www.designworldonline.com December 2016
INSIDE: MOTION CONTROL: Realtime control SoCs improve drive designs PAGE 94
LINEAR MOTION: Force-current relationship important when using linear motion for part production PAGE 100
MECHANICAL Slip clutches: Where they excel PAGE 118
Smart motors make high-tech e-bikes 68
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Leadership in Engineering
2 0 1L 6 eadership » Here in our tenth annual issue on
Winners
Advanced Materials
Digital Manufacturing
Electrical
Leadership in Engineering, we announce the
Fastening & Joining
Fluid Power
winners in the Leadership Awards Program that we
Industrial Automation
have been promoting throughout
Mechanical
the year. The Design World User Community has cast votes
Mechatronics
Motion
and we are pleased to celebrate the winners in this
Networks
Software
special section of “Leadership in Engineering.”
Switches & Sensors
Test & Measurement www.designworldonline.com
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December 2016
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2016
Leadership in Engineering
Advanced Materials
Congratulations
Boyd Coatings Research Co. Inc. Boyd Coatings Research Co. applies a variety of highperformance coatings, specializing in the medical, industrial and aerospace markets. In addition to applying virtually every coating from every manufacturer on the market, Boyd manufactures a line of custom-developed fluoropolymer coatings for specialty applications. Boyd Coatings is an ISO 9001:2008 certified, registered and licensed applicator for Teflon, Whitford, 3M and hundreds of popular coatings and finishes providing non-stick, heat resistant, conductive, insulative, hydrophobic or other desirable properties. Boyd is a Licensed Industrial Applicator of Teflon fluoropolymers including PTFE, ECTFE, ETFE, FEP, PFA, PVDF. Other fluoropolymer brands and formulations are also available.
PRESENTED BY
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DESIGN WORLD
Boyd Coatings 2016 winner.V3.LL.indd 4
December 2016
www.designworldonline.com
12/1/16 2:14 PM
2016
Leadership in Engineering
Digital Manufacturing
Congratulations 3D Systems 3D Systems provides advanced and comprehensive 3D digital design and fabrication solutions, including 3D printers and additive manufacturing systems. Its ecosystem transforms industries by empowering users to bring their ideas to life using its vast material selection, including plastics, elastomers, metals and bio-compatible materials. 3D Systems’ leading personalized medicine capabilities include end-to-end simulation, training and planning, and printing of patientspecific surgical instruments and medical and dental devices. Its 3D digital design, fabrication and inspection products provide seamless interoperability and incorporate the latest immersive computing technologies. 3D Systems’ products and services deliver improved results and empower its customers to manufacture the future now.
PRESENTED BY
www.designworldonline.com
3D Systems 2016 winner.V3.LL.indd 5
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2016
Leadership in Engineering
Electrical
Congratulations WAGO WAGO Corporation provides North America with innovative Interconnect, Electronic Interface, Terminal Block and Automation solutions. Headquartered in Germantown, Wis., WAGO features state-of-the-art manufacturing and 75,000 square feet of storage capacity for 36,000 product locations. Extensive engineering resources, a 25,000+ product portfolio, custom manufacturing, and a global network of dedicated professionals ensure WAGO has the resources and expertise to help you get the job done.
PRESENTED BY
6
DESIGN WORLD
WAGO 2016 winner.V3.LL.indd 6
December 2016
www.designworldonline.com
12/5/16 3:46 PM
2016
Leadership in Engineering
Fastening & Joining
Congratulations Master Bond Master Bond is celebrating 40 years of formulating cutting edge adhesives, sealants, coatings and potting/encapsulation systems using advanced technology for challenging applications. High Performance Adhesives, Sealants & Coatings Our expansive line of epoxies, silicones, UV curable and LED curable compounds can be customized to meet a myriad of property requirements including: High/low temperature resistance, Electrical conductivity/insulation, Thermal conductivity, High/low viscosity and more.
PRESENTED BY
www.designworldonline.com
MasterBond 2016 winner.V3.LL.indd 7
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2016
Leadership in Engineering
Fluid Power
Congratulations Yates In the spring of 1972, in a small Detroit location, Yates industries Incorporated was founded by William H. Yates II. Yates Industries began as a distributor of fluid power products and repair facility for the fluid power industry. Today, with expanded facilities in St. Clair Shores, MI, Decatur and new location Austell, Georgia proves that Yates continues to grow to meet the ever changing needs of its customers.
PRESENTED BY
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DESIGN WORLD
YATES 2016 winner.V1.indd 8
December 2016
www.designworldonline.com
12/1/16 2:17 PM
2016
Leadership in Engineering
Industrial Automation
Congratulations Automation Direct A well-recognized name in the industrial automation market, AutomationDirect provides quality products with free awardwinning in-house sales and technical support. AutomationDirect provides customers with quick order and delivery through an online store and toll-free number. Prices on most products are well below the industry average and a 30-day money-back guarantee is offered on nearly all items. The company also provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. A Customer Forum provides peer support on technical and application questions.
PRESENTED BY
www.designworldonline.com
AutomationDirect 2016 winner.V3.LL.indd 9
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2016
Leadership in Engineering
Mechanical
Congratulations igus ÂŽ
igus is committed to using its polymer materials to develop products that provide creative solutions and exceed customers’ expectations, while delivering fast, accurate service. These plastic blends are used throughout each of igus product lines of plastic bearings, guides and slide tables, spherical bearings, and cable carriers. igus has been manufacturing engineered plastics for more than 50 years and develops each of the materials and all technology behind its products. igus is continually expanding its base of plastic materials and performs rigorous testing to prove its products meet and exceed industry standards.
PRESENTED BY
10
DESIGN WORLD
igus 2016 winner.V3.LL.indd 10
December 2016
www.designworldonline.com
12/1/16 2:21 PM
2016
Leadership in Engineering
Mechatronics
Congratulations
Mitsubishi Electric Automation As one of many Mitsubishi automation affiliates around the world, Mitsubishi Electric Automation, Inc., is part of a $40 billion global company serving a wide variety of industrial markets with a family of automation products including programmable logic controllers, variable frequency drives, operator interfaces, motion control systems, computer numerical controls, industrial robots, servo amplifiers and motors, and industrial sewing machines. The corporate philosophy of the company includes a commitment not only to providing superior solutions and service to Mitsubishi customers, but also to contributing to the local community and creating a rewarding work environment for its employees.
PRESENTED BY
www.designworldonline.com
Mitsubishi Electric 2016 winner.V4.LL.indd 11
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2016
Leadership in Engineering
Motion Control
Congratulations AMETEK AMETEK Dynamic Fluid Solutions Business Unit specializes in the design and manufacture of intelligent, variable speed brushless motors, blowers and pumps, with embedded drive and control electronics. Each product type can be customized for various industry uses and applications offering end users precise system control. Customizable options include serial communications interface, logic inputs and outputs, and an external pressure/ flow sensor. AMETEK Dynamic Fluid Solutions is a unit of AMETEK, Inc., a global manufacturer of electronic instruments and electromechanical devices with annual sales of $4.0 billion.
PRESENTED BY
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DESIGN WORLD
AMETEK 2016 winner.V4.LL.indd 12
December 2016
www.designworldonline.com
12/5/16 2:56 PM
2016
Leadership in Engineering
Networks
Congratulations Beckhoff Automation In the movement toward Industry 4.0 and IIoT, PC-based control technology from Beckhoff Automation provides the ideal toolbox to implement the leading automation concepts of our time. These concepts include the Internet of Things, cloud computing, centralized PC-based control systems, and ever-more connected devices via industrial Ethernet and OPC-UA. Many users are already integrating Beckhoff controllers into their production networks, enabling them to communicate with databases, perform remote maintenance over the Internet or request cloudbased services.
PRESENTED BY
www.designworldonline.com
Beckhoff 2016 winner.V4.LL.indd 13
December 2016
DESIGN WORLD
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2016
Leadership in Engineering
Software
Congratulations COMSOL COMSOL is a global provider of simulation software for product design and research to technical enterprises, research labs, and universities. Its COMSOL Multiphysics product is an integrated software environment for creating physics-based models and simulation applications. A particular strength is its ability to account for coupled or multiphysics phenomena. Addon products expand the simulation platform for electrical, mechanical, fluid flow, and chemical applications. Interfacing tools enable the integration of COMSOL Multiphysics simulations with all major technical computing and CAD tools on the CAE market. Simulation experts rely on a PRESENTED BY
local installation of the COMSOL Server product to deploy applications created from COMSOL Multiphysics models to their design teams, manufacturing departments, test laboratories, and customers throughout the world.
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December 2016
www.designworldonline.com
12/1/16 2:28 PM
2016
Leadership in Engineering
Switches & Sensors
Congratulations BEI Sensors BEI Sensors specializes in speed and position sensors for extreme applications. With an extensive product offering including optical and magnetic encoders, Hall effect sensors, and potentiometers, BEI Sensors offers standard configurations to completely customized solutions. Through uncompromising quality, performance, and reliability, BEI Sensors upholds a standard of excellence in its products, customer service experience, and commitment to being a global leader in sensor technology. BEI Sensors is now a part of Sensata Technologies. Through hard work and innovative thinking, BEI Sensors’ engineers have led the way in developing products that provide rugged and reliable position sensing solutions in the motion control industry. For over 30 years, BEI Sensors has and continues to strive to produce the best position sensing products for harsh environments while delivering the most exceptional customer service found anywhere.
PRESENTED BY
www.designworldonline.com
BEI Sensors 2016 winner.V4.LL.indd 15
December 2016
DESIGN WORLD
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2016
Leadership in Engineering
Test & Measurement
Congratulations Cognex Cognex is a trusted vision company, with more than 1,000,000 systems installed in facilities around the world, and more than thirty years of experience focused solely on machine vision and image-based industrial ID technology. Products include barcode readers, machine vision sensors and machine vision systems that are used in factories, warehouses and distribution centers around the world to guide, gauge, inspect, identify and assure the quality of items during the manufacturing and distribution process.
PRESENTED BY
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DESIGN WORLD
Cognex 2016 winner.V4.LL.indd 16
December 2016
www.designworldonline.com
12/1/16 2:32 PM
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Co nten t s |
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December 2016 • vol 11 no 12
designworldonline.com
F E AT U R E S
94
122
MOTION CONTROL Realtime control SoCs improve drive designs
MECHANICAL Shock and vibration mitigation by design, not by mistake
Industrial drive functions on off-the-shelf MCUs now let designers forgo FPGA builds to focus on motion and motor control.
100
LINEAR MOTION
Shock absorbers and isolators are not nonessential fixit elements to add to original equipment only if it shows vibration or shock problems. Here we debunk common misconceptions.
CAD 128 3D Simulation is becoming
Force-current relationships affect linear motion design
democratised—at last (Part 1)
Applying an electric motor is easier when one knows what it will output for a given input. The simpler it is to predict that, the more elegant and robust the design.
108
MECHATRONICS I
Next Dimension 144
150
Quantifying 3D printing
Additive lays the
for surgical simulation
Quality control questions to ask your low-volume manufacturer
S
I
D
E : USB connectors • Spring-loaded contacts • Selecting twin-axial cables • Cable ampacity
A supplement of Design World • December 2016
A supplement of Design World • December 2016
2016
3D Printing’s
TEST & MEASUREMENT
N
Inter
The last industrial revolution Computer intelligence is being deployed in layers throughout the business enterprise—enabling artificial intelligence to provide deeper insight into all aspects of manufacturing.
112
Software choices for simulation continue to expand. Here’s an overview of the latest offers.
Cable & Connector
138
Reference Guide
foundation for full production
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47-67
136-155
Low-volume manufacturing companies are pushing the boundaries of manufacturing. Asking them a few key questions will help you ensure quality results.
118 MECHANICAL Slip clutches: Where they excel Slip clutches can boost machine speeds and protect against overloads, as well as apply constant tension in indexing applications.
ON THE COVER The BIKEDRIVE includes a permanentmagnet ironless-core motor to make e-bikes more efficient. Image courtesy maxon motor
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DESIGN WORLD
CONTENTS DECEMBER 2016_first page_Vs3.LL.indd 18
A | S |B |P|E
A | S |B |P|E
A | S |B |P|E
A | S |B |P|E
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A | S | B | P| E Fostering B2B editorial excellence
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2016 National
ONLINE Award Winner
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161101_ACCESS_EEW_US.indd 1 Digi-Key 12-16_Immediate Access.indd 19
11/1/16 12/1/16 3:35 3:45 PM PM
CS Hyde Company
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Follow the whole team on twitter @DesignWorld EDITORIAL
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December 2016
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12 . 20 1 6 D E PA R T M E N T S
68
22 Insights 24 Teschler on Topic 26 Technology Forward 28 Green Engineering 32 Design For Industry 68 Design Notes 82 CAE Solutions 86 Coupling Notes 88 Internet of Things
Depiction of Frequency Waves
156 Products 160 Ad Index
INNOVATING SHOCK & VIBRATION SOLUTIONS
88 32
MADE IN THE U.S.A.
800.838.3906
www.sorbothane.com December 2016
Contents DECEMBER_second page_Vs3.LL.indd 21
DESIGN WORLD 
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I n s i g ht s What’s the future for industrial distribution? Distribution continues today to be a player in many areas of industrial components and has survived many death knells over the years. Recently, I heard a presentation from Frank Hurtte of River Heights Consulting, and he discussed some of the scares that distributors have been through, as so-called experts have incorrectly predicted the demise of these businesses many times. Some examples include: 1995: Disintermediation—the Internet will eliminate the need for distributors! 1996: Integrated supply—Unless you can sell everything, you will be blocked out of customers! 1999: The Y2K threat—The rollover from 1999 to 2000 will shut down everyone’s businesses! 2008: Private equity threats—Private equity is rolling up distributors and they will steal business on price and build volume! 2014: Millennials—The next generation sees no value in the distribution model! 2016: Amazon takes over the world—Everyone wants to buy in an Amazon-like environment! But the industry has a pretty resilient business model, not to mention a track record of adoption. Some examples include dealing with logistics changes (UPS and FedEx’s growth in the 1970s), computers, consolidation and the idea of value-add in the 1980s, the birth of logistics and email in the 1990s, recession, mega-consolidation and eCommerce in the 2000s, and vending machines, private equity and remote monitoring/troubleshooting in the 2010s. Hurtte polled the audience (largely comprised of distributors) as to where they thought their growth would be. Most (35%) said it would be through acquisitions and mergers, while 26% said organic growth with existing customers would be their main strength. Others said organic growth with new types of customers in the same territory (22%), expanded geography and more customers (13%), and expanded product offerings (4%). Today’s distributors have valid concerns that include an aging sales force, succession planning, more competition, and a shrinking customer base—not to mention figuring out how to get eCommerce right. Yet, as OEMs outsource more of their engineering design, distributors have an opportunity to become engineering partners, building subsystems and truly integrating themselves into the design process. If any business can find a way to adapt, my money is on distributors to find a way to do it. DW
Pa ul J. He n ey - Edi tor i al D i re ctor phe ney@wtwhme di a.com
On Twitter @ DW—Editor
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DESIGN WORLD
December 2016
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9/8/2016 8:10:48 AM 12/2/16 11:38 AM
Te s c h l e r o n To p i c
Tech job interviews produce arbitrary results. Here’s why. Most engineers have probably been in at least one job interview that didn’t pan out for reasons that, afterward, seemed a bit ambiguous. In at least one corner of the tech employment industry, there is a move to eliminate some of the goofier outcomes that can arise in meetings between engineering job applicants and potential employers. Meet Aline Lerner. She runs a site called interviewing.io that serves both as a platform for online job interviews and as a way for potential job candidates to practice interviewing. Her site has hosted numerous real and practice interviews over time, and she’s collected a lot of data about what has gone on there. All that data has led her to interesting conclusions about engineering resumes and the interviewing process. For example, when it comes to resumes, Lerner thinks typos and grammatical errors matter more than anything else. Having attended a top school doesn’t matter, nor does your GPA. But at least for the software engineers she deals with, having worked at a top company matters a lot -- working at places like Google and Facebook has become a proxy for aptitude, she thinks. Similarly, Lerner has a low opinion of technical interviews. She says technical interviewing is a process with results that are nondeterministic and often arbitrary. “I started out as a software engineer and then became a recruiter. In both situations, I never
felt good about the interviewing process,” she says. “What if the person we interviewed had an off day? What if the technical questions we asked required specialized knowledge the candidate didn’t have, or what if they’d seen a question before so they had a big edge? I didn’t really feel as though interviews got at the fundamental potential of someone to be a good engineer.” As Lerner’s site collected more and more data about what went on during interviews, her misgivings crystalized. “We looked at how the same person did from one interview to the next and found the variance in performance was astonishing. You might see one individual who blew half their interviews out of the water and failed in the other half. And it wasn’t because some interviews were more difficult than others,” she says. The thing that bugged Lerner the most was that successful job interviews seemed to have little to do with technical competence. “Sometimes it was rapport with the interviewer. Sometimes it was familiarity with some arbitrary piece of subject matter that doesn’t come up in anyone’s day to day work. Other times it was just something not clicking in the applicant’s head until too late. Especially in the software engineering market which is plagued with scarcity, it didn’t seem to be the right way to assess whether people should get a job or not,” she says.
Another realization to come out of Lerner’s interviewing data: Most people aren’t good at gauging how they perform in a specific job interview. “People routinely over and underestimate their own performance, but they underestimate twice as often as they overestimate,” she says. It’s easy to see why. “You’re typically given problems to solve during an interview. If you stumbled and didn’t finish before time ran out, you might feel you did poorly, though objectively, based on how far you got, you may have done better than most people,” she says. Though Lerner deals specifically with software engineers, lessons learned through her site probably apply to finding jobs in other engineering disciplines as well. “Interviewing is a game,” she says. “People have to practice interviewing and accept that the interviewing process isn’t perfect. So don’t beat yourself up if you fail. A lot of it comes down to working problems that come up during interviews till you’re comfortable with them.” DW
Le la n d Te sc h le r - Exec u t i ve Edi to r ltesc h ler@wtwh m edi a .co m
On Twitter @ DW—LeeTeschler
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Te c h n o lo gy Fo r wa rd
Liquid metals show promise in speeding additive manufacturing The task of removing support
Now, new research indicates that metal additive designs can still include support without all the hassle of post processing. The research out of Arizona State University suggests that dissolvable metal material may work as a support material for metal additively made parts. The benefit is reduced post processing. Co-authors Owen Hildreth, Arizona State University (Tempe), Abdalla Nassar and Timothy Simpson, Pennsylvania State University (State College, PA), and Kevin Chasse, Naval Surface Warfare Center (W. Bethesda, MD), wrote a paper on this technique,” first published in the journal 3D Printing and Additive Manufacturing. The researchers discovered that if they took advantage of the different chemical and electrochemical properties of different metals, they could develop metal supports that are more easily removed. One example given in their research paper was a stainless steel bridge that had a 90-degree overhang. The sacrificial metal support was Metco 91 carbon steel. Electrochemical etching in a 41 wt.% nitric acid with bubbling O2 solution was used to dissolve the support.
structures for metal 3D printed / additively manufactured parts has always been a challenge. So much so, that it’s often better to design the part so that it doesn’t need support. But when the design must have an overhang that requires support, or support to reduce thermally induced distortion, you know finishing will be required.
Stainless steel tends to resist nitric acid, but it can still have small amounts etched away. Carbon steel, on the other hand, dissolves in the nitric acid, although quite slowly. In initial trials, the researchers noted that it took ten hours to remove 1.4 mm of the carbon. That’s why they experimented with speeding up the process with a bubbling O2 solution. With this approach, they were able to remove 7 mm of carbon in six hours. Their research indicates that other metals may be suitable for this purpose, but the material must meet the following criteria. The sacrificial material must be metallurgically compatible with the main material used for the part. Thus, sacrificial material characteristics include similar crystal structure, thermal characteristics, and similar coefficient of thermal expansion. But the sacrificial material should not be too similar to the part material to avoid unwanted intermetallics. The sacrificial material must be strong enough to handle the additive build and the part, but not so strong as to be hard to remove. Dissolvable metals are an exciting development in metal additive manufacturing. Other research has shown that postprocessing tasks can be time-consuming and costly, and are often not accounted for in the overall decision to work with additive machines. But the additive industry is in a dynamic phase. Other methods of speeding post-processing are just on the horizon. DW
Le sli e La n gn a u - M a n ag i n g Edi to r lla n g n a u r@wtwh m edi a .co m
On Twitter @ DW—3Dprinting 26
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» Green Engi neeri ng
The demonstration base of the Nongrid Wind Power Water Desalination System draws power from several wind turbines and boasts of 100 tons of freshwater/day.
Chinese wind powered system converts 100 tons of seawater into fresh per day n Paul J. Heney • Editorial Director
Our thirsty world has problem with an insufficient amount of potable water. A Chinese research effort may have an answer in an off-grid, wind powered, seawater-desalination system developed by the Jiangsu Academy of Macroeconomic Research. The demo project can produce 100 tons of freshwater per day (about 1,000 gal/hr) from sea water. The system, which consumes 2.1 to 2.4 kWh of electricity for every ton of processed seawater, scales to larger output, and can be powered with electricity from a variety of sources. The next step, says research lead Professor and Dr. Gu WeiDung, is a commercial design for converting 10,000 tons of seawater a day. The system was recently announced as winner of the sixth BlueSky Award. The design produces fresh water by pushing pressurized seawater through a reverse osmosis module. Dr. Gu says the system increases its efficiency by 10 to 15% over the previous model by means of mechanical energy transfer. The system is said to be easy to install and maintain because it fits entirely inside the lower portion of a wind turbine tower. The Academy says when compared with a traditional membrane desalination system, the design allows an 80% reduction in footprint over traditional membrane desalination systems (it’s tall), a 60% reduction in failure rate, a 40% drop in cost, and a 30% improvement in energy use. Another plus says Dr. Gu, is that all production is localized due to its independently developed technology. Power to drive the system can come from a variety of sources but is expected to be deployed in coastal locations where winds are plentiful. The latest model, a fifth-generation, uses power from a wind turbine to drive an integrated pressure boost and energy recovery device. The BlueSky Award for Global Top Investment Scenarios says it and the supporting organizations were assembled to provide guidance on large-scale applications of renewable energy in developing countries in a move to ease conventional fossil fuel shortages and mitigate the impact of greenhouse gas emissions on global climate. DW
Redesigning the reverse osmosis equipment into a vertical column allows mounting inside a turbine tower at its base. One goal is a sufficiently sized turbine and column to produce 400,000 tons of fresh water per day, says Dr. Gu.
CONTACT: Dr.Gu WeiDung, Phone: +86 135 0515 5607, E-mail: gu-wd@hotmail.com
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Vision for the future
John Stanczuk Vice President, Sales and Marketing Kuebler
Q: What technologies will most change manufacturing for the better in the next 10 years, and why?
A: We believe Internet of Things will change some of the fundamental rules in manufacturing. It will bring us to a higher level of flexibility allowing us to manufacture single pieces with similar costs to that of mass production. The interaction between man and machine and collaborative robotics will play a significant role in that revolution. The backbone of all this are the sensor networks connected together on the factory floor as well as over the world wide web. This allows also new functionality to improve efficiency such as predictive maintenance via condition monitoring. Our challenge as sensor manufacturer is to provide products, which can be easily integrated in such sensor networks and which have the right functionality to not only provide the classical process data (ex. for encoders speed and position) but also interactive data (such as condition monitoring).
Q: How will new materials affect your business in the coming decade?
A: Currently we do not see any new material being revolutionary for sensor manufacturing.
Q: In 10 years, do you think the IoT/Industry 4.0 trend will have faded or will connected machinery have become a way of life for diagnostics, maintenance and overall machine health?
A: As mentioned in my first answer we see in i4.0 as a real long term trend and I think that in 10 years every machine will be connected – this will become as natural then as today every company has their own website. But diagnostics and maintenance is not the primary target of i.4.0. – it is much more about absolute flexibility and man and machine interaction.
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Q: What do you think will be the next big thing in manufacturing? A: Besides I.o.T. we see the reduction of cabling and connection as a driving factor especially because it is a big cost factor in every machine and plant as well in terms of material costs and also installation costs. Here especially one cable technologies (power and data in one cable) and wireless transmission solutions.
Q: Do you foresee your product (or certain components of it) being manufactured via 3D printing in the future? If so, what’s the primary development that will need to take place in order for this to happen? If not, what’s the main obstacle (i.e. materials, time required for 3D printing, tolerances, etc.)?
A: As a matter of fact we already use 3D-printing in order to speed up the development of new products and to some extent to realize prototypes. Unfortunately the 3D-print materials still have huge deficiencies in the robustness of the material especially when it comes to temperature, shock and vibration. If the quality of the material improves we will certainly consider 3D-printing as an option for smaller production series.
Q: How do you foresee Big Data changing the way you do business?
A: For us big-data goes hand in hand with Industry 4.0 and of course it requires that our sensors generate much more information and it requires that we transfer this information to different cloud solutions. Therefore new interfaces such as OPC-UA have already become a topic for us, and we are now starting to implement this into our industrial Ethernet encoders. We see here the focus on diagnostics and maintenance solutions.
December 2016
12/1/16 3:09 PM
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» Design for Industry
energy
Ac drives help reduce energy costs
The more efficient a drive, the lower the energy costs. The AllenBradley PowerFlex 755T drives offer harmonic mitigation, regeneration and common bus system configurations. The latest versions include TotalFORCE technology, which enhances motor control through precise, adaptive control of velocity, torque and position of electric motors. “AC drive technology is an important investment for our customers, and they want their application up and running every possible minute,” said Brad Arenz, product manager, Rockwell Automation. “The PowerFlex 755T drives have been designed to provide savings from installation, through operation and maintenance with advanced features that allow you to optimize use of your assets.” This line of drives includes: PowerFlex 755TL drive, which uses active, front-end technology and an internal harmonic filter to reduce harmonic distortion. The drive is available from 250 to 1,800 Hp (160 to 1250 kW). PowerFlex 755TR drive, which delivers power from 250 to 3,000 Hp (130 to 2,300 kW). It includes regenerative and harmonic mitigation solutions. The drive helps reduce energy consumption and costs by delivering energy back to the incoming supply, resulting in a more energy-efficient solution.
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PowerFlex 755TM drive system, which lets users build the system that best fits their needs for regeneration and coordination of multiple motors in common bus configurations. To optimize their system requirements and meet power-consumption needs, users can select from a series of predesigned modules with a power range from 250 to 3,000 Hp (130 to 2,300 kW). The three drive solutions have predictive diagnostics to estimate and provide notification of the remaining life span of drive components, such as fans, relay contacts, power semiconductors and capacitors. Users can actively monitor parameters, such as temperature and runtime, of the drive and motor to allow for preventive action if necessary. Key to simplified installation and maintenance is a design that allows complete removal of a module from the cabinet. This creates ample space for wire installation and allows the power wiring to stay connected while the module is rolled out. The drives can be fully configured in the Rockwell Software Studio 5000 design environment. This helps to reduce programming time, simplify startup and streamline diagnostics. DW Rockwell Automation Rockwellautomation.com
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12/2/16 11:51 AM
machine tool/aerospace/military
food/beverage
» Design for Industry
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A safe approach to food and beverage lubrication Jim Girard • VP/CMO, LUBRIPLATE Lubricants Co.
This chart displays the sections in the FDA’s Title 21 and presents brief descriptions of some of the more popular ingredients used by lubricant manufacturers to produce their food grade lubricants.
Technological advances in H-1/food grade lubricants mean that food, beverage and pharmaceutical processors should not hesitate to convert to a 100% H-1/food grade lubrication program. Converting to such a program helps consolidate lubricant choices, reduces lubricant misapplication, and helps to ensure a safe product for the consumer. Food grade lubricants were first introduced and used in the United States market since the early 1960s. Since their initial development, there have been technological advances with research, development, introduction and use of food grade lubricants. Title 21 of the FDA’s Code of Federal Regulations (CFO) presents many sections on authorized ingredients that may be used to produce food grade lubricants. The Food Safety and Inspection Service (FSIS) of the United States Department of Agriculture (USDA) monitors and authorizes
lubricants that could be used on machinery that may have incidental contact with food. This is known as the USDA/FSIS “Prior Approval Program for Non-food Compounds and Proprietary Substances.” The lubricants’ industry authorization and monitoring program changed drastically in 1998 when the USDA/FSIS eliminated its “Prior Approval Program” and “White Book” authorization program for non-food compounds. The question was, should the lubricants industry engage in self-monitoring for H-1/food grade lubricants, or would a thirdparty professional monitoring organization step forward and adopt a food grade lubricants’ monitoring program? The National Sanitation Foundation (NSF,) based in Ann Arbor, Michigan, stepped forward and produced an industry authorization and monitoring program, which closely mirrored the former USDA/FSIS program. The worldwide lubricants industry quickly committed to
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the NSF’s program, and today, the NSF is the leader in authorizing and monitoring H-1/food grade lubricants for all lubricants manufacturers. NSF H-1 authorized food grade lubricants are posted on the NSF’s website. The International Standard Organization (ISO) also developed the ISO-21469 certification and registration process for lubricants used in specialized industries such as food, pharmaceuticals, cosmetics, animal feed manufacturing. This is a very stringent standard and registration process in which lubricants manufacturers must first be registered and maintain the ISO9001 Quality Management standard, which demonstrates the commitment to an overall Quality Management System. Finally, H-1/food grade lubricants also are part of Hazard Analysis Critical Control Point Programs (HACCP). In the United States, the FDA and the USDA demand that food
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food/beverage
The National Sanitation Foundation (NSF,) produced an industry authorization and monitoring program, which closely mirrored the former USDA/FSIS program. The NSF is the leader in authorizing and monitoring H-1/food grade lubricants for all lubricants manufacturers.
and beverage processors develop HACCP programs in which lubricants may be considered as potential chemical hazards. However, if food and beverage processors switch to 100% H-1/food grade lubrication programs, then lubricants are not considered potential chemical hazards and an HAACP plan is not necessary for a 100% H-1/food grade lubrication program. Lubrication suppliers should be aware of all industry standards that affect H-1/food grade lubricants. Food grade lubricants packaging and literature should clearly define the product and relate to all of these industry standards. Consumers must watch for unscrupulous and confusing claims on packaging and in product literature. H-1/food grade lubricants have not been immune to high technology. In the 1960s there were not many fluid base stocks, additives or grease thickeners available listed in the FDA’s Title 21 CFR sections. This resulted in poor performance of H-1/food grade lubricants. However, technological has changed the availability of H-1/ food grade lubricants. In 2014, H-1/food grade lubricants can accommodate every application on machinery in food, beverage and pharmaceutical processing facilities from refrigeration
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12/2/16 11:53 AM
POWER TRANSMISSION
RETAINING DEVICES & maintenance & assembly tools
compressors, to freezer conveyor chains, to gear boxes to filling, seaming and closing equipment. For example, in the early 1960s, it was impossible to find an H-1/food grade grease that delivered both anti-wear and extreme pressure protection. Today, calcium sulphonate thickened greases made with USP white mineral oils and synthetic polyalphaolefin (PAO) base stocks are truly anti-wear and extreme pressure lubricants. Lubricant manufacturers have been able to add anti-microbial additive to their products. Anti-microbial additives help prevent the decomposition of lubricants caused by microorganisms. Many antimicrobial additives are registered with the EPA. The use of synthetic polyalkylene glycol (PAG) base stocks to manufacture H-1/food grade gear oils has produced H-1/food grade gears oils, which deliver extended drain intervals and long anti-wear and extreme pressure protection. Gear reducer original equipment manufacturers (OEMs) now have no fear in recommended H-1/food grade synthetic PAG-based gear oils. Synthetic polyol ester (POE) food grade fluid technology delivers optimum lubrication protection for high heat oven chains in bakeries. POEs have unmatched oxidation stability that nearly eliminates carbon deposits and keeps the chains clean. Silicones and PTFE are also used effectively as H-1/food grade lubricants. Synthetic H-1/food grade technology also helps to consolidate the amount of lubricants required. For example, synthetic PAOs work effectively in both air compressors and hydraulic systems. It is possible to use the same ISO-46 fluid for both air compressors and hydraulic systems. All of these technological advances in H-1/food grade lubricants mean that food, beverage and pharmaceutical processors should not hesitate to convert to a 100% H-1/food grade lubrication program. Converting to 100% H-1/food grade program delivers money-saving lubricants consolidation, a reduction in lubricants misapplication, sustainability and helps to ensure a safe product for the ultimate consumer. DW
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Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALLUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS
HARDENED TONGUE WASHERS
SPLIT COLLAR
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ADJUSTABLE SPANNER WRENCH
BEARING ASSEMBLY SOCKET
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HI
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LUBRIPLATE Lubricants Co. lubriplate.com
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WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.
WHAT DO YOU THINK?
Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.
Connect and discuss this and other design engineering issues with thousands of professionals online
33 Higginson Avenue, Central Falls, Rhode Island 02863 Telephone: (401) 728-0700 • FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com December 2016
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» Design for Industry
medical
Printer marks medical instruments for better tracking
Tube bending
perfection in stainless Eagle has the expertise and the specialized machinery for bending tubing exactly to spec. Call us for a quote !
Eagle Stainless
Tube & Fabrication, Inc. Franklin, Massachusetts
The METAZA MPX-95 is a photo impact printer. With its diamond stylus it can add custom text, data and images with photographic detail onto a variety of hard metals, such as stainless steel, iron, titanium and platinum, as well as softer substrates like gold, silver, copper, nickel, aluminum and acrylic – quickly and with pinpoint accuracy. One application is medical and industrial part marking. Within healthcare environments, the MPX-95 can serve as a UDI (Unique Device Identification) barcode impact printer. It allows the user to easily imprint individual instruments with a serial number, 3D symbol or other marking to better manage the stock availability, location, usage history and maintenance records of those instruments. A DPM (Direct Part Marking) Kit enhances the impact printer’s specialized capabilities. The DPM kit consists of software that generates unique identifiers for each instrument, as well as a gripping vise, a moveable center vise and clamp pins. Both vises allow the position of the item to be fine-tuned by aligning it with the laser pointer after it has been clamped. The MPX-95 has a removable base table and plate, allowing it to work with a greater range of items, including larger objects. Bundled METAZA Studio software lets users import, edit and process images and text out of the box. A laser pointer assists in identifying the area to be marked, enabling users to imprint items easily and precisely without any special training. DW Roland DGA Rolanddga.com
Phone (800) 528-8650
www.eagletube.com DFI 12-16_Vs.3.LL.indd 36
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12/2/16 11:56 AM
m e d i c a l » Design for Industry
4
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Kit for touchless gesture controls IS
a development platform that helps engineers develop control solutions with gesture controls enhanced by tactile feedback sensations. The UHDK5 TOUCH Development Kit includes hardware and software that can be embedded in product designsbfrom prototypes through to volume production. Ultrahaptics uses ultrasound to provide a unique touch sensation, enabling users to ‘feel’ virtual buttons, switches, dials and other objects in mid-air. Touchless controls are hygienic for use in medical, industrial and domestic environments, while their use for automotive dashboard functions enhances safety, allowing drivers to keep their eyes on the road. The disruptive nature of gesture control with haptic feedback, providing two-way communication with devices, also opens up possibilities in consumer electronics, computing and gaming applications. The self-contained plug-and-play UHDK5 TOUCH development kit works out of the box and can be up and running in a few minutes to provide demonstrations that require no technical knowledge from the user. For developers, the embeddable architecture (using an ARM Core plus FPGA) eases integration and provides a production ready design that minimizes BOM cost. Similarly the provision of APIs, coded using the widely adopted C++ programming language, allows software engineers to easily adapt their application interfaces with custom sensations. DW
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ISO 13485
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91
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Ultrahaptics, specialist in mid-air touchless haptic technology, introduced
0 90
Laser machining
perfection in stainless Eagle has the skills and the technology required to produce all of your custom exotic metal parts. Let us help !
Ultrahaptics ultrahaptics.com
Eagle Stainless
Tube & Fabrication, Inc. Franklin, Massachusetts
Phone (800) 528-8650
December 2016
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www.eagletube.com 12/2/16 11:57 AM
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machine tool
» Design for Industry
Hollow shaft rotary encoders The rotary encoder series ECI 4000/EBI 4000 is a modular device without integral bearing and with a 90 mm hollow shaft. It enables the user to replace the conventional toothed-belt drive for coupling a motor feedback system to torque motors. With fewer components, these rotary encoders provide wear-free operation. They open up new applications for inductive rotary encoders, for example, on highly dynamic motors, drive modules and machine components that require a corresponding hollow shaft in the encoder. The singleturn version of the ECI 4000 features resolution of 20 bits. As an alternative, the EBI 4000 offers a multiturn variant with a revolution counter option with resolution of 16 bits and that is backed up by an external battery buffer. The inductive rotary encoders consist of a scanning unit and the scale drum. The scanning is performed all-round. In this setup, the complete graduation structure of the scale drum (rotor) with the associated scanning band of the scanning unit (stator) is involved in obtaining the position signal. In this way, the rotary encoder evaluates two incremental scanning tracks of differing periodicity. This scanning principle has a positive effect on the mounting tolerances and the positioning accuracy. Additionally, over the entire velocity range up to 6000 rpm, it largely compensates position error arising from a rotational center offset of the measured shaft. The inductive rotary encoders ECI 4000 and EBI 4000 are equipped with the digital EnDat 2.2 interface. Certification for SIL 2 applications in compliance with EN 61508 is planned for the encoders. By employing additional measures in the subsequent electronics, users can raise the security level of the EnDat 2.2 devices to SIL 3. The relevant fault exclusion criteria for a safe mechanical connection are of course part of the certification. The encoders are designed for easy installation and integration into the applications of motors and machines. Among other things, they fulfill protection class of IP40 for this. Thanks to an external and an internal centering diameter on the scanning unit and scale drum respectively, they can be mounted quickly without any special tools for adjusting and testing and immediately put into operation. An application-specific axial offset of the scale drum to the scanning unit is tolerated in a range of ±1.5 mm. The maximum drive shaft runout tolerance is 0.2 mm. The operating temperature range for encoders with EnDat 2.2 interface is up to +115°C. Vibration resistance is 400 m/s² for the stator and 600 m/s² for the rotor in accordance with EN 60068-2-6. DW HEIDENHAIN Corp. heidenhain.us
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12/5/16 10:49 AM
Power Review
Altra Industrial Motion Vol. 5 | No. 4 | 2016
The Power Brands in Power Transmission
Featured in this Edition... Twiflex Introduces New Turning, Locking & Braking System
Advanced Braking Solutions For Industrial Applications
Nuttall Moduline® Inline Speed Reducers Orderto-Delivery in 3 Weeks! Altra Launches Webinar Series Inertia Dynamics Introduces New Website and Product Catalog Boston Gear Reducer Express Deliveries Formsprag Products for Aerospace Applications TB Wood’s Form-Flex® Floating Shafts Svendborg BSFA 1000 Series Braking Systems
Find Altra Industrial Motion on:
Altra Industrial Motion Ameridrives Couplings
The Power Of Experience
Bibby Turboflex
Delroyd Worm Gear Formsprag Clutch Guardian Couplings Huco Dynatork Industrial Clutch
Kilian Manufacturing Lamiflex Couplings Marland Clutch Matrix International Nuttall Gear
Svendborg Brakes TB Wood’s Twiflex Limited Warner Electric Warner Linear
Boston Gear
Inertia Dynamics
Stieber Clutch
Wichita Clutch
Ameridrives Power Transmission Bauer Gear Motor
Altra Industrial_#1_12-16.indd 39
For more information contact us at: info@altramotion.com or visit www.altramotion.com
Scan to download the interactive version of the Power Review
12/1/16 3:46 PM
Twiflex Introduces New Turning, Locking & Braking System The Twiflex system comprises a Turning gear, Locking device, and shaft Brake (TLB) together with a power unit (e.g. Hydraulic Powerpack) and a control panel for local operation of the system close to the equipment. TLB is available as a continuous turning option as shown or as an indexing system using a simple hydraulic ‘push-pull’ arrangement with the brakes and brake disc to inch the propeller shaft for maintenance and accurate alignment. For a more cost effective solution, a simple manual option is also available for this purpose. Benefits of a Complete Integrated System When purchasing a complete turning gear system integrated with locking and braking from Altra, customers can consolidate 3 separate interfaces into one multi-functional solution: Turning ‘T’, Locking ‘L’, and Braking ‘B’, which enables customers to save dimensional space, decrease installation and maintenance time and reduce costs! A Superior Solution From A Single Source. Download P-8052-C from www.AltraLiterature.com
Scan to watch Twiflex TLB video
Nuttall Gear Moduline® Inline Speed Reducers Order-to-Delivery in 3 Weeks! Moduline® Reducers Order-to-Delivery in 3 Weeks!* Moduline Type R concentric shaft speed reducers utilize a modular concept to deliver standard units and ratios in just three (3) weeks.* Choose from eight (8) standard reducer sizes and readily available drives to accommodate output torque requirements up to 90,000 in-lbs. Nuttall’s New Delivery Commitment Standard Units and Ratios can be ordered for delivery in 3 weeks!* 8 Standard Type R Inline Gear Reducer Catalog Sizes: 10–21–32–43–54–64–76–88 Most spare parts are in inventory for same week delivery Output Torque Ratings at 1750 RPM input: 2,500 in-lbs to 90,000 in-lbs For more information, download the Moduline Inline Speed Reducers brochure. * Reducer only. Motor, accessories and modifications will affect lead time.
For more information download P-8103-ND & P-8104-ND from www.AltraLiterature.com
Altra Launches Webinar Series Altra Industrial Motion announces a new webinar series that will highlight product and service solutions for various applications relating to a variety of Altra brands. The Altra Webinar Series is open to the public and will be held on the first Wednesday of each month at 10 AM (CST). Topics will include product solutions, proper product selection, installation and service. Because the Altra Webinars are public events, they will be posted to the websites for access. For more information, please contact altra-webinar@altramotion.com For OnDemand information, download P-8121-5-C from www.AltraMarcom.com
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Inertia Dynamics Introduces New Website and Product Catalog Inertia Dynamics has recently launched an updated website and product catalog. The website enhancements include a Featured Content Slider on the Home Page to highlight the newest brand information, and a News & Press area that links direct to the Altra Newsroom for quick access to the most recent news. The website also features a new responsive design, so the site is easily viewed on various types of electronic devices. The newly expanded Inertia Dynamics Electric Clutches & Brakes catalog features the full line of Electromagnetic Power-On Clutches and Brakes, as well as Spring Applied Brakes, Motor Brakes, Controls and Moment of Inertia Measuring Equipment. The same updated product information is included on the new website as well. New metric offerings and dimensional information has been added for Inertia Dynamics Power-On Brakes and Spring Set Brakes. Ordering information has been updated and simplified in the revised catalog, along with the Part Numbering System and the 4-Step Selection Process. For more information, download P-7874-IDI from www.AltraLiterature.com and visit www.idicb.com
Boston Gear Reducer Express Deliveries The Reducer Express Program • Phone, fax or e-mail your purchase order by 2:00 PM Eastern time with a purchase order clearly marked with “Reducer Express”. • Contact our team of customer service representatives to confirm the part number eligibility. • Our production team will build and ship your Reducer Express order same day. Orders received after 2:00 PM Eastern time will be shipped the following business day. Shipments are guaranteed on time or the freight cost is free! For more information download P-8119-BG from www.AltraLiterature.com
TB Wood’s Form-Flex® Floating Shafts
Formsprag Products for Aerospace Applications Formsprag Clutch sprag retainer assemblies and bi-directional clutches and backstops are used on fixed and rotary wing aircraft flight controls, actuators, positioners, and APU and engine starters, as well as on a variety of onboard material handling actuation and holding systems including davits, hoists, and lifts. Formsprag clutches and backstops can also be found on marine vessel main propulsion layouts and auxiliary power generation systems, land based vehicles and systems, and satellites and space applications. For more information relating to aerospace and defense products, please contact Formsprag directly by phone 586.758.5000.
Svendborg BSFA 1000 Series Braking Systems
TB Wood’s supplied a custom coupling to a major OEM that was modified with limited end float features to keep the sleeve bearing motor rotor from being damaged. The large 21.5 ft. long coupling is being used for an operating speed of 600 RPM, but the first critical speed is much higher due to the oversized tube diameter (24 in.) to meet the torsional requirements of the fan drive system.
Svendborg Brakes recently supplied complete braking systems for 6 new ball mills that are part of a major expansion at an open-pit copper/molybdenum mine. Each mill is 9.5 m (27 ft.) in diameter and equipped with a 22 MW gearless drive. The new mills will increase the mine’s concentrator output to 360,000 tonnes/day, making it one of the largest copper mines in the world.
The Form-Flex floating shaft has a continuous torque capacity of 1,100,000 lb.in. with a peak torque rating of 2,400,000 lb.in. The robust coupling design features an alloy steel motor hub with provisions for hydraulic removal, carbon steel flange adapter, welded steel spacer, high-strength alloy steel hardware and stainless steel disc packs.
The braking systems for each ball mill consist of BSFA 1000 Series mono-spring caliper disc brakes that provide a minimum of 18,103,932 Nm braking torque per mill. Each system is controlled by a Svendborg gearless mill hydraulic power unit (HPU).
For more information download P-8096-TBW from www.AltraLiterature.com
For more information download P-8109-SV from www.AltraLiterature.com
{
Bauer Gear Motor www.bauergears.com
Boston Gear www.bostongear.com
Warner Electric www.warnerelectric.com
WE'RE COMMITTED TO THE
FOOD & BEVERAGE MARKET The industry-leading global brands of Altra Industrial Motion provide precision engineered power transmission components to meet the most demanding washdown requirements for all types of food processing and beverage applications. Altra offers a full range of drivetrain solutions including clutches & brakes, speed reducers, air motors, gear motors, overload clutches, torquelimiting devices, belted and synchronous drives, stainless steel mounted bearings, shaft couplings & universal joints, capping headsets and precision bearings.
www.AltraMotion.com
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semiconductor
» Design for Industry
6
0
High current ICs This family of fully integrated current sensor linear ICs in a core-less package senses ac and dc currents up to 100 A. ACS780/ACS781 are provided in an automotive-grade, low-profile (1.5 mm thick) sensor IC package. This package has a small footprint and delivers high power density for current sensing applications. The Hall sensor technology also incorporates common-mode field rejection to optimize performance in the presence of interfering magnetic fields generated by nearby current-carrying conductors. The devices consist of a precision, low-offset linear Hall circuit with a copper conduction path located near the die. Applied current flowing through this copper conduction path generates a magnetic field which the Hall IC converts into a proportional voltage. Device accuracy is optimized through the close proximity of the primary conductor to the Hall transducer and factory programming of the sensitivity and zeroampere output voltage. Chopper-stabilized signal path and digital temperature compensation technology also contribute to the stability of the devices across the operating temperature range. High-level immunity to current conductor dV/dt and stray electric fields is offered through proprietary integrated shield technology, for low-output voltage ripple and low-offset drift in high-side, high-voltage applications. The output of the device has a positive slope (>VCC / 2) when an increasing current flows through the primary copper conduction path (from terminal 8 to terminal 9), which is the path used for current sampling. The internal resistance of this conductive path is 200 μΩ typical, providing low power loss. The thickness of the copper conductor allows protects the devices at high overcurrent conditions. The terminals of the conductive path are electrically isolated from the signal leads (pins 1 through 7, and 10), allowing the device to operate safely with voltages up to 100 V peak on the primary conductor. The devices are fully calibrated prior to shipment from the factory. The ACS780xLR family is lead (Pb) free. All leads are plated with 100% matte tin, and there is no Pb inside the package. DW Allegro MicroSystems, LLC allegromicro.com
December 2016
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maxon product range
The solution is always a matter of the right combination.
If versatility and intelligent drive solutions are called for, the maxon product range provides the answer: A wide range of brushed and brushless DC motors up to 500 watts complemented by gearheads, sensors, brakes, positioning controllers and accessories offer a consistent modular system to realize whatever you have in mind.
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maxon motor is the world’s leading supplier of high-precision drives and systems of up to 500 watts power output. maxon motor stands for customer specific solutions, high quality, innovation, competitive prices and a worldwide distribution network. See what we can do for you: www.maxonmotorusa.com
12/1/16 3:50 PM
semiconductor
» Design for Industry
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Switches have more channel density and extended speeds The RF-MEMS is, according to the company, a breakthrough in switch technology that provides a long-sought replacement for electromechanical relay designs first adopted by the electronics industry more than 100 years ago. This switch technology enables faster, smaller, lower power, more reliable instrumentation equipment by resolving multiple performance limitations commonly attributed to relays. With the commercial release of products enabled by this technology, original equipment manufacturers (OEMs) can significantly improve the accuracy and
versatility of automatic test equipment (ATE) and other instrumentation tools to help their customers reduce testing costs, power and time to market. The ADGM1304 and ADGM1004 MEMS switches have precision and RF performance from 0 Hz (dc) to 14 GHz. Each switch contains two die – an electrostatically actuated switch in a hermetically sealed silicon cap, and a low-voltage, low-current driver IC. The switching element has a highly conditioned, reliable metal-to-metal contact that is actuated with an electrostatic force generated by the companion driver IC.
The ADGM1304 and ADGM1004 increase cold-switching lifetime by a factor of 10 compared. Additionally, the small height of the switch packages suits surfacemounting needs. An integrated charge pump removes the need for external drivers, further reducing ATE system size, while a multiplexer configuration simplifies the fan-out structure compared to DPDT relay designs. DW Analog Devices Analog.com
Where prototype meets final product.
When you use a CPC connector, you’re connecting more than fluids. Your vision becomes reality. That’s our commitment to every customer. From custom designs to over 10,000+ existing solutions, we work tirelessly to find the right connection for your application. That’s fluid thinking. Visit cpcworldwide.com/customs to connect to a problem solver today.
©2016 Colder Products Company
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High Speed PCB Adapters SIM High Speed PCB Adapters Bring More Versatility to the SIM Product Line Following the success of VPC’s VTAC High Speed Data (HSD) contact, our engineering team developed a new right angle PCB configuration that is capable of providing transfer speeds of 10+ Gbps and compatible with VTAC HSD patchcords and SIM modules. While broadband speeds are integral to projects that require large data acquisition, VTAC Right Angle contacts provide the signal integrity to keep up with those speeds. The contacts are uniquely situated in four differential pairs that isolate signals to reduce signal cross talk and preserve signal integrity when transmitting at high data rates. When signal transmission is faulty, speed is irrelevant.
Features and Benefits • 10+ Gbps per differential pair • Signal/Ground arrangement reduces cross talk • Signal routing ensures 100 Ohms of impedance
For more information, please visit our website
vpc.com/DW1
To ensure the best signal performance, our engineers also focused their efforts on matching impedance. The right angle insert uses a precision tuned signal routing to ensure that each differential pair has 100 Ohms of impedance, guaranteeing compatibility with other connectors of the same impedance. Since our team focused on quality over speed, future engineers can expect to use VTAC in their projects without fear of signal degradation.
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Inter
A supplement of Design World • December 2016
2016
Cable & Connector
Reference Guide
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BIOMETRIC SCAN IN PROCESS... B I O M E Tr i c d e c r y p t i o n i n p r o c c e s s . . . Analyzing key points... Checking... AES - 256 BIT ENCRYPTION BEgining... CHECKING USERS ACCESS rights... FINALIZING
You are
YOUR own
KEY
BIOMETRIC SCAN SUCCESSUL ACCESS GRANTED
mpd devices can be found in biometric devices around the world
MPD m e m o ry p r o t e c t i o n d e v i c e s
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M P D i s a g lo b a l m o t h e r e l e c t r o n ic c o m p o n e nt s s h o u l i s w h y w e a r e a lw
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a n u fac t u r e r o f b at t e ry h o l d c o m p o n e nt s . W e b e l i e v e t h at d f i t e a s i ly i nto y o u r d e s i g ay s c r e at i n g i n n o vat i v e n e w
e r s a n d o u r n s , w h ic h p r o d uc t s .
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Sorting out USB Connectors The variety of connection styles available for the USB standard can be confusing. But the recent release of USB 3.1 will likely speed the phase-out of some older versions and help simplify the specification of cables and connectors involved in the charging of peripherals.
Leland Teschler • Executive Editor
Engineers designing with the widely used USB standard can be excused for being a bit befuddled about nomenclature. One reason: The recently released USB 3.0 is now officially called USB 3.1 Gen 1; USB 3.1 is called USB 3.1 Gen 2. Another complicating factor is that there are about 12 different connector styles available for handling USB signals. The recent development of USB 3.0 and 3.1 standards is expected to make several of these obsolete. But until obsolescence comes, designers must be able to differentiate one USB style from another. First a few basics about connection speed: USB connections in the 1990s provided two speeds, 12 and 1.5 Mbps. The USB 2.0 specification in 2000 provided a third transfer rate of 480 Mbps. The USB 3.0 standard released a few years ago moved data rates up to 450 MB/sec while retaining backward compatibility with USB 2.0. The current version of the standard, USB 3.1,
USB type 3 connectors and sockets such as these examples from CUI Inc. support data rates up to 5 Gbps. Offered in jack or plug connector types with horizontal or vertical orientations depending on the model, the USB line spans mounting styles that include surface mount, cable mount, mid mount SMT and through hole. All models carry a voltage rating of 30 Vac, current ratings of 1 or 1.8 A and reliability as high as 10,000 mating cycles for specific models. The USB connectors also operate over -25 to 85°C and have RoHS compliance. 50
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USB Type-C connector pin assignments A1
A2
A3 A4 A5 A6
A7 A8 A9 A10 A11 A12
GND
TX1 +
TX1 -
+ V
CC1
D+
D-
SBU1
+ V
RX2 -
RX2 +
GND
GND
RX1 +
RX1 -
+ V
SBU2
D-
D+
CC2
+ V
TX2 -
TX2 +
GND
B3 B2
B1
B12 B11 B10 B9 B8 B7 B6 B5
B4
USB 3.1 super-speed+ 10 Gbps
Secondary bus
USB 2.0 high-speed 480 Mbps
USB power delivery communication
A noteworthy point about the USB type C spec is that the connectors are reversible; flip one upside down and it will still fit in a type C socket and function just fine. One reason is that the pin assignments are symmetrical, a fact that becomes evident by examining the pin assignments on a type C connector.
extends the performance range to 1 GB/ sec. Another point to note about speed is that USB 3.0 ushered in “SuperSpeed” 5 Gbps, and the USB 3.1 maximum rate of 10 Gbps is called “SuperSpeedPlus.” USB 3.1 peripherals share bandwidth through a protocol that lets peripherals be attached, configured, used, and detached while the host and other peripherals are in operation. USB 3.1 also provides backward compatibility with USB 2.0 by means of a dual-bus architecture: One bus is a USB 2.0 bus while the other is an Enhanced SuperSpeed bus. The USB 3.1 spec uses the term Enhanced SuperSpeed as a generic adjective referring to any valid collection of USB features that were defined for the
bus that runs in parallel to the USB 2.0 bus in a USB 3.1 system. One reason USB 3.0 is becoming widely used is its capability for handling power. The 3.0 spec boosted handling power because USB 2.0’s limit of 500 mA at 5 V had become problematic for charging small electronics. Now USB 3.0 can provide 900 mA at 5V while USB 3.1 delivers more when paired with a TypeC cable, capable of delivering 5 A at 20 V. This power handling ability has led to the use of USB 3.0 connections in several new schemes. For example, one called Quick Charge is expected to make heavy use of USB Type C connectors. Developed by Qualcomm, it aims to charge batteries in a way that is more
USB Generation
USB 2.0
(HI-SPEED)
energy efficient than ordinary tricklecharge setups. Several suppliers provide USB connectors. “It is difficult for suppliers of USB connectors to differentiate themselves,” says CUI Inc. director of product management David Carroll. “One way we compete is by providing a broader range of mounting options, including a waterproof version we have in the works.” However, one differentiating feature that USB specifiers should indeed watch out for are connector markings that indicate certification, says Carroll. Set up by the USB Implementers Forum, a compliance program uses a test regime at third-party testing organizations that is designed to signify a certain level
USB 3.0 (SUPERSPEED)
Backward Compatible USB 1.1 USB 1.1/2.0 Max. Transfer Rate Charging Power First Available
(SUPERSPEED+) USB 1.1/2.0/3.0
480Mb/s
4.8Gb/s
10G/s
100 mA
900 mA
900 mA
2001
2009
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USB 3.1
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USB connector styles
USB 2.0A
USB 3.0A
USB 3.0 micro-B
USB 3.0B
There are several styles of USB connectors. A look at the pin outs of some of the most widely used versions help differentiate one from another.
of quality. Only products that pass have the right to license the USB-IF Logo.
Cables and connectors Of course, the most visible difference between USB 2.0 and 3.0 is in the cable and connectors. USB Type-C connector and cable is reversible (the connector has no “up” side) and the cable is reversible (either end can plug into any device). The spec also provides more internal wiring than USB 3.1 strictly needs, allowing it to work with other standards such as DisplayPort. Nevertheless, experts say for the most part, USB 2.0 devices will work on USB 3.0 hardware, and most USB 3 devices will work on USB 2.0 hardware. All USB 3.0 ports include the necessary pins and logic to process USB 2.0 signals, except perhaps for those using USB 3 connectors that are physically incompatible with their 2.0 counterparts. These include USB 3 Type-B, USB Type-C, and USB 3 Micro-B. The power options on USB 3.0 are more flexible. Of course, USB 2.0 peripherals could draw power from the host port and function without an external power supply. USB 3.0 includes something called the Powered B (or PoweredUSB) connector. It incorporates the standard USB comm signals plus two additional wire pairs for extra power. The Powered B male plug is only available hard-wired to devices that specifically support it. 52
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Standard USB B devices can connect to USB 2.0 hosts through a USB 2.0 A-to-B cable, which is compatible with USB 3.0 B ports. PoweredUSB devices, though, have a non-removable, hardwired cable. Thus there is no chance of running a PoweredUSB via a USB 2.0 cable, nor any risk of plugging a Powered USB B device into a USB 2.0 port.
USB nomenclature There are 12 types of USB connectors now in use. Some of these formats are expected to fall into disuse because Type C devices are better alternatives. USB Type-A Is the classic USB connector that is essentially the same as when introduced in 1995. The A-socket connector provides a “downstream” connection intended for use solely on host controllers and hubs. It was not intended to be an “upstream” connector on a peripheral device. Though not that common, A-A cables are used to connect USB devices with an A-style female port to a PC or another USB device, and for data transfer between two computer systems. To make matters a bit complicated, there is a second A-type connector called the USB 3.0 A-type. It is nothing at all like the original USB type A connector. Known as “SuperSpeed,” this connector has additional pins that are not found in the USB 2.0 and USB 1.1 AType. The USB 3.0 A-Type connector is designed for USB SuperSpeed applica-
tions; however, it will carry data from slower connections and is backwards compatible with USB 2.0 ports. USB 3.0 A connectors are often blue (Panton 300C) in color to distinguish them from previous versions. The USB 3 Type-B connector has a squarish shape and slightly beveled corners on its top. Like the A connector, it uses the friction of the connector body to stay in place. The B-socket is an “upstream” connector only used on peripheral devices. Because of this, most USB applications require an A-B cable. To add further confusion, there is a USB 3.0 B type connector that is different from the USB 3 Type B device. It uses an added area overhead the usual connector body to hold five new pins, a counterpart to the additional pins in the A connector. Unlike Type-A, this connector won’t work with USB 2.0 Type-B receptacles. This connector is designed to carry data and power in USB SuperSpeed applications. Cables with this connector won’t work with USB 2.0 or USB 1.1 devices. But USB 3.0 devices with this connection type can accept the older USB 2.0 and 1.1 cabling. The USB Type-C (or USB-C) connector format was introduced along with the USB 3.1 spec in late 2014. Predictions are that it will eventually replace all current USB connectors. It is orientation and direction-free, and enables both SuperSpeedPlus at 10 Gbps and power transfer up to 100 W.
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™
i-CLamPS
(I D C)
One-Way Series Two-Way Series
T-Series
• IDC (Insulation Displacement Connectors) • Easy to use • Quick and reliable connections • Tamper Proof • Designed to withstand shock and vibration • Housing made from durable Polycarbonate • Tin plated High Performance copper alloy contacts • For use with 10-22 AWG insulated wires • One Way Series for splicing several lines together • T Series for branching off acommon wire run • Two Way Series uniquely designed for pre-assembly to add fixtures or components to existing wiring
It’s what’s on the InsIde that counts ® E L E C T R O N I C S
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•
(718) 956-8900
C O R P.
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A USB-C cable can carry USB 3.1, USB 3.0, USB 2.0, and USB 1.1 signals. It also has built-in support for DisplayPort video and four-channel audio (speaker and microphone). There are several flavors of what are called micro and mini USB connectors. The Micro-USB A connector can be found on newer mobile devices such as cellphones, GPS units, PDAs and digital cameras. It still supports the high-speed transfer rate of 480 Mbps. The connection is distinguished by its white-colored receptacle and a fivepin design. Micro-USB A connectors also follow a spec called USB On-The-Go, often abbreviated USB OTG or OTG. First used in late 2001, it lets USB consumer devices such as digital audio players act as hosts, allowing the attachment of other USB devices such as USB flash drives, digital cameras, and so forth.
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Similar to the Micro USB A is the Micro USB B. It handles the same 480 Mbps and has five pins as well, but its receptacle is black. It also supports Onthe-Go features. Then there is the Micro-USB AB connector. This one is designed exclusively for USB On-The-Go devices. It can accept either a Micro-USB A or MicroUSB B cable connection. This interface is distinguished by its gray-colored receptacle and five-pin connection. This connector type only exists as a receptacle for On-The-Go devices and won’t be found on a cable. Finally, there are USB Mini connectors. The five-pin Mini-b is the most widely used style of Mini-b connector and the only one recognized by the USB standards body, USB-IF. This connector is about two-thirds the width of an A-style connector and works with USB On-The-Go.
There is also a four-pin version of the USB Mini. It is unofficial but can be found on digital cameras. It resembles the shape of a standard B-style connector with its beveled corners, but it is smaller. A similar unofficial connector is a version of the USB Mini-b made by Fuji. It mainly exists on Fuji digital cameras and has a flat rectangular shape that resembles an A style connector. References CUI Inc. cui.com USB Implementers Forum, Inc. usb.org
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INNOVATIVE CONNECTIVITY SOLUTIONS
C
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CM
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CY
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Rugged, sealed, circular connectors for high-performance applications in every industry Over 30,000 configurations Cable assembly solutions, including silicone
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S P R I N G - L O A D E D
C O N T A C T S
What are the benefits of spring-loaded contacts? Martin Houlroyd • Principal Engineer, Preci-Dip
Probably the fastest growing type of interconnect being used by engineers is the spring-loaded contact. Spring-loaded contacts (aka SLCs) are ideal for creating solderless interconnections between mating modules, such as a handheld instrument to docking station, instrument to recharger, stacking PCBs, etc. SLCs are ideal for new product design for the following reasons: 1. They’re forgiving to stackup tolerances and uneven mating surfaces. 2. They’re ideal for blind mating applications—the SLC only needs to mate to a gold-plated PCB land. 3. They’re extremely easy for engineers to use. Typically the words pogo and SLC are loosely interchanged by the engineering community. The common use of the phrase pogo is to describe a type of SLC with a hardened Beryllium Copper piston that is chisel, tulip, waffle, or pointed. These types of SLCs are used for piercing through dielectric surfaces (such as oxidation). These types of SLCs are traditionally used in Bed-of-Nails test beds, for high-cycling repetitive testing. The other type of SLC has radius tipped pistons. Some manufacturers use BeCu, others use brass. These types of SLCs are used in the docking station, recharging station, and stacking type applications. There are countless manufacturers who make SLCs. Here, you will find three uncommon styles and the advantages of each. 56
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Spring-loaded pins Image courtesy of Mill-Max Manufacturing
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binder
Best of binder
• • • •
HEC Outdoor Power NCC IP67 unplugged M12 X-Coded 10 GB M12 S- & T-Coded Power
www.binder-connector.us
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MEDICAL CONNECTOR AND CABLE SOLUTIONS
S P R I N G - LOA D E D CO N TAC T S
Spring-loaded pin models Image courtesy of Preci-Dip
Horizontal SMT SLC — Ideal for low-profile design; a good example is LED lighting strips, which are typically daisychained to increase length. Floating Pin SLC — This type of SLC is assembled into a molded cavity that permits vertical float, which will help it in applications upon uneven surfaces. This style SLC is ideal when used as an interposer between a top and bottom PCB when both PCBs will be mechanically clamped down together. This product achieves solderless interconnection.
LEMO offers a variety of connector solutions for medical device manufacturers:
Pin-in-Paste SLCs — With the evolution of SMT assembly, emerging is the concept of assembling traditional throughhole components now using high-speed SMT pick-andplace. Assembling a through-hole component onto a SMT board is called intrusive-reflow or pin-in-paste. Simply, there is a through hole on a SMT board and solder paste is screened along the annular ring of the land. The throughhole component is reflowed soldered from the top side, instead of a solder fillet to a tail on the bottom like traditional wave soldering. Pin-in-Paste SLCs feature a short stubby tail (typically less than 1.5 mm in length), a tail purposely intended not to protrude beneath the PCB. Since the Pin-inPaste SLC does have a tail, it naturally becomes much more mechanically strong than just a SMT SLC, and it has bulls-eye alignment, since the SLC cannot migrate on the PCB land during reflow.
• • • • •
Metal Connectors Plastic Connectors (PEEK or PSU) Single-Patient Use Connectors Hybrid and Custom Configurations Custom Wire & Cable Assembly Services • ISO 13485:2003 Certified LEMO will showcase the new HALO LED at MD&M! Visit booth #1955 February 7-9, 2017 Anaheim, CA
Preci-Dip precidip.com
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LEMO USA, Inc. 800-444-5366 info-us@lemo.com www.LEMO.com
REDEL is a LEMO Group Company
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specify twin-axial, high-speed I/O cabling? Ed Cady • Contributing Editor
diverse applications, there are many newly released raw cable products being used for several new generation I/O interface standard and custom cable assemblies. These cables are being used for both internal and external assemblies applications used within new consumer, enterprise infrastructure, commercial datacenter and very high performance computing systems. There are still challenges and issues for the manufacturers and users of these new products; for example, budgeting for very expensive test equipment for 56 Gbps per lane circuits and designing in the capability of handling 100-W power closely adjacent to sensitive high-speed digital signaling per interface specs like USB3.1 and the latest Power over Ethernet IEEE-802.3 specifications. 60
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Here are some suggestions a cable assembly developer might consider as part of the component engineering process. 1 Pick strong suppliers that can address any and all material, process, quality, performance and testing variations details. I/O Link assemblies should use raw cable from one reel because of slight but critical performance variations from one reel and to another.
Image courtesy of Hitachi Cable America
It is amazing that after five decades of copper twin-axial raw cable developments, shipments and
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SAB CABLES FOR AUTOMATION THE RIGHT SOLUTION FOR EVERY APPLICATION
Visit www.sabcable.com to download your copy of our Cables for Automation brochure or contact your sales representative today!
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344 Kaplan Drive Fairfield, NJ 07004 Phone: 866-722-2974 info@sabcable.com www.sabcable.com
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221 Series
COMPACT Splicing Connectors for All Wire Types 24-12 AWG
Request a free sample at: www.wago.us/221sample
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ping. The same is true for cable bundle shields and fillers. Bundle diameters and bend radius need to be designed relative to cable routing. Image courtesy of 3M
It’s all related to how tight the cable is reeled up and the difficulty of maintaining structural symmetry. Usually each reel of raw cable is individually measured, characterized and documented for use by the cable assembly supplier and traceability by the OEM or end-user. 2 Look for very pure copper conductor elements with very low oxygen content for optimized conductivity. Take note of conductor silver-plating smoothness and purity. This enables best electrical skin effect relative to signal launch path, insertion loss, jitter and reflection loss.
5 Be aware of the latest cable jacket regulatory testing and material constraints required by UL, Telcordia, TUV, NEC, IEC and ISO per application. Some customers require inline testing and histograms for raw cable and cable assemblies. 6 The most critical area to manage is wire termination to contacts or PCB pads for both signal and ground conductors and cable bundle shield termination. Learn and apply the best technologies for wire termination shaping, smoothness, welding or soldering processing. Some new cable product offerings with positive market feedback include: • TE’s new Silver internal flat twin-axial cable for cabled backplanes • Lorom’s new 56 Gbps twin-axial cable for external and internal I/O assemblies • 3M’s internal flat-foiled micro-twin- axial cable for cabled backplanes • Wireworld’s new Starlight Cat 8 ribbon twin-axial cable with Tite-Shield 3 layer shield for infrastructure applications
3 Ascertain tradeoffs and best criteria when selecting wire conductor gauge size versus electrical signaling reach. Look closely at dielectric material properties that will achieve needed signaling performance ranges. This may include evaluating air, solid and foam types. Look for process variation tolerance and control of bubble size, symmetry, density and distribution. 4 Twin-axial differential pair elements need to be layered within the bundle for optimized element fan out and prepping relative to termination zone. The pair shields, whether solid or wrapped, need to hold tight geometries when processing and wire termination prep-
Some other top raw cable suppliers with excellent product to keep track of are Hitachi Manchester, Molex TempFlex, Leoni, Prysmian and Microcoax Inc.
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Medical-Industrial Actual Micro-Coax cable bundle diameter compared to a penny.
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Actual catheter cable diameter compared to a penny.
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December 2016
When Size and Performance Matters
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Understanding the basics of
ampacity
for safe cable and wire designs Mary C. Gannon • Senior Editor
When selecting a cable, one must know its ampacity rating. This rating has been determined by the NEC (National Electrical Code), which lists ampacity ratings for real-life installation examples. Most cable manufacturers provide ampacity tables on their websites. The IEEE (Institute of Electrical and Electronics Engineers) also offers more than 3,000 ampacity tables for extruded dielectric power cables rated through 138 kV and laminar dielectric power cables rated through 500 kV. This rating is the maximum allowable current that a conductor, its jacket and insulation can carry without compromising safety at ambient temperatures. Each cable and its jacketing and insulation is rated for specific temperatures. As current moves through a conductor, heat is created. If the heat exceeds the cable’s rating, the cable could fail, even possibly catching fire. To avoid this damaging occurrence, heat must be dissipated outside the cable. If grouped, bundled or enclosed, the Amps running through a cable must be decreased to ensure heat dissipation. Choosing the right cable with the right ampacity isn’t as simple as looking at conductor size. When reviewing cable ampacity, consider the application and the environment. Depending upon the application and/or environment, a correction factor may need to be applied to obtain the correct, safe ampacity rating. A correction factor is a multiplier applied to the ampacity rating to adjust the value based on a specific condition. The multiplier may be less than, equal to, or greater than one. 64
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Image courtesy of TPC Wire & Cable
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A sample table showing allowable conductor ampacity. Image courtesy of Lapp Group.
• Number of conductors As more conductors are energized in a cable, more heat is generated. • Ambient temperature Therefore a correction factor is Ampacity tables in the National applied when a cable holds more Electrical Code list ampacity values than three current-carrying that are based on an ambient conductors. Ampacity values are temperature. Should the tempera- reduced to compensate for the ture of the application differ from added heat generated within the the referenced ambient temperature, conductors. a correction factor is applied to adjust the ampacity. As the application • Reeling applications temperature rises above ambient, the Cable on a reel with multiple layers ampacity value is reduced, and vice- of cable does not have the ability to versa. radiate heat away from the lower
Areas to review where correction factors apply include:
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layers. When multiple layers of cable are installed on an energized cable reel, you must apply correction factors to compensate for the inability of the cable to radiate heat away, or risk de-grading or damaging the cable.
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â&#x20AC;˘ Duty-cycle In certain applications, especially resistance welders, a correction factor based on the duty-cycle is applied to gain the correct ampacity value. In summary, the first step in applying correction factors in regards to the ampacity value of a cable is to define and understand the application, and to consult the standards or authority having jurisdiction (National Electrical Code, UL, CSA, ICEA, etc.). With this understanding, choosing the correct conductor size for your application can reduce the time and costs associated with unnecessary repairs or replacement of materials.
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» D e s i g n N o te s
Edited by: Lisa Eitel • Senior Editor
Smart motors make high-tech e-bikes Use of electric bikes or e-bikes — those with power-assist and full drive capabilities — is exploding in Europe and now the Americas as more people than ever look for green modes of transportation in dense urban centers and beyond. Recently introduced to the world market, maxon motor makes an integrated drive (sometimes called a hub motor) consisting of motor, gearbox, and controller designed to convert any bike into an e-bike. Electric bikes in the U.S. are becoming popular not only for commuters and sport riders, but hardcore offroad riders, too. “In ten years, there will be no more commercial mountain bikes without electric motors ... it’s going to be the next big thing,” said Gary Fisher, inventor of the mountain bike, at Eurobike 2015. Many manufacturers base their e-bike drives on inefficient motors that generate a lot of heat — even though they quickly drain the batteries. In contrast, maxon’s BIKEDRIVE is a permanent-magnet ironless-core design that outperforms other options on the market, particularly in terms of power density, acceleration, heat dissipation, and efficiency. The electric drive can deliver 500-W continuous (in U.S. versions) while operating at 85% efficiency and maintaining 75% continuous efficiency even when climbing uphill. The maxon BIKEDRIVE is a pedal-assist drive, so there’s no throttle. The drive adds additional torque (to 50 Nm peak or 25 to 30 Nm continuous) while the rider pedals. Power is electronically limited with speed held to 20 mph in the U.S. to comply with federal regulations for e-bikes. The maxon BIKEDRIVE also lets riders convert normal bikes into e-bikes. Here, the rear wheel motor is mounted to a DT Swiss Wheel and includes a battery, charger, cables, and a quick release or through-axle adapter for easy use. Control of the e-bike drive is simple and intuitive through a maxon Powergrip that lets the rider pick from four twist-click positions and fifth option to turn the drive off. Power Level 1 (10 Nm), 2 (20 Nm), and 3 (30 Nm) are continuous settings.
The max on electr ic BIKED accelerat RIVE es from 0 t o 2 0 mph in less th an three seconds. lets a 175-l It b cy
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maxon offers bl ack DT Swiss wheels in 700c and 26, 27.5, and 29-in . versions. The drive comes in installation widths of 135, 142 or 148 mm for conversion into an e-bike.
Power Level 4 (Turbo Boost) is to temporarily accelerate over demanding obstacles or zooming out of a corner with a throttle-like feeling. The Powergrip also has twin LED indicators to show remaining battery and motor temperature. Besides high-performance output, the way in which the maxon design is integrated makes for a physically balanced assembly.
In its BIKEDRIVE iteration, the hub is about 7 lb and the battery is about 6 lb. The whole 13-lb setup is balanced enough to let professional riders to jump their bikes. Many early-generation e-bikes in this style are unbalanced and heavy because of their lithium-ion batteries and motor style. Currently the BIKEDRIVE is the only system on the market that’s compatible with
the new 148-mm (Boost) hub standard and 12-speed SRAM Eagle Drivetrain. maxon is also working on even faster motors and new highercapacity batteries. The manufacturer makes the bike drive at its new maxon advanced robotics & systems ltd. (MARS) facility in Switzerland — including the controller, motor, gearbox, and encoder. The technology, already proven as a performance e-bike drive, will also be used for other applications. DW maxon precision motors maxonbikedrive.com
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Your Global Automation Partner
Edited by: Leslie Langnau • Managing Editor
» De sign Note s
Moving from 3D printing to thermoforming: when, why and how When a project is ready to move beyond 3D printing prototyping, you have a number of options for production, including thermoforming.
WARNING Not suitable for repairing crummy sensors (or your reputation).
A thermoform ing machine in op eration. Thermoforming can be the next step af ter a 3D printed prot otyping process.
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thermoformed,” said Brian Ray, president of Ray Products, Ontario, CA. “A skilled thermoformer will be able to help you easily make those adjustments.” Thermoforming is a plastic manufacturing process where a flat sheet of plastic is heated to be pliable. Then it’s pressed against a 3D mold. Thin gauge thermoforming is typically used for manufacturing disposable packaging for consumer goods, food and medical products. Heavy gauge thermoforming is used for durable, reusable products.
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There are two types of thermoforming: • In vacuum forming, the air is vacuumed out from below the mold. • In pressure forming, the air is both vacuumed from below the mold and pressed from above the mold to create more complex shapes and sharper details, similar to injection molded parts. www.designworldonline.com
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Once a part is formed and cooled, it’s trimmed—often by a robotic trimmer. Then, it can be painted, finished and assembled into a final product.
Thermoforming versus other processes Any time you move beyond 3D printing, you have many other processes to choose from. So what makes thermoforming an option for any particular project?
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• Size, quantity and cost Thermoforming suits medium-to-large sized production runs with larger parts. “When my grandfather was running the company, he used to say that thermoforming was great for anything ‘bigger than a bread box,’” said Ray. “Now we usually say, ‘bigger than a toaster oven.’” For anything larger than about 12 in. x 12 in., thermoforming often has lower setup costs than more common processes like injection molding. The larger you go, the more significant setup cost savings you get. “When you’re dealing with a part that’s about 4 ft x 4 ft, thermoforming tooling is going to be about 1/10th or less than the cost of injection molding tooling,” said Ray. When evaluating the size of a project, consider the cumulative size of all the parts in a multi-part assembly. Thermoforming allows several parts to be formed together on a single sheet of plastic, which are separated into individual parts during trimming. This can reduce cost and production times. 72
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Your Global Automation Partner
Quick facts about heavy gauge thermoforming • Best for 12 in. x 12 in. or larger parts • Comparatively low tooling costs • Best for quantities between 100–3,000 • Can be molded in color and texture or painted • Thousands of material options with features like fire resistance or antimicrobial properties
There are variables to every project, but if you’re making larger parts in quantities of between 100 and 3,000, there’s a good chance that thermoforming would be cost-effective. • Materials, finishing and recyclability Besides cost, the process has several advantages. Thermoforming produces a high-quality finish, and it can be molded in custom or off-the-shelf colors with custom textures. This means that thermoformed parts look good unpainted. Of course, they can be painted for specialty or multi-color finishes. Additionally, thermoforming offers thousands of options for starting materials with variables like thickness, opacity, color and specialty features, such as fire resistance or antimicrobial properties. Finally, thermoforming is one of the plastic manufacturing processes that’s 100% recyclable. The trimmings from manufacturing can be sent back to suppliers to be reused.
Making the move from 3D printing “Most often, what we see is a designer that’s made a few proof-of-concept 3D parts to turn their CAD models into something more
tangible,” said Ray. “We love that 3D printing gives us this option.” The process of adapting a 3D printed model into a thermoformed part begins with a conversation. Thermoformed materials generally have more rigidity than a 3D printed part, which allows a reduction in thickness and the elimination of many ribs and gussets. “If they’ve been using 3D printing to create 2-sided parts, that’s another thing we’ll need to look at,” said Ray. Thermoforming is a 1-sided process, so sometimes there are adjustments that need to be made to the overall design to accommodate that.
WARNING
Not suitable for repairing flimsy connectors (or your reputation).
Manufacturing times One of the biggest advantages of 3D printing is the elimination of tooling. As soon as your model’s ready, you hit “print,” and you’ve started production. Thermoforming, however, requires the creation of tooling but often makes up for that in production speed. “Creating high-quality aluminum tooling can take a few weeks, but, once we’ve got that, creating a single part only takes a few
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A part during the thermoforming process. Thermoforming offers a number of mat erial choices.
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Overmolded Deutsch Connectors Designed for longevity in demanding environments where shock, vibration, cold, moisture and oils can affect performance.
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minutes,” said Ray. “Recently, we were working with a customer who was creating 8 ft x 10 ft plastic enclosures on a tight schedule. So we suggested that they might want to 3D print the first few, while we make tooling for the thermoformed production run,” said Ray. “But when they looked at it, creating a few sets of parts at that size on 3D printers was going to take longer than our entire tooling process.” When choosing a provider of thermoforming, look for a few key qualities: • Location. There are definite advantages to working with someone near you. • Technology. It’s also important to look at the technology used on your project. Thermoforming has been around since the 1930s, but you’re not going to get the same quality from 70-year-old equipment, or even 17-year-old equipment, as you would with new, modern thermoforming equipment.
• Robotic trimming. Traditionally, thermoformed plastic sheets were trimmed by hand, but 6-axis robotic trimmers offer higher-speed and higher-precision trimming. • Finishing capabilities. Some thermoformers offer on-site painting, finishing and assembly services. These can help simplify your product process and reduce both time and costs. DW Ray Products rayplastics.com
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Edited by: Mike Santora â&#x20AC;˘ Associate Editor
Top tips for proper spring selection
Many times, a designer may require not on ly a spring, bu t also a custom sp ring assembly. Working with a manufacturer capable of doin g both is more cost effective. A few factors that may affect cost for design and manufacturing include materia ls, time, tolerances , space allowan ce s and any specia lized tooling.
Evaluating spring components for an industrial application can be a challenge. A spring needs to improve the performance of a product cost effectively. Here are a few considerations for choosing the best spring for a given application. Quality Depending on the application, less expensive materials might be an option. However, springs for specific industries like the medical or defense sectors require methods and materials that are more costly because of quality standards and the end use of these springs. For example, micro springs in surgical staple guns and other medical devices should use stainless steel (often austenitic and precipitation hardened) to maintain the durability, and cleanliness needed. While stainless steel costs more, its superior cleanliness often makes it a good choice for these and other applications.
few factors that may affect cost for design and manufacturing include materials, time, tolerances, space allowances and any specialized tooling. As mentioned previously, different materials are more effective against corrosion and other problems, and costs will vary. Wire diameter and other dimensions need to be exact as well. Consulting with a manufacturerâ&#x20AC;&#x2122;s design department on calculation and configuration accuracy is always a smart decision.
Cost Cost is determined by a number of factors. A stock spring will be more affordable than a custom spring; however, a custom spring ensures the right specifications, especially in unique application scenarios. Many times, a designer may require not only a spring, but also a custom spring assembly. Working with a manufacturer capable of doing both is more cost effective. A 76
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Application It may seem obvious, but each spring is meant to perform a specific action or function, thus there are differences in springs. For example, design engineers in the military and aerospace fields may look for industrial springs that offer
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Your Partner in Custom Plastic Components
counterbalancing. In that instance, constant force springs or spiral torsion springs have more unique capabilities than traditional helical springs. They offer a smooth range of motion and a uniform and consistent load. Taking into consideration other components necessary to allow traditional helical springs to function with a steady force deflection profile, constant force springs are typically more cost effective as well. A constant force spring, in many instances, suits any application that requires more power with length of travel and a flatter gradient. When looking to counterbalance loads ranging from less than one pound to more than 50 pounds, spring reels are recommended. Unlike constant force springs, spring reels provide assistance to any assembly that must be raised. Spring reels reduce the “felt” weight or the required energy to lift a delivery truck door or window. On the other hand, a sash style window manufacturer counterbalancing a window sash would want to use constant force balance assemblies. This configuration would reduce “felt” operating forces in single and double hung configurations. When working with a spring manufacturer, it’s important to choose one that is truly knowledgeable not only in spring manufacturing, but also design. Consulting the manufacturer or designer of the spring ensures the right dynamic component for a product. Manufacturing companies with engineering www.designworldonline.com
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When looking to counterbal ance loads rang ing from less th an one pound to m ore than 50 poun ds, spring reels are recommended. U nl ike constant force springs, spring re el s provide assistan ce to any assem bly that must be ra ised. Spring reel s reduce the “felt” weight or the required energy to lift a delivery truck door or w indow.
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Edited by: Mike Santora â&#x20AC;˘ Associate Editor
4 tips for building electrical equipment to North American standards
The Allen-Bra dley Bulletin 140G molded case circuit breakers are U L-listed as curre nt limiting and can help engineers achieve a higher short-circuit rating in the co ntrol panel.
For global machine and panel builders looking to sell their equipment into North America, one of the bigger challenges is complying with local standards and codes. Building compliant machinery and control panels for North American end users requires understanding the electrical codes and standards, as well as staying informed about emerging changes. Machine and panel builders serving the North American market should consider these four steps:
1 Key Standards Some North American electrical standards have been evolving to harmonize with global standards for more than a decade. However, much work remains as the two sets of standards still have a number of differences. The three standards that every machine or panel builder should be familiar with include: â&#x20AC;˘ UL 508A, Standard for Safety for Industrial Control Panels: Applies to general and special-use panels, including requirements to comply with NFPA 79. There is no exact equivalent European 78
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Tools like the Global ShortCircuit Curren t Ratings (SCC R) Selection Tool fr om Rockwell Automation ca n provide coordinated SC CR ratings for al l power devices us ed in a circuit.
counterpart to UL 508A. Although EN/IEC 61439-1 and EN/IEC 60204-1 have similar requirements, there are differences between these standards. For example, the European and North American standards use different methodologies for determining a system’s short-circuit current rating (SCCR), and the scope of coverage is slightly different. • NFPA 70 National Electrical Code (NEC): Provides guidance for the proper installation of electrical equipment and safeguarding of persons and property from electrical hazards. Its European counterpart is EN/IEC 60364-1.
• NFPA 79, Electrical Standard for Industrial Machinery: Covers not only a machine’s control panel, but also its operating environment, operator interface, warning signs, documentation and testing. NFPA 79 has been undergoing harmonization with its European counterpart, EN/IEC 60204-1, since 2002. Differences exist, such as grounding, voltage and protection requirements. But by standardizing on the NFPA 79 requirements, builders will reduce the number of changes needed to comply with EN/IEC 60204-1.
2 Confirm Specifications and Requirements While many customers have some type of design specification, not all do. Even if a customer does provide specifications, they may lack crucial details. Types of information that should be requested and confirmed with the end-user customer include the following: • Power supply, including voltage, phase, frequency, system grounding and required short-circuit current rating • Operating conditions, such as temperature, vibration and environmental factors
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DIN rail or chassis mount solid state contactors and SSRs which are UL508 rated for motor loads, and feature integrated heat sinks, fans and large load terminals. Designed for switching CARLO GAVAZZI single phase loads up to 85 amps A(15 and pole u t Hp) oma t i otwo n Cor o three mpon ents 847.465.6100 800.222.2659 types for switching up to 75 ampsUSA per Tel: phase (25 Fax: Hp). Canada Tel: 888.575.2275 Fax: 905.542.2248
Specialty SSRs for your growing demands: System Monitoring SSR for line /load voltage and load current, fused SSRs provide more protection, and 1, 2 and 3 pole proportional controllers with several switching modes: phase angle, distributed burst (1, 4 or 16 cycle), or soft start.
Mexico Tel and Fax: 55.5373.7042 Carlo Gavazzi is one of the fastest growing SSR manufacturers worldwide! Contact us if you’re interested in a free evaluation sample (qualified OEMs only). www.GavazziOnline.com • Info@CarloGavazzi.com
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December 2016
CARLO GAVAZZI Automation Components
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» D e s i g n N o tes
• Loads for devices, such as motors, drives, heaters and transformers • Functional descriptions, including sequence of operation and operator interfaces • Applicable standards and certifications, including local requirements
the proposed machine solution and project estimate. Some of this can come from the standards. For example, NFPA 79 provides a helpful “inquiry form” in its Annex B that can be used to document a machine’s requirements.
4 Using Training and Resources Design engineers shouldn’t hesitate to contact their automation vendors with questions. The industry sees itself as a collaborator (or an ally) for machine and panel builders, system integrators and end users. Automation vendors and distributors also host a number of educational opportunities throughout the year that specifically address North American standards. These include
3 Documentation One of the most basic but important things a machine or panel builder can do is document important project elements as part of the proposal process. The documentation should include the customer’s specifications and requirements; national and local standards and codes that apply to the project; and
individual classes, individual speaking engagements at customer locations, and seminars at trade shows. Standards and codes can be daunting, but they shouldn’t be a barrier to success in a new market. By understanding the standards, confirming and documenting project details, and working with automation vendors, OEMs and panel builders will be primed to meet compliance requirements and improve their competitiveness in North America. DW Rockwell Automation Inc. www.rockwellautomation.com
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»»
» CA E S o lut i o n s
Software for smart wiring
The Eplan Smart Wiring software opens new perspectives for wiring switchgear systems. A key feature is the system’s simplicity: the clearly arranged, touchoptimized user interface is suitable for mobile devices. The system includes step-by-step directions for the wirer. No schematic is necessary for wiring – thus making any interpretation of such complex documentation redundant. EPLAN Smart Wiring visualizes the mounting layout, devices, connections and routing tracks, based for instance on data from EPLAN Pro Panel. Connection lists and wiring list can for instance be prepared in other ECAD systems, read into an MS-Excel format and then processed in EPLAN Smart Wiring. The automatic project comparison for last-minute changes ensures that all changes find their way into production and are taken into consideration. Problem and error reporting, status reports and manufacturing reports can be prepared at the push of a button and can then be e-mailed to engineering or those responsible in production planning. 82
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The system’s simplicity offers companies scalability of their resources while simultaneously increasing efficiency along the entire workflow. Data relevant to manufacturing can be standardized with EPLAN Pro Panel, thereby be quickly prepared and made available for manufacturing with EPLAN Smart Wiring. This provides greater flexibility in the wiring process and high-quality results. DW Eplan Eplan.de
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12/2/16 3:40 PM
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» CA E S o lut i o n s
Version 14 of TIA Portal is here Version 14 (V14) of the Totally Integrated Automation (TIA) Portal shortens the time to market for machine manufacturers. This package focuses on diagnostics, virtual commissioning and multi-users. The technology update has enhanced energy management and motion control, cloud connectivity, and digital twin for virtual commissioning. Cloud-based engineering helps users access the ‘plant controller’ from their private cloud with the TIA Portal Cloud Connector. Cloud-based engineering can also be accessed through MindSphere for additional digital services. Version 14 new features include: • PLCSim Advanced, with interfaces to simulation software, such as Plant Simulation and Process Simulate. A Simatic S7-1500 controller can be simulated as a digital twin with PLCSim Advanced. • New interface for product data management in Teamcenter. The user can easily create model-based programs with a new interface to Matlab/Simulink. • Extended motion control functions and applications within the S7-1500 controller family. The Simatic S7-1500 T-CPUs help Simatic users solve advanced motion control tasks, such as gearing and camming, in a familiar environment. • A multi-user function has been added for decentralized work concepts. These concepts include automatic synchro- nization and the facilitation of device, object, and function-based organization of automation tasks. Parameter assignment and evaluation of the 3VA molded-case circuit breaker and the 7KM PAC series of measuring instruments are also new features of the TIA Portal V14. This simplifies acquisition of energy values for the infeed system, electrical outputs and individual loads.
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• The ProDiag option offers detailed plant and machine monitoring with minimal configuration and visualization costs. Support is provided with automated code generation and HMI synchronization functions. WinCC/WebUX help monitor plant processes and control them through the Internet or intranet with mobile HMI devices, such as tablet PCs and smartphones. The process data are available worldwide for easy access to the machine. • The Simatic Energy Suite makes it easy to assign parameters and evaluate many measuring components. It increases the transparency of energy flows and helps to save energy in accordance with ISO 50001. DW Siemens Corp. Industry.usa.siemens.com
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12/5/16 3:48 PM
» CAE Solu t i ons
CFD for Solid Edge Mentor Graphics FloEFD is an embedded computational fluid dynamics (CFD) solution for Solid Edge software from Siemens. Users can simulate fluid flow in their design process. When used during the design process, it can reduce overall time to a solution by as much a 65%-75%. FloEFD CFD solution automates many CFD steps, which include transferring model geometry to the CFD application, modeling internal cavities if needed and creating a “mesh.” The CFD technology takes the geometry directly from the CAD application, automatically performs the necessary translations and cavity modeling, and generates an optimized mesh before executing analysis. This approach provides accurate analysis results quickly thus enabling designers to validate designs early and often. It also allows the designer to explore a succession of ideas without risking project deadlines.
Key features include: • Robust 3D fluid flow and heat transfer analysis software capable of solving complex real-life engineering problems. • The ability to conduct multiple design studies and evaluate how the modifications influence the design performance immediately. • An intuitive user interface with built-in intelligent automation including real-time feedback and timely outputs that can be generated quickly in Microsoft Word and Excel. • Parametric study to compare a range of project variations. • Fast, automated SmartCell meshing technology to create realistic simulations for complex 3D models including rotating equipment and transient flow behaviors, speeding-up the overall design process. DW Mentor Graphics Mentor.com
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» Co u p li n g N o tes
When are beam couplings the best choice for an application? Joyce Laird • Contributing Editor Engineers in the design phase of a motion control related project are faced with the selection of many components, from motors and leadscrews to bearings and fasteners. One other key component that is critical to the function of any new design, and which is often overlooked, is the flexible coupling connecting the motor and leadscrew. Randy Kingsbury, Vice President, Sales & Marketing for Helical Products Company points out that a flexible coupling is always recommended over a rigid or solid coupling. “The fact is, there will always be some misalignment between the connected shafts as well as a slight amount of movement from thermal expansion/contraction of the various components. Additionally a coupling may be necessary between the lead screw and a 86
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feedback device or other element of the system,” he says. “When considering the options available with the various types of flexible couplings it can be difficult to discern the benefits of one over the other. Certainly the torque being transmitted through the coupling is a key factor but also is the misalignment capability. The primary misalignments referenced by the various manufacturers are angular, parallel and axial motion.”
The Backlash Issue Kingsbury also notes that one important aspect of a flexible coupling used in motion control applications that can have very detrimental effect on performance and accuracy is backlash.
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»» “Backlash comes from free-play between the mating components that make up a multi-piece coupling. A majority of the flexible couplings on the market are these types of multi-piece assemblies. Although advances in manufacturing techniques have significantly improved, and essentially removed, this backlash does occur.” “When the part is new, consideration should be given to how well the coupling and the fit between its mating parts will hold up over time because the purpose of these couplings is to flex, which stresses the assembly points.” Kingsbury says that the answer to this concern lies in selecting a coupling made from a single-piece of material because there are no points of assembly to loosen and induce backlash. “The most well-known type of single-piece flexible coupling that does the best job of transmitting torque for its outside diameter, compensates for significant misalignment and does not exhibit backlash is the beam type coupling. These types of couplings have been around for 50+ years and are still common in motion control applications.”
The Beam Coupling Solution “The beam coupling is both compact and affordable while offering a proven track record for reliability,” Kingsbury says. “For more demanding high torque applications they are available in high strength 17-4 stainless steel. Another benefit of the beam coupling and the fact it’s machined from single-piece of material, is the incorporation of features to further simplify and add value to the overall assembly.” In conclusion, he says that not only does the incorporation of the features of this type of coupling relieve the engineering department of managing drawings for the integrated components but the purchasing department only needs to order, receive, and inventory one full featured coupling rather than numerous parts. He advises that if faced with this type of application, there are always coupling suppliers who can advise and specify the proper coupling to meet any need. DW Helical heli-cal.com
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.......................................... ................................ ........................ ................... .............. ........... ........ Servo terminals feature ...... .... .. safe torque off function
To increase safety technology in motion control applications, the EL72x1-9014 EtherCAT servo terminals implement STO (Safe Torque Off) functionality. The integrated features correspond to safety level Cat 3/PL d, according to EN ISO 13849-1:2015. The I/O terminal form-factor of the EL72x1-9014 promotes space-saving, cost-effective motion solutions through advanced servo drive technology with built-in safety functions and One Cable Technology, which combines power and feedback signals to servomotors into one standard cable. In addition, 2-channel shut-off with corresponding contactors in the motor cable reduces cabling effort, space requirements and cost â&#x20AC;&#x201C; a single cable connects the TwinSAFE safety output terminal (such as the EL2904) and the STO input of the servo terminal. The OCT solution reduces cable costs and space needed for motor connections. 88
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The EL7201-9014 variant comes in a 12 mm terminal housing and supplies an output current of up to 2.8 ARMS, while the 24 mm EL72119014 version can supply a maximum of 4.5 ARMS. Both power servomotors from the Beckhoff AM8100 series. The integrated electronic type plate of the AM8100 motors can be read-in automatically by the servo terminals, simplifying machine commissioning considerably. DW Beckhoff Automation Beckhoff.com
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12/5/16 3:57 PM
Data acquisition system includes EtherNet/IP EtherNet/IP capability has been added to the Memograph M RSG45 Data Manager. The RSG45, a data acquisition system for small process control applications, cost effectively integrates legacy 4-20 mA, RTD, thermocouple and HART-based instruments into a modern control system. The system can quickly integrate up to 20 individual instruments into an EtherNet/IP environment using a single standard Cat 5 cable. The EtherNet/IP connection also allows a plant to control batch start/stop activities from the control room. The RSG45 is able to accept up to 14 discrete and 20 universal/HART analog inputs from process sensors. It can then display this sensor data on its 7-in. multicolor TFT screen, records the data internally, performs math calculations and alarm checks, and transmits the data to a PC or any control system through EtherNet/IP, Ethernet , RS232/485, Modbus, Profibus DP or PROFINET digital communication links. Data can also be stored to external memory plugged into the USB or the SD port. In case of a wiring failure, the RSG45 continues to record data on the storage device, and can download this data to the control system when communications are restored. DW Endress+Hauser Us.endress.com
Servo motor with EtherNet/IP capability The ASCI Integrated servo motor with EtherNet/IP has a keyed Add-on Profile (AOP) and a full suite of Add-on instructions (AOI) for easy, seamless integration into Rockwell Automation PLCs. The ACSI servo motor controller creates an all-in-one (motor/drive/controller) electric actuator for single-axis applications. Available in two sizes (NEMA 23 & 34), the ACSI servo motor control has easy-to-use operating modes such as digital I/O index moves, analog position (0-10 Vdc or 4-20 mA), ODVA conformant EtherNet/IP and Modbus TCP. The EtherNet/IP implementation is based on an I/O assembly object that does not require a motion axis from a Rockwell Automation motion PLC. The ACSI is designed to be controlled from a PLC or master controller through 24 Vdc digital I/O, 0- 10 Vdc or 4-20ma analog I/O, EtherNet/IP or Modbus TCP. Additional features include a standard IP65 rating, industry standard M12 connectors, dual Ethernet ports with LED indicators and a USB programming port. The ACSI supports a rotary axes and third-party actuator control. DW Tolomatic Tolomatic.com www.designworldonline.com
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IoT application development system The Node-RED development environment runs on the groov Box industrial appliance, decreasing IIoT application development time and complexity. Node-RED makes it easier to prototype, develop, and deploy applications for connecting physical assets to cloud applications and IT systems. groov fuses together an industrially rugged hardware platform, data visualization for mobile and web clients, industrial automation protocol support including Modbus/TCP and OPC UA, and advanced data flow processing. Node-RED running on the groov appliance enables nearly anyone to rapidly prototype and develop IIoT applications to connect data streams from industrial assets to IT assets, bridging the gap between the worlds of physical equipment and digital computing systems. Node-RED is a visual wiring tool to connect edge-computing systems such as industrial automation controllers to cloud services such as Amazon Web Services (AWS) IoT, IBM Watson IoT, and Microsoft Azure. It is an open-source, cross-platform technology available on GitHub.com and npmjs.org, and is currently available for a variety of platforms. groov is a zero-programming, web-based way to build, deploy, and view effective, scalable operator interfaces and system dashboards to monitor and control systems and equipment using mobile devices and other computer-based systems. These operator interfaces can be viewed on almost any mobile device or computer regardless of its manufacturer, operating system, or screen size, including smartphones, tablets, PCs, and even smart high-definition televisions. DW
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Opto 22 Opto22.com
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........................................ .............................. ...................... ................. ............ ......... Analytics cloud ...... .... .. for OEMs FactoryTalk Analytics for Machines is a Microsoft Azure cloud-enabled application that provides access to performance analytics from deployed systems. It helps drive productivity and output while reducing maintenance costs. OEMs can embed a FactoryTalk Cloud gateway device onto the machines they provide. Once commissioned, the machine starts collecting data. The data from selected controllers are sent to the FactoryTalk cloud application securely with minimal configuration by the equipment builder or the end user. The equipment builder then has access to real-time analytics and actionable information through prebuilt dashboards. This is a cloud-based application provided as software-as-a-service (SaaS). DW Rockwell Automation Rockwell Automation Inc.
Port to Port, End to End, Sensor to Actuator More Reasons to Connect with Alpha Wire End-to-end industrial connectivity has a new name: Alpha Connect, the dependable connectivity solution from sensor to actuator.
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Cyber update services Schneider Electric, a global specialist in energy management and automation, introduced cybersecurity protection services that help industrial customers manage and secure their connected plants. Cyber Update services automatically distribute Schneider Electric’s qualified operating system patches and endpoint protections, reducing the risk of applying improper patches and updates. It also eliminates potentially unsecure sources of data from affecting plant and business operations. The services, which meet IEC62443 and other leading industry standards, automatically deliver third-party-tested operating system security patches and anti-virus endpoint protection updates through a secure, authenticated and encrypted
Windows Software Update Server to a customers’ onsite server. The services enable customers to quickly and efficiently apply patches and updates across multiple sites on the same secure network, allowing them to manage multiple, disparate systems that run various O/S software levels and versions. DW Schneider Electric Schneider-electric.com/us
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PBC’s Superior Component and Created for the Most Demanding Washdown Operations PBC Linear solutions for washdown performance will keep your operation running clean. • FDA compliance • 316 series stainless steel shafts and bearings 316 stainless steel bearing Bonded linear material eliminates grooves and crevices 316 stainless steel shaft
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• Unique design properties eliminate potential bacteria traps Read: Linear Motion Solutions for Washdown Applications http://bit.ly/pbc-washdown
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N EWS: ........................................ .............................. ...................... ................. IoT analytics extract ............ ......... ...... actionable insights .... ..
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Nutonian, a machine intelligence company, announced an OEM relationship with Autodesk. Autodesk’s Fusion Connect, an IoT cloud platform, will embed Nutonian’s artificial intelligence (A.I.) modeling engine, Eureqa, to interpret IoT data. Eureqa automatically discovers the simplest possible predictive models from raw data. With Eureqa enhancing Fusion Connect, companies can automatically churn through connected machine IoT data to predict product failure, receive recommended improvements for product designs and identify potential new designs. Bryan Kester, director of IoT at Autodesk, said that Nutonian will easily allow Autodesk to deliver a one-of-a-kind IoT analytics service. Eureqa can determine the baseline for how a piece of machinery behaves under normal conditions. If a machine’s sensors indicate abnormal or suboptimal behavior, Fusion Connect’s dynamic predictive analytics, powered by Eureqa, will generate
end-user alerts and dashboards explaining what’s happening and why. This will allow customers to automatically anticipate machinery maintenance, identify product flaws and develop smart, proactive business processes. “IoT data is noisy and complex to analyze, which has limited its impact on business applications to date. We created Eureqa to overcome this challenge,” said Michael Schmidt, Nutonian’s founder and CTO. “The integrated power of Eureqa and Fusion Connect enables businesses to use IoT data to automatically predict and explain in real time why events happen, like equipment failure or maintenance.” DW Autodesk Autodesk.com
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C o n t r o l
realtime Control Socs
improve drive designs
Brian Fortman • DesignDRIVE Marketing Manager • C2000 Microcontrollers • Texas Instruments
Industrial drive functions
Many industrial inverter and servodrive manufacturers rely on fieldprogrammable gate-array (FPGA) or ASIC technology to complete functions unsupported by commercial off-the-shelf (COTS) products such as 32-bit microcontrollers (MCUs). There are drawbacks to these technologies, though. Case in point: Adding FPGAs and ASICs to software-programmable controllers for supporting position sensor feedback or sigma-delta filtering also increases system cost and development complexity. So designers should ask if the functions placed in the FPGA are bringing real differentiation to drive products. Will customers pay more for the functions in FPGAs? Or have those functions become standard features for every drive maker to include? In short, are they just table stakes to play in the industrial drives and servo industries? Let’s find out.
on off-the-shelf MCUs now let designers forgo FPGA builds to focus on motion and motor control.
History of FPGA-enabled drive architecture evolution There are challenges to introducing an FPGA into a drives development flow, and (as we’ll see) new capabilities of industrial drive control SoCs (COTS MCUs) shift the cost-benefit model of using FPGAs for industrial drives. First some background: FPGAs became common in inverter-drive architectures when new system functions were impossible with the COTS MCUs available at the time. For example, many developers had to implement their specific PWM/IGBT protection scheme outside the MCU. Others may have felt that their current loop timing was too short to be handled by a programmable MCU so could only be accomplished in gates.
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Once an FPGA is in a system, it then becomes the logical place to integrate support for new technologies introduced to the evolving market. So, FPGAs came to integrate clockwise-and-counter-clockwise (CW/CCW) and pulse-train-output (PTO) ports for communications with PLCs and motion controllers. Then FPGAs began to support emerging standard and proprietary position sensor interfaces such as EnDat and BiSS. Next, filtering circuits for modulated outputs of isolated sigma-delta ADCs were integrated into FPGA devices. In addition, some industrial Ethernet standards have made their MAC controllers available in FPGA gates. As FPGAs absorbed this expansion of drive functions, a new dynamic was emerging. COTS controllers started bringing these functions on-chip and creating off-theshelf features for any drive developer to use. The difference here is substantial: On-chip functions are available for the developer
to use immediately — that is, to purchase an MCU from a catalog without needing to construct these solutions themselves using an FPGA. So developers can now avoid many FPGA pitfalls. Drawbacks of FPGAs for drive applications FPGAs are reprogrammable and most believe they provide system adaptability and improved system performance, but they have drawbacks when compared to MCUs for industrial-drive applications. Developers should weigh the impact of the specialized engineering skillset, the total project effort and the total system cost when an FPGA is employed. Many drives systems being developed maintain a COTS C-programmable microcontroller or microprocessor coupled with an FPGA. The processor’s C code generation and debug development environments are well known and required. Introducing an FPGA into the system
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Texas Instruments’ C2000 MCUs with DesignDRIVE technology are COTS MCUs that deliver drive system integration to save development time and system cost. The off-the-shelf C2000 Delfino MCU SoC can handle myriad tasks traditionally completed in an FPGA.
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This shows the development of an EnDat system on an FPGA versus drives SoC. Use of FPGAs involves what’s essentially nonstandard development of a printed circuit board (PCB) and MCU gatelevel register interface, software abstraction, and system integration. In contrast, TI’s Delfino TMS320F28379S and TMS320F28379D MCUs and DesignDRIVE Position Manager allow for easy and direct connections to EnDat2.2 and BiSS-C absolute position sensors. DesignDRIVE software with Delfino F28379 MCUs expand on-chip functions.
necessitates an additional development flow and toolset. Despite claimed advances in ease-of-use of these tools, it’s typically not the same engineering staff that develops the MCU C code and FPGA VHDL code. What’s more, the VHDL coding style and development flow are quite different from MCU software development and require special engineering resources. Plus it’s the FPGA development staff that must also become low-level and system-level experts for the hardware IP they’re implementing. Not only must they know how to implement the VHDL for a BiSS master, for example, but they also need to know the BiSS protocol — as they need to validate that their FPGA implementation meets (in this example) BiSS sensor requirements. This specialized engineering skillset may not be something every motion control or inverter manufacturer can afford to staff — and it certainly is a diversion of effort away from their true differentiation of motion and motor control performance As we’ll see, it’s probably easier to just use a microcontroller that supports BiSS encoders natively.
FPGAs are reprogrammable and can provide adaptability and high system performance ... but are less suitable than MCUs for industrial-drive applications.
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FGPA development is custom design. From a development perspective, managers should view FPGA creation as a custom development. Their development teams have heightened ownership and responsibility for the product features taken to market in the FPGA. If the VHDL isn’t coded or tested properly, they cannot turn to the FPGA vendor; they can only turn to themselves as the cause of the issue and to themselves as the source for the remedy as well. When comparing the FPGA development model to using a COTS MCU, custom responsibilities go well beyond custom gates designed into the FPGA. The printed circuit board (PCB) impact, the MCU gate-level/ register interface, the software abstraction and overall system integration are all nonstandard — not off-the-shelf solutions. Beyond just development, this model has added engineering complications of customer support, product maintenance releases and long-term conformance as new interfacing components are released or revised. It’s easier to use a standard MCU with these features implemented and let the supplier take responsibility for the whole
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12/1/16 3:18 PM
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Haydon Kerk Motion Solutions hybrid and can-stack linear actuators continue to offer equipment designers new motion control solutions that provide unmatched performance-to-size ratios, patented technologies and thousands of configuration options, and a vast experience in customized solutions. HYBRID actuators are available in six sizes from Size 8: 21 mm2 (0.8 -in.) to Size 34: 87 mm2 (3.4-in.) – capable of delivering up to 500 pounds (2224 N) of force. Travels per step range from .001524 mm (.00006-in) to .127 mm (.005-in), with micro stepping capability for even finer resolution. An integrated, programmable IDEA™ Drive is also available for Size 17 hybrids. The G4 Series represents the industry’s most robust and most powerful CAN-STACK linear actuators. The G4 Series offers diameters of 20 mm (.79-in), 26 mm (1-in), and 36 mm (1.4-in). The can-stack product line also includes motors with diameters of 15 mm (0.59-in), 20 mm (.79-in) , 26 mm (1-in), 36 mm (1.4-in) and Ø 46 mm (1.8-in), available with captive, non-captive or external linear lead-screws. Haydon Kerk Motion Solutions continues to be an innovative motion control technology company with a global network of people, facilities and services dedicated to engineering and manufacturing the world’s most advanced linear motion solutions. For more information: www.HaydonKerk.com > Linear Actuators
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product solution — including hardware, software, tools, and design. Next and most obvious is the impact of an additional components on the bill of materials. FPGA cost goes beyond just the unit price. FPGA devices need additional PCB area and pins for MCU interfacing and power supply. These costs are unavoidable when using FPGAs but avoided when these functions already exist on the drives SoC MCU. Investigations show that some FPGAs even need an additional (or more complex) power supply circuit than the drives SoC devices by themselves. What’s worse, implementing FPGA introduces gates that are otherwise unnecessary to the system — such as the register interface to the MCU and the interface to an external analog to digital converter (ADC) for phase current and voltage sensing. In contrast, drives SoCs include high-performance ADCs built for drives applications and don’t require this extra logic. So using a single COTS drives SoC includes many opportunities for overall system cost reduction vs. MCU plus FPGA architectures. In fact, some MCUs deliver this higherlevel of drive system integration with a whole-product philosophy that benefit drives developers by reducing the need for specialty engineering talents. These system-on-chip (SoC) devices handle several items FPGAs traditionally handled — including fast torque loop calculation; filtering of modulated delta-sigma ADC signals; high-performance PWMs; PWM protection and interfacing with performance position sensors. In fact, one MCU’s on-chip comparator subsystem and PWM trip-zone capabilities can invoke a safe PWM state (off) in 50 nsec. These MCUs are flexible when generating on-chip conditions for triggering a trip-zone event. Designers can implement myriad PWM protection concepts using these onchip resources, eliminating the need to place the circuits in external FPGAs. Consider that some new MCUs and software also allow for easy and direct connections to EnDat2.2 and BiSS-C absolute position sensors, which are features that required FPGAs in the past. What’s
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New MCUs and software such as TI’s DesignDRIVE Position Manager support leading analog and digital position sensors. Try out DesignDRIVE and industrial drive-design topologies with TI’s Kits TMDXIDDK379D or TMDXIDDK379D-MTR-BNDL available through store.ti.com and authorized TI distributors. DesignDRIVE Position Manager technology helps designers get industrial inverter or servo-drive products to market quickly.
This is an industrial drive control SoC — the C2000 TMS320F28379 MCU. Delfino MCUs can get sub-3-msec floating-point torque-loop calculations and contain flexible 150ps high-resolution PWMs. The CLA real-time coprocessor is a suitable target for these algorithms to minimize time between the sample and next PWM command. Up to eight channels of integrated sigma-delta filters are also on-chip and include parallel under-range or over-range comparators on the same channel.
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more, by using some of the sophisticated analog circuits on-chip, these devices can decode resolver signals as well as angles from SIN/COS transducers. One such solution is the first of its kind to offer a breadth of position-sensor support, flexibility, scalability and robustness to let developers decrease system cost — specifically by reducing the board area of the FPGA or ASIC. In short, on-chip solutions for industrial drives (integrated into COTS real-time MCUs) save board space and development effort, which frees developers from making unnecessary investments in features that are non-differentiating in the industry. Instead, developers can focus on product differentiation and competencies such as motor control and motion control, and not on building FPGAs or writing complex code to complete nondifferentiating tasks. DW
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Force-current relationships affect linear motion design
Brian Scott, Ph.D. â&#x20AC;˘ Nippon Pulse America
Applying an electric motor is easier when one knows what it will output for a given input. The simpler it is to predict that, the more elegant and robust the design. To this end, some linear motors have linear force-current relationships so engineers donâ&#x20AC;&#x2122;t need to accommodate nonlinear effects through approximation or additional terms in F(I) equations. This boosts accuracy and repeatability, as output force is the force requested every time.
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Consider the world of machine tooling for parts production. Here, machine-movement accuracy and precision are paramount to get tolerances and surface finishes required today. Final part dimensioning, surface finishing, and mill cutters sharpening is often only possible through grinding operations. But grinding is a particularly demanding operation that generates significant vibration, heat, and abrasive particles ... and must maintain positioning and speed accuracy. Here, the axis-translation mechanisms dictate maximum accuracy possible, as well as the long-term cost of machine ownership. Machine designs must move axes to set positions and track that position relative to the workpiece. Maintaining movement of workpieces or tooling requires solid design of three machine features: the mechanical components; the command and control of the movement (through control boards and servo loops); and the translation mechanism (whether that takes the form of linear motor or rotary motor driving a ball screw). Let’s consider one permutation — force generated by linear electric motors.
Patented Nippon Pulse Linear Shaft Motors drive the axes on this SCR stage for robust and simple construction.
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This shows the F(I) for two linear-motor types. The basic structure of Linear Shaft Motors from Nippon Pulse eliminates the generation of eddy currents that cause the F (I) relationship to be nonlinear.
Newton’s first law tells us that to alter an object’s motion, a force must act on it (F=ma). So in a machine-tool application, we must apply a force of enough magnitude to overcome the object’s mass as well as resistive forces to put it on the necessary path for shaping, honing, or grinding to specification. Applied force vectors must maintain accuracy and precision so they output the right motion every stroke. But this is only to get our workpiece into the target position during a set time, and doesn’t account for the effects of work hardening, elastic and inelastic deformation, tool deflection, and other production factors. Within a linear electric motor, motion arises from the interaction between an electromagnetic field created by current-carrying coils and permanent magnets. Creating motion necessitates generation of force, and electric motors output force when a current supply creates a magnetic field within them. When opposite polarity fields of the electric
and permanent magnets align, the motor is stationary. When the electromagnetic fields are offset, it generates a force and movement occurs. Force generated is directly related to the current magnitude in the coils, as current determines the magnetic field size ... and this determines output force. That’s why the magnitude, timing, and direction of the current are important control inputs for creating any given motion profile with electric motors. The relationship between current and motor performance lays the foundation for how a motor executes motion commands. If a 20-N force must move to position (X, Y) the controls must know how much
Linear Shaft Motors from Nippon Pulse have an exceptionally linear F(I) relationship, so make strokes exactly as set with no need for advanced servo control. One is this Series SL083 linear motor with magnetic encoder for positioning to within 5 µm. It has a tubular stainless-steel shaft and noncontact forcer for almost no residual force.
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current to supply. Ideally the force-(F)current-(I) relationship (F(I)) is linear so that a small change in current prompts a similarly small change in force over the entire operation range. But it’s more complicated when the relationship is nonlinear or has a nonlinear regime that takes large changes in current to get smaller changes in force. Motors with nonlinear regimes necessitate advanced servo loop systems to accommodate changing force outputs for current.
(but can’t eliminate) eddy currents in these situations.
Why some motors have nonlinear F(I) relationships Some motors have a nonlinear F(I) relationships because the changing electromagnetic fields that create and control motor motion induce current flow in magnetically susceptible conductive materials. They are called eddy currents and arise just as current flow in conductors creates magnetic fields. In short, electromagnetic coils in some motor types induce eddy currents in adjacent motor parts. These eddy currents then create an additional magnetic field. Because magnetic fields are a vector quantity, the direction and magnitude of all the interacting fields are important, as they sum up over space ... affecting the overall force generated by reducing the field strength between the primary magnetic components. What’s more, as controls increase current to generate more motor force, eddy currents and their magnetic fields grow. This effect produces a nonlinear F(I) relationship in iron-core-type linear motors. When any large amount of a conductive material moves in relation to magnetic fields, eddy currents result. The presence of necessary heat sinks on ironless linear motors also creates nonlinear affects in F(I) because eddy currents also arise from interactions between the magnetic fields and heat sink. Some design features aim to reduce 104
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Some linear-shaft motors have a linear force-current relationship The basic structure of linear shaft motors from some manufacturers eliminates generation of eddy currents that cause the F(I) relationship to be nonlinear. Here’s some background on how magnetic fields create large or small eddy currents to explain why these motors avoid the problem on nonlinearity. Each material type has set level of susceptibility to magnetic-field-created eddy currents. For magnetic fields with low frequency of change, the main materials differentiator is conductivity. When the frequency of the fields increases, the magnetic permeability of the material also comes into play. This is reflected in the depth of penetration of the magnetic field into the material called skin depth. When a magnetic field creates an eddy current within a metal, that consumes
“The basic structure of linear shaft motors from some manufacturers eliminates generation of eddy currents that cause the F(I) relationship to be nonlinear.”
energy through resistive heating of the metal and by the eddy-current magnetic fields’ effect on the primary magnetic field. Power dissipation of the eddy currents per unit volume is: 2
=
2 2 2
(1)
6 Where σ is the material conductivity, Bp is the peak magnetic field, d is the thickness of the material or laminations, f is the frequency of the field switching, and δ is the material density. So reducing material thickness and conductivity while increasing material density decreases power consumption for a given magnetic field strength and frequency. If the frequency of the field is high enough, the magnetic permeability of the material becomes relevant, as the change in the field direction is fast enough to prevent the magnetic field from penetrating all the way through the material before switching directions. This creates a skin effect, in which the magnetic field only partially penetrates the metal. The depth of penetration is the effective depth for calculating power dissipation. Skin depth is:
=
√
1
(1)
(2)
(2) 0
With μr the relative magnetic permeability of the material and μ0 the permeability of a vacuum. As μr and σ increase, skin depth decreases, which is why high-conductivity and high-permeability materials are suitable around magnetic fields. Reconsider power dissipation. A relevant component here on the force-versuscurrent relationship is the magnetic field in equation 1. As the magnetic field increases, power dissipation increases as the second power of the field intensity magnitude. The coil-generated magnetic field that generates the eddy current is:
=
0
(3)
Where n is the turn density of the coil and I is the current. This equation shows www.designworldonline.com
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L i n e a r magnetic-field intensity is linearly related to current. In iron-core motors, μr is the relative permeability of the iron composition in the core. For those motors, the core is present to create a larger magnetic field than that of an air-core coil (as the design uses half the permanent magnets’ magnetic flux). Next, consider force generated by coil interacting with a permanent magnetic field. Force between the magnetic field generated by the coil and permanent magnet is (in a general sense):
=
0
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(4)
(4)
For permanent-magnet motors the magnets are laid out so that only one pole interacts with the magnetic field of a coil at any given time. It’s this relationship that creates linear force. (If both poles interacted, rotational torque would be created.) The equation shows that the forcecurrent relationship is linear for a given angle orientation between the field direction of the coil and field direction of the permanent magnet. When the field lines cut each other at 90° it generates maximum force. Linear-shaft motors from some manufacturers have a linear F(I) relationship because the motors don’t have a significant amount of conductive material surrounding or adjacent to the electromagnetic coils. For other motors that have this material, there’s a counteracting magnetic field and power dissipation through resistive heating (I2R). We can see this in a qualitative sense by contemplating equations 1, 3, and 4. Current and the created magnetic field in the coils is linear (as is the current-force relationship) but the power dissipation of the eddy currents is not. When a design has enough material to interact with the motor’s magnetic field, power dissipation becomes important at higher currents (magnetic field strengths) due to the nonlinear power dissipation relationship. For an electric motor, power into the motor is current time voltage (P=IV) and power dissipated is usually due to the resistive heating loss or I2R. Consider eddy currents. Energy goes to generating current and magnetic fields in the conductive material. This energy isn’t used to generate force between the coils and permanent
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L i n e a r magnets. This non-useful power dissipation grows as the square of the magnetic field and has greater negative impact on the production of force at higher currents. This is the origin of the nonlinear relationship seen in iron-core and core-less with heat sinks at higher force outputs. Complicating matters is that there’s an insignificant amount of conductive material surrounding and in the magnetic coils (iron-core motors) or external heat sinks (core-less motors) to keep the motor cool enough to operate. One linear shaft motor avoids this problem. It has a permanent-magnet shaft with a high-intensity magnetic field and a small spatial distribution at each pole. The symmetry of electromagnetic coils about its shaft (and field properties of the
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permanent magnets) generate significant force without necessitating an iron core to boost the coil-generated magnetic field. This linear shaft motor’s operating temperature is 135°C without loss of force or motor stiffness due to the motor design. That’s in sharp contrast to core-less motors in which heat can cause separation or movement of the permanent magnets from fixed locations. DW Nippon Pulse nipponpulse.com
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M e c h a t r o n i c s
The last industrial revolution In this next, and may be last, Industrial Revolution, computer intelligence is being deployed in layers throughout the business enterprise—enabling artificial intelligence to provide deeper insight into all aspects of manufacturing. These insights translate to dramatically higher efficiencies in the production process. Steve Meyer • Contributing Editor
A
A lot of effort often goes in to learn something new. Sometimes
that effort can simply be the trial and error that goes into figuring out how to do something that’s never been done before. Effort can also appear in the cost of time, materials, scrapped inventory and other cash costs. Commissioning new machinery requires learning in all of these dimensions and more. Introducing new machinery into a production facility requires that engineers learn, or improvise, how to integrate the machine smoothly into an existing production environment. Operators must quickly learn, usually on the fly, how the new machine performs. Mainte-
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nance personnel must develop a good working knowledge of the new machine’s nuances to keep it running. All of which amounts to a lot of costs that aren’t always counted. Mitigating risk, eliminating downtime Some years ago, major manufacturers made a change in the contracting of custom production machinery, especially where new processes were involved. All new equipment would have to be commissioned and run for 90 days in a staged work environment to prove that the new equipment worked as expected. Prior experience showed that many times, custom machinery was put into production prematurely, resulting in plant shutdowns. In addition—and maybe more importantly—critical fault conditions
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M e c h a t r o n i c s
The new ‘gold rush’ in manufacturing is to deliver information technology that increases the capacity of existing assets.
can be observed during the 90 day ‘shakedown’ and operating code can be written to compensate for any issues. Plant shutdowns cost a lot of money. Any company that mass-produces a product knows the cost of downtime precisely. And that means they know what every hour of additional production is worth. So reducing expenses on the repair and maintenance of plant equipment at the same time that the plant revenue can be increased is a compelling value. Manufacturing investment rests on the size of the investment and the rate of return. Unscheduled downtime in the process industries has been reported to cost producers $20 billion last year. So the new ‘gold rush’ in manufacturing is to deliver information technology that increases the capacity of existing assets. The relatively low cost of processor power means we can apply powerful analytical tools at the edge, where the sensors can generate useful information to prevent outages and increase operational effectiveness, or uptime. These might be functional definitions for oldschool learning about machines. Consider what they
mean in automation. The best machinery designs do not include an exhaustive list of faults and diagnostics; only the most obvious things can be anticipated. Users really find out what’s going on after the machine is in operation. What appear to be bugs in the control code are often the stuff designers weren’t thinking about or combinations of conditions within a complex system that no one could have anticipated ahead of time. Machine learning Machine learning is a special branch of computing in which software algorithms are used to explore the relationships that exist within a complex system using statistical methods. These techniques allow the computer system to learn about the equipment that is being controlled. This is drastically different from the processes that the controls industry has used in the past. We are no longer simply collecting information as single variable files and determining threshold values for ‘good’ opera-
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M e c h a t r o n i c s tion as with waveform signatures and bearing failure. Instead, the computer is searching for non-obvious relationships across many variables simultaneously—things that humans simply cannot do. As sensors, computers and software become cheaper and easier to deploy, the cost and effort required to implement advanced learning tools becomes cheaper as well. The computer can run thousands of trial-anderror correlations in the stream of sensor information. The big difference is not only that the analysis is across all the variables simultaneously, but that it can interpret the relationships in time–short term or long— with equal ease, where no human would ever be able to extract meaning. Machine learning is producing some amazing results. Observations that might have gone unnoticed are now made explicit for humans to act on. The failure of components in the system can be accurately forecast based on the relationships developed in the analytics. So what we should expect in the factory of the future is computer monitoring control systems that are running real world mechanisms. This will free up the controllers from trying to do complex analysis while trying to control processes. Plant-wide optimization and reporting to business information systems can be easily managed by an independent layer of computer production and increase the return on plant investment. Real-world pump control Consider the pump—the humble pump of Archimedes has been with us for more than 2,200 years. Powerful and efficient variants have been produced over the centuries, such as the counter-rotating screw pump, gear pump, positive-displacement pump and centrifugal pumps. With 225 years of experience, Flowserve Corp. of Irving, Tex. is very much aware of the complexities of keeping pumps operating reliably and efficiency. Conceptually, a centrifugal pump is a mechanical system with only one moving part. As pumps have been refined, there are ball bearings and seals to contend with to maximize flow and efficiency. Pumps are used for delivering liquids of all kinds, some that are abrasive, some that are corrosive. It has taken a lot of effort to perfect efficient
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reliable systems that operate under adverse conditions. Pumps powered by an electric motor and coupling add only two more components that need to transmit speed and torque to the input. There still doesn’t seem to be a lot of complexity. Yet by paying attention to the details, Flowserve has created a state of the art solution that is much more than the sum of the parts. The suite of sensors—pump seal temperature, multiple bearing vibration sensors, output flow and pressure, three-phase motor current signals—are all hosted on a National Instrument Compact Rio system, providing high speed data capture. This data architecture creates the means to analyze the total system performance from ‘wire to water.’ Overcapacity is often designed into equipment to allow for contingencies, but in today’s operating environment, overall efficiency and uptime are most critical. Without the ability to combine power monitoring with all the other system sensors, the most important overall relationship would be impossible to evaluate. Flowserve has been a long-term user of PTC Creo’s Pro Engineer software for engineering its products. PTC has been on its own technology migration extending its technology to include Product Lifecycle Management (PLM). PTC’s leadership concluded that products must also be understood in terms of their performance over the life of the product, and that the Internet offers a strategic solution to acquiring this data. Thus, PTC has expanded its software portfolio to allow customers to connect, analyze, store and display real world measurement of the product their customers engineer in 3D solid model with their Thingworx platform. The Compact RIO instrumentation acquires the data at 30 kilohertz sampling rate, generating more than 50 megabytes of data. It then runs initial filtering of the raw sensor data down to 80 kilobytes of data. The filtered files are then transmitted to Thingworx to process and analyze. PTC’s Thingworx software provides the machine learning and analytics to understand the data and provide insight to the health of the pump system. In traditional control systems, tracking a process variable
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like a bearing vibration was costly, not to mention data intensive. In the past, traditional control systems were limited to sensing only ‘out of tolerance’ vibration values and setting an alarm. In the Thingworx platform, the monitoring system can differentiate between system variations that are within the range of normal operation versus conditions leading to failure. Based on deeper learning about the system components, the software will output predicted ‘time to failure’ values—based on history and trending values. The operator interface to the pump system is now a powerful dashboard with data displayed dynamically. This interface includes a range of new information. Not only are there new process variables, like power and efficiency, but there are predictions plainly visible indicating the estimated time to failure of all the critical components of the system. This gives maintenance staff the means to order repair parts and schedule downtime. The PTC Creo CAD software has a further extension that allows the AI local computer to store the original 3D model of the actual pump. The Augmented Reality feature provides the original CAD model as an overlay of the object as seen in a digital camera. This augmented view includes the real time data stream about the pump and its operating conditions, allowing a never-before possible type monitoring that will change the manufacturing plant of the future and how it runs. DW Flowserve flowserve.com National Instruments ni.com PTC ptc.com
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Quality control questions
to ask your low-volume manufacturer Gordon Styles • Star Prototype Manufacturing Co., Ltd, • China
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Low-volume manufacturing companies are pushing the boundaries of manufacturing. Asking them a few key questions will help you ensure quality results.
Low-volume manufacturing generally refers to the production of 50 to 100,000 maximum parts, depending on the process, tooling and materials being used. It lets product developers take advantage of cutting edge and traditional manufacturing techniques from CNC machining to plastic injection molding to 3D printing. Importantly, it can also be used for bridge production prior to mass production and help companies, both large and small, get their products to market first while offering the design flexibility that mass manufacturing cannot match. This mitigates risk and reduces the cost involved when making a design modification. These are just a few of the benefits lowvolume manufacturing offers. Just like any manufacturing job, proper quality control protocols must be in place for low-volume manufacturing to ensure a quality product. For designers, engineers and entrepreneurs looking to take advantage of the benefits of low-volume manufacturing, these questions could help you determine which manufacturing facility to entrust your design to. Can I tour the manufacturing floor? If you ask to tour the manufacturing floor and the answer is “no,” consider that a red flag. The business relationship with any low-volume manufacturer should be transparent. The equipment being used shouldn’t be a secret, but rather a selling point. When touring the manufacturing floor, take notice of your surroundings. Is it well-organized and well-equipped? Be prepared to request records for employee training and certification and talk to the machinists. Also, be prepared to ask for verification of all documentary information, whether it’s in the form of business licenses and registrations, proof of insurance or ISO certificates.
The coordinate measuring machine (CMM) is highly accurate and can be programmed to make repeat measurements quickly.
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Robot exoskeleton case study Dr. Peter Neuhaus, director of the exoskeleton project at the notfor-profit Institute for Human and Machine Cognition (IHMC), contacted Star Prototype to help them make a series of custom parts. They sought help with the Mina V2, a powered robotic exoskeleton designed to provide assisted mobility to people with a physical disability. It uses microcontrollers, sensors and electric motors with a sophisticated user interface. “We love working with Star Prototype for all of our fabrication needs,” said Dr. Neuhaus. “They provide quotes quickly so we don’t waste time waiting, especially when the parts are needed to keep the project moving… What we really appreciate is the great customer service. Getting fast quotes, updates during the process, and pictures of the parts before they send them makes the entire process go smoothly.” After completing a design for manufacturing review of the project, the Star team set to work making the components. The project required that all parts be made to tight tolerances, and that they fit together seamlessly to build the complex three-dimensional geometry required of a moving robotic device. During the course of manufacture, there were a few areas that needed special attention. The main process used to make the steel, brass and aluminum parts for the Mina V2 was CNC machining. Each part was made using a tool and CNC machine appropriate for the level of tolerances and angles required. A turning center is the best way to make precisely round and concentric parts like a spring mount. In that case, a stainless steel rod is held firmly in the jaws of the rotating chuck to prevent any unwanted vibration as it’s being turned down to the final size. With the need for tight tolerances, Star decided to machine the most complex parts on its 5-axis CNC mill. Having such equipment helps to avoid moving the piece from one holding fixture to another on different machines, which makes it tough to hold tight tolerances. For instance, a parallel spring mount with multiple faces and rounded edges made it difficult to hold properly when drilling out the center hole. In the end, Star created a special fixture to hold this part securely to maintain the right dimensions. Once the primary machine work was finished, all of the aluminum parts were bead blasted, cleaned and prepared for aluminum anodizing. Anodizing improves the corrosion resistance of the aluminum, provides a hard scratch-resistant surface, and enhances the cosmetic appearance. Not all alloys accept the anodizing treatment equally well, but AL6061 is a good choice and produces nice results. After bead blasting and cleaning, the aluminum has a non-reflective, matte finish. After anodizing, the parts have a uniform, semi-gloss dark blue metallic coating. Anodizing adds a thin layer of material onto the surface, about 3 to 5 microns. This is enough to interfere with close fit tolerances and machine threads, so threaded holes must be cleaned after anodizing, exposing bare metal.
Star Prototype built custom parts for the Mina V2, a powered robotic exoskeleton designed by the Institute for Human and Machine Cognition. The process involved a design for manufacturing review followed by fabrication via CNC machining of the steel, brass and aluminum parts. 114
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"If you ask to tour the manufacturing floor and the answer is “no,” consider that a red flag.
Personal CNC
The business relationship with any low-volume
Prototyping - Product Design - R&D - Engineering
manufacturer should be transparent. The equipment being used shouldn’t be a secret, but rather a selling point. "
Can you support me in optimizing my CAD design for manufacturing? It’s important to make sure you’ve selected the correct manufacturing process for your design and it’s equally important to have a design that’s been optimized for manufacturing. There are ways to design products that will reduce time and money spent manufacturing while achieving the same results. Having an engineering team checking your design will make your life easier and will prevent avoidable errors. Design for manufacturing is especially applicable to 3D printing. Designing specifically for 3D printing is not an easy task as multiple variables need to be accounted for. For example, it’s important to ensure that the 3D CAD file is optimized to be compatible with the tolerances of the machine that will be printing it. The AM250 printer, manufactured by Renishaw in the UK and used at Star Prototype, requires a minimal wall thickness of 0.2 mm and holes/gaps must be 0.4 mm or larger. These parameters are functions of powder size, beam profile and table movement among other variables. Closer tolerances can be achieved on the exterior of the 3D printed parts through a variety of techniques, including CNC machining. However, the post-finishing of December 2016
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Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line. To read more about this story, and to see what others are doing with their PCNC mills, visit www.tormach.com/design. PCNC 1100 Series 3
Titanium bone screws and surgical spinal implants manufactured by Eisertech LLC.
PCNC 770 Series 3 PCNC mills shown here with optional stand and accessories.
www.tormach.com/design
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The quality control lab at Starâ&#x20AC;&#x2122;s facility includes a diverse array of test equipment including OES, CMM, and Faro laser scanners.
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used by the low-volume manufacturer. There is sophisticated metrology equipment for the testing of bar and plate stock for subtractive manufacturing. Star Prototype, uses an Oxford Instruments Optical Emissions Spectrometer (OES) for inspecting incoming metal supplies, which enables a spark test to be conducted on incoming metals. At Star, a hand-held PolyMax gun is used for Positive Material Identification of plastics. The PolyMax uses Raman scattering for the testing of plastics. These are just a few of the effective methods that can be used by a low-volume manufacturer for the testing of incoming materials.
internal features is somewhat limited. Features like holes and pockets can be added, but must fall within the line-of-site of a straight drill bit or mill to do so. Do you test incoming materials? The quality of raw materials varies widely around the world. To ensure that the materials are not fraudulent or non-conforming, find out where the material was purchased from and request a website address or other identifying information. Powder for 3D metal printing, for example, is only available from a relatively small number of suppliers or from the actual company that created the 3D printer. Knowing that the powder came from one of these sources should provide peace of mind. This little bit of legwork up front could pay large dividends down the road. For subtractive manufacturing techniques like CNC machining, itâ&#x20AC;&#x2122;s also beneficial to find out what material identification tools are being GM070 DW 07-16 Half Page Ad Matls AF_PDFx1a.pdf
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What type of measurement tools do you use on finished parts? There are a variety of technologies that can be used for ensuring a finished product meets the original design specifications. Laser scanning can be effective for measuring parts with 1
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complex geometries. The surface of a part is scanned to create a digital file that can be compared to the original CAD file. However, performing a complete dimensional measurement of a finished part should be a common practice of low-volume manufacturers. This can be completed using a coordinate measuring machine (CMM), which has a massively stable granite table with a very flat surface. A precisely made sapphire crystal mounted on a touch probe assures measurement accuracy. To reduce temperature-induced measurement variations, the CMM should be located in a climate-controlled room. To ensure that the finished part matches the original CAD file, the CMM can be programmed to use the coordinates from the CAD file. Programming the machine using the CAD file allows it to automatically measure parts in succession. DW
Star Prototype Manufacturing Co., Ltd www.star-prototype.com
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Slip clutches:
Where they excel Jessica Mallinus â&#x20AC;˘ Dynatect Manufacturing
Slip clutches can boost machine speeds and protect against overloads. They also work to apply constant tension in indexing applications and those that involve the processing of webs or wires.
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Torque limiters abound in industry but slip clutches are a leading way to limit torque. In fact, there are many types of clutches — including friction slip clutches as well as electromagnetic, toothed jaw, and one-way clutches. Any of these operate in small spaces in a similar torque range — so it’s useful to know the differences between the technologies. Torque limiting with servomotors versus mechanical and electromagnetic options Most motion designs need stopping, holding, or indexing at some point during the machine cycle. Setups that incorporate an electric motor may in some cases rely on that motor to both accelerate axes and bring them to stops. One caveat: Electric motors excel at delivering sophisticated motion profiles, but cost ten times what mechanical and even electromechanical clutch options cost. So generally speaking, only high-performance or high-speed equipment uses servo and stepmotors to stop and hold loads. Mechanical torque limiters versus electromagnetic versus servomotor options Common mechanical slip clutches use friction pads to transmit torque from clutch-hub flats to mating flats on inside plates. Then torque goes through outer plates through torque pins to housing and output axis. Installers can adjust torque through a nut on a compression spring. Or for a fixed-torque clutch, a collar attaches to the hub in a fixed position (and not the adjusting nut). That way the shaft or the housing can act as input when running — with the other driven. A key benefit of mechanical devices is the added mechanical safety in electronically controlled systems. In addition, mechanical slip clutches deliver smooth and reliable breakaway and continuous slip; bidirectional operation; life to 30 million revolutions under slipping; and torque of 0.5 to 750 lb-in.
In this medical application, a Dynatect Polyclutch Slip-Ease clutch works as a retention hinge on the mounting platform of a surgical device.
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Slip clutches can prevent both damage to drives or airlinepassenger injury if something obstructs a screen.
Here, a Polyclutch Slipper clutch applies precision torque control during the manufacture of dental implants.
fficiency
Continuous-slip clutches transmit torques from delicate ounces per inch to more than 1,000 lb per inch depending on speed and duty cycle — with heat limiting operation: Watts = 0.011 x torque (in. lb) x rpm Heat that exceeds design wattage reduces the life of the clutch. However, friction-plate clutches that run within design limits may run millions of cycles and often outlast the rest of the machine. Slip clutches excel in setups needing overload protection. Shear pins do the same job but are one-use items that require replacement. In contrast, ball-detent clutches slip at design torque by pulsating from zero to breakaway. When the axis blockage clears, the clutch returns to normal operation to protect the drive from the next blockage that may occur. In contrast, friction-plate clutches slip constantly at breakaway torque. The most common setup uses friction pads and axially loaded plates to transmit torque. That means higher axial load results in higher transmitted torque. Pneumatics, electromechanical elements, or simple springs transmit axial load. Pneumatics and electromechanical elements are adjustable with air pressure or voltage. Taking adjustability are servomechanisms that let users vary torque at will.
Shown here is a clutch in an automatic door control. Torque is adjustable by changing pressure on the clutch pack with compression springs. Or in fixed clutches, a collar on the hub stays put — and torque sets by locking the collar to a setting.
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Electromagnetic torque limiters versus mechanical versus servomotor options Electromagnetic clutches boost efficiency and avoid the leakage problems of comparable hydraulic alternatives. They come in both power-on and power off versions. The former engages when power energizes a holding coil. The latter design releases when energized with a spring holding the brake closed or engaged (unenergized) during operation. Power-off clutches are more common than power-on versions because they can hold loads in fixed positions during power failures. Usually these clutch run off 12 to 24 Vdc. Electromagnetic clutches can sometimes outperform servomotors for stopping or slowing rotary motion. That’s because they’re generally less expensive for a given level of performance. Plus, thanks to their unmatched stopping torques (and high torque-to-inertia ratios) they deliver very accurate stops. In fact, electromagnetic clutches are most suitable in designs that need the rotary axis to turn in both directions; to start and stop in reaction to unpredictable external conditions; to deliver soft stops; and to stop from very high speeds — even from thousands of rpm. Common applications for continuous slip clutches Continuous slip clutches are particularly suitable for cushioning and tension control. So during a machine axis acceleration, slip clutches can work so static friction is lower than dynamic friction. That makes for gradual torque increase to cushion sudden loads on the axis. Consider a web application: When paper, film, wire, or thread tensioning is gradual, it ultimately lets machines run faster without ripping or snapping the web material. Cushioning also helps minimize shock loads on pulleys, gears, chains, and motors. Other applications include tension control on winding, labeling, printing, and knitting machinery or even consumer-grade designs such as light balances and fishing reels. Here, the clutch makes a roller turn as the material unspools to overcome the slip-clutch torque setting. That subjects the web or line of material to a force that drops to zero when the axis or spool stops pulling on it. Otherwise, some setups use clutches that turn slowly to oppose
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the spool feed and take-up slack. That way, force stays constant and minimizes jerking. Slip clutches can also extend tool life in screw and bottle-capping designs. In these setups, clutches prevent tool slipping against product and accommodate that slipping internally. Consider how capping machinery includes polymer wheels to screw caps onto bottles advancing along conveyors. Older machines bottom out the caps by letting the wheels slip along the cap even if that sometimes damaged the bottles or prematurely wore the wheels. In contrast, newer machines use slip clutches to allow for slipping and stop the wheels when the caps bottom out. In fact, slip clutches also improve the accuracy with which capping machines apply torque â&#x20AC;&#x201D; and even allow operators to reset a machine to accommodate switches in which product is being processed. Here, pneumatic
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or electric actuation takes it a step further with on-the-fly torque adjustments. Clutches capable of continuous slip also work on conveyors and index tables. Here, low-speed indexers can sport a holding a pin on a wheel to use slip clutches for continuous slack. A solenoid removes the hold on the indexing wheel so the holding component goes back to position before the wheel advances to the next pin. Designers can install pins to allow for partial or full revolutions; moving pins changes the cycle. Slip clutches also protect against overloads in these indexers. Slip clutches also work for force control. Case in point: Conveyors moving items can push against gates fitted with slip clutches without breaking said items or the conveyor. The clutch also isolates overloads. Such force control works in ice machines to push frozen arrays of cubes
into a bin. After a full revolution, controls trigger a new freeze cycle. Itâ&#x20AC;&#x2122;s an inexpensive mechanism that cuts cycle time. Slip clutches that work as friction hinges install at pivots to hold doors and display screens in place. Here, one-way clutches also reduce resistance to keep open covers raised. Such slip clutches deliver cushioned moves or temporary holding when a mechanism stops at a position. When a motor moves an axis (such as a door) to a locked position, sometimes a bit of slip at the end of the cycle is useful. Here, a time delay can prevent motor overheating ... but a slip clutch is a better solution because it can disengage the motor from the load for extended periods. DW Dynatect Manufacturing www.dynatect.com
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Shock and vibration
mitigation by design,
not by mistake Design engineers and equipment operators often view shock absorbers and isolators as nonessential fixit elements to add to original equipment only if it shows vibration or shock problems. Here we debunk this and other common misconceptions.
Christopher Kudla â&#x20AC;˘ Product Manager â&#x20AC;˘ ITT Enidine
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Engineering design is always evolving. With its progress comes a need to revolutionize the way plant managers and product engineers think of shock absorption and vibration isolation. Thatâ&#x20AC;&#x2122;s because all industries are demanding faster production or higher performance. In most manufacturing (including that in industrial, food and beverage, and biopharmaceutical markets) demand for efficiency means running machines more often and at faster speeds. Complicating matters in food and beverage and biopharmaceutical designs is the concurrent increase in regulation. Confounding designs in industries such as oil and gas is rapid innovation thatâ&#x20AC;&#x2122;s completely changed (in just a few years) the machinery of choice. Here, minimizing shock and vibration from the start makes for longer-lasting designs.
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Currency-counting machines rely on small Enidine TK Series absorbers to prevent errors and jamming. Incorporating shock absorbers in original equipment boosts operating speeds, machine safety, and competitive advantage. December 2016
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fficiency
Enidine compact wire-rope isolators help eliminate vibration from UAV applications so they can soar more steadily.
Modern engineering is also incorporating more sensing and processing technology into all aspects of design. This shift calls for mitigation tuned specifically to applications and prevention of vibration and shock in even the smallest parts of machinery — as in a sensor on a piece of agricultural equipment, or on military vehicles subject to harsh impact landings, for example.
The primary goal when handling shock and vibration is to reduce acceleration to which the equipment or design is subject.
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Basics of vibration mitigation In industrial applications, shock and vibration is everywhere. It degrades overall safety, efficiency, and machine output. Many times, equipment operators react to shock and vibration problems by seeking and integrating products to mitigate shock and vibration only after issues arise. However, proactively designing mitigation into equipment boosts long-term machine health and reduces total cost of ownership by preventing failures. To review, shock is impact that occurs at the end of a movement, and it can take place
anywhere there’s a hard stop or collision. For example, in automated designs, that might be in a warehouse storage and retrieval system, in doors that open and close, or on a facility’s conveyor. In contrast, vibration is small, high-speed oscillations caused by frequency excitation through some inherent imbalance. Vibration occurs in rotating or reciprocating equipment (electric motors, pumps, compressors, engines and gearboxes, for example) and often fatigues components and mounting points. The primary goal when handling shock and vibration is to reduce acceleration to which the equipment or design is subject. Industrial shock absorbers are mechanical devices that bring a moving object in industrial machinery (such as a conveyer system or crane) to rest. They provide controlled deceleration by converting kinetic energy into thermal energy. This thermal energy then safely dissipates into the atmosphere to prevent additional equipment shock and
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damage. Other commonly used shock absorbers include rubber bumpers or springs and cylinders. However, these often exhibit undesirable recoiling and different forms of shock loading and vibration. Vibration isolators reduce the effects of shock and vibration. A major problem in industry is how vibration causes damage to internal machine components and electronics. Here, wire rope isolators, air springs, and elastomers are some solutions. One caveat: Elastomeric products attenuate noise and vibration levels, while wire rope isolators do this and also provide shock attenuation capability. Damping misconceptions versus reality Needing shock absorption is not a sign of bad engineering. As mentioned, a common misconception is that shock absorption is no more than a Band-Aid solution to address fundamental design flaws. The logic is that if a piece of equipment or manufacturing process needs a shock absorber to boost uptime, then it was improperly designed or is malfunctioning. In fact, nearly all industrial equipment experiences some level of shock during operation. By incorporating shock absorption into equipment or facility up front, engineers can get higher equipment operating speeds with lower reaction forces on structures, equipment, and products. What’s more, integrating shock-absorption technology reduces impact forces, which often lets designers choose smaller, cheaper, and more efficient design structures. Lower forces mean less maintenance and downtime because equipment is subject to less overall wear and tear. More specifically, reduction of acceleration g reduces force where: Force = Equipment weight x Number of gs Reduced impact forces means less stress on structural members. So lower stress lets engineers use smaller parts or build designs with less support structure while still maintaining a given amount of strength and performance. In addition, incorporating shock absorption into the design lets it run at higher velocities in production processes while eliminating concern about end-of-motion impact. In other words, shock-absorption products manage kinetic energy at the very ends of machine-axis movements — so moves can happen as fast as possible without slamming, banging, bouncing or breaking afterwards. This boosts production speeds and throughput from the start, for shock absorbing that’s better tailored than what’s installed after machine failure. Plus high-velocity applications with shock absorbers don’t need to slow down before the end of motion and there will not be any bounce when the movement stops. This also means an increase in production speeds since the time spent moving the product or material is done as quickly as possible and without threat of failure. In addition to higher throughput, proactively adding shock absorbers to equipment can improve product quality since there are lower accelerations (number of gs) during movement. When molds and dies are cushioned upon closing, overall production quality sees improvements as well. Without any residual energy remaining when the mold closes there will not be any bounce or rebound which can cause molding defects. December 2016
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M e c h a n i c a l Ultimately, building shock-absorption technology into original equipment and facility design means that equipment can handle higher forces more quickly and with smoother motion. Approaches to vibration isolation As with vibration mitigation, vibration isolation can also be misconstrued as an afterthought, rather than a proactive solution. Operators generally believe that if equipment needs to be isolated with flexible mounts it is because the equipment is worn out, bearings are old or something is out of balance. Facility personnel can’t entirely prevent vibration in equipment but can be proactive in reducing it by building vibration isolation into original designs. It’s expensive to keep equipment perfectly balanced and maintain tight tolerances. It’s also inefficient to add structural braces and patches as a way to prevent damage to the surrounding structure. In contrast, adding vibration isolation such as wire rope isolators or air springs is cost effective and efficient. Designing equipment and
Shock-absorption technologies must withstand harsh environments that include extreme temperatures, caustic washdown areas, and high cycle rates. Shown here are shock absorbers on a turntable conveyor that increases handling forces while making motion smoother.
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M e c h a n i c a l processes upfront with vibration isolation reduces forces to save machinery structures from fatigue on brackets and welds. With less equipment wear and tear comes more efficient structure design without the threat of broken parts and downtime. In addition, reciprocating equipment such as pumps and compressors with higher levels of vibration can be used in the manufacturing process without damage to bolts or adding heavy and inefficient structural braces. Adding vibration isolation can reduce this risk and boost pump and compressor performance. Proactive mitigation also improves operator safety with better ergonomics. With less vibration, operators are able to handle equipment more productively and with greater ease of use. Reducing vibration in equipment and facilities with built-in isolation solutions lets components vibrate by controlled design and not at random.
Application examples for shock and vibration mitigation Cameras on remote operated vehicles often face issues with excessive vibration. These devices are typically not designed with isolators, but as the performance of today’s compact cameras continues to increase, vibration from surroundings is increasingly evident in output video. Getting smooth video and images necessitates incorporation of isolators. Due to the size of these cameras, it’s challenging to get the right fit and meet requirements with retrofit isolators. But OEMs who incorporate compact wire rope isolators into original designs get great design performance for this high-end market. Bank-note counting machines use vibration isolation to prevent bounce in moving components as each note is counted. Any bounce disrupts the precise movement of the machine and causes counting errors or jamming. Financial applications have zero tolerance for error. When one OEM designed
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shock-absorption technology into one such counting machine, it realized increased speed and efficiency without risk of inaccuracies. DW ITT Enidine enidine.com
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Optimization of a robot gripper claw in solidThinking Inspire resulted in 35%+ mass reduction. Source: solidThinking solidThinking-Inspire
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3D CAD
Simulation Is Becoming Democratized— At Last (Part 1) Software choices for simulation continue to expand. Here’s an overview of the latest offers. Bruce Jenkins • President, Ora Research
Two decades ago, engineering software developers launched their first efforts to make simulation and analysis capabilities accessible and safe to use by engineers and designers who were not professionally trained analysts. The result was a wave of CAD-integrated finite element analysis (FEA) applications that were made usable and safe for non-analysts by having their functionality sharply curtailed in comparison with traditional full-featured FEA software intended for specialist users.
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3D CAD
Autodesk Inventor’s Shape Generator helps engineers design structurally efficient, lightweight parts right within their CAD system. Source: Autodesk
After early enthusiasm, more and more buyers as well as prospects evaluating those volume-market FEA products began to conclude that, in being made safe for generalist users, the tools had been dumbed down to the point of delivering disappointingly less value than users had hoped for. Although they did find some adherents, the result in many engineering organizations was widespread and longstanding disillusionment with the idea of trying to de-bottleneck product development and get more value from simulation by expanding its use beyond the analysis department. However, across the past handful of years, a wealth of new technological avenues are at last making advanced simulation capabilities accessible, practical and safe for use by non-analyst engineers and designers in ways that no longer depend on neutering their function. These include: far more sophisticated and intelligent CAD/CAE interconnection than those early attempts, meshless structural analysis and other techniques to simplify and accelerate problem setup, very affordable cloud-based HPC (high-performance computing) resources, and a rising wave of new fit-forpurpose vertical simulation “apps.” Accelerating geometry preparation and problem setup Effectively every CAD and CAE software vendor today offer tools that link those two domains in ways that put significant simulation and analysis capabilities in the hands of non-analyst engineers and designers, safely 130
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and efficiently. This overview is representative but far from exhaustive. Altair’s HyperWorks open-architecture, multiphysics CAE platform includes HyperMesh, a multidisciplinary finite element pre-processor that manages the generation of large, complex models, from the import of CAD geometry to exporting a ready-to-run solver file. HyperMesh is a solver-neutral environment with an extensive API for advanced customization. Altair’s SimLab is a process-oriented finite element modeling application especially suited for solid element modeling. Not a traditional off-the-shelf pre/post-processor, SimLab is instead a vertical application development platform for capturing and automating simulation processes. Altair’s solidThinking Inspire software improves concept development by generating optimal structural concepts for parts and assemblies. Designed for use with all CAD systems, it lets design engineers, product designers, and architects create and investigate structurally efficient concepts quickly and easily. Where traditional structural simulation allows engineers check if a design will support required loads, Inspire enhances this process by generating a new material layout within a defined package space using the loads as input. Ansys’ AIM is an easy simulation environment designed for all engineers that offers
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3D CAD integrated single-discipline and multiphysics solutions based on best-in-class solver technologies in a modern, immersive user environment. Ansys SpaceClaim is fast and intuitive 3D modeling software that lets any analyst or engineer create, edit and repair geometry no matter where they are in the workflow. This CAD-neutral tool lets users quickly and easily manipulate geometry themselves, instead of having to send it back to the CAD department. Ansys DesignSpace is an easy-touse simulation package with tools to conceptualize, design and validate ideas on the desktop, using the same solver technology as Ansys Mechanical. DesignSpace users do not need advanced analysis knowledge to perform real-world static structural and thermal, dynamic, weight optimization, vibration mode and safety factor simulations. DesignSpace works directly with existing CAD systems through bidirectional connections, or with standalone geometry files.
Across the past handful of years, a wealth of new technological avenues are making advanced simulation accessible, practical and safe for non-analyst engineers and designers.
Autodesk mechanical simulation products use finite element analysis to predict product performance through linear, nonlinear, thermal and dynamic analysis. Autodesk Simulation Mechanical includes Autodesk Nastran FEA solver software, and provides designers, engineers, and analysts
with tools for FEA and modeling. Users can set up advanced simulations with vibrational analysis tools including Mechanical Event Simulation (MES), Autodesk Nastran FEA solver software, multiphysics simulations, multi-CAD format support, and composites. Autodesk Nastran In-CAD is CADembedded FEA software intended as a general-purpose FEA tool for engineers and analysts. It offers a range of simulation powered by the Autodesk Nastran solver with CAD integration and integrates with compatible software to simulate real-world behavior. Autodesk Inventorâ&#x20AC;&#x2122;s Shape Generator is a new approach to designing lightweight, structurally efficient parts that provide a creative strategy for maximizing part stiffness based on user-specified constraints. Integrated into Inventor, making it convenient to incorporate into the design process, Shape Generator produces a 3D mesh that can be used to guide design refinement.
MSC Apex, a linear structural analysis system, helps streamline CAD cleanup, simplification and meshing workflow. Source: MSC Software
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3D CAD Autodesk Within generative design software helps engineers and orthopedic implant specialists create lightweight, latticed designs that are functionally optimized and accurate for additive manufacturing. Varying the densities of surface skins and internal lattices using Within design optimization software achieves results that are lighter-weight than the original, as stiff or as flexible as needed, and have the desired aesthetics. A built-in optimization engine automatically refines parts for additive manufacturing. Autodesk Research’s Project Dreamcatcher is a generative design system that lets designers define their design problem in terms of goals and constraints. The software uses this information to synthesize an array of alternative design solutions that meet the defined objectives. Designers can explore tradeoffs among these alternative approaches, then select the best design solution for manufacture. Comsol offers a family of LiveLink products that let users access Comsol Multiphysics analysis capabilities from within their 3D mechanical CAD software environment. LiveLink is available for Solidworks; Autodesk Inventor, AutoCAD and Revit; PTC Creo Parametric and Pro/Engineer; and Siemens PLM Solid Edge. DS Simulia’s Simulation-Based Design portfolio provides powerful, yet easy-to-use design-centric simulation tools including guided workflows and active assistants to help designers and engineers achieve their design goals through simulation. The portfolio uses Abaqus simulation technology to help designers solve problems within their familiar design and engineering environment. The portfolio consists of applications targeted to specific user “roles.” For example, Structural Analysis Engineer is a “Simulation Role for the Design Engineer” using finite element techniques to assess structural integrity of products subject to a range of loading conditions to guide design decisions for product performance and quality. DS Solidworks’ Solidworks Simulation, part of its Premium 3D CAD design package, provides core simulation tools including Solidworks Motion, Structural Analysis and Nonlinear Analysis. Full integration with Solidworks modeling creates a short learning curve and eliminates redundant remodeling tasks required with traditional analysis tools. Product designs can be tested for strength and safety, and have their kinematics analyzed. Product engineers can evaluate structural product performance under a range of physical scenarios using the virtual testing environment of Solidworks Simulation Professional. Fully embedded with Solidworks 3D CAD, Solidworks Simulation Professional helps engineers determine product mechanical resistance, product durability and natural frequencies, and test heat transfer and buckling instabilities. Pressure vessel analysis and complex loading are also supported. Solidworks Conceptual Designer, a cloud-based 3DExperience Solution, provides mechanism synthesis and motion analysis to help validate mechanical operation during concept development. 132
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Automatic background simulation and real-time analysis during design confirm the model’s operations. Users can define design goals, then receive automatic alerts if designs fall outside of specified parameters. ESI Group‘s VisualDSS is a framework to let users make a final decision on the product. It provides seamless connection with various CAD systems to extract data to build virtual tests, and lets users build and chain multiple virtual tests upstream and downstream for an integrated process. Simulation content from those virtual tests is collected and managed efficiently and appropriately by VisualDSS through capture, storage and reuse of enterprise knowledge and best practices. It automates repetitive and cumbersome tasks in virtual prototyping, and propagates engineering changes and design changes from one domain to another. Finally, it lets globally dispersed virtual product development teams work together on a design. Exa’s preparation tools PowerDELTA with PowerCLAY streamline and automate simulation model creation for input to its PowerFLOW aerodynamic, aeroacoustic and thermal management simulation software, PowerTHERM thermal management solution, and PowerCOOL heat exchanger simulation software. PowerDELTA applies parametric feature modeling, direct mesh morphing and history tree model management to simulation model creation. Design data in most major CAD and mesh formats is supported. Meanwhile, Exa’s PowerCASE provides an intuitive, fast interface for preparing cases with any level of geometric complexity. On completion of a simulation, PowerVIZ lets results quickly be analyzed, while PowerINSIGHT allows results analysis to be automated. Finally, PowerREALITY fosters collaboration between engineers and product designers/stylists through photorealistic visualization of simulation results. MSC Software’s Apex Modeler is a CAE-specific direct modeling and meshing solution to streamline CAD cleanup, simplification and meshing workflow. Direct modeling lets users create and edit geometry interactively by selecting the entities of interest such as a face, edge or vertex, then pushing, pulling or dragging to modify them. Direct Modeling is complemented with built-in meshing technology. With Direct Modeling and Meshing, for models that have already been meshed and need further geometry modification, users can employ any of the Direct Modeling or Geometry Clean-up/ Repair tools, and the mesh will be immediately regenerated. MSC Apex Structures is a fully integrated and generative structural analysis solution for engineers and analysts. An addon product that expands MSC Apex Modeler functionality with capabilities for linear structural analysis, MSC Apex Structures packages a user interface for scenario definition and results postprocessing with integrated solver methods. MSC characterizes the solution as unique in that it combines computational parts and assemblies technology with a generative framework, thus enabling interactive and incremental analysis. Apex Fossa, the sixth release of MSC Apex, adds capabilities
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for solving problems related to vibration. Conventionally, solving vibration problems has been a tedious trial-anderror process. Apex Fossa allows design exploration to happen in the analysis results space, without having to go back to CAD to redesign the part or assembly. This feature can slash the time to achieve an optimal solution from days to hours, and make vibrational analysis more accessible to engineers. nCode‘s new Aqira is an integrated engineering solution for all levels of users across manufacturers’ physical test and virtual simulation departments globally. Intended to address the requirements of engineers, managers and IT professionals in an intuitive and efficient system, Aqira is meant to help ensure the right product durability with greater reliability than ever, and in less time. For organizations that rely on a few key individuals for important corporate knowledge, Aqira enables engineering insights from more people at the right time. Finally, Aqira is multi-platform, accessible from anywhere on any device.
The Simcenter portfolio for Predictive Engineering Analytics is a robust suite of simulation software and test solutions. Source: Siemens PLM Software
Effectively every CAD and CAE software vendor today offers tools that link these two domains in ways that put significant simulation and analysis capabilities in the hands of non-analyst engineers and designers.
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PTC‘s Creo product suite offers a range of interoperable simulation solutions, all with a simplified user interface and intuitive workflow. The aim is that, with a few clicks, simulation can fit easily and conveniently into the user’s design life “without requiring data translation, eye-popping math, or the sudden acquisition of mysterious skills,” as PTC puts it. Creo Simulate, closely integrated with Creo Parametric, has comprehensive FEA capabilities for thermal and structural analysis. Users simply apply constraints, loads and forces, and the software provides results. Users can change inputs as needed and continue refining the product based on feedback from the reanalysis. Siemens PLM Software‘s Simcenter Solution Portfolio combines system simulation, 3D CAE and test to help engineering teams predict performance across all critical attributes, both early and throughout the product lifecycle. By combining physics-based simulations with insights gained from data analytics, Simcenter helps optimize designs and deliver innovations faster and with greater confidence. Simcenter lets users create a digital twin of their product, a multifidelity model that reflects reality and continually evolves throughout the product lifecycle to accurately simulate performance from concept through actual use. By combining simulation and physical testing with intelligent reporting and data analytics, Simcenter helps produce digital twins that more accurately predict product performance throughout product development. Simcenter helps engineers go beyond simple verification to performance prediction by combining simulation, physical testing and data analytics to spot unforeseen trends. Siemens PLM Software’s Solid Edge offers scalable simulation capabilities that range from Solid Edge Simulation Express for individual parts, to Solid Edge Simulation for assembly analysis, to Femap for defining and analyzing complete systems. The
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product line provides a scalable upgrade path for users who need to solve progressively more challenging engineering problems. Solid Edge Simulation is a new, built-in FEA tool to let design engineers digitally validate part and assembly designs within the Solid Edge environment. Solid Edge Simulation Express offers users entry into embedded simulation through first-pass simulation of individual solid or sheet metal components for statics and modal analyses. The next article in this series will examine how meshless structural analysis and other technology advances are simplifying and accelerating the traditionally time- and labor-intensive tasks of analysis model creation and problem setup. It will also explore the explosive growth of commodity cloud-based high-performance computing, which is finally making adequate computational resources for simulation accessible and affordable for engineering organizations of all sizes. DW
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A supplement of Design World â&#x20AC;˘ December 2016
3D Printingâ&#x20AC;&#x2122;s Next Dimension 144
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Quantifying 3D printing
Additive lays the
for surgical simulation
foundation for full
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3D Printing’s Next Dimension Leaders in the 3D printing industry give insights into where 3D printing / additive manufacturing will go next.
The higher profile industrial-grade 3D printing / additive manufacturing has experienced over the past decade has led to notable technology developments and potential new applications. The buzz over 3D printing has also created much speculation about whether this 30-year-old technology is poised to make a giant leap forward in capabilities. “We are just now starting to see the fruits of these developments,” said Rob Connelly, vice president of additive manufacturing for Proto Labs, referring to recent announcements about advances in new machines, materials, and software. Three leaders from the 3D printing industry were interviewed for insight into the current and future state of 3D printing. The interviewees were: • Rob Connelly, Vice President, Additive Manufacturing, Proto Labs • Patrick Dunne, Vice President, Advanced Application Development, 3D Systems, which manufactures and sells 3D printers • John Murray, President and CEO, U.S., Concept Laser, a global provider of 3D metal printing systems
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» The utility of stereolithography will move
beyond prototyping into the manufacture of end-use parts.
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Q: What’s new regarding 3D
printing machines, processes, and capabilities?
A: John Murray, Concept Laser: We just built three, six-cylinder engine blocks for a major European automotive OEM that are running around on Germany’s Autobahn right now, which is pretty cool. So, I would point to the ability to print large parts as new and notable. The other modular machine we’re excited about, which is in Beta testing, is our Factory of Tomorrow, which will link up hundreds of machines into a single, totally automated and autonomous environment. A: Patrick Dunne, 3D Systems: The way I see it, development in 3D printing is about new capabilities, not new products. The only thing that matters is, after all, what we can get out of machines. And we’re seeing capabilities advance rapidly in many of the existing 3D printing technologies.
“The explosion in computing power and corresponding power of software has been an enabler in much of the expansion in 3D printing applications. Notable trends are better user interfaces, process-specific analysis/simulation, and the establishment of a new file format standard that will someday replace the STL-faceted file as an input to 3D printing processes.” - Rob Connelly
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obtaining the best systems and quickly integrate them into our service offering.
Q: What about on the materials side? A: Dunne:
We’re seeing materials today that are taking 3D printing beyond prototyping and into manufacturing functionalgrade parts. We’re seeing that take place in both metals and plastics. One
“One trend is customers seeking a competitive advantage through the development of specific alloys. One metallurgist for an aerospace OEM recently told me with a smile, “I love your technology, because, for the first time, I can play God with metals.” - John Murray
A: Rob Connelly, Proto Labs: We are excited to be one of the foundational customers of the new HP Multi Jet Fusion technology. It shows signs of significant potential to change the game for the sintered plastic part portion of the 3DP industry, and we intend to work closely with HP to evaluate it, guide its evolution, and position it to help customers. We’re not an equipment manufacturer, nor are we affiliated with any machine OEM, so we have the luxury of
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notable development on the plastics side comes from our recently unveiled Figure 4 platform, which brings high-speed additive manufacturing to the automated production environment. Because of the characteristics of this system, we can use new polymers with previously unachievable properties— and even beyond into functional thermosets.
A: Murray:
UNLIMITED
We’re focused solely on metals. One trend is customers seeking a competitive advantage through the development of specific alloys. I call them boutique alloys. One metallurgist for an aerospace OEM recently told me with a smile, “I love your technology, because, for the first time, I can play God with metals.”
A: Connelly: The Carbon platform stands to augment and extend the utility of stereolithography beyond prototyping, into manufacturing end-use parts. Carbon’s process has strengths and weaknesses like all of the others, but one strength is the new chemistries of its resins. Due to the fact that only a small amount of material is in use at any one time, Carbon’s process allows for the economic use of two-part materials with limited working time. This opens the door to chemistries that have higher performance than today’s long shelf-life resins. We are evaluating these developments and determining where they might benefit customers. Printing parts with multiple materials within the same part is another exciting development. This, too, is a capability that we are currently evaluating.
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“The second area of development is in software that controls and interacts with 3D printing itself. These software tools control and manage the entire process of taking a digital file and exporting it as a physical file.” - Patrick Dunne
Q: Any software trends to discuss?
with 3D printing itself. These software tools control and manage the entire process of taking a digital file and exporting it as a physical file.
A: Connelly: The explosion in computing power and corresponding power of software has been an enabler in much of the expansion in 3D printing applications. Notable trends are better user interfaces, process-specific analysis/ simulation, and the establishment of a new file format standard that will someday replace the STL-faceted file as an input to 3D printing processes.
A: Murray:
Our new QM Meltpool 3D system is a powerful tool for monitoring and inspecting parts. After the build is complete you have a virtual CT scan of that entire build…this is getting lots of attention in aerospace and medical.
A: Dunne: On the software side, there are two areas that are exciting. The first is topological optimization: using algorithms to design structure, as opposed to a human iterating at a low frequency. These algorithms enable the maximum level of efficiency and optimization. Interestingly, the optimized geometries are almost never compatible with traditional manufacturing techniques, which creates a sort of symbiotic relationship between topological optimization and 3D printing. The second area of development is in software that controls and interacts 142
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In addition, our Parameter Editor offers customers the capability to develop, qualify, and tweak every variable for their materials…with the goal of better overall part quality.
Q: Using additive manufacturing for
prototyping remains strong, but what about using it for production—are more advances needed?
A: Connelly: Production using 3D printing has been the “holy grail” for companies for many years. In reality, it has been in constant use for some production applications for decades. As process innovation continues, and technologies evolve, more and more applications will
become viable for production using 3D printing.
A: Murray:
3D printing for production is here now; it’s not the wave of the future. One of our largest customers has been in production for implantable knees and hips for six years now, and that shocks people. Also, in aerospace, aircraft manufacturer Airbus is aggressive in moving toward high-volume manufacturing with 3D printing.
A: Dunne:
We already have additive manufacturing workflows that yield more than 150,000 unique parts per day. In addition to these “mass customization” manufacturing workflows, we see more and more “mass complex” manufacturing workflows in which engineers tap into part complexity to increase the value of end products. A great example here would be 3D-printed spine cages used in spinal surgeries. The implants are all the same, but offer performance characteristics that exceed traditionally manufactured devices.
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Q: Why does 3D printing have a seat at the traditional
manufacturing table?
A: Murray: It’s not the answer to everything, it doesn’t do everything, but it is one more tool. 3D printing allows you to combine ten parts into one, get lighter parts, stronger parts, more efficient manufacturing. Q: Are there any industries that are taking full advantage of 3D printing?
A: Dunne: Aerospace and health care come to mind. With aerospace, it’s all about part-count reduction, performance improvement, and weight reduction. There is a lot of inefficiency in aircraft with respect to weight and a lot of metal hitching a free ride through the air. With topological optimization, you can cut a lot of that weight out…health care companies are reaping similar benefits from 3D printing. Q: Any other trends worth noting? A: Connelly:
One trend worth considering is the de-emphasis of the consumer/ hobbyist market for desktop 3D printers. It is now evident that that portion of the industry was overhyped early on, and is now in a period of decline.
A: Dunne:
The most intriguing trend is that, as a consequence of the maker (hobbyist) movement, we’re really starting to see a generation of designers coming into the industry who are familiar with the process and promise of 3D printing. They assume 3D printing technology has always existed and see it as a primary tool to solve problems, rather than a specialty tool. n MPF 3D Systems 3Dsystems.com Concept Laser Conceptlaserinc.com
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Proto Labs Protolabs.com Material for this article was provided by Proto Labs Inc.
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Quantifying
3D printing for surgical simulation The use of 3D printing to create surgical models shows promising results for improved patient care. The next step involves research studies.
Edited by: Leslie Langnau â&#x20AC;˘ Managing Editor
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As president of the Walter E. Dandy Neurosurgical Society, Dr. Saleem Abdulrauf, is a leading neurosurgeon who has served over 100 universities around the world. He currently sits as the professor and chairman of the St. Louis University Department of Neurological Surgery and as Neurosurgeon-in-Chief at the St. Louis University Hospital. Dr. Abdulrauf’s mission is to improve patient outcome during complicated neurosurgical operations using all the innovative tools available to him. One of those innovative tools is 3D printing technology. Under Dr. Abdulrauf’s efforts, the St. Louis Department of Neurological Surgery partnered with the St. Louis School of Engineering to begin quantifying how advanced manufacturing practices such as 3D printing will enhance the training and surgical practice for neurosurgeons. Their on-going study, which focuses on the task of saving a patient experiencing a brain aneurysm, will compare 3D printing against traditional training methodologies such as cadavers (human, animal), foam models, and other conventional practices.
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»
Additive Manufacturing
» The PolyJet 3D printing process can print a range of durometers into a single part. This capability gives the
best feel for the skull of the model.
“I personally perform a lot of brain aneurysm surgeries. It is a complex operation given the number of anatomical issues that we’re dealing with under the microscope. I knew if there was a way of simulating those complications before the operation using the same tools and under the same microscope we’d have a higher positive impact on the outcome for the patient,” explains Dr. Abdulrauf. Brain aneurysms fit the capabilities of additive manufacturing well. Each aneurysm is different from patient to patient. During the operation, a surgeon must calculate, in real time, the optimum angle to get into the area while factoring in the depth at which the aneurysm occurs and the size of the clip to close the aneurysm area. “Every aneurysm is different in size, contour, and location. We have
“To obtain the ideal simulation model requires an accurate highresolution map of the patient’s brain translated into a 3D CAD model.”
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hundreds of clip sizes and types we can use and we’re typically making the decision on clip size during surgery. If I can make that decision beforehand by practicing on a model using the same tools and clips I plan to use in the final operation it really makes a difference during surgery,” explains Dr. Abdulrauf. Developing a method to simulate an individual patient’s specific brain aneurysm presented a few challenges. Because the simulation would be most effective as a physical model that the surgeon could interact with and practice the procedure on, the models needed to be a 1:1 scale of the patient’s brain. If the models could additionally mimic the feel and look of brain matter, so that surgeons could use the same equipment on the model as they would on the patient, it would be even more beneficial.
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Additive Manufacturing
To obtain the ideal simulation model requires an accurate highresolution map of the patient’s brain translated into a 3D CAD model. Next, an extremely fast manufacturing method is needed because patients will be suffering from the aneurysm in real time. Lastly, for simulation models to demonstrate their potential as a future business model for doctors, a fast and a cost-effective production approach is required. Ideally, each model would be created as a one-off part unique to each patient’s particular brain abnormality. Therefore conventional production, with high costs for single tools dedicated to large volumes of identical parts, would not be sustainable for the low volume needs of a patient case-by-case creation. As one of the fastest and most cost effective production methods for one of a kind parts, 3D printing was on the top of the list as a viable solution for creating the brain models. From the selection of additive manufacturing technologies, PolyJet stood out as the better 3D printing process because it met the time, cost, and material challenges Dr. Abdulrauf’s team faced. Additionally, PolyJet is one of the only 3D printing processes capable of printing a range of durometers into a single part, a significant boon to achieving the best feel for the skull of the model. To create the models for the preliminary patients, scans of the patients’ brains were sent to the St. Louis University School of Engineering. The engineering students translated the scans into
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“As one of the fastest and most cost effective production methods for one of a kind parts, 3D printing was on the top of the list as a viable solution for creating the brain models” high-resolution models, which were exported as STL files. Although the University had its own PolyJet machine, to achieve the quality and materials diversification necessitated by the project the decision was made to outsource the models. The team sent multiple CAD files of the brain, skull, and aneurysm to Stratasys Direct Manufacturing for printing. Together, the Stratasys team and the engineering and medical students noted the critical area of the aneurysm. The Stratasys team focused on maintaining flawless accuracy and detail on the aneurysm area throughout the entire production process. Stratasys Direct Manufacturing was chosen as the 3D printing provider for the project for its capacity, expertise, and dedicated anatomical department. The anatomical department, based in Poway, California, is one of the leading innovators in manufacturing methods
throughout the field of anatomical training models. Some of their key achievements include providing 3D printing and urethane components for birthing simulators, dental, heart, bone, and kidney models. Stratasys Direct Manufacturing collaborated with the St. Louis University Department of Neurological Surgery to build the scans of the brains, aneurysm and skulls using PolyJet and urethane casting. The two combined teams chose PolyJet Rigid VeroYellow for the skull and an overmolded TangoPlus material with a durometer of Shore 27A for the brain. The TangoPlus brain was built as a multi-functional piece. Initially, it served as the solid brain. Within the CAD design, the aneurysm was 3D printed according to the aneurysm pattern experienced by the actual patient. Finally, the skull was built with the inner support material that hugged the grooves and depressions of the sulci and gyri likeness of the patient’s brain. This support material served as the pattern for creating the inner brain matter. The interior of the TangoPlus brain was filled with a specially formulated gelatinous colloid material that mimics the feel of the spongey sulci and gyri in the brain. The urethane material filled in around the anatomically correct PolyJet printed aneurysm. The mixture cured within the TangoPlus and, with the aneurysm intact and in place according to the patient’s exact brain map, resulted in a completed, multi-material piece ready for operation. Preliminary surgeries using a 3D printed model to simulate the
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procedure prior to operation provide valuable feedback for Dr. Abdulrauf and his team. “I’ve done a lot of aneurysm operations in my career and I can confidently say that having the 3D printed model here has a very positive impact on the procedure results. The model has helped to identify and overcome surgical challenges, like optimum access to the aneurysm or the depth and angle of the approach, before surgery begins.” With these preliminary positive results, the next move is to measure the success of 3D printed models through blind studies. Dr. Abdulrauf has proposed a two-arm study with resident neurosurgeons. All of the residents will be asked to perform a procedure on a cadaver. Half of the residents will receive a 3D printed model of the cadaver’s brain prior to surgery while the other half will prepare for the surgery without a 3D model. The two groups will then be compared. The assessors will be blind to which group received the 3D printed model. The success of one group over the other will be measured by time undertaken during the process, absence of errors, and the ability of the groups to keep the circumference of the surgery as minimally invasive into healthy tissue as possible. From this study, Dr. Abdulrauf hopes to quantify the use of 3D printed models in pre-surgical planning. A second study will involve measuring the outcomes of patients who receive the traditional gold standard of care during surgery and patients who receive the gold standard plus their neurosurgeons receive a
3D printed model of their brain to practice on prior to surgery. The recovery time of patients and overall patient comfort post-surgery will be carefully monitored in both groups. By studying actual patient outcomes, Dr. Abdulrauf will gain measureable insight into the benefits of 3D printing for surgical procedures. “The future of medicine is all based on measuring outcomes. The most important thing is quantifying what’s better for patients, and improving the lives of patients. To do that, we must know the absolute best measures we can take using the tools we have to improve their lives,” explains Dr. Abdulrauf. “We cannot thank Stratasys Direct Manufacturing enough for the work you’ve done. Having a heart in this kind of work always produces better results.” n MPF Stratasys Direct Manufacturing stratasysdirect.com
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Additive
lays the foundation for full production 2016 was the year additive manufacturing took center stage. Leslie Langnau • Managing Editor
EnvisionTEC’s SLCOM 1 uses a process it calls Selective Lamination Composite Object Manufacturing. It builds composite parts using layer-by-layer laminated thermoplastic composite fabric sheets from a roll.
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n
The Stratasys Robotic Composite 3D Demonstrator: is a hybrid approach for
While the low-cost desktop 3D printer market retrenches,
automated composite part production.
the biggest news in additive manufacturing (AM) for 2016 was not
It offers eight axes of motion for precise
the long awaited release of HP’s 3D printing systems, although, that
directional material placement. Carbon infused filament delivers strong parts.
was news. No, the biggest story is how several large companies—GE, Siemens, Schneider Electric, PTC, among others—are taking additive seriously and staking their claim in this industry. GE made the most moves. It’s most recent being the purchase of a controlling interest in Concept Laser, the developers of LaserCusing. Soon, it may do the same with Arcam AB, the company that uses electron beam melting as its additive manufacturing technology. Several years ago, GE bought Morris Technologies, an additive service bureau with expertise in metals. Plus, GE is a major investor in Carbon3D, the inventors of the CLIP stereolithography process. GE is also looking at automotive. It has an arrangement with Local Motors, called Fuse. Fuse is a new approach to manufacturing that should accelerate product and technology development by innovating small batch production. Physical operations for Fuse will be micro-factories that bring together GE teams, customers, entrepreneurs, student groups and more. Micro-factory operations will include rapid prototyping, small-batch manufacturing, and modular experimentation. The initial Fuse micro-factory should open its doors in Chicago this month.
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Additive Manufacturing
3D Systems’ newest entry is the Figure 4 mini-manufacturing system. It combines stereolithography with robots to streamline and automate an AM workflow.
“The biggest news in additive manufacturing is how several large companies are taking additive seriously and staking a claim in this industry.”
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Of course, HP’s entrance was a big media event at the 2016 RAPID show. HP launched two 3D printing systems; the HP Jet Fusion 3D 3200 Printer is for prototyping and the HP Jet Fusion 3D 4200 Printer is for prototyping and short-run manufacturing.
The software gap Software is often seen as an obstacle to wider adoption of additive manufacturing. Either CAD programs lack features that would ease design for AM, or the overall functions of AM systems could be improved with better software. This year, the major additive vendors have formed strategic partnerships with the major software and controls vendors to address the software issue. Stratasys, HP, and Local Motors are all working with Siemens on several additive projects. Siemens offers software platforms for the control of additive printing, and that help additive vendors shift from prototyping
December 2016
to production. Recently Siemens announced a “comprehensive approach to unleash the full potential of the AM revolution.” This approach includes Siemens’ NX software, an integrated computeraided design, manufacturing and engineering (CAD/CAM/CAE) software, the Simcenter portfolio, a suite of simulation software and test solutions, Teamcenter software, a digital lifecycle management system, and SIMATIC IT Unified Architecture Discrete Manufacturing and SIMATIC WinCC, two elements of Siemens’ Manufacturing Operations Management (MOM) portfolio for production execution and manufacturing automation. PTC is stepping into the additive arena. It has formed a strategic partnership with 3D Systems, which
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Stratasys Ltd. launched two additive machines for manufacturing production. Here is the Infinite-Build 3D Demonstrator. Parts “grow” out of the machine to an almost infinite Z length.
announced it would shift its focus to additive manufacturing for production, not just prototyping. And Schneider Electric is working with Stratasys to include 3D printing into its manufacturing processes to meet short and longer-term efficiency goals. Materials company Alcoa opened a 3D printing powder plant at its Technology Center. It will produce proprietary titanium, nickel and aluminum powders specifically for 3D printed aerospace parts. Alcoa already has 3D printing capabilities in California, Georgia, Michigan, Pennsylvania and Texas.
New additive machines for production This year, nearly all the major vendors introduced additive machines capable of building parts in production quantities.
• 3D Platform introduced its Excel Series
Platform at IMTS. The Excel series includes a parallel gantry configuration that can support multiple simultaneous processes including additive, subtractive, and robotics. The build table is initially 4 ft x 4 ft x 8 ft (1.2 x 1.2 x 2.4 m), but is expandable to almost any length by adding gantries. The XL-Delta system from 3D Platform is targeted at the additive production of tall items. The work area lets you 3D print a part that can be up to 2.5 m across and 2 m in height.
• 3D Systems plans on developing more
systems for manufacturing production. The company has several hardware systems ranging from 3D scanning to metal additive production. Its newest entry is the Figure 4 manufacturing system. This mini-manufacturing operation combines stereolithography with robots to streamline and automate an AM workflow that can replace or complement traditional manufacturing workflows. It is a configurable system.
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Additive Manufacturing
3D Platform introduced a parallel gantry configuration that can support multiple simultaneous processes including additive, subtractive, and robotics. The build table is expandable to almost any length by adding gantries.
• The Arcam Q10plus is the new
generation EBM machine specifically for cost-efficient production of orthopedic implants. It replaces the Arcam Q10 systems. The size of the build area allows optimal stacking of common implant types, and the build chamber interior delivers easy powder handling and fast turn-around times. The Arcam Q10plus is for production of high volume press fit implants with advanced Tribecular Structures as derived from CT scans of individual patients. It has the latest generation electron beam (EB) gun, which improves productivity and resolution. It also includes Arcam LayerQam, a camerabased monitoring system for inline part quality verification. It comes with a powder recovery system (PRS) for efficient powder handling. The Arcam Q20plus is specifically for cost-efficient production of aerospace components, such as turbine blades, structural airframe components and more. The build envelope handles large components and enables optimal stacking of smaller ones.
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• Carbon (Carbon3D, Inc.) unveiled • EnvisionTEC introduced its the M1, its first commercial 3D printer. The M1 leverages Carbon’s Continuous Liquid Interface Production (CLIP) technology and engineering-grade materials. Product designers and engineers can produce parts that have the resolution, surface finish and mechanical properties required for functional prototyping and production-quality parts. Internet-connected, the M1 collects more than one million process control data points per day. These data help Carbon deliver precise remote diagnostics, assist with print optimization, and improve print quality over time. Plus, an internet-connected architecture ensures the latest features, performance enhancements, and resins are always available to users, while the browser-based interface enables printer operation inside a network without the hassle of software installs or compatibility problems.
SLCOM 1, an industrial composite 3D printer. It uses a patent pending process known as Selective Lamination Composite Object Manufacturing. It is targeted at applications with “demanding mechanical and environmental properties that can only be delivered from woven composites.” The SLCOM technology builds composite parts using layer-by-layer laminated thermoplastic composite fabric sheets from a roll. It can build parts to the following maximum dimensions: 24 in. x 30 in. with a 24 in. height.
• Optomec launched a new tool
series for low-cost, high-value metal additive manufacturing. The LENS Machine Tool Series integrates Optomec’s LENS metal additive manufacturing technology into conventional CNC Vertical Milling platforms, resulting in a Hybrid VMC Controlled-Atmosphere System. The LENS Machine Tool series combines high-quality CNC platforms from Fryer Machine Systems with
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the LENS Print Engine technology to bring metal additive manufacturing capabilities to a broader market.
• Stratasys Ltd. launched two
additive machines for manufacturing production. With its Infinite-Build 3D Demonstrator, the engineers found a way to use the Fused Deposition Modeling (FDM) process to produce very long parts by turning the Z axis on its side. The build plate is oriented as if it were a vertical wall and the extrusion nozzle deposits material on that “wall” layer by layer. Thus, the part can “grow” out of the machine, coming at you on its side, to whatever length is needed, an almost infinite Z. The bottom floor of the machine’s build area is 7 ft, so parts longer than 8 to 10 ft may need additional support. Build speed is 10 times faster than current extrusion processes. The second system is the Robotic Composite 3D Demonstrator. It combines Stratasys’ extrusion technology with Siemens motion control hardware and PLM software. The Robotic Composite 3D Demonstrator 3D prints in 8 axes of motion for precise, directional material placement and strength while also dramatically reducing the need for support strategies. The build material is carbon fiber reinforced plastic. New additive machines and processes for 2016 The HP Multi-Jet Fusion 3D 3200 Printer is for prototyping “with the capacity to grow usage at a lower cost per part.” The HP Multi-Jet Fusion 3D 4200 Printer is for prototyping and short-run manufacturing needs. Also, these systems will need a Jet Fusion 3D Processing Station and HP Jet
Fusion 3D Build Unit. The processing station mixes build materials into the Build Unit before it is inserted into the printing section. The processing station is essentially a material management system. HP’s additive process is a sintering process that uses heat to fuse or compact the powder into a solid shape without liquefying the powder. The chemical agents control the heating process. A layer of plastic powder is rolled onto the build bed. The powder is kept at a high temperature to speed the print process when it begins. At least two chemical agents are sprayed onto the layer in the build pattern. One agent absorbs the heat needed to sinter the plastic powder. The other agent stops the heat absorption process to ensure sharp part details. It takes about a light second to cure the exposed area. The latest 3D printing technology to emerge for working with metal materials is MagnetoJet technology from new startup, Vader Systems. This patent pending MagnetoJet technology is based on Magneto Hydro Dynamics (MHD) or the manipulation of liquid metal through magnetism, and Liquid Metal Jet Printing (LMJP). In a MagnetoJet machine, such as the Mk 1, aluminum wire is deposited into an 800°C ceramic chamber, where it is heated to a molten state. The molten version is then electromagnetically pulsed to cause a precisely sized droplet to form. The droplets are ejected from a custom ceramic nozzle that is similar to inkjet nozzles in that it deposits large quantities of material quickly. The Mk 1 will deliver 1000 droplets per second with micron level www.makepartsfast.com
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accuracy. It can deposit aluminum at a rate of 1 lb/hr in a build envelop of 12 x 12 x 12 in. The droplet size is 200 micron. This capability would make the build speed about twice as fast as that of conventional 3D powder bed metal printers. The initial material is aluminum. This metal 3D printer builds 100% dense parts. Another way to print with metal is the NanoParticle Jetting system from XJet. XJet takes stochastic metal-nanoparticles and engulfs them in a proprietary liquid, forming drops. These drops are then jetted in a pattern to build parts. The build chamber is heated to an extremely high temperature so that when each drop touches the build tray, the liquid carrier material holding the metal particles in suspension evaporates and the metal particle material adheres to the layer beneath it. The XJet printer has 24 print heads, a total of 512 standard inkjet nozzles, each of which can jet 18,000 drops/ sec for a total of 221 millions drops/ sec in a build. The size of the metal particles delivers fine detail to the part. You can build thin layers and walls, which will have smooth surfaces. You can build parts of any geometry. The print heads also jet support material as needed. That’s a lot of new additive choices for any engineer’s needs. n MPF
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Prod uc t World Small timing belts and pulleys Automation Direct automationdirect.com SureMotion MXL series timing belts are 1/4-in. wide, have a 0.080-in. pitch, and are available in neoprene with fiberglass reinforcement and urethane with polyester reinforcement styles. Neoprene belts have resilience and flame resistance, are available in lengths from 36 to 500 teeth.
Flat cable configurator Cicoil cicoil.com The EZ-Flexx cable design makes flat cables easy to separate and strip, just like any round cable, and also makes the flat cable light and flexible.
With a few simple mouse clicks or touch of a screen, flat cables can be constructed
of many elements, including power conductors, shielded signal pairs, video and coax wires and tubing for liquid and air. Over 1 million flat cable designs are available for immediate production. In addition, users can move around, add and remove any elements in their flat cable, in any variation up to 3.75-in. wide.
The urethane belts also have strong wear resistance as well as oil and ozone resistance and are available in lengths from 36 to 400 teeth.
Also referred to as sprockets, MXL-
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Dc UPS power backup systems Altech altechcorp.com The Ultra Capacitor UPS (Uninterruptible Power Supply) systems are available in 12 Vdc and 24 Vdc output versions from 3 A to 40 A, depending on model. The CTEC and C-TEC P versions perform with separate main power supplies (with the C-TECH P system able to produce an output spike for applications requiring a temporary surge of power). The AC-C-TEC systems augment these designs by incorporating a built-in power supply with ac input for maximized ease and convenience.
The systems excel at controlled shutdown functions, resist shock and vibration, and
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For further information about products on these pages visit the Design World website @ www.designworldonline.com
Flange bush eliminates bulky housings NB Corp nbcorporation.com The Flange Linear Ball Bushing line has the benefits of a slide bush with the mounting ease of a flange. When an application calls for ease of assembly, a completely integrated system can be selected. Single, doublewide, or center mount configurations are available. Flange types are also available in inch, Asian or European metric dimensions. Drawings and tables provide dimensional and mechanical information. Now also available in 3D CAD.
Diagnostic system predicts slip ring service life Leine Linde Systems heidenhain.us The ADSR is a diagnostic system for analyzing condition and predicting remaining service life within slip rings, can be used in onshore and offshore wind turbines. This is a new smart solution for condition-based maintenance of slip rings.
The centerpiece of the ADSR is the integrated sensors for measuring
vibrations, the level of voltage and current, number of revolutions, internal and external humidity, and temperature. This systematic monitoring and analysis enables the expected remaining service life of the slip ring to be displayed, both in terms of time and revolutions.
Actuator simplifies OEM design-in Delta delta-americas.com/ia The LU-Series linear ballscrew actuator for OEM design-in improves machine automation cost efficiencies and cycle times. This actuator comes assembled in a patented coupling-less mounting configuration to reduce torsional backlash and shorten installation footprint. The rigid design reduces settling time by 20 msec and produces repeatability within +/- 3 micrometers. The series is available in stroke lengths of 2.1 in.-32 in., with peak thrust up to 2700 Nm, and is plug-n-work with Delta’s A2 and B2 series servo amplifiers 100 W and 400 W sizes.
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Ad I n dex
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A3 ...................................................................157 All Motion ........................................................ 22 Alpha Wire .......................................................91 Altech Corporation ..........................................17 Altra Industrial Motion ..................39,40,41,42 AMETEK PMC ...................................................29 AMETEK/DFS ...................................................75 Aurora Bearing Co. ......................................... 80 AutomationDirect ......................................IFC, 1 Bird Precision ..................................................87 Bison Gear ......................................................IBC Bonfiglioli ......................................................132 Brogan & Patrick Mfg. ....................................77 Carlo Gavazzi ..................................................79 Clippard Instrument Laboratory, Inc. ...........BC CPC-Colder Products Company .....................45 CS Hyde Company ......................................... 20 DATA IMAGE Corp. ...........................................85 Del-tron Precision, Inc. ................................. 99 DieQua .................................................. 116, 127 Digi-Key Electronics ........................... Cover, 19 Dunkermotoren, part of Ametek ............... 103 Eagle Stainless Tube & Design ...............36,37 Fluid Metering, Inc. ......................................133 FPZ Inc. ..........................................................135 Griffin Motion ................................................117 Groschopp .................................................insert Haydon/Kerk, part of Ametek .......................97 Helical Products Company ............................25 IGUS ..................................................................81
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Reference Guide
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LEMO USA, Inc. ...................................................59 Master Bond .......................................................54 Memory Protection Devices, Inc. .....................49 NTE Electronics, Inc. ......................................... 67 SAB North America ............................................ 61 Wago USA ............................................................62
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Proto Labs, Inc..................................................147 Renishaw Inc. ..................................................136 solidThinking, Inc. ........................................... 141
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Quantifying 3D printing
Additive lays the
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