of people who tried the Paexo exoskeleton for overhead work at a Volkswagen plant in Bratislava said they’d recommend it to their colleagues.

Comau SpA developed its Muscular Aiding Tech Exoskeleton (MATE) with Iceland-based ÖSSUR and Italy-based IUVO. MATE is designed to be lightweight, easy to use, and suitable for tasks such as restocking shelves.

Similarly, automakers including BMW, Ford, and Hyundai are already using San Diego-based Levitate Technologies Inc.’s AIRFRAME exoskeleton (see sidebar). Each of these industrial exoskeletons advances the state of the art for weight, battery duration, and responsiveness. RR

The Paexo exoskeleton assists manufacturing and service workers with strenuous activities, particularly overhead work. | Paexo

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The Robot Report

Why Engineers

Should Attend the Healthcare Robotics Engineering Forum

Exoskeleton designers and other roboticists can learn from experts and peers at this new event.

Eugene Demaitre • Senior Editor • The Robot Report

Assistive and intelligent systems for healthcare have the dual challenges of high expectations and difficult problems to solve. The Healthcare Robotics Engineering Forum is intended to help engineers understand the component technologies, develop best practices, and successfully bring robotics products to market.

The Healthcare Robotics Engineering forum will be on December 9-10, 2019, at the Santa Clara Convention Center. It will address challenges in overcoming complexity for commercialization of healthcare and medical robotics. This includes surgical systems, logistics robots in hospitals, laboratory automation, and assistive and therapeutic devices.

The Healthcare Robotics Engineering Forum will include tracks and sessions around enabling technologies, tools and platforms, design and development, and management and opportunities.

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Ekso Bionics has sponsored clinical research using its EksoGT exoskeletons with spinal cord injury participants, among others. | Ekso Bionics

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The Robot Report Health Expenditure as % of GDP 18%

1995

% of GDP

16%

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14% 12% 10% 8%

Interest in healthcare robotics keeps growing Healthcare robots are not yet as well-established as their industrial cousins, but most industry analysts agree on the growing demand. For instance, analyst firm Tractica has forecast that the number of healthcare robots shipped will increase from 3,400 in 2016 to 10,500 units per year worth $2.8 billion in 2021, with exoskeletons and prosthetics surpassing surgical robots.

Similarly, BIS Research predicted that the global market will grow from $5.4 billion in 2017 to $11.44 billion by 2023.

In the Asia/Pacific region alone (excluding Japan), healthcare providers could spend $7.03 billion by 2021, reported IDC Healthcare Insights.

“The effective adoption of robotics will augment physician efficiency, eliminate medical errors, plug care gaps, and enable bigger patient volume to access high-precision care delivery,” said Manoj Vallikkat, research manager at IDC Asia/Pacific Healthcare Insights.

IDC also noted that the percentage of total spending on robots by healthcare providers will increase from 3.1% this year to 4.9% by 2022.

The global market for exoskeletons will grow to $5.8 billion by 2028, predicted ABI Research, and Grand View Research predicted a compound annual growth rate of 58.4% between 2018 and 2025.

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provider Myomo Inc. offering $6.4 million in stock, and ReWalk Robotics Ltd. raising $5 million. NextStep Robotics raised $600,000 for its assistive technology.

Healthcare robotics engineering forum comes to Silicon Valley After the success of June’s Robotics Summit & Expo in Boston, WTWH Media LLC announced the new event. WTWH Media is the parent organization of The Robot Report and Design World.

The Healthcare Robotics Engineering Forum will be co-located with DeviceTalks.

The forum and expo in Santa Clara, Calif., will enable designers and engineers to speak with and learn from researchers, manufacturers, investors, and other experts in healthcare robotics.

Other features for robotics developers will include keynotes by technology leaders, workshops, demonstrations, and networking events. There are also opportunities for potential speakers, sponsors, and exhibitors.

Visit www.healthcareroboticsforum.com for more information. RR

Investors look for promising products In the first half of 2019, The Robot Report tracked a total of $7.7 billion in 30 transactions around healthcare robotics and related technologies. The biggest was Johnson & Johnson’s $3.4 billion acquisition of surgical robotics provider Auris Health Inc. Surgical robotics leader Intuitive Surgical Inc. raised $2 billion, and Verily, which is owned by Google parent Alphabet Inc., raised $1 billion.

Exoskeletons also received investor interest, with Ekso Bionics Holdings joining a $100 million joint venture in China, wearables

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The Robot Report

Myomo Scales Up Production, Training for Upper-Body Mobility Device

Myomo has refined the hardware and software design of its wearable devices and is working with therapists and insurers to help people regain arm function.

Eugene Demaitre • Senior Editor • The Robot Report

From perception and analysis to actuation, many robotics technologies have applications in healthcare, particularly in prosthetics and exoskeletons. Myomo Inc.’s MyoPro is a wearable brace that uses sensors and algorithms to restore mobility to users.

More than 3 million people in the U.S. have lost control over their arms and hands because of stroke, brachial plexus injury (BPI), cerebral palsy, or other neuromuscular diseases or injuries.

“After six months of rehab, many patients are essentially told that they won’t be able to use that arm again,” said Paul R. Gudonis, CEO of Myomo.

“That’s 1% of the population, or 3 million people in the U.S.”

The MyoPro wearable device can restore mobility for everyday tasks. | Myomo DESIGN WORLD

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The Robot Report

Developing ‘power steering’ for the arm Cambridge, Mass.-based Myomo is based on technology developed at the Massachusetts Institute of Technology and Harvard Medical School.

“A dozen years ago, we spun out of MIT,” Gudonis told The Robot Report.

“Dr. Woodie Flowers was a pioneer in powered prosthetics, and his lab originally focused on amputees. However, a pair of grad students said there was a much larger group of people who could be helped.”

Myomo uses sensors built into a cuff that fits over the bicep and tricep muscles. They detect electromyographic (EMG) signals and activate motors to move the arm at the elbow.

“Unlike implants in the brain, which are still experimental, electromyogram sensors sit in a device on the surface of the skin,” said Gudonis. “In able-bodied individuals, the muscle emits voltage when activated, and there’s 100% signal strength, but after a stroke or other injury, the signals are attenuated.”

“The myoelectric orthosis, or powered arm brace, detects the intention to move as the muscle sends a micro EMG signal,” he explained. “Onboard software deciphers it, providing power steering for the arm.”

MyoPro can restore function for some people after years of disability. | Myomo “The control unit on the side of the brace has the battery and a circuit board and sends control signals to two motors at the elbow and hand,” Gudonis said.

Myomo’s technology can be liberating for people using it, according to Gudonis.

“People can feed themselves, open doors, and carry objects,” he said.

Myomo makes software, hardware refinements There have been several improvements over time, Gudonis said. “First is the refinement of the software algorithms and electromechanical interface,” he said.

MyoPro enables people to use both arms. | Myomo

“Second, taking our original design and making it a lightweight — 2.5 to 3 lb. — custom-fabricated orthosis or brace,” said Gudonis. “This takes it out of the clinic or rehabilitation hospital, and it can be used in the home or office.”

“Every few years, we bring out a new revision,” he said. “MyoPro 2 has the added ability to open and close hands. It has four sensors, on the bicep, tricep, flexor, and extensor, and it connects to a mobile app with Bluetooth.”

“We’re working on finer motor controls and lighter weight.” said Gudonis. “We use small motors from Maxon, and the battery is designed to be used all day. It can pop out, and we provide a spare battery.”

A major hurdle for exoskeletons and other wearable devices in the U.S. has been reimbursement by insurance providers. Myomo is working with healthcare service providers.

“Our device is provided through orthotics and prosthetics clinics and billed to insurers,” Gudonis said. “The out-ofpocket price to the user depends on the his or her insurance plan, and it may be just a few thousand dollars.”

Reaching and training users “This is really disruptive technology in the rehabilitation industry,” claimed Gudonis.

“Prior solutions have been hands-on therapy at the hospital or big stationary machines in clinics, but nothing portable that people can use at home.”

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“We’re using online advertising to inform 3 million people that there’s something for them,” he said. “We’re inviting them to free screening days, where they can be evaluated by a medical professional, and we can help them get reimbursed.”

“When people try on the demo device, they either laugh or cry,” said Gudonis.

“One user was a veteran who was injured at 25. In 40 years, it was the first time he could use that arm. Another was an 18-year-old in Milwaukee who suffered a BPI at birth and hadn’t used her right arm since then. She’s now using both arms.”

Users then go to local therapists to be trained in how to use Myomo’s devices, and the therapists themselves need training.

“After users get insurance authorization, they place an order, and the local orthotist measures the arm and hand,” Gudonis said. “Like with prosthetics, they send an order to us for custom fabrication. We use a shop in Ohio, and lightweight plastic elements fit over the robotic elements, like a custom ski boot.”

“We have a training staff consisting of certified prosthetists, orthotists, and occupational therapists,” he said. “They train clinicians on how to evaluate patients, as well as work with occupational therapists at rehab hospitals around the country.”

“The software settings can be adjusted by the clinician,” noted Gudonis. “As muscles are used over time, the nerve signals can get stronger and need less amplification. We can adjust the gain applied to each joint of the arm. In other cases, such as ALS [amyotrophic lateral sclerosis], signals can decrease over time, but Myomo can help users remain functionally independent.”

Adding capabilities Myomo is working on a pediatric version of the MyoPro 2. “It’s currently registered with the FDA for adults and adolescents,” Gudonis explained. “But millions of children are affected by conditions like stroke, cerebral palsy, birth brachial plexus injuries, spinal muscular atrophy, and AFM [acute flaccid myelitis], which is like polio.”

To work with children, Myomo’s device must be lighter, expandable, and “pass the sandbox test,” he said, adding that the MyoPro is water-resistant: “Users can wash dishes, but they shouldn’t go swimming or take a shower with it on.”

“We’re working with Boston Children’s Hospital, Philadelphia Children’s Hospital, and Easter Seals,” said Gudonis. “Some of these improvements in terms of lighter weight and algorithmic changes will eventually apply to MyoPro 3.”

Scaling up Myomo went public in June 2017 and has raised $25 million in the public capital markets.

“We’ve outsourced manufacturing of some robotics components to Cogmedix in Worcester, Mass., and a fabrication company in Cleveland,” Gudonis said.

“We’re also talking to other custom fabrication shops in the U.S. and Europe to have sufficient capacity.”

“We were just doing controlled rollouts in just a few markets, and we’re now really scaling up commercial rollouts to the top 50 metropolitan service areas in the U.S.” said Gudonis. “We’re registered with the FDA and have a medical device license in Canada and a CE mark in Europe.”

“For lower-extremity paralysis, there have been a number of solutions, such as exoskeletons from ReWalk, Ekso Bionics, and Indego from Parker Hannifin,” he said. “But for upper extremities, we offer the only commercially available product, protected with 21 patents in the U.S., Japan, and Europe.”

“Almost 900 devices are in use, and we’re growing strongly now,” Gudonis said. “Myomo built out its nationwide distribution in the past year, and we have our first distributors in Europe, Chile, and Australia. Our goal is to be in all major regional markets by the end of this year.”

RR

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The Robot Report

Sarcos Robotics Readies Guardian Alpha for Industrial Use

After years of development and industry feedback, Sarcos exoskeleton to get more comfortable.

Eugene Demaitre • Senior Editor • The Robot Report

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Late last year, Sarcos Robotics unveiled its Guardian XO Max, a “full-body,

powered industrial exoskeleton robotic system.” While it’s bigger than wearable technologies designed for hospital or home use, the robot is the only one designed for full-shift commercial use.

The Salt Lake City-based company’s latest industrial exoskeleton is able to run for up to eight hours on a single charge. It also has “hot-swappable” batteries and uses a “Get-Out-of-the-Way” control system that’s designed to follow its operator’s lead rather than need lots of sensors.

With a strength amplification of 20 to 1, the Guardian XO Max can help users lift 200 pounds. Sarcos’ exoskeleton is entering its alpha phase of testing.

Demand grows for industrial exoskeletons Back injuries cost U.S. employers more than $100 billion per year, so avoiding injury is just as important as enhancing strength, noted Sarcos.

“There are many misperceptions regarding the commercial readiness and viability of full-body industrial exoskeletons that are capable of substantially increasing human strength and endurance, including the amount of power required to operate these machines,” stated Ben Wolff, chairman and CEO of Salt Lake City-based Sarcos.

“Sarcos’ Guardian XO Max will be a game-changer for the industrial workforce, improving strength and capabilities, reducing the risk of injury on the job, and increasing the quality of life and longevity of workers,” predicted IDC analyst John Santagate.

The company raised a $30 million Series B round of funding last September.

| Sarcos Robotics

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Military roots of exoskeleton design Sarco’s development of exoskeletons can be divided into different phases.

“In 2000, it was through DARPA and U.S. Department of Defense [DOD] programs,” said Chris Beaufait, chief operating officer of Sarcos. “It evolved from helping a soldier to carry a pack to a full-body exosuit, in which we initially used hydraulics in the prototype.”

The U.S. Special Operations Command has worked with Sarcos on the Tactical Assault Light Operator Suit (TALOS), an exoskeleton designed to protect forces from small arms fire while providing support for strenuous activities.

The U.S. military is also working with Lockheed Martin and other contractors to develop wearable robotics.

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The Robot Report

The Raytheon Sarcos XOS 2 military exoskeleton was released in 2010. | Raytheon

“We’re looking at manufacturing, logistics, and construction -- those sectors are driving a lot of our specifications.”

-- Chris Beaufait, COO, Sarcos

However, the Guardian XO Max is designed primarily for civilian use.

“Because we’ve had almost 19 years of interaction and experience with defense programs, military needs did influence our design, but as we look forward today, we’re tailoring our requirements to how robots interface with industrial environments,” Beaufait told The Robot Report. “We’re looking at manufacturing, logistics, and construction -- those sectors are driving a lot of our specifications.”

The Guardian XO Max can lift 200 lb. | Sarcos

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Managing power requirements, components “We then added some forms of energy recovery, and in 2010, we had a much more packaged unit,” said Beaufait. “Two big things have changed since then. The first was the source of energy -- you don’t want hydraulics oil at 3,000 PSI in industrial environments, so we had to go electric for energetic autonomy. We’re allelectric now.”

“The second things was reducing the power,” he recalled. “We expect the final product to be less than 500 W, down from 6,800 W.” Sarcos relies on a combination of supply chain partners and custom design.

“At the actuator or linkage level of the robot, there’s an enormous amount of bespoke design,” said Beaufait. “We have strong relationships with motor suppliers, electronic board suppliers, and machining houses. If a potential supplier has something that’s better than the industry standard, we’d love to talk with them.”

“They meet the specifications we provide, and we don’t have a lot of offthe-shelf components -- just some sensors,” he said. “We’ve been pretty fortunate in finding partners who can help reduce the computer and power demands.

We’re doing some pretty unique things to use minimal power.”

“Another aspect of our business model is how we’re using our global supply chain,” he noted. “We’re initially handling DESIGN WORLD

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The Robot Report things like alpha, beta, and low-rate production ourselves, but we can work with contract manufacturers to scale.”

Working with testers “In March, we announced the X-TAG [Exoskeleton Technical Advisory Group],” said Beaufait. “We have about a dozen companies that we’ve been engaging with, and they’ve already given us feedback on specifications such as being able to lift 200 lb.”

“Given that we’re between the prototype and the alpha phase, they have questions around the tangible aspects of somebody using it on the operations side,” he said. “On the company side, they’re interested in what we’re doing about safety and potential faults. They’re comfortable about where we’re at.”

“We’ll deliver one alpha unit to the DOD in December,” Beaufait said. “It’s not a military version but for logistics, effectively beginning alpha testing.”

The Guardian XO will begin alpha testing in December. | Sarcos

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Moving from motion to comfort Sarcos’ “Get-Out-of-the-Way” control system reflects advances in humanmachine interaction.

“The robot monitors the human, who moves the way they normally would, and responds,” said Beaufait. “Our algorithm is quite mature.”

“We’ve now moved on to things like employee comfort,” he added. “Many companies have passive exoskeletons, and we hear from them on heat and discomfort. Workers don’t want to share harnesses.”

“The items we’re spending a bit of time are making sure that wherever there’s a soft-tissue interface -- chest and pelvis harnesses, then hands and feet -- we make sure that they don’t chafe,” Beaufait said. “We want to make sure that somebody can use the exoskeleton for appropriate times for manufacturing, construction, or logistics tasks. We want it to be as comfortable as getting into your car.”

“We’ve done things in the past for different government agencies for space and underwater, but our X-TAG members have shared the most important lessons learned -- anywhere people wear suits for long periods,” he explained.

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The Robot Report “Personalization is important for what an individual wears, such as harnesses and footwear.”

“We’re looking very closely at what’s needed for males and females of varying heights,” Beaufait said. “We’ve already shown that an average-size male wearing the robot can fit through a normal 36-in. door.”

one to three per week to our team.”

“As we evolve from the development stage to production and commercialization, we’re looking for engineers with electromechanical, control, and software experience, as well as those who have worked in a field that have experience with industry and product,” he said.

Managing expectations by use case “There are specific user-customizable items for people in different tasks, and we provide a high level of adaptability in software and controls,” said Beaufait.

“We’ll be looking in alpha testing at what customers want for different uses, such as center of gravity or different modes.”

“We want to put configurability into the robot but not give too many choices.

It might be customer by customer or industry by industry,” he added. “We really want to understand what the use cases will be.”

“Once they understand the Guardian’s adaptability with a human inside, we’ll see how they get comfortable in the environment and what are the best end effectors by use,” Beaufait said.

Competition and ROI “When you look at what’s out there today, there’s basically passive exoskeletons that extend endurance, then medical rehabilitation, and then a few looking at industrial exoskeletons to augment human performance,” Beuafait said. “Based on what we’ve heard from two academic institutions -- including Virginia Tech, which has an NSF grant -and the X-TAG members, there’s nobody doing what we’ve been doing since 2000.”

“A few companies, particularly in Asia, are working on industrial exoskeletons, but they appear to be where we were 10 years ago,” he said. “Once we put our product out there, we have to continue to invest and stay ahead.”

“There’s nobody doing a full-bodied exoskeleton that people can use for an eight-hour shift and can lift 200 lb.,” he said. “That said, our real challenge isn’t competition, but showing customers

Looking for talent “We’re definitely looking for people,” said Beaufait. “At Sarcos.com/careers, we have about 20 jobs listed, and we’re adding

the return on investment and how our exoskeleton can reduce injuries and help one worker do the work of four people.”

“I believe that we’re at an inflection point, as we look at the unstructured robotics space,” Beaufait said. “I expect we’ll see a lot of technology to improve power usage and applicability. It’s a very exciting time for robotics in general.”

Sarcos’ industrial exoskeleton will be available for pre-orders later this year under a robots-as-a-service (RaaS) model and will ship to the first customers in early 2020. RR

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

Sarcos expects to customize exoskeletons and tools by use case. | Sarcos

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The Robot Report

Robotic Hand

Uses Machine Learning to Detect Wearer’s Intent

A

A South Korean team of researchers has developed Exo-Glove, which could help users with day-to-day tasks.

Seoul National University

A research team at Seoul National University

in South Korea has created a wearable hand robot called the Exo-Glove Poly II that can aid people who have lost hand mobility. The robot can detect the user’s intention by collecting and analyzing behaviors with machine learning.

The vision-based machine learning algorithm. | Soft Robotics Research Center, Seoul National University

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The research team at the Soft Robotics Research Center (SRRC) in Seoul is led by Prof. Sungho Jo from the Korea Advanced Institute of Science & Technology (KAIST) and Kyu-Jin Cho at Seoul National University. Collaborators include Daekyum Kim and Jeesoo Ha from KAIST, as well as Brian Byunghyun Kang, Kyu Bum Kim, Hyungmin Choi from Seoul National University.

The SRRC team has proposed a new intentiondetection paradigm for soft wearable hand robots.

It predicts grasping and releasing intentions based on user behaviors, enabling spinal cord injury (SCI) patients with lost hand mobility to pick and place objects.

The researchers developed a method based on an algorithm that predicts user intentions for wearable hand robots by using a first-personview camera. Their development is based on the hypothesis that user intentions can be inferred

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The goal of the robotic hand system is to enable wearers to conduct everyday tasks without additional commands. | Seoul National University BioRobotics Lab

through the collection of user arm behaviors and hand-object interactions.

The machine learning model used in this study — Vision-based Intention Detection network from an EgOcentric view (VIDEO-Net) — is designed based on this hypothesis. VIDEO-Net is composed of spatial and temporal sub-networks, where the temporal sub-network is to recognize user arm behaviors, and the spatial sub-network is to recognize handobject interactions.

An SCI patient wearing the soft wearable hand robot Exo-Glove Poly II successfully grasped various objects. The patient was able perform day-to-day DESIGN WORLD

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tasks, such as drinking coffee, without any additional help.

The SRRC team said its innovative system can detect user intentions without requiring any person-to-person calibrations or additional actions. This enables the wearable hand robot to interact with humans seamlessly.

The research was published in the January issue of Science Robotics. The research team explained more about the system.

How does this system work?

This technology aims to predict user intentions, specifically grasping and www.designworldonline.com

The research team at the Soft Robotics Research Center (SRRC) in Seoul has proposed a new intention-detection paradigm for soft wearable hand robots.

August 2019

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The Robot Report releasing intent toward a target object, by utilizing a first-person-view camera mounted on glasses. Something like Google Glass could be used in the future.

VIDEO-Net, a deep learning-based algorithm, is devised to predict user intentions from the camera based on user arm behaviors and handobject interactions. With Vision, the environment and the human movement data is captured, which is used to train the machine-learning algorithm.

Instead of using bio-signals, which are often used for intention detection of disabled people, we use a simple camera to find out the intention of the user.

Whether the person is trying to grasp or not. This works because the target users are able to move their arm, but not their hands.

We can predict the user’s intention of grasping by observing the arm movement and the distance from the object and the hand, and interpreting the observation using machine learning.

Who can benefit from this technology?

This technology detects user intentions from human arm behaviors and handobject interactions. This technology can be used by any people with lost hand mobility, such as spinal cord injury, stroke, cerebral palsy, or any other injuries, as long as they can move their arms voluntarily.

To use this technology in daily life, what do you need?

In order for this technology to be used in daily life, these devices are needed: a wearable hand robot with an actuation module, a computing device, and glasses with a camera mounted. We aim to decrease the size and weight of the computing device so that the robot can be portable.

So far, we could not find compact computing devices that fulfill our requirements, but we expect that neuromorphic chips that are able to perform deep learning computations will be commercially available. RR

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What are the limitations and future goals?

Most of the limitations come from the drawbacks of using a monocular camera.

For example, if a target object is occluded by another object, the performance of this technology decreases.

Also, if user hand gesture is not able to be seen in the camera scene, this technology is not usable. In order to overcome the lack of generality due to these, the algorithm needs to be improved by incorporating other sensor information or other existing intentiondetection methods, such as using an electromyography sensor or tracking eye gaze.

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CGI Inc. Advanced Products for Robotics and Automation At CGI we serve a wide array of industries including medical, robotics, aerospace, defense, semiconductor, industrial automation, motion control, and many others. Our core business is manufacturing precision motion control solutions.

CGI’s diverse customer base and wide range of applications have earned us a reputation for quality, reliability, and flexibility. One of the distinct competitive advantages we are able to provide our customers is an engineering team that is knowledgeable and easy to work with. CGI is certified to ISO9001 and ISO13485 quality management systems. In addition, we are FDA and AS9100 compliant.

Our unique quality control environment is weaved into the fabric of our manufacturing facility. We work daily with customers who demand both precision and rapid turnarounds.

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CS HYDE COMPANY Eliminating friction unleashes a Gantry robots full potential

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Applying UHMW tape is a performance upgrade to all robotic rail systems. UHMW or (Ultra-high-molecularweight polyethylene) is an abrasion resistant material with anti friction performance similar to PTFE. This plastic can be used on conveyor or guide rail systems across many industries. This tape is extremely abrasion and impact resistant which enables it to withstand the repeatability of robotic gantry systems. Its low friction non stick surface allows gantry robots to slide across rail systems freely. Eliminate drag and protect your rails from potential wear and tear. UHMW Tape is available in slit to width rolls, sheets, strips, or custom die cut parts. UHMW is supplied in sheet stock for mechanical fastening or tape with a PSA adhesive for easy

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Robotics Robotics

FESTO Corporation Size Your Perfect System With the Festo Handling Guide Online The Festo Handling Guide Online (HGO) is an all-in-one configuration and ordering tool that cuts your engineering and design time for Cartesian systems. Simply specify a single axis, 2D or 3D Cartesian robot, then insert basic application data like load, cycle time, load voltage and workspace size.

Our intelligent engineering software automatically works out suitable solutions—including downloadable CAD models and data sheets. You can order your robot as disassembled modules or as a fully assembled, pre-parameterized and pre-tested system.

HGO Benefits • Reduce your time to market by 70 percent • Receive a quote within two business days • Competitive pricing due to standard parts

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FAULHABER MICROMO Power in New Dimensions: New BXT Flat Brushless Motor New winding technology, optimized design, & impressive performance make the new FAULHABER BXT Flat Brushless DC Motor Series ideal for applications in robotics, exoskeletons, & automation. The external rotor BXT motors are designed for a continuous output power up to 100 W, and deliver torque up to 134 mNm. • Flat design for space-critical applications • Outstanding ratio of torque to weight & size • Available in 22mm, 32mm, 42mm diameters • Available with or without housing • Matching encoders, gearheads & controllers available Since 1961, FAULHABER MICROMO has been the micro DC motor expert, serving OEM engineers to deliver outstanding service and the highest quality products. As the exclusive provider for FAULHABER micro motion products to North America, FAULHABER MICROMO creates value through advanced design and engineering services.

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Festo Corporation 1377 Motor Pkwy. Ste 310 Suffolk County Islandia, NY 11749

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Robotics Robotics

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Harmonic Drive FHA-Mini Rotary Actuator with Dual Encoders Introducing Dual Absolute encoder versions of the FHA-C mini actuator. Featuring BiSS-C bi-directional communication for both encoders, the dual absolute encoders are incorporated in essentially the same package size as the long-standing FHA-C mini single incremental encoder version. The actuator combines a high precision Harmonic Drive® gear component with a pancake brushless servo motor. A single turn 14bit (16384 cpr) gear output encoder has been integrated along with a single turn 14bit (16384 cpr) motor input encoder providing a true absolute encoder that does not require a battery within 360° of rotation of the output.

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Honeywell Intelligrated Solve Loading Dock Challenges With Robotic Unloading Challenges on the loading dock are characteristic of greater pressures from the rise of e-commerce.

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August 2019

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igus Customize low-cost robotic joints and complete arm assemblies The new robolink designer is an online configurator tool from igus® that allows users to quickly and easily configure individual robotic systems. With the tool, users can select robolink components individually and configure a robotic arm step by step. They can also configure the length of the arm to match the dimensions a specific work environment, as well as simulate motion of the robot through rotating its joints. Furthermore, a parts lists can be saved for future reference, and a quote can be requested for the configured system.

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Kollmorgen KBM™ Series Frameless Motors The KBM™ Series is designed to be directly embedded in a machine. With a vast selection of standard motors—plus Kollmorgen’s ability to create optimized modifications—design engineers can choose the exact-fit motor that yields the highest performance in the most compact space.

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Direct load connection eliminates maintenance of gearboxes, belts or pulleys Zero backlash and compliance provides more responsive system performance Eliminates coupling devices, reducing overall machine size Embedded motor enables compact machine design Solutions for operating from 48 VDC to 600 VDC Many standard windings for optimized motor performance Standard thermal and hall sensor options Industry-leading torque density

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Contact: Gene Matthews 203A West Rock Road Radford, VA 24141 Phone: 1.540.633.3545 Email: www.kollmorgen.com

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Robotics Robotics

LAPP LAPP SKINTOP® HYGIENIC and INOX Cable Glands Feature NSF Approval for Food Applications LAPP SKINTOP® HYGIENIC and INOX cable glands meet NSF 169 requirements—permitting their use in food handling and processing equipment. Applications include filling systems in dairies and breweries, as well as sensitive areas in the chemical and pharmaceutical sectors. Constructed from stainless steel, both series feature smooth, edge-free surfaces that prevent fluids from accumulating and microorganisms from gathering.

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maxon Drive Systems for Robotics Reliable, Powerful, Efficient A complete joint actuation unit. Includes a brushless DC motor, an internal high resolution encoder, planetary gearhead with absolute encoder and position controller with CAN and RS232 interface.

Exoskeleton Joint Actuator • Compact Housing • Integrated Controller • Reduced Weight and Cost • For Use in Hip and Knee Exoskeletons maxon is your single source for motion solutions. When you choose maxon, you can expect outstanding service, creative options and quality without question. Want to get your ideas moving? Contact maxon today.

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maxon precision motors, inc.

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Robotics Robotics

Mitsubishi Electric FR Series Next Generation, High Performance Industrial Robots Integrate Seamlessly with iQ Platform Controllers for Advanced Cooperative Functions “FA-IT Integration Functions” with the full line of Mitsubishi Electric FA products such as PLCs, motion controllers, VFDs, HMIs, and CNC, as well as MES/SCADA packages provide a level of performance, functionality and ease of use unparalleled in the industry. In addition, the open platform architecture OS enables integration with 3rd party devices normally difficult or impossible to use on closed platforms. With such flexibility, capability and performance, increases to both productivity and maintainability can be achieved, resulting in a lower TCO (Total Cost of Ownership).

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backed with “Next-Generation” features, and options, the MELFA FR-Series line of robots are ready to handle all of your automation needs. Vertically articulated, horizontally articulated SCARA, ceiling mounted horizontal type, and dual arm high precision for micro-assembly • Industry’s best initial warranty - 3 year on-site for most models

mk North America Enhance Your Automation with Pallet-Handling Conveyors Pallet-handling conveyors utilize pallets to transport workpieces asynchronously between stations. Pallets range in size from 10x10 inches to 48x48 inches, and are capable of carrying loads of nearly 1,000 lbs.

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Email: info@mknorthamerica.com

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Robotics Robotics

New England Wire Technologies Advancing innovation for over 100 years Why accept a standard product for your custom application?

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

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SICK, Inc. Motor/Position Feedback Encoder with SIL2 Safety Certification for Robots Robot manufacturers are moving to direct drive motors to eliminate costly gear reduction mechanisms. SICK’s SES/SEM motor/position feedback encoder gives accurate position feedback for direct drive motors, providing backlash-free motor integration. Certified in accordance with IEC 61508 for safe motion control, the SES/SEM retains safe operation in human-robot collaborations without sacrificing efficiency or productivity.

Your benefits • Increased reliability and uptime from battery-free absolute position retention • Accurate position feedback up to 8,500 RPM to accommodate high-speed operation • Bearing-free mechanical design provides longer encoder lifecycle • Easy installation with no special mounting tools required • Commonly used HIPERFACE interface ensures robust communication with most drive manufacturers

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SICK, Inc. 6900 West 110th St. Minneapolis, MN 55438 USA www.sick.com info@sick.com

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common mistakes to avoid when specifying and using step motors

The mistakes we outline here have been corrected countless times by thousands of step-motor users around the world.

Avoid these mistakes with the presented solutions — and help make your next application a successful one.

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Eric Rice • National Marketing Director • Applied Motion Products

Step motors offer the automation industry a cost-effective and simple method to digitally control motion in a wide range of applications — including packaging equipment, 3D printers, material handling and sorting lines, benchtop CNC machines, and more. They serve as critical components of many rotary and linear positioning axes.

The cost-performance benefits of step motors lie in their simplicity and their ability to position accurately in open-loop control schemes, without any feedback from the motor to the controller. Getting the optimal performance benefits of an open-loop stepper system requires understanding how to specify and install a step motor into an application. Following are six common mistakes that step motor users, both novice and experienced, can easily avoid.

1

“The torque specification of the step motor is higher than what I’m seeing in practice.”

After calculating the torque required to move the load in an application, a user selects a step motor based on (1) the holding torque specification of the step motor or (2) the speedtorque curve. Once mounted and coupled to the load, the motor doesn’t produce the amount of expected torque.

The first mistake is using the holding torque as a measure of performance to specify the step motor. Holding torque defines the torque a motor produces when maintaining a position and not moving. It is generally a poor indicator of the torque the motor produces when moving.

When a step motor starts moving, the produced torque falls precipitously from the holding torque value, even after just a few rpms. As speed increases, the torque falls further. For this reason, don’t select a step motor based on holding torque alone. Instead, refer to published speed-torque curves.

The second mistake is failing to understand the nature of speed-torque curves. A speedtorque curve represents the torque at which the step motor stalls. When a step motor stalls, the rotor loses synchronization with the stator and the shaft stops turning.

To ensure the step motor continues to turn and provides enough torque to move the load, evaluate the speed-torque curves by estimating a margin of safety. A simple way to do this is

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by imagining a line parallel to the speedtorque curve at roughly ½ to 2/3 the height of the published curve. This imaginary line represents an amount of torque that a step motor can reliably produce with minimal risk of stalling. See Figure 1 (typical speedtorque curve of a step motor) for more on this.

2

“The step motor is so hot; there must be something wrong with it.”

Step motors are designed to run hot. The most common insulation class used in step motors is Class B, which is rated for operation up to 130° C. This means that the surface temperature of a step motor can reach 90°C or more before failing. This temperature is much hotter than a person could touch without burning the skin. For this reason, mount step motors away from areas with a high chance of human contact.

Step motors are designed to run at high temperatures because of their use in openloop control systems. Because an open-loop step motor operates without any current feedback (or velocity or position feedback), the current supplied by the drive is constant, regardless of the torque demand.

To get the most torque from step motors, manufacturers specify them with the Class B insulation in mind; so, current ratings are designed to maximize torque output without overheating. The end result is that step motors produce a lot of torque … but they also get quite hot in doing so.

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Figure 1 — typical speed-torque curve of a step motor. In published data from the manufacturer, only the solid line is shown, which indicates stall torque versus speed. The user must estimate a usable torque range as shown by the dashed line.

specified with a rated voltage, it is typically no more than the step motor’s winding resistance times the rated current. This is useful for producing holding torque but of very little use when the step motor moves.

Like all electric motors, when the shaft starts moving, the step motor produces a back EMF (BEMF) voltage that impedes

the current flowing into the windings. To produce usable torque, the supply voltage must be substantially higher than the BEMF. Because no hard and fast rules exist for how high to specify the supply voltage, users should review the published speedtorque curves for a given step motor, drive, and power supply combination. The supply

“Can I use a 12-volt power supply to power my step motor and drive?”

For any kind of electric motor, not just step motors, the supply voltage is directly related to motor speed. As higher voltages are supplied to the system, the motor achieves higher speeds. The rated supply voltage specified for servo and dc motors correspond to other rated specifications including speed, torque, and power. If a step motor is

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Figure 2 — two speed-torque curves of the same step motor and drive combination. Only the power supply voltage is different. The dark green line shows stall torque with a 48-V power supply. The light green line shows stall torque with a 24-V supply. A 12-V supply would result in an even lower curve.

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voltage specified in the speed-torque curve is essential information. If ignored, say by using a 12-V supply when the published curve uses a 48-V supply, the motor won’t reach the expected torque. See Figure 2 (two speed-torque curves of the same step motor and drive combination) for more in this.

4

“Can’t I run this step motor with a couple of PLC outputs? Why do I need a drive?”

Two-phase stepper drives use a set of eight transistors connected to form an H-bridge.

Creating an equivalent H-bridge from PLC outputs would require eight outputs. Some two-phase step motors with six lead wires are driven with as few as four transistors. For these, you could use four PLC outputs to rotate a step motor forward and backward. However, a stepper drive does much more than simply sequence the transistors in the H-bridge.

Stepper drives regulate the current in each phase of the motor using PWM switching of the bus voltage. As noted in the previous section on voltage, the supply voltage must be high enough to overcome BEMF and produce torque at speed.

Stepper drives with microstepping capabilities further refine the PWM switching logic to ratio the current in each phase according to a sine wave, getting finer positioning than a step motor’s basic step angle.

Moving beyond the most basic stepper drives, those that have trajectory generators on board can automatically ramp the motor speed up and down according to preset acceleration and deceleration rates.

Using PLC outputs to drive a step motor could be a neat project for someone interested in dissecting how step motors work. For any serious motion control project, you’ll want a proper drive.

5

“The step motor is so noisy ... there must be something wrong with it.”

Every time a step motor takes a step, it generates a little bit of ringing noise as the rotor settles into position (think of the classic mass on a

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spring). The ringing is the motor’s natural resonant frequency, which is based on the motor construction. The natural resonant frequency is amplified when the frequency of motor steps approaches or equals it.

This noise is most pronounced when the step motor is driven in full step sequence (the lowest resolution available; equal to the motor’s step angle) and at low speeds, typically in the range of 1 to 5 revolutions per second.

The question of noise most often arises when a user tests a step motor for the first time with the motor unmounted and uncoupled to any load. In this scenario, the motor is free to resonate as much as it likes without anything to damp the resonance.

Fortunately, a few easy steps can mitigate the resonance: Add mechanical damping to the system by mounting the motor and coupling the motor shaft to a load. Coupling the shaft to a load adds some amount of inertia or friction to the system ... and that in turn alters or damps the motor’s natural resonant frequency.

Reduce the step angle with microstepping. When microstepping, the step angle is much smaller with each step and the natural resonant frequency is excited less.

If neither of these steps works, consider using a stepper drive with an anti-resonance algorithm built into its current control logic.

Applied Motion Products step motors come in a wide range of frame sizes — from NEMA 8 to NEMA 42 and beyond.

6

“I need an encoder to run a step motor, right?”

No, an encoder is not required to run a step motor in openloop control. Step motors are the only type of brushless dc motor that accurately and repeatedly position a load using open-loop control. Other motors need some type of position feedback. Open-loop control works well when:

tasks are the same over time.

• Motion The load doesn’t change.

• The required speeds are relatively low.

• Failure to complete motion task does • not result in critical the or dangerous

If the application doesn’t meet the stated criteria, consider introducing feedback into the system to permit some level of closed-loop control. Adding an encoder to a step motor system offers benefits ranging from basic functions that are essentially open-loop control but with subtle, effective improvements, to fully closed-loop control where the step motor operates as part of a servo control system. Contact your step motor and drive supplier for information on the range of feedback and closed-loop control options they offer. DW

machine failure.

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

Shown here are step motors from Applied Motion Products with various stack lengths.

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

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Sensors report down to

the wire

When it comes to measuring position in linear systems, draw-wire sensors are still a simple, durable, and low-cost option.

Miles Budimir • Senior Editor Danielle Collins • Contributing Editor

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Motion system designers have quite a few options for tracking and measuring the position of a linear system. Some of the options include magnetic and optical linear encoders that read changes in magnetism or light, to linear variable differential transformers (LVDT) that operate on the principle of mutual induction, to magnetostrictive sensors that rely on torsional strain induced by magnetic fields.

However, each of these technologies requires that a critical part of the measuring system be attached to the object being tracked. What if the environment, application, or installation space doesn’t permit attaching critical measuring equipment — such as a read head, push rod or magnet — to the target object? Another type of linear measuring device, known as a drawwire sensor, solves this problem.

Draw-wire sensors go by a few other names that include: draw wire transducers, cable transducers, string potentiometers, string encoders, linear position string pots, and yo-yo pots or yo-yo encoders (due to the way the spring-wired drum pulls the wire back when it’s removed from the load).

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Draw-wire sensors are relatively simple in construction, with four main parts: a measuring wire, a drum (aka spool or reel), a spring, and a position sensor.

The measuring wire is commonly made of braided steel or stainless steel and covered with nylon or polyamide, although wires can be made of plastic and other materials for harsh environments or special application requirements. The passive wire connects to the object being measured by a clevis or loop, and the wire is mechanically attached to and single-wrapped around a

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precision-machined drum. Threading on the drum guides the wire to ensure consistent unwrapping and retraction without overlap, maintaining the exact relationship between the wire’s motion and the linear distance traveled. A coiled spring maintains tension in the wire to prevent sagging, especially in horizontal applications. A sensor is attached to the axle of the drum and measures the drum’s rotation.

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When the target object moves, the wire is extended (or retracted), and the drum rotates. The sensor measures this rotation and outputs a position signal proportional to the drum’s rotation, and therefore, to the wire’s movement. The type of sensor used depends on the application requirements, with common choices being optical or magnetic encoders, with incremental or (for longer measuring lengths) absolute output. For applications that require an

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The SGH50 draw-wire sensor from SIKO is an absolute position sensor for hydraulic cylinders, telescopic cylinders, and piston accumulators, based on the company’s tried and tested wire-actuated sensor technology.

A draw-wire sensor (far left) is shown embedded in a telescoping cylinder.

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analog signal, potentiometers can also be used.

Draw-wire sensors can measure distances up to 50 km (50,000 m) and can operate with wire extension and retraction speeds up to 10 m/ sec and acceleration rates up to 5 g. One of the most important specifications when choosing a draw-wire sensor is linearity, which refers to the difference between the ideal output-position plot (a straight line) and the sensor’s actual outputposition plot (See graph at right). Draw-wire sensors typically range in linearity from ± 1% to ± 0.05% of the measuring range, but designs are available with linearity of ± 0.01% of the measuring range.

A unique property of draw-wire sensors is that they can measure linear distance even with indirect measuring paths. When the measuring path is not a straight line, low-friction, highprecision pulleys, or guide rollers, can be used to create diversions without jeopardizing the measurement’s integrity.

Draw-wire sensors are simple, rugged (available in IP67, IP68, and IP69K protection classes), and low-cost. They’re a suitable option for applications with intermittent measuring requirements, but generally aren’t recommended for applications with high or continuous duty cycles. Typical applications include patient beds, hydraulic and pneumatic actuators, lifting devices, and mobile equipment such as forklifts and construction machinery.

New draw-wire sensor offerings A number of manufacturers provide a range of draw-wire sensor options to accommodate a wide variety of applications and uses. For example, SIKO’s new SGH50 draw-wire sensor uses a cable mechanism for absolute measurement of hydraulic or telescopic cylinders. This sensor

Voltage

L i n e a r

Displacement is the latest generation of the SGH wireactuated encoder family from SIKO and now makes it possible to measure distances up to 5 m. Suitable applications are agricultural machinery, construction machines, municipal vehicles, forestry machines, piston accumulators and other industrial applications. The main features include an extension of measurement length, improved durability, and compatibility with a wide range of interface protocols.

The SGH50 can be integrated right into hydraulic and telescopic cylinders. A specially developed plastic is characterized by an extension of fluid temperature resistance from 85 to 105 °C, making for an extremely durable design. It also meets the specifications of extreme vibration

These tiny draw-wire sensors from MicroEpsilon weigh just 8 g and are 19 x 19 mm. This MT series of sensors feature aluminum housings and maximum measuring range of 130 mm.

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Linearity is a key factor when choosing a draw-wire sensor, with some designs achieving linearity of ± 0.01% of the measuring range.

standards, which are used for testing helicopter turbines, and can handle shocks 100 times the force of gravity. Unlike rodbased sensors, its flexible cable completely absorbs vibrations with the hydraulic medium providing additional damping of any vibration.

Designed for the highest requirements of mobile hydraulics, the wire-actuated sensor meets the prerequisite of an extremely long service life. It’s been tested and designed for the service life of a cylinder both electrically and mechanically. In order to cope with the harsh conditions of the mobile world, all of the sensors integrated into the cylinder are completely protected from external factors, with a protection rating of IP69K and making use of KV1H plug connections.

Analog interfaces, CANopen or SAE J1939 provide communication between the sensor and machine control system.

Applications in which maximum functional safety is essential can be supplied with redundant SGH50 versions (CAT3, PLd) in accordance with EN13849. For safety variants, SIKO also offers redundant or analog interfaces, redundant CANopen, redundant SAE J1939 or CANopen-safety.

Also from SIKO is the SG61 wireactuated encoder that can measure lengths up to 6 m. These sensors feature a robust aluminum housing, coupled with impact-

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resistant plastic that lets them survive harsh operating conditions. They’re designed to operate in temperatures between -40 and +80°C, and can withstand high shock and vibration loads, dirt, dust and water.

For outdoor applications in low temperature ranges, there is a variant with integrated water drain holes, which avoids the problem of water freezing in cold temperatures and increases service life.

The wire outlet also offers the advantages of the company’s Wire-Flex technology. It ensures that the wear on the wire is kept to a minimum, even if it pulls out at an angle. The conical shape of the wire outlet and the various types of wire mean that any deposits on the wire can be removed easily.

Mechanical tolerances for the machine or vehicle can be offset automatically, even in harsh ambient conditions.

The SG61 wire-based linear sensor provides increased safety in combination with the redundant SIKO WV58MR safety rotary encoder and can be used in the overall system in applications up to performance level d (PLd).

On the other end of the scale is a sensor from Micro-Epsilon. The wireSENSOR MT19 draw-wire sensor has a weight of only 8 g and a size of just 19 x 19 mm. This linear sensor is used for displacement and distance measurements with a measuring range of 40 mm. The dynamic sensor is compact and enables wire accelerations up to 60 g.

The company’s new wireSENSOR MT series includes extremely compact draw-wire displacement sensors that can be integrated into tight spaces. The wireSENSOR MT19 model is the smallest draw-wire sensor in the world and is particularly suitable for use in applications needing high dynamics such as in crash testing, simulators, or test benches.

This series comprises two more miniature draw-wire sensors – the MT33 and MT56 models which cover measuring ranges up to 130 mm. Equipped with a robust aluminum housing, these three miniature draw-wire sensors are suited to industrial applications.

Two through-bores in the housing and an integrated eyelet attached to the measuring wire make for fast and easy mounting. DW

SIKO | www.siko-global.com Micro-Epsilon | www.micro-epsilon.com

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CAD AI: making design better, and

faster, and easier

AI has the potential to allow engineers to design products faster than before while meeting design specifications, sometimes in new and unique ways.

A Jean Thilmany | Senior Editor

Artificial intelligence could be said to be the new hot buzzword, as it seems to be making inroads

into all types of software.

“We don’t see a lot of AI yet in a CAD environment, but it’s coming,” says Andreas Vlahinos, chief technology officer Advanced Engineering Solutions, a research and design firm in Castle Rock, Colo.

AI is a broad field focused on using computers to do things that require human-level intelligence.

But how CAD will make future use of AI is still up for debate, he adds.

While some CAD makers are delving into AI functionality, the marriage of AI and design software is in the early stages, says Jon Hirschtick, chief executive officer of Onshape, which makes cloud-based CAD software.

“AI has great potential, but so far no one has illustrated how it will unfold,” he says.

AI doesn’t have a one-size-fits-all definition within any industry yet, says said Gian Paolo Bassi, chief executive officer at Dassault Systèmes. “Today, there’s a huge debate about what AI is. People say AI is

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AI has a role in CAM as well as CAD. For instance, SolidWorks CAM automatically generates a part’s manufacturing toolpath after design. CAM software uses the CAD models to generate the toolpaths that drive computer numerically controlled manufacturing machines. Such a features helps engineers evaluate designs earlier in the design process to ensure that they can be manufactured.

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With proper validation in place -- AI tools can help ensure parts will meet manufacturing specifications and allow for quicker design than traditional methods.

It also can create unorthodox, sometimes never-beforeseen-shapes that can be manufactured through 3D printing.

The software asks the user preliminary questions. What sorts of materials would you consider for your design? Where does it connect with other things as part of an assembly? What are the loads? What are the pieces of geometry?

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machine learning, or they say it’s related to the neural network or to neuroscience.

Definitions vary.” The machine learning that AI depends on is actually already present to a certain degree in the CAD systems that include topology optimization and generative design capabilities. “The primary functions of these features within CAD is to automate the analytical steps of design, Vlahinos says. The computer generates designs from an engineer’s preliminary directions.”

The key focus of AI in CAD right now is design optimization achieved through the creation of more intelligent designs which are lighter, stronger and more economical.

And, in some cases, more artistic, continues Vlahinos.

Typically, designers create their design step by step, analyzing certain junctions to get critical feedback about performance.

They tweak the design if it doesn’t meet performance needs or customer specifications. The incorporation of AI, as it stands now, allows the designers to skip these time-consuming steps allowing the task to get over quickly and effectively.

Last year, for example, Autodesk released generative design to subscribers of its

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Fusion 360 Ultimate product development software. The design concept allows engineers to define design parameters such as material, size, weight, strength, manufacturing methods, and cost constraints–before they begin to design.

Then, using artificial-intelligence-based algorithms, the software presents an array of design options that meet the predetermined criteria, says Ravi Akella, who headed the product management team for Autodesk’s generative manufacturing solutions before moving last year to become director of product development at Roblox. The feature focuses on helping designers define the problem they’re trying to solve, he says.

“The software asks the user preliminary questions. ‘What sorts of materials would you consider for your design? Where does it connect with other things as part of an assembly? What are the loads? What are the pieces of geometry?’” Akella says.

After a short period of time, the software then presents designers and engineers with an array of design options that best meet their requirements. Designers choose the best design. Or, if none of the options meet their needs, they can begin the generative process again, this time offering slightly different inputs.

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Like other big-name CAD makers, SolidWorks also includes topology optimization capabilities within its CAD software.

“We expect the computing platform to anticipate your design goals,” says Bassi.

But, Vlahinos adds, the AI in those systems is used for simulation rather than for design.

It’s by continual simulation that the designs are found. The tools allow the engineer to skip all the step-by-step analyzing. The human is still involved in the process and must validate the simulation the CAD system returns.

“The generative process could get you plus or minus 15 percent of the real answer but with 2 percent of the effort,” he says. “So, you know how to make the heat exchanger this way or that way – you’ve isolated the design alternatives and you can find them right away and validate.”

Even though the tools function through simulation, “You get amazing design insights and design innovation so you can see how something can be done,” he says.

But Vlahinos cautions against relying fully on the current AI-enabled CAD optimization tools.

“They are not simulation replacement,” he says. “Don’t let the vendors oversell them.

They are design guidance, like a spell checker for you design concept. But they do give you more amazing results.”

Still, by helping engineers more quickly meet their prescribed design specifications, AI also frees up time engineers can spend focusing on other aspects of the piece—like its inherent shape or its artistic merits.

And – with proper validation in place -- these tools can help ensure parts will meet manufacturing specifications and allow for much quicker design than traditional methods.

It also can create unorthodox, sometimes never-before-seen-shapes that can be manufactured through 3D printing.

The engineer as artist Design for manufacturability, as it’s called, is of course an important—some might say bedrock—necessity. AI techniques have a role to play in other aspects of design. And some of its uses may not have been conceived of yet, as CAD makers focus on these first AI implementations, Vlahinos says.

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3 D

“Right now, it’s ‘Please tell me what the optimal shape is to achieve my engineering goal,” Vlahinos says. “We could see AI answering other questions in the future.”

Though his career has focused on rapid product development -- Vlahinos recognizes that AI could help engineers design products faster than before -- at the same time it offers engineering company customers new and unique ways to meet needs they may not even know they have.

For instance, broaden the view beyond the focus on manufacturability and AI can also lend artistic value to an engineered piece or product, he says.

“We’ve never properly valued the artistry of the design. But we could,” he says.

A product’s design artistry is, of course, subjective, so putting a monetary value to that number -- as opposed to function -- has always been elusive. Likewise, the capability to add never-before-seen geometries that create swirls and whorls in new and unexpected ways to pieces can bring a great deal of satisfaction, or headaches, for designers, depending on their liking to bring creativity to their engineering work.

If CAD can evolve, in the not-too-distant future, everyday objects like your blender, electric toothbrush or even the engine within your automobile, will take the shape of nothing you’ve ever seen before, said Hod Lipson, a mechanical engineering professor Columbia University and director of the school’s Creative Machines Lab. He is a roboticist who works in the areas of AI and digital manufacturing.

Most 3D printers take their printing instructions from 3D CAD files. Because the 3D printer receives its instructions from CAD files, the printers are limited in the shapes that those CAD systems generate, Lipson says. CAD software only allows for designers to work with recognized geometries: circles and ovals, squares and rectangles, and so on, he says.

That’s changing as topology optimization and generative design capabilities make their way into design tools, Vlahinos adds.

So the day of the twisted blender may be upon us sooner than we think.

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C A D

Beyond simulation Feature and character recognition, which have been part of AI for many years, are part of the SolidWorks system. In fact, they’re so standard that many users may not recognize the AI component of those features—until, for instance, they begin to type a misspelled word they use frequently and see that word corrected automatically, Bassi says.

And AI has a role in CAM as well. For instance, SolidWorks CAM automatically generates a part’s manufacturing toolpath after design. CAM software uses the CAD models to generate the toolpaths that drive computer numerically controlled manufacturing machines. Engineers and designers who use CAM can evaluate designs earlier in the design process to ensure that they can be manufactured, Bassi says.

“The toolpath captures design strategies and recognizes features and types of materials, so you can have a CAM solution that’s almost completely automated,” Bassi says. AI drives the way the toolpath is automatically created.

“You can create a toolpath in a couple of clicks. You don’t need a lot of details for intelligent manufacturing,” Bassi said.

One thing is certain, Vlahinos says.

AI will never take the human engineer or designer out of the equation.

Even intelligent machines need guidance. That means engineers will always be vital to the design process, he adds. A human will always be needed to view shapes and designs in the same way other humans will. To translate a part’s use, -- its form, and its function -- with an eye toward other human users. DW

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

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Choosing the right coupling for robust crane and hoist applications

Cranes and hoists are only as good as the components that make them up. One of their key components is the coupling, which is essential to maintaining uptime and enhancing the safety and reliability of your operation. Without the right coupling, your crane or hoist may not function properly, causing your manufacturing process to grind to a halt.

Edited by Mike Santora

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There are two main types of couplings that meet the demands for reliability and safety in crane and hoist applications. Here, we explore the coupling design features you should look for.

| AdobeStock

Barrel couplings: Hoists — which also refer to the lifting mechanism in cranes — lift and lower loads using a drum or lift-wheel, around which a rope or chain wraps. Hoists can be manually operated, as well as electrically or pneumatically driven. They can also use chain, fiber, or wire ropes as their lifting medium.

From steel mills to manufacturing plants, hoists are used in a range of applications that involve moving large, heavy products up and down.

A proven coupling solution for hoists, barrel couplings connect the cable drum to the gearbox output shaft and are also used in winch conveyors and platform hoists. These couplings transmit torque via barrel-shaped hardened pins that fit into semicircular machined openings on the hub and sleeve — ensuring radial forces are transmitted safely.

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•• •• M e c h a n i c a l •• The design advantages of barrel couplings The barrel coupling’s design offers several benefits:

• Due to the profile of the barrels and teeth, the coupling is

subjected to lower bending stresses at the bottom of the teeth — improving protection against bending and radial loads.

The larger contact surface between the barrels and teeth also allows radial loads to be better distributed, which increases the lifespan of the coupling.

The use of high-strength materials, such as steel, increases the coupling’s transmission capability without requiring a change in the design or dimensions. As a result, a smaller coupling size can often be selected — leading to improvements in energy efficiency due to the lower weight and acceleration forces.

Internal and external covers, each equipped with a lip seal, prevent foreign matter from entering and lubricant from escaping.

A wear indicator attached to the external cover lets you check the wear and axial position of the housing relative to the hub. Also, markings facilitate easy reassembly should you need to dismount the coupling.

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Figure 1. Rigid gearbox — drum connection (statically indeterminate).

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Figure 2. Gearbox — drum connection using barrel couplings (statically determinate).

Creating a statically determinate system Fixing the gearbox output shaft to the cable drum creates a rigid, statically indeterminate mounting (Figure 1) — making perfect alignment and leveling critical during the assembly process.

Both, however, are difficult to achieve in practice. Additionally, mounting inaccuracies, structural deformation and wear in moving parts create additional forces in the gearbox output shaft. These forces occur in alternating bending loads and can lead to shaft breakage and severe damage to bearings and gears.

This is where barrel couplings come into play.

Barrel couplings perform the function of an articulated joint, making the connection between the cable drum and gearbox statically determinate (Figure 2) and avoiding high bending moments. They also prevent angular and axial shaft misalignment caused by mounting inaccuracies, structural deformation, and normal wear and tear. Without the flexibility provided by these couplings, the forces generated by the alternating bending loads can lead to shaft breakage and other costly, disruptive damages.

Figure 3 illustrates the mounting of a barrel coupling in a typical lifting mechanism. Because this coupling allows axial displacement, a self-adjusting bearing must be mounted—fixed laterally—at the opposite end of the drum shaft. In special applications, however, the barrel coupling can be designed as an articulated joint that withstands axial forces by itself.

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Claw and disc couplings In addition to gear couplings, claw and disc couplings can be used to connect the drive motor and gearbox in crane and hoist applications.

Like the gear coupling, these other two options are designed to compensate for angular, radial, and axial shaft misalignment: Claw coupling — Torsionally flexible, these couplings transmit

torque via elastic buffers made from Perbunan (Pb), which are joined together as an intermediate ring. This ring dampens shocks and torsional vibrations, is resistant to oil, and can handle a wide temperature range. Because of their dampening capabilities, claw couplings are preferable in many crane applications.

Figure 3. Mounting of the barrel coupling in a lifting mechanism.

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Disc coupling — Unlike claw couplings — which contain rubber — rigid,

Calculating T in terms of consumed motor power:

all-metal disc couplings require no lubrication and will operate reliably with little to no wear or maintenance.

Gear couplings: Although the style and function of cranes and hoists vary, these machines maintain many of the same basic design principles — including the need to connect shafts, drums and brakes to the prime and auxiliary movers that power the drive, travel, and hoist functions. With their high-power density and ability to accommodate various design and misalignment variations, gear couplings have become an industry standard.

Gear couplings are designed to transmit torque between two shafts that are not collinear. They typically consist of two flexible joints — one fixed to each shaft — which are connected by a spindle, or third shaft. The gear coupling connects the drive motor to the gearbox in hoist mechanisms, but it can also connect the gearbox directly to smaller wire rope drums using a flanged half. In terms of their design, gear couplings transmit torque via hubs with crowned gear teeth that are in permanent mesh with the straight gear teeth of the sleeves — a design that provides the highest torque transmission for the smallest size. They also run at high speeds, conform to the AGMA bolting pattern and compensate for angular, radial, and axial shaft misalignment.

Sizing a barrel coupling Sizing a barrel coupling comes down to three things: transmission torque (T), the applied radial load, (F) and shaft diameter of the gearbox unit.

What follows is a simplified version of the process, including some of the calculations involved at various steps:

1 Calculate the nominal transmission torque (T) based on maximum installed motor power or consumed power. This value must be less than the transmission torque (TKmax) of your selected coupling according to the datasheet.

Calculating T in terms of installed motor power:

Where: Pi = maximum installed motor power n = rotary speed of the rope drum K1 = service factor (see table)

Where: Pc = maximum consumed motor power FP = drum static pull, including cable and pulley efficiency Vr = drum cable lifting rate n = rotary speed of the rope drum D = drum pitch diameter K1 = service factor

2 Calculate the applied radial load (F). The next step in the process requires you to evaluate the radial load that will act on your coupling. Radial load refers to the fraction of the load that your coupling must withstand due to the pull of the load and hoisting tackle. This calculated value must be lower than the admissible radial load (Frad) indicated in the datasheet.

For systems with double line to drum. Where: FP = static pull of drum, including cable and pulley efficiency w = weight of the drum, including the rope and connected parts of the coupling

3 Verification of the geometric dimensions. Finally, make sure the diameter of your gearbox shaft is smaller than the coupling’s maximum admissible diameter (d1kmax) as indicated in the datasheet. These values are valid for shafts with keyways according to DIN 6885/1. Please contact our technical team for other types of fixing. DW Ringfeder | ringfeder.com

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BallscrewsState-of-the-art machining technology, providing in-stock solutions, solutions exact groove profiles by grinding or precision rolling, with protective coating options.

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Product World High-speed couplings Zero-Max zero-max.com The SFM coupling line is now available for direct sale to OEM’s in North America. SFM couplings are designed for high-speed power transmission applications up to 24,000 rpm where high torque and precision alignment is critical.

Available in 10 sizes, SFM couplings transmit torque

by connecting two shafts while damping system vibrations and accommodating misalignment. The couplings have a disk spring design that provides high torsional rigidity and axial flexibility. The high response, zero-backlash design, has a high torque to weight ratio.

Capable of a speed range up to 24,000 rpm, SFM couplings have a torque rating from 60 N•m to 600 N•8 depending

on model size. They have a high torsional stiffness range from 104,000 Nm/rad to 970,000 Nm/rad with parallel misalignment of 0.02 mm.

Mounted thrust bearing solution Auburn Bearing auburnbearing.com The MT-114-RG mounted thrust bearing is a bearing assembly that allows the T-114-RG style thrust bearing series to be conveniently threaded onto a shaft for mounting or to be bolted into place. This bearing and mount combination allows fast and easy mounting of this small, self-contained thrust bearing.

The MT-114-RG can be installed using a variety

of mounting configurations, including bottom thread mounting, shoulder mounting, and lock nut mounting, making this bearing and mount assembly a convenient solution for a variety of applications that require the T-114-RG style thrust bearing.

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All updated models use TFT-LCD screens displaying a range of vivid colors, with the three

larger-sized HMIs improving the resolution to 1024x768 pixels, while the 5.7-in. model remains

Linear Guideways

Rotary Tables

Ballscrews Ball Splines

AC Servos & Drives Articulated Robots

Harmonic Gearing System Linear Motors Single Axis Robots

Crossed Roller Bearings Positioning

Torque Motors

Measurement Systems HIWIN Grease

at 640x480 pixels. The entire range of HMIs in the series offers top-performing brightness, in this case ranging from 600 to 800 cd/m2, to deliver greater visibility, even in high-glare

Huntley, IL USA

locations such as direct sunlight. Backlight life ratings are 100,000 hours minimum.

847.827.2270

www.hiwin.com DESIGN

WORLD

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Product World Rolling bearings for motors and generators

Ground fault sensor NK Technologies nktechnologies.com The AG-LC Series is a new ground fault

NKE nke.at

sensor that makes it easy to monitor larger

Specifically designed for motors and

feeding marinas and boatyards, where these

generators, these bearings are noted for their

services often carry up to 800 amps. Most

low running noise, efficient seals, high load ratings,

sensor designs do not allow the conductors

and long service life.

to pass through a single sensing ring,

requiring a separate sensing device such as

Electric motors are the driving force behind most industries. In close cooperation

circuits. The 2011 NEC requires ground fault protection of the main over-current device

with the customers, these bearing solutions were designed for many types of electric

a zero-sequence current transformer. The

machines, such as electric motors of various sizes and for various applications, e.g.

AG-LC Series resolves this issue with a large

vibrator motors, traction motors for rail vehicles, as well as generators for hydro and

solid-core housing design that provides ample

wind turbines and UPS (uninterruptible power supply) systems. The most commonly

space for multiple conductors to pass easily

used bearing types in these applications are cylindrical roller bearings, deep groove

through one sensing window.

ball bearings, and angular contact ball bearings. Besides offering cost-effectiveness, all bearings must operate with low noise, be durable enough to perform to the highest

Key applications include:

standards in long term operation and, for certain bearing types, have efficient seals.

• Monitoring large machines: Early detection

of leakage to earth

Deep groove ball bearings are suitable for locating and non-locating bearing

positions on small and medium-sized electric motors and generators, and for locating

• Water treatment and delivery: Keeping

bearing positions on larger motors. They are suitable for high rotating speeds and

pumping systems safe and in operation

moderate radial and axial loads. The bearings are quiet-running and economical. Besides

• Generators: Shut down equipment when

the open configuration, they can also be supplied pre-lubricated with shields or seals.

leakage current exceeds hazardous levels

Rigid shaft couplings Stafford staffordmfg.com These rigid shaft couplings offer numerous design options for attaching unsupported shafts in a range of new and retrofit power transmission applications. Featuring inch, metric, and combinations of both and step bores to mate dissimilar shafts, they can incorporate axial keyways and annular keyways for higher loads and accurate and repeatable shaft location.

Available off-the-shelf as 1-piece, 2-piece, and 3-piece styles, Stafford Rigid Shaft Couplings

are offered in bore sizes from 1/4 to 3-in. I.D. machined from steel, stainless steel, and aluminum.

Heavy-duty styles, many material choices, shaft adapters with round, square, hex, D, threaded, keyed, tapered, and machinable shaft ends, and specials are also available.

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

Providing Value Through Technological Advancements

Wire-actuated encoders SIKO siko-global.com

Introducing the HIWIN® Harmonic Gearing System, Datorker®

SG61 wire-actuated encoders are suitable for measuring lengths up to 6 m. Based on 30 years of experience in development and production, a wireactuated sensor has been designed that impresses with its compactness, sturdiness, and flexibility.

The measurement length and a housing that is as

compact as possible are important factors when choosing sensors for intralogistics and mobile equipment. The SG61 wire-actuated sensor has an installation depth of 70 x 8% x 105 mm and rugged construction.

The robust aluminum housing, coupled with impact-resistant plastic, survives even the harshest of operating conditions. Factors such as temperatures between -40 and +80°C, high shock and vibration loads, dirt, dust, and water pose no limitations for the wire-actuated encoder.

For outdoor applications in low-temperature ranges, there’s also a variant with integrated

water drain holes — this avoids the problem of water freezing in minus temperatures and increases the service life.

Industrial-grade touchscreen Weintek weintek.com

Compact and Light Weight The cMT-iV6 touch panel with built-in

High Torque

cMT Viewer can connect with multiple cMT-SVR or cMT Series HMIs for

Variety of Reduction Ratios

monitoring. Equipped with a 9.7-in.

High Precision Motion Control

1024×768 touchscreen, built-in speaker,

For More Information: info@hiwin.com

and high-performance 1-GHz processor, it delivers strong visuals, sound effects, and operation experience.

The cMT-iV6 inherits most of its functions from cMT-iV5 — but has an

additional SD card slot. By using an external SD card, it can support many software features that were otherwise not available on cMT-iV5. For example, file browser, media player, picture viewer, PDF reader, and screen hardcopy, in addition to VNC Viewer. Plus, the touch panel’s upgraded 4-GB eMMC memory lets it cache more

Linear Guideways

Rotary Tables

Ballscrews Ball Splines

AC Servos & Drives Articulated Robots

Harmonic Gearing System Linear Motors Single Axis Robots

Crossed Roller Bearings Positioning

Torque Motors

Measurement Systems HIWIN Grease

data for the connected devices — enabling seamless switching between devices and ensuring smoother operation.

Huntley, IL USA 847.827.2270

www.hiwin.com DESIGN WORLD

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Ad Index Allied Electronics ........Cover,3,121 AllMotion .......................................... 4 Altech Corp. ..................................... 1 AS-Interface Organization North America ......................... 24 Aurora Bearing Company .......39 AutomationDirect ........... .Gatefold Centritec Seals .............................19 Clippard ........................................ BC Del-tron ........................................ 105 Digi-key ........................................... 13 Dorner .............................................20 Dynatect Manufacturing, Inc. ............. 115 EXAIR Corporation ....................... 5 EZAutomation ...................... Insert FAULHABER MICROMO .......... IBC Fixtureworks ..................................14 HIWIN ..............................123,125,127 HYDAC Technology Corporation .............................. 17

SALES

IDEC Corporation ........................25 Interpower .....................................33 J.W. Winco, Inc. ............................ 37 Keller America ............................... 21 Key Bellevilles .............................. 37 MW Industries Century Spring ..................... 116 NB Corporation ............................. 9 OKW ..................................................15 Oriental Motor .............................43 Phoenix Contact ........................... 11 Pyramid Incorporated ...............39 Smart Products USA ................... 7 The Lee Company ................... 107 Tompkins Industries, Inc. ........... 2 Tormach ..........................................111 Trim Lok ..........................................23 Vlier ..................................................41 Whittet-Higgins ............................ 31

Make Parts Fast Supplement HP 3D Printing ....................................................49 PBC Linear ...........................................................56 Xcentric Mold & Engineering .........................52

A supplement of Design World August 2019

Jami Brownlee

jbrownlee@wtwhmedia.com 224.760.1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Bill Crowley

bcrowley@wtwhmedia.com 610.420.2433

Jim Dempsey

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LEADERSHIP TEAM

Michael Ference

Publisher Mike Emich

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mfrancesconi@wtwhmedia.com Scott McCafferty smccafferty@wtwhmedia.com 630.488.9029 310.279.3844 @SMMcCafferty David Geltman dgeltman@wtwhmedia.com EVP 516.510.6514 Marshall Matheson @wtwh_david mmatheson@wtwhmedia.com 805.895.3609 Neel Gleason @mmatheson ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

50 Better post processing will aid additive manufacturing acceptance

54 Preparing to switch from traditional to additive manufacturing

8/5/19 7:56 AM

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A Supplement to Design World - August 2019 www.designworldonline.com

Myomo Scales up Production, Training for Upper-Body Mobility Device page 76

INSIDE: • Exoskeleton Developers Must Keep Refining Capabilities, Cost, Says maxon Manager .....60

Follow the whole team on twitter @DesignWorld

• Industrial Exoskeletons Gain Capabilities, Expand Into New Uses ....................................66 • Why Engineers Should Attend the Healthcare Robotics Engineering Forum .........................72

CGI ....................................................................................92 CS Hyde Company ..................................................... 80 Festo ............................................................................... 69 Harmonic Drive .............................................................63 Honeywell Intelligrated .............................................59 igus .................................................................................. 85 Kollmorgen .................................................................... 89 LAPP USA ..................................................................... 64 maxon precision motor .............................................. 71

Courtney Nagle

printing’s benefits for prototyping 46

COVER_MPF 8-19_FINAL.indd 45

The Robot Report

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

• Sarcos Robotics Readies Guardian Alpha for Industrial Use ..............................................82 • Robotic Hand Uses Machine Learning to Detect Wearer’s Intent ....................................90

ROBOT REPORT COVER_8-19_FINAL2.indd 58

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FAULHABER MICROMO...............................................81 Mitsubishi Electric Automation ..............................75 mk North America, Inc. ..............................................79 New England Wire Technologies & New England Tubing Technologies ........... 94 SICK, Inc. .........................................................................87

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Expanding the universe of motion MICROMO is now FAULHABER MICROMO

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As a member of the FAULHABER Group since its inception, FAULHABER MICROMO’s long-standing partnership and coordination with FAULHABER Drive Systems is now amplified. Reorganized as a united, fully-integrated part of FAULHABER Drive Systems, FAULHABER MICROMO now has expanded design and engineering capabilities, providing improved customer support, faster lead times on products, and additional motion control expertise for OEMs in the North American market.

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