Design World December 2023

www.designworldonline.com December 2023

2023 Fastener Engineering PA G ES 25 -4

0

inside: LINEAR MOTION

The basics of ballscrew buckling and rigidity

p.22

EV ENGINEERING

Silicon-carbide technology addresses high-voltage challenges

p.42

INTERCONNECTS Improving connector sustainability

p.58

Custom cables

help keep shipping channels clear PAG E 12

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Reshoring manufacturing — and the Texas-Mexico connection JCB recently announced that it will

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build a new factory in North America, creating 1,500 new jobs over the next five years. The British company is a global manufacturer of construction equipment and also builds machinery for the agricultural and waste-handling industries. JCB said this new facility will manufacture machines mostly for North American customers. This continues a trend of local for local manufacturing that we’ve seen, as well as onshoring or reshoring manufacturing jobs to the U.S. Construction on the 720,000 sq-ft factory is slated to begin in the early months of 2024, on a 400-acre site in San Antonio. And if you’ve been paying attention to geopolitics over the last few years, this shouldn’t surprise you at all. Texas has seen an incredible boom, especially in San Antonio, Austin, and Houston. Sectors such as energy and tech are big drivers of the growth, and these high-paying jobs are changing how these cities look. Austin’s skyline today is hardly recognizable compared to 10 years ago, and the apartment towers continue to sprout up like weeds.

Peter Ziehan, who speaks regularly on geopolitics at industry events like the National Fluid Power Association’s and Power Transmission Distributors Association’s conferences, has been predicting continued growth here for some time. He notes that the state has had among the fastest growing demographics over the last three decades. Plus, the cost of living is relatively low there. But another key aspect is the state’s proximity to Mexico. Roughly half of U.S.-Mexico trade is actually Texas-Mexico trade —

2

insights – dw december 2023 v2 final.indd 2

December 2023

and of the remaining, half of that travels through Texas. (I highly recommend Ziehan’s free daily video newsletter; you can subscribe at zeihan.com.)

According to Ziehan, a problem with U.S. manufacturing is that we don’t have different wage and skill levels here; in that respect, our country is fairly homogeneous from state to state.

In other regions of the world, say, Southeast Asia, various skill levels and wages exist across nearby countries that are mostly friendly toward each other. Think Singapore for high-skilled, Indonesia for medium-skilled, and Laos for low-skilled jobs. This makes setting up localized manufacturing ecosystems easier, as the proper jobs go to the proper areas. Efficiency!

But when you add Texas and northern Mexico together, there is some of the synergy needed for robust manufacturing facilities, where some jobs are more basic and others more skilled. It’s not a complete answer, and northern Mexico seems poised to run out of manufacturing workers soon, given the explosion in facilities in Mexico that have cropped up in recent years.

Still, it will be an interesting area of the country to watch in the coming years. As my eldest son finishes up his engineering degree at college, I’m left to wonder if his career path will eventually take him to that ever-growing region. DW

Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On X (formerly Twitter) @wtwh_paulheney

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DESIGN WORLD

12/11/23 8:36 AM

theleeco.com/medical-equipment

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We’re not just talking about off-the-shelf solutions, either. A Lee engineer will be happy to discuss your application, and develop a custom design if needed. From managing nanoliter droplets to creating fully integrated fluidic systems, we’re unsurpassed in breadth and experience to deliver the precise, reliable performance you require.

Whatever problem you face, make the solution easy.

Contact The Lee Company today.

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LeeCo_GoAhead_DesignWorld_Dec-2023_rev.indd 1 the lee company – dw december 2023.indd 5

11/14/23 2:50 PM 12/11/23 9:44 AM

Contents 12 • 2023

•

vol 18 no 12

•

designworldonline.com

12

ON THE COVER

CUSTOM CABLES HELP KEEP SHIPPING CHANNELS CLEAR

| Helukabel

19 MOTION CONTROL How to do instantaneous mode switching with servo motors

SUPPLEMENTS DECEMBER 2023

www.fastenerengineering.com

Instantaneous mode switching can help smooth transitions between different servo motor control modes in complex motion applications.

A DESIGN WORLD SUPPLEMENT

2023 How do vdc and non-vdc adhesives compare?

22 LINEAR MOTION Review of ballscrew buckling and rigidity

The geometry, orientation, and supports of linear mechanical components dictate their performance.

4

December 2023

toc (features + supps) – dw december 2023 v1.indd 4

Interconnects A supplement of Design World • December 2023

December 2023

keeping a

low profile:

How micro screws support lighter, more aerodynamic designs page 30

25-40

www.designworldonline.com

page 26

How does “direct-pass” ultrasonic metal welding support evs?

ALSO INSIDE: Rare earths and EVs — it’s not about batteries

Reduing range anxiety: PAGE 48

page 34

what are the different styles of retaining rings?

2023 Cable & Connector Reference Guide

How automakers are increasing EV battery voltages

Rotary slip ring connectors — what are they for? .................................. 54 How can connector sustainability be improved? ................................... 58

PAGE 42

page 37

41-52

53-62

DESIGN WORLD

12/11/23 8:36 AM

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11/8/23 1:22 12/11/23 9:44PM AM

12 .2 3 • CONTEN TS

readycable

®

cable assemblies

departments 02

Insights

08

Design For Industry

12

Design Notes

17

DfAM

63

Ad Index

64

Technical Thinking

®

CHAINFLEX CHAINFL

®

®

CHAINFLEX CHAINFL

®

Meets 20+ manufacturer standards

6

toc (dept) + staff – dw december 2023 v1.indd 6

December 2023

www.designworldonline.com

DESIGN WORLD

12/11/23 8:49 AM

DESIGN WORLD Follow the whole team @DesignWorld

Executive Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel

Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

Front End Developer Melissa Annand mannand@wtwhmedia.com

Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

Software Engineer David Bozentka dbozentka@wtwhmedia.com DIGITAL MARKETING

Senior Editor Rachael Pasini rpasini@wtwhmedia.com @WTWH_Rachael

VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

Associate Editor Heather Hall hhall@wtwhmedia.com @wtwh_heathhall

Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com @WTWH_Taylor

CREATIVE SERVICES

Digital Marketing Coordinator Meagan Konvalin mkonvalin@wtwhmedia.com

VP, Creative Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Digital Marketing Coordinator Francesca Barrett fbarrett@wtwhmedia.com

Art Director Allison Washko awashko@wtwhmedia.com

Webinar Coordinator Emira Wininger ewininger@wtwhmedia.com

Senior Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel Graphic Designer Shannon Pipik spipik@wtwhmedia.com @wtwh_shannon

2023

2023

2023

SILVER NATIONAL AWARD

SILVER REGIONAL AWARD

BRONZE REGIONAL AWARD

asbpe.org

asbpe.org

asbpe.org

VIDEO SERVICES

Videographer Garrett McCafferty gmccafferty@wtwhmedia.com Videographer Kara Singleton ksingleton@wtwhmedia.com PRODUCTION SERVICES

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Renee Massey-Linston renee@wtwhmedia.com Customer Service Representative Trinidy Longgood tlonggood@wtwhmedia.com Digital Production Manager Reggie Hall rhall@wtwhmedia.com

FINANCE

Digital Production Specialist Nicole Johnson njohnson@wtwhmedia.com

Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

WTWH Media, LLC TOP 1111 Superior Ave. WORK PLACES 2022 26th Floor Cleveland, OH 44114 Ph: 888.543.2447

Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

Webinar Coordinator Dan Santarelli dsantarelli@wtwhmedia.com

Controller Brian Korsberg bkorsberg@wtwhmedia.com

2011 - 2020

2013 - 2017, 2021

Meets 20+ manufacturer standards

Events Manager Brittany Belko bbelko@wtwhmedia.com

®

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

®

OPERATIONS

Managing Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

CHAINFLEX CHAINFL

WEB DEV / DIGITAL

cable assemblies

®

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney

readycable

Events Manager Jen Osborne josborne@wtwhmedia.com @wtwh_jen

®

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

CHAINFLEX CHAINFL

EDITORIAL

®

EVENTS

Digital Design Manager Samantha King sking@wtwhmedia.com Marketing Graphic Designer Hannah Bragg hbragg@wtwhmedia.com Digital Production Specialist Elise Ondak eondak@wtwhmedia.com HUMAN RESOURCES

2014 - 2016

Medical Design & OUTSOURCING DESIGN WORLD

toc (dept) + staff – dw december 2023 v1.indd 7

www.designworldonline.com

Vice President of Human Resources Edith Tarter etarter@wtwhmedia.com

December 2023

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12/11/23 8:49 AM

Design for Industry Medical

Slim, fanless edge computer brings data to the source Edge computing technology is transforming healthcare by bringing real-time information and insights closer to medical teams. As such, hospitals are becoming smarter faster with low-latency computing and optimized workflows.

Taiwan-based Advantech recently introduced the USM-100H, a medical-grade, slim mini-computer tailored for clinical applications in the healthcare industry. The new device measures 230.6 x 169.5 x 43 mm — making it suitable for tight spaces — and provides easy integration and mobility for medical equipment manufacturers in healthcare environments.

It’s powered by 12th-generation Intel Core i7-1265UE/ i5-1245UE processors and incorporates DDR5 4800, NVME SSD, Wi-Fi 6E, and Bluetooth 5.3. Its fanless design ensures noise-free operation, while the top side of the system features VESA 75 x 75 mm and 100 x 100 mm mounting options. Additionally, the USM-100H is certified to meet medical safety standards (IEC/EN 60601-1 3.2th, IEC/EN 60601-1-2 4.1th), offering a cost-effective computing

MEDICAL MOLDED CABLE ASSEMBLIES

solution for a wide range of hospital applications, and can be deployed as an intelligent operating room solution. It supports Windows 10 and Linux OS, providing an open-source environment that facilitates software development.

The adaptable Mylar surface simplifies customization, allowing for specific logos and colors to promote brand awareness. This ease of customization and expandability empowers system developers to swiftly create unique solutions based on the USM-100H, ultimately reducing timeto-market. DW

Advantech | www.advantech.com

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12/11/23 8:51 AM

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Micro Solutions For Big Innovations® accu-mold.com

canula-match-vertical-wtwh.indd 1 accumold – dw december 2023.indd 5

9/18/23 11:39 AM 12/11/23 9:44 AM

Design for Industry Food/Beverage

Supercharging the adoption of electric automation The Festo Power Up initiative for food and beverage machine builders aims to spur efficient adoption of electric automation and the development of next-generation compact, flexible, energy-efficient, and data-rich machines.

Three pillars support the initiative.

Machine builders now have the option of a Festo one-stop shop of readily available, high-quality, and cost-competitive electric automation components. The online productivity tools allow one-, two-, and three-axis electric automation systems to be designed and ordered in minutes.

Engineers receive a quote, shipping date, parts list, and 2D and 3D CAD files and continue designing while the electric automation system is prepared.

Such design and commissioning tools reduce engineering overhead and help bring products to market faster.

Festo also recently introduced a remote and decentralized I/O platform that lowers integration costs and boosts OEMs’ ability to add capabilities easily and cost-effectively to a machine or cell. Together, these three — products, productivity tools, and the automation

10

December 2023

design for industry – dw december 2023 v2 final.indd 10

platform — can transform the food and beverage machine builder’s business.

The automation platform enables all CPX-AP-A remote I/O and CPX-AP-I decentralized I/O to be integrated by the control engineers as a single integration point under one IP address.

This makes integration with the PLC simpler, and since all I/O is under a single IP address, the machine builder can use a smaller, less costly PLC. The platform is compatible with the EtherNET/IP, EtherCAT, PROFIBUS, and Modbus communication protocols.

OEMs building similar machines with a customer-preferred PLC simply apply a protocol-specific AP bus interface

www.designworldonline.com

module. I/O can remain the same or be easily changed, all under a single integration point and one IP address.

The AP platform uses IO-Link masters to incorporate third-party devices within a machine or cell.

Overall, Power Up gives engineers, maintenance personnel, and technicians one unified system to learn, lower inventory requirements, and simplify field support. With this initiative, Festo aims to supercharge electric automation adoption and help OEMs reach electrification goals faster. DW

Festo | www.festo.com

DESIGN WORLD

12/11/23 8:51 AM

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

Bosch Rexroth | www.boschrexroth.com

December 2023

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

Machine tool performance directly depends on its motion components’ capabilities. The Bosch Rexroth BSCL ball rail system addresses applications requiring linear bearings in the mid-performance range, and the structural design delivers an optimum price-to-performance ratio.

BSCL ball rails are available in five sizes, six runner block types, three preload classes, and three accuracy classes. The simplified profile allows the ball rails to be easily customized to the desired length using simple hand tools and without costly end machining.

This system is ideal for assembly jigs and fixtures, welding systems, and metal-cutting applications.

Automation and assembly, automotive manufacturing, woodworking, and machine tool industries benefit from its reliable guidance and customizable design. Machine builders, integrators, and automotive manufacturers also benefit from the price-to-performance ratio and fast deliveries. Plus, Rexroth’s precision grinding technology allows any runner block type within the BSCL family to be used on any BSCL rail of the same size. This interchangeability allows machine builders to keep a flexible, optimized inventory to meet the needs of their customers.

These ball rail linear guides have speeds of up to 5 m/ sec and acceleration of up to 500 m/sec2 with nominal rail widths from 20 to 45 mm. Rexroth’s rail product line additions complement the high-performance BSHP ball rail systems. DW

design for industry – dw december 2023 v2 final.indd 11

RETAINING DEVICES & maintenance & assembly tools

Ball rail system for mid-performance applications

DESIGN WORLD

POWER TRANSMISSION

11

INCH and METRIC THREADS LEFT HANDED as well as RIGHT -HANDED

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALLUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

TT

ET

-H

IG

GI

NS US

A

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.

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.

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12/11/23 8:51 AM

Design Notes

Custom cables help keep shipping channels clear Edited by Mike Santora

The new 90-meter cutter-suction dredger called the General MacArthur has three diesel engines that together output 24,000 hp. The engines provide the energy necessary to drive two 6,900-hp electric motors that, in turn, run deck pumps and two other 2,500-hp electric motors.

International cable manufacturer and supplier HELUKABEL recently partnered with dredging and marine construction company Callan Marine to power their new General MacArthur dredging vessel.

Galveston, Texas-based Callan Marine dredges for both private and public clients throughout the United States to restore and maintain the required depths and widths of main navigation channels, smaller transportation waterways, docks, and berths. After all, large shipping vessels can only navigate waterways and ports if silt and other debris carried by currents is kept clear from their

12

December 2023

design notes – dw december 2023 v2 final.indd 12

seabeds. Otherwise, ships could run aground and get stuck.

The new 90-meter cutter-suction dredger called the General MacArthur has three diesel engines that together output 24,000 hp. The engines provide the energy necessary to drive two 6,900-hp electric motors that, in turn, run deck pumps and two other 2,500-hp electric motors — one for an underwater pump and the other for a cutterhead.

Crew accommodations include a galley, gym, TV room, laundry facility, conference room, and engineer’s office.

Yet other accommodations include 33 beds, captain and chief engineer

www.designworldonline.com

staterooms, and bathrooms — all with their own power needs.

An Italian electric-motor manufacturer connected a Callan Marine engineer designing the dredger with HELUKABEL; the motor manufacturer suggested HELUKABEL because they’d previously worked together on many successful projects in Europe.

HELUKABEL began the cabling design with the underwater pump and cutter motors power section.

“One of the biggest challenges in building the General MacArthur was finding the appropriate submersible cable for the high-ampacity demand

DESIGN WORLD

12/11/23 9:02 AM

from these motors,” said Callan Marine automation manager Stanley Hamidjaja. The cables run through a structural arm (the ladder) that submerges both motors. It wasn’t possible to deliver the necessary capacity via a single cable for each phase.

“The team at HELUKABEL was very involved for over a year in submitting and resubmitting their proposal until they provided the cable specification and quality to our satisfaction,” said Hamidjaja.

Working with Callan Marine’s engineering team, HELUKABEL provided eight AWG4/0 cables per phase for 32 cables total to provide the necessary power. These cables have submersible ratings to 10 bar of pressure, and the necessary American Bureau of Shipping approval required for cables on ships and offshore structures.

The next challenge was to assist in designing a water-tight transition box for the system to terminate the VFD cables’ braided shields. Here, HELUKABEL designed the transition box to include KVA-XXLMS metal cable glands and KVA-XXLMS-E

Accessory Power Strips & Jumper Cords with 1-Week Lead-Times!

EMC cable glands rated for 10 bar or submersion to 328 ft (100 m). These glands accept cables with large outer diameters. What’s more, they accommodate custom inserts that deliver strain relief and a water-tight seal between the gland and cable.

The latter is especially unique as the system’s AWG4/0 cables have overall diameters beyond those serviced by standard inserts. The custom gland inserts were designed, manufactured, and delivered in less than eight weeks.

Other products to complete dredging-related tasks aboard the cutter included various sizes of nickel-plated cable glands capable of withstanding up to 10 bar and Category-7 data cables having Lloyd’s Register marine and offshore approvals.

After the General MacArthur came out of dock, it was sent off to the Gulf Coast for its first assignment to keep the vital shipping lanes near Texas clear for the continued safe passage of marine vessels. DW

Interpower® Accessory Power Strips (APS) incorporate IEC 60320 inlets with multiple IEC 60320 outlets allowing international integration.

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An Italian electricmotor manufacturer connected a Callan Marine engineer designing the dredger with HELUKABEL; the motor manufacturer suggested HELUKABEL because they’d previously worked together on many successful projects in Europe.

DESIGN WORLD

www.designworldonline.com

design notes – dw december 2023 v2 final.indd 13

December 2023

13

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12/13/23 12:54 PM

Industrial safety with precise instruments Edited by Mike Santora

For industrial manufacturers, using precise, analytical instruments designed for the specific requirements of an application is critical. Unfortunately, instruments are often incorrectly selected for the job, improperly calibrated, or fail prematurely, resulting in production downtime and safety risks.

“Inaccurate moisture measurement or composition analysis could lead to miscalculations in the creation of a new polymer, for example, resulting in a weak product that is unsafe for real-world use,” said John Bogart, Managing Director of Kett US, a manufacturer of a full range of moisture and organic composition analyzers. “It could result in failure to meet safety standards, impurities in raw materials, misjudged shelf-life, or

the wrong product potency. It can also waste process time due to inefficient practices or mechanisms that don’t serve the needs of the processor or manufacturer.”

To understand the issue of industrial instrument problems in greater depth, Bogart and his team at Kett reviewed many independent studies across industries and sectors.

The results indicated that facility managers encounter several types of instrument challenges.

In some cases, facility managers could not find the appropriate moisture measurement or composition analysis instruments for their specific type of production.

Instead, they relied on analyzers that did not provide the required accuracy, consistency, or repeatable results.

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December 2023

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12/13/23 9:47 AM

POWER TRANSMISSION-PART CONVEYING

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Design Notes

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Alternatively, some instruments failed due to abrasive wear and tear or exposure to harsh conditions. Extended exposure to salts, moisture, or chemical solvents, for example, can accelerate corrosion, breakdown, and the need for replacement.

Facilities also reported that they often did not have enough support from suppliers to evaluate, install, and calibrate the instruments or train their personnel on proper operation. Errors occurred when employees improperly handled and used the instruments, particularly when they had unanswered questions.

“In these kinds of situations, many manufacturers come to us already frustrated. We understand because selecting the wrong instrument is upsetting, timeconsuming, and incredibly costly,” said Bogart.

Based on their research findings, Kett developed a comprehensive framework called their “Total Care

12/4/2018 4:56:13 PM

Solution Package” to reduce the risks and errors related to inaccurate measurement and composition analysis.

Support comes in the form of assistance with calibration curve development to ensure accurate readings, along with on-site operator training. A calibration curve is one approach to the problem of instrument calibration. The calibration curve is a plot of how the instrumental response (the analytical signal) changes with the concentration of the analyte (the substance to be measured). Because industrial settings can be harsh, the OEM designs instruments that can endure the rigors of the field as well as the wear and tear of production.

As the need to increase production while maintaining safety and quality continues, manufacturers and processors that partner with an OEM that can provide the instruments and expertise required will have a competitive advantage in the market. DW

Kett | www.kett.com 16

design notes – dw december 2023 v2 final.indd 16

December 2023

DESIGN WORLD

12/11/23 9:02 AM

Design for 3D printing and Additive Manufacturing

3D printing improves spine surgery precision and safety Spinal fusions — a treatment option to drill, tap, and place pedicle screws for fractures, deformities, or instability quickly and safely. With HP’s industrial in the spine — typically involve pedicle Multi Jet Fusion technology, FIREFLY screws for extra strength and support. is streamlining and reducing printing However, if placed incorrectly, patients turnaround time so that more patients could experience critical injuries, can benefit from an elevated level of including spinal cord damage. While personalized care. robotic solutions can alleviate errors “It was important for us to maintain associated with freehand pedicle screw our focus on the spine and develop insertion, such technology is expensive innovative solutions that make surgical and has a steep learning curve. procedures safer and more efficient,” After 11 years of using additive said Heidi Frey, president of Mighty manufacturing to enhance and produce spinal technologies and medical devices, Mighty Oak Medical is no stranger to the benefits of 3D printing or the pain points Mighty Oak Medical associated with spinal surgeries. makes surgical models To alleviate the errors associated and guides with HP’s Jet with freehand pedicle screw Fusion 5200 3D printers. insertion and eliminate the | courtesy of HP challenges and complexity of robotic systems, they had to rethink the surgical workflow.

This year, the company partnered with HP to 3D-print medical models and surgical guides using HP’s Jet Fusion 5200 3D printers. With its cornerstone FIREFLY solution — a patient-specific pre-surgical planning and navigation platform — Mighty Oak Medical produces FDA-cleared and CE-marked products to improve operating room efficiency and make spine surgery safer.

FIREFLY provides surgeons with concierge pre-surgical planning, which is accurate to the millimeter and done in 3D on a virtual rendering of patients’ spines. Then it supplies 3D-printed anatomical models and 3D-printed disposable guides that surgeons use DESIGN WORLD

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Oak Medical. “We have always viewed 3D printed, patient-specific solutions as an ideal way to achieve those two objectives, and now, the healthcare industry is undergoing a massive transformation in terms of the solutions, patient experience, and outcomes new 3D printed medical devices can provide.”

Before installing HP’s Jet Fusion 5200 printers directly onto its factory floor, Mighty Oak Medical outsourced

December 2023

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Design for 3D printing and Additive Manufacturing

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its production. At the time, the models and guides were made using stereolithography (SLA) and a white photopolymer material.

While it closely matched the color of bone, the material was very reflective, which made it difficult to read the markings on the surgical guides. Lack of contrast with the bony anatomy also made guide fit difficult to see in the operating room.

Now, the models and guides are manufactured using HP’s nylon PA-12 material for its strength, detail, and surface finish. Each part is embossed with a unique patient identifier number and marked to allow the surgeon to easily find and place them in the right location on the spine. The models can even be personalized with the name of the hospital or physician. HP’s nylon PA-12 material features a mineral gray color that makes such markings easier to read in an operating room environment.

It also offers higher contrast, allowing the surgeon to check for anomalies and gaps.

“Surgeons are always looking for better results,'' said Rob Bronersky, VP of operations at Mighty Oak Medical. “Additive manufacturing is becoming more widely adopted because it helps them achieve that mindset. It’s being embraced because it helps them deliver superior outcomes.”

To streamline the presurgical planning and guide the design process, Mighty Oak Medical uses sophisticated analytics based on data collected from previous cases. For each new case, trajectories and guides are automatically generated depending on patient demographics, with only minor manual review and modification required by the engineering team. Mighty Oak is further developing these analytics into machine learning algorithms using their ever-expanding pool of data to further improve analytics and efficiency. DW

Mighty Oak Medical mightyoakmedical.com HP hp.com 18

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Instantaneous mode switching can help smooth transitions between different servo motor control modes in complex motion applications.

C o n t r o l

instantaneous mode switching HOW TO DO

CHARAN BHAMRA MECHATRONICS ENGINEER • EZ MOTION

WITH SERVO MOTORS

In

closed-loop servo control systems, there are three essential control modes; torque, speed, and position.

Each of these parameters can be individually controlled depending on the application. While a single control mode may be enough for some applications, other more advanced applications may require multiple control modes within the same motion operation.

In most traditional servo control systems, a given motion must be completed before switching between different control modes. Otherwise, the drive signal may experience a spike or significant drop in winding current that can adversely affect the performance of the motion profile. This creates complications for designs that require using multiple control modes without interruption.

Instantaneous mode switching One solution to this challenge is servo motors and controllers with instantaneous mode switching.

These motors and controllers provide DESIGN WORLD

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instantaneous mode switching capability, enabling seamless switching between multiple control modes while the motor is in motion.

Instantaneous mode switching can also be categorized as bumpless switching between servo control modes. While bumpless switching generally applies to mode switching between manual mode and automatic mode in proportional integral derivative (PID) control, it can be used similarly in servo motor control.

The feedback of all control signals is constantly monitored to develop the nested loop control structure of these types of servo motors and controllers. Typically, only one of the

three control loops is connected to the output signal; however, unconnected control loops can also develop as if they are connected to the output signal.

Therefore, when switching between control modes, the motor can smoothly transition between different control loops without any jumps in the output control signal.

Advantages of instantaneous mode switching Instantaneous mode switching provides advantages that are highly relevant in various applications, particularly in fields that involve industrial automation, control systems, and manufacturing.

The block diagram shows the cascade control loop structure used in EZmotion servo motors.

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•• •• •• •• •• •• •• • • • • • • • • • • • • • • • • • • • •• •• •• •• •• •• •• •• •• •• •• The control output signals during mode switching show no spikes or major disruptions in the current, IQ.

Maintaining continuous and smooth operation is vital for product quality and consistency. These advantages help avoid disruptions that can affect overall motion-related process efficiency.

The benefits of instantaneous mode switching include: • • • • •

Allowing for seamless transitions between all control modes Preserving tuning and loop parameters during control mode switching Providing outstanding stability and performance during switching operation Offering additional flexibility and functionality to deploy advanced control algorithms for applications Useful in haptic force feedback control schemes

Definitions and comparison metrics The current in motor windings is typically responsible for torque generation and rotation. In three-phase field-oriented control (FOC), the threephase motor system is simplified and transformed into a two-axis directquadrature-zero (DQZ) transformation reference system. The minimized D-axis current (ID) is parallel to the rotor pole axis, and is not responsible for torque generation. The maximized Q-axis current (IQ) is perpendicular to the rotor pole axis, and is responsible for torque generation in the motor.

FOC with triple cascade loop control is the foundation for seamless mode switching in motor control. In a triple cascade loop configuration, each loop is responsible for regulating different aspects of the system such as current,

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speed, and position. The output of one loop is used as the setpoint for another loop, creating a cascading effect.

IQ feedback is a reliable indicator of the motor system’s performance and stability. Therefore, examining and comparing IQ feedback during mode switching can help evaluate the motor’s seamless mode switching performance.

With instantaneous mode switching, the motor starts in speed control mode with a target speed of 3,000 rpm and an acceleration of 10,000 rpm/sec. At 5 sec, the motor seamlessly switches to position control mode with the speed at 1,000 rpm. After a few seconds of operating in position mode, the motor transitions to torque control mode with the target torque set to 20% of the motor’s nominal torque. Finally, the motor switches back to speed control mode with a target speed of 3,000 rpm.

As the figure above shows, there are no bumps and spikes observed in the IQ signal during mode switching, and the respective control output signals are appropriately controlled to the reference signals after switching. Thanks to instantaneous mode switching, the motor is physically stable with no shaking or bouncing behaviors observed. In comparison, traditional motors that lack seamless mode switching capabilities shake or attempt to bounce off the ground during actual operation mode switching. IQ spiking may trigger a fault or protection, leading to an abrupt pause in motor operation.

Some application examples A few examples illustrate how servo motors and controllers with instantaneous mode switching are used in applications requiring more than one control mode.

The insert placement and pressing process for an industrial cobot.

www.designworldonline.com

DESIGN WORLD

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• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• Cobot with feeding or insertion applications Feeding and insertion applications require a cobot to accurately place parts and apply precise insertion force.

In these types of applications, the servo can operate in position control mode to align the part, then switch to torque mode to apply the appropriate mechanical insertion force. Seamless mode switching allows the cobot to smoothly transition between position and torque mode while maintaining stability and performance. For example, consider a plastic clip insertion application, where the clip must be seated at a set location and depth before being pressed into the mating assembly with precise insertion force.

Automated centrifuge systems Centrifuge systems use centrifugal force to separate liquid, gas, and solid substances based on the density.

Automated centrifuge applications interact with pick-and-place machines, requiring precise speed control during the centrifuge process and accurate position control to stop. During the centrifuge separation process, the rotor holding the samples spins at a set speed for a given time, then seamlessly transitions to position mode. This

stops the rotor at the target position in a single motion operation. The accurate stopping position allows the pick-and-place robot to load or transfer samples to their designated locations.

An integrated pick-and-place robot in a centrifuge system.

the wafers requires position control Spin rinse dryer (SRD) systems mode to stop in an upright position for wafers without interruption. Instantaneous Spin rinse dryers (SRDs) clean and dry mode switching can enable seamless semiconductor wafers in a series of transition between speed and position cycles that includes rinsing, purging, control modes to achieve the SRD and drying the wafers. A cassette process in a single motion operation. DW holding a rack of wafers is loaded into the rotor inside the SRD chamber. This EZ Motion load-balanced rotor is responsible www.ezmotion.co for the spinning motion in the wafer Longer lasting Belts, HEHT Split Spools -- no regrind wide_Layout 1 8/22/2023 6:05 PM cleaning process.

The rinse, purge, and dry cycles Longer Lasting Belts & Pulleys are driven in speed control Round, Flat, Vee and Better than mode for a set Poly-V belts and pulleys Lifetime duration at given Warranty speeds. After all cycles are completed, the rotor holding

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December 2023

21

Dura-Belt

800-770-2358 614-777-0295

Fax: 614-777-9448 www.durabelt.com

12/15/23 8:45 AM

•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• L i n e a r

M o t i o n

Review of ballscrew

buckling & rigidity One

potential concern with ballscrews is buckling.

To understand why, imagine two columns — one short and wide … and the other long and narrow. As weight is applied to these two columns, the long and narrow one gradually begins to bend until it becomes permanently deformed and eventually breaks. In contrast, the short and wide column handles the weight with ease.

In the same way a thin column reaches its buckling point earlier than a squatter column — so too does a long ballscrew with a small diameter deform and buckle under a smaller axial load than a shorter screw with a larger diameter.

Determining the buckling load is key to ballscrew sizing. The buckling (compressive) load

can easily be calculated based on the screw’s root diameter, unsupported length, and end bearing configuration.

Where Fc = maximum compressive load (N); fb = End bearing factor; d1 = Root diameter of screw (mm); and L = Unsupported length (mm).

Application tip: The end bearing factor fb is dependent on the end fixity of the screw. Ballscrew manufacturers recommend a safety factor of at least 2 for the maximum applied buckling load, and some incorporate this into this published end bearing factors. To avoid over or undersizing, check whether the manufacturer has built a safety factor into the published fb values.

For a given diameter and length ballscrew, permissible buckling load can be increased by changing the support

bearing arrangement. The more rigid the support bearings, the higher the bearing factor … ranging from approximately 2.5 for a fixed-free arrangement to 40 for a fixed-fixed arrangement. This means that a fixed-fixed bearing arrangement will result in approximately sixteen-fold the permissible buckling load than a fixedfree arrangement on the same screw assembly.

In a horizontal application, axial force is generally equal to the load times the screw assembly’s coefficient of friction … so buckling is typically less problematic than other performance factors such as critical speed or drive torque. But some horizontal applications (such as pressing and injecting) introduce an additional axial load on the screw assembly — and the buckling load can easily become a constraining factor in screw selection.

When a ballscrew is used in a

Ballscrew in a CNC machine

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TENSION

LOAD

includes a fixed bearing to avoid excess compressive forces on the screw.

The rigidity of a ballscrew determines the amount of elastic deformation it will experience in the axial direction, under a given load.

Elastic deformation and therefore rigidity is a fundamental characteristic in selecting and sizing a ballscrew, as it affects system positioning accuracy:

Where δ = Elastic deformation (μm) Fa = Applied force in axial direction (N) Rtot = Rigidity of the screw assembly (N/μm)

COMPRESSION Buckling is a relatively straightforward but sometimes overlooked factor in ballscrew sizing. Always check process forces in horizontal applications and the location of the fixed bearing in vertical applications. For the latter, orienting the fixed bearing on top puts the ballscrew in tension.

vertical application, it sees the full load as an axial force. That force renders buckling a more acute concern.

Mounting a screw assembly with the most rigid support (typically a fixed bearing) at the top puts the screw in tension rather than compression and counters the effects of the axial load.

In the unusual case of a high reversing force — for example, pushing a plunger into a housing on the screw’s upward stroke — the most beneficial bearing arrangement is to orient the fixed bearing at the bottom of the screw assembly.

Another application tip: Most but not all screw-driven linear actuators use a fixed bearing on the motor side and a floating bearing on the non-driven end. For vertical applications, be sure to check which end of the actuator DESIGN WORLD

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In this equation, the value for rigidity is based on the screw assembly, not simply the screw shaft or the ball nut.

A complete screw assembly typically includes the screw shaft, ball nut, support bearings, and housings for the ball nut and bearings … all of which contribute to rigidity:

Where Rtot = Rigidity of the screw system (N/μm) RS = Rigidity of the screw shaft (N/μm) RN = Rigidity of the ball nut (N/μm) RB = Rigidity of the support bearings (N/ μm) RH = Rigidity of the ball nut and bearing housings (N/μm)

Rigidity of the ball nut and support bearings are given by their respective manufacturers, while rigidity of the housings depends on their construction and mounting. But besides these components, screw-shaft rigidity tends to be the lowest of all the components … and based on the inverse nature of the equation, has the biggest influence on total system rigidity.

Screw shaft rigidity depends on the end bearing arrangement, the minor diameter of the screw, and the distance between the thrust bearing and the ball nut. For a fixed-free or fixed-floating arrangement, the screw shaft rigidity is:

Where A = Cross-sectional area of the screw (mm2) d1 = Minor diameter of the screw (mm) E = Modulus of elasticity of steel (2.06 x 105 N/mm) L = Distance between the ball nut and the fixed bearing (mm) When the end-bearing arrangement includes two fixed ends, the rigidity of the ballscrew shaft is influenced by the distance of the ball nut from each of the fixed end bearings:

Where La = Distance between the ball nut and one fixed bearing (mm) Lb = Distance between the ball nut and the other fixed bearing (mm)

L Lb

La

La

L Lb

Fixed-fixed arrangements have the shortest

Unsupported lengths require Fixed-fixed arrangements have the shortest unsupported lengths. special consideration.

unsupported lengths.

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M o t i o n

In the fixed-fixed arrangement, the rigidity will be lowest when the ball nut is located halfway between the two fixed ends with La = Lb = L/2 — and the rigidity equation then becomes:

Fixed-free arrangements provide the least rigidity.

Floating-floating support includes a simple radial bearing at each end.

The equations show that rigidity for ballscrew assemblies having fixed-fixed mounting is quadruple that for assemblies with fixed-free (or fixed-floating) mounting.

That means the end-bearing configuration is the first thing to consider if a screw assembly is not rigid enough for the application. Another method to improve rigidity is to use a larger diameter screw.

This increases not only the rigidity of the screw shaft, but also of the ball nut and (in most cases) of the end bearings.

Conversely, increasing the preload of the ball nut generally has only a small effect on rigidity, because the ball nut is a minor factor in the total system rigidity.

Increasing preload also has the potentially detrimental effect of higher frictional torque, more heat generation, and greater material expansion of the screw shaft. DW

A fixed-floating arrangement has bearings at both ball screw ends, but a thrust bearing only at one.

A fixed-fixed arrangement provides maximum rigidity.

Ballscrew supports affect rigidity.

Fa

Fa

Nuts can also help boost rigidity.

A double ball nut can also contribute to ballscrew rigidity.

Additional reading on linearmotiontips.com • •

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How to improve ballscrew rigidity Benefits of a rotating nut (driven nut)

December 2023

DESIGN WORLD

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December 2023 www.fastenerengineering.com

2023 How do vdc and non-vdc adhesives compare?

keeping a

low profile:

How micro screws support lighter, more aerodynamic designs page 30

cover – fastener hb december 2023 v3 final.indd 1

page 26

How does “direct-pass” ultrasonic metal welding support evs? page 34

what are the different styles of retaining rings? page 37

12/7/23 2:21 PM

adhesives Did you know that 100% solid epoxies typically contain no Volatile organic compounds (VOCs)? They’re ideal for applications in enclosed spaces and those with large bonding or coating areas.

How do

VOC and non-VOC adhesives compare?

Article courtesy of Master Bond

Volatile

organic compounds (VOCs) are compounds that have high vapor pressure and low water solubility. Many VOCs are human-made chemicals used and produced in the manufacturing of paints, pharmaceuticals, and refrigerants.

VOCs are typically industrial solvents or by-products produced by chlorination in water treatment, such as chloroform. They’re common ground-water contaminants and often components of petroleumbased products, hydraulic fluids, paint thinners, and cleaning agents. They’re also emitted by an array of products numbering in the thousands.

A few examples of products that contain VOCs include paints and lacquers, industrial adhesives, paint strippers, cleaning supplies, pesticides, building materials and furnishings,

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office equipment (such as copiers and printers), correction fluids and carbonless copy paper, graphics materials, permanent markers, and photographic solutions.

Concentrations of many VOCs are consistently higher indoors (up to 10 times higher) than outdoors.

Health effects of VOCs The extent and nature of the health effects of VOCs will depend on several factors, including the level of exposure and the duration and frequency of exposure.

Some of the symptoms that can occur after exposure include: • Eye and respiratory tract irritation • Headache • Nausea and dizziness • Visual disorders • Memory impairment www.fastenerengineering.com

Some VOCs can also cause cancer in animals (based on toxicological studies).

VOC regulations Clean Air Act standards, Environmental Protection Agency (EPA) VOC standards, and regulations pertaining to the use of solvents in various industries are as follows.

• National Emission Standards for Hazardous Air Pollutants (NESHAP) • New Source Performance Standards (NSPS) • Control Techniques Guidelines (CTG) • Alternative Control Techniques (ACT) • National Volatile Organic Compound Emission Standards – 183(e) VOC Rule

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Pressure Sensitive

Polymer Film

adhesives

Adhesive Lamination

Process Benefits • Short run laminations • Adhesive versatility • Fast turnaround • Uniform Adhesive Coating • Liner Application Types of Products • PTFE made with Teflon® Fluoropolymers • Kapton® Polyimide • PEEK • Nylon® 6/6 • ULTEM® PEI • Mylar® • PVDF • UHMW

The EPA recommends that states adopt requirements consistent with the presumptive Reasonably Available Control Technology or RACT (groundlevel VOC). These measures are only a recommendation, and states may develop their own RACT requirements on a case-by-case basis, based on the economic and technical circumstances of individual sources.

Currently, no federal laws or regulations preclude states from requiring more stringent controls than those recommended as RACT. Some states might require additional control to meet the national ambient air quality standards (NAAQS) for ozone in some areas.

VOCs are an extremely important consideration in industries such as aerospace, medical, electronics, oil &

chemical processing, and industrial OEMs. The key to ensuring that VOCs are mitigated is to select compounds that contain no solvents or high levels of VOCs. This will limit the VOC from the start and reduce the outgassing of VOCs over time at a device level.

Reformulation to lower VOC content would be beneficial from health and safety aspects and require less VOC control measure equipment.

Epoxies that are 100% solid typically contain zero volatile organic compounds, making them ideal for applications in enclosed spaces and those with extensive bonding or coating areas.

Learn more at masterbond.com

Resources Guidelines from the Environmental Protection Agency (EPA):

Adhesive Options Acrylic High Bond Acrylic Silicone

•

Volatile Organic Compounds' Impact on Indoor Air Quality tinyurl.com/AirQualityVOCs

•

“Control of Volatile Organic Compound Emissions from Coating Operations at Aerospace Manufacturing and Rework Operations” tinyurl.com/ControlVOCs

Additional Services Custom Die Cutting Roll Slitting Rewinding Automated Sheeting

800-461-4161 www.cshyde.com 28

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DESIGN WORLD

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12/11/23 10:14 AM

screws

what are

low-profile screws?

By Hiroki Goto, Engineering Manager | NBK America LLC

Low-profile

screws are made with a lower head height than typical screws. These fasteners are designed with a minimal or flush head that sits close to the surface of the material being fastened — providing low visibility but a secure attachment. These components are also referred to as slim head, micro, or lowprofile cap screws.

The smaller size and thinner (lower) heads mean these fasteners are typically used for smaller devices and equipment or where clearance is limited. For example, they’re ideal for applications with limited space for bolt mounting.

With minimal protrusion after mounting, they can also reduce concerns about interference.

Low-profile screws solve specific problems, like fastening to thin sheets where counterboring is impossible. In

such cases, regular screws require deep counterbored holes, calling for larger surface material. Low-profile screws completely eliminate the need for counterboring.

Additionally, these screws are commonly used in applications where aesthetics matter, and the appearance of the fastened surface is important. By design, low-profile screws offer a sleek, discreet finish.

•

• Typical features • Head design: Low-profile screws usually have a flat or slightly countersunk head design. The head is flush with the surface or slightly recessed, ensuring minimal protrusion.

• Reduced height and weight: Compared to conventional screws, those with lower profiles often have a shorter overall length, allowing them to remain close-to flush with a surface without protruding. The thin head means these fasteners are

lighter than ordinary screws, making them ideal for many lightweight applications.

Thread size: Sometimes, lowprofile screws also have a reduced thread height, where the threads are shorter to prevent them from protruding out the other side of the material. This is helpful in the context of fastening materials with limited thickness.

Variation: Much like typical screws, low-profile fasteners are available in various sizes, materials, and drive types, providing flexibility for different applications and a range of industries.

Applications Given their minimal design, lowprofile screws are widely used in the electronics industry for securing components, circuit boards, and electronic enclosures. Their flush or recessed heads minimize interference.

They’re also used in drones, automation

Drones are designed to minimize air resistance and achieve efficient flight. Using low-profile screws in their assembly helps maintain a smooth, lightweight surface, reducing protrusions that could disrupt airflow around the drone.

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DESIGN WORLD

12/11/23 9:55 AM

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screws robots, and certain automotive components (securing interior trims, panels, and consoles) because these fasteners are lightweight and unobtrusive. They support unrestricted energy flow and can result in cost savings.

Thanks to their aesthetic nature, these fasteners are also frequently used in cabinetry, woodworking, and the furniture industry to secure hardware. They provide a clean and discreet appearance while maintaining structural integrity.

Low-profile fasteners are also used in critical applications, such as medical devices and other applications where space and weight are critical factors.

Choose wisely There are several advantages to using low-profile screws, given their smooth, lightweight characteristics. However, it’s important to do your due diligence and choose the fastener that ideally fits your application.

Although these screws offer secure and reliable fastening in most applications, their thin head is not always an advantage. It can result in lower strength with different widths than conventional hex socket head cap screws. Also, when using both hex socket head cap screws and low-profile screws, different tools may be required, causing extra challenges. Nevertheless, low-profile screws offer a streamlined, secure option for many applications.

Low-profile screws are ideal for use to prevent interference when opening and closing equipment doors (top image) or for equipment that does not allow for deep countersunk holes.

The advantages of low-profile fasteners…

•

•

• •

Minimalism – a thinner head means these screws are smaller and lighter than typical screws, making them ideal for space-saving designs, smaller devices, and lighter-weight equipment Safety – low-profile screws reduce the risk of catching, snagging, or even injuries that can result from exposed or protruding screw heads Aesthetics – a clean, smooth appearance Maintenance – for the most part, smaller, low-profile fasteners mean easier maintenance

Low-profile fasteners ensure minimal protrusion after mounting, reducing the risk of snagging, catching, or interference.

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welding

Alex Yeung, Global Product Manager, Branson Welding and Assembly at Emerson

how does “direct-pass”

ultrasonic metal welding support evs?

Manufacturers

of electric vehicles (EVs) continue to look for ways to improve battery technologies despite a substantial recent reduction in the cost per kilowatt-hour for lithium-ion batteries. Many aim to significantly increase energy densities to provide greater driving distance between charges, faster charging times, and a reduced risk of overheating. This will also enable the use of nonflammable electrolytes. Increasing the energy density of EV batteries requires adding substantially more layers of the anode/ cathode/electrolyte thin foil materials used by the industry. These thin foil layers give EV batteries the ability to charge, store, discharge, and release electrons that produce the electric current that powers the vehicles.

In current EV batteries, graphitecoated copper is the most widely used thin foil material, welded to a single, heavier, nickel, or nickel-coated copper tab. Cathode foils are made from aluminum and are welded to a single, heavier-gauge aluminum tab. These foilto-tab weld assemblies let the current charge and discharge through the external casing of individual battery cells.

By adding layers of these thin foils — while staying within the physical parameters of existing battery designs

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(for example, 18650/20700 cells or flat prismatic cells) — these more powerful batteries have increased surface area to collect and transport electrons, increasing energy density and battery capacity.

However, increasing energy density by this method can present problems.

The ultrasonic metal welding technology typically used for the foil-to-tab bonding process can only produce reliable assemblies using a maximum of 40 to 50 foil layers. Adding foil layers requires higher welding amplitude to bond the layers.

When the number of foil layers (ranging in thickness between five and eight microns) approaches 60 or more, the higher amplitude needed to bond them results in increased particulates and damage to the metal foil — such

as wrinkling, cracking, and tearing.

Such damage, which increases the risk of short circuits and threatens battery quality by reducing current capacity, can be detected by monitoring weld quality data/limits, performing strength tests, and conducting visual inspections.

Conventional ultrasonic welders could not effectively make the foilto-tab welds. They used a horizontal oscillation technique that delivered weld energy through a cantilever-type actuator, which extended outward before adding clamp force. When more foil layers were added, the actuator arm created additional vibration that compromised clamp stability and allowed foil layers to wobble and shift.

Unfortunately, increasing amplitude to compensate made the excessive vibration worse. Clearly, a new metal

Ultrasonic welds provide the most proven and reliable solution for interconnecting the thin copper foils and tabs that are typically used as anode current collectors, as well as the aluminum foils and tabs used in many cathode current collector structures.

Photo courtesy of Emerson

www.fastenerengineering.com

DESIGN WORLD

12/11/23 10:01 AM

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welding

welding technology was needed to deliver reliable, foil-to-tab welds on these thicker stacks of metal foils, and engineers have delivered.

A new form of ultrasonic welding A new “direct press” ultrasonic metal welder makes it feasible to weld thicker foil layers. It has a vertical actuator that applies more clamp force on the welded parts, holding them with greater stability.

Several factors contributed to the welder’s success.

The motion of the vertical actuator could be more carefully controlled, undesirable actuator stress and vibration could be eliminated, and the tooling “grip” on the parts was improved.

The result is a weld process that’s much gentler and provides more consistent, higher quality due to the lower amplitude required. The new method has been validated, consistently welding up to 80 or even 100 thin foil layers without damaging the fragile foils.

In trials with manufacturers, this new directpress welding technology has proved its ability to produce high-quality spot welds on 100 layers of 10 micrometers (µm) copper foil to a 0.5 millimeter (mm) copper plate and 86 layers of 10 µm copper foil to a 0.2 mm nickel-coated copper tab.

Using the new direct-press technology, battery manufacturers can produce more reliable, longerrange, more energy-dense batteries. These batteries, coupled with improved charging systems and nonflammable or even solid electrolytes, should result in electric vehicles with greater driving range and operational safety.

The Branson GMX-20DP “Direct Press” Ultrasonic Metal Welder from Emerson. The reliability of the welds produced by this method have been validated by laboratory and customer tests.

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December 2023

DESIGN WORLD

12/11/23 10:01 AM

rings

what are the different styles of

retaining rings?

Retaining

rings — unassuming but critical components in engineering and mechanics — come in various forms, each with unique characteristics and advantages. They secure assemblies onto a shaft or in a housing or bore.

Selecting the ideal style and assembly method is crucial. This guide sheds light on their different features and benefits.

Tapered section rings: Axial, also known as circlips, tapered section retaining rings feature a tapered design where the radial width of the crosssection decreases from opposite the gap down toward the lugs. This profile allows the ring greater radial flex to tightly grip the bottom of the groove, equipping it to withstand significant thrust loads.

Functioning as a lightweight alternative to conventional fasteners (such as screws, nuts, and bolts), these rings can handle substantial forces in a properly designed application.

Alternative tapered section rings can alleviate vibration,

movement, or noise in applications.

Bowed and beveled retaining rings use the spring properties of the ring to effectively counteract the impact of accumulated tolerances, assembly wear, and endplay.

Most axial assembled retaining rings feature lugs and lug holes, offering ease of installation and removal.

Simple automation allows for the ring to be expanded over a mandrel for positioning in the groove and is recommended for high volumes or when repeatability of installation is important.

Tapered section rings: Radial retaining rings combine function with simplicity, offering a choice of configurations.

They’re engineered for applications requiring low thrust loads and when radial installation is imperative due to interference from other components.

Radially

Article courtesy of Rotor Clip

installed rings are available in various styles, including e-rings, c-rings, and poodle rings, in configurations to suit several assembly requirements. One advantage is these rings are often a cost-effective alternative to their axial counterpart.

Since radial rings do not need to flex as much as an axial ring during installation, they provide greater contact with a retained part when designing smaller assemblies.

Similar to axial rings, there are options for bowed configurations that effectively counteract vibration and shock impact. The spring-like nature of the rings enables them to absorb movement, reducing the transmission of forces to the rest of the assembly.

Constant section or snap rings, commonly known as snap rings, exhibit a consistent width (or radial wall) along their entire circumference — typically establishing three points of contact within the groove.

This uniformity guarantees a steady, unvarying interface that serves as a shoulder, firmly anchoring an assembly

Tapered section retaining rings

DESIGN WORLD

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www.fastenerengineering.com

December 2023

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rings in position. Thanks to their lug-free design, these rings excel in scenarios with restricted clearances or confined spaces.

Snap rings are frequently chosen for their reliable cross-section, bolstering their capacity to effectively withstand impact loads. This makes them ideal in applications where strength and durability are paramount.

Self-locking or push-on rings offer a comprehensive solution, combining small size, easy installation, and high security. These rings incorporate notches or indentations around the inner or outer diameter, ensuring the ring remains securely in place, even when vibrations or dynamic loads are present.

Self-locking rings can operate without grooves or complex machining in the mating components. This simplifies the “push-on” design and manufacturing process, making them an efficient choice for applications that

demand simplicity without compromising performance.

Spiral retaining rings serve as an artificial shoulder seated within a groove on a shaft or housing. This design ensures precision and stability in mechanical assemblies.

What sets spiral rings apart is their coiled structure, which grants them an exceptional degree of flexibility for sizing and material selection. In multiple-turn construction, the ring provides 360-degree contact with the groove.

Spiral rings ensure strong retention capabilities without the need for assembly lugs.

They’re also easy to install and remove, requiring no specialized tools.

When selecting a retaining ring, the choice of ring style can significantly influence the outcome of a project. Fortunately, there are several options to meet your unique

Spiral retaining rings

requirements.

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

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

bokers.com

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www.fastenerengineering.com

DESIGN WORLD

12/11/23 10:11 AM

J.W. Winco, Inc. Spring Loaded Devices from JW Winco When you need to align, hold, or latch different parts of equipment together, you need a spring loaded device.These locking systems are designed to facilitate repetitive positioning operations on machines and equipment or parts undergoing machining. Spring loaded devices create a secure connection with limited play. JW Winco has many different versions and types for your application requirement.

Check out www.jwwinco.com to find out more!

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

Wide variety of spring to meet your innovation needs When it needs a specific spring to empower mechanical function of your product for best performance, such as Tensioning & Loading, Counterbalancing, Retrieving & Returning, Drive Motor, you are welcome to contact design engineer of Ming Tai Industrial Company for best solution. Based on 60 years manufacturing experience of steel strip spring, well experienced engineers of Ming Tai Industrial Company are capable to provide you with the best solution to meet your innovation needs.

Check out www.powerspring.com.tw for more interesting innovation stories!

Ming Tai Industrial Co., Ltd. No. 250, Sing Jhong Road Tamsui, New Taipei City 251 Taiwan Phone: 886-2-26228651 Fax: 886-2-26220202 E-mail: mtis@powerspring.com.tw

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rings – fastener hb december 2023 v7 final.indd 39

www.fastenerengineering.com

December 2023

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12/11/23 10:11 AM

NBK Acquired Solid Spot’s Plastic Fastener Business and Expanded Lineup NBK is a manufacturer of Specialty Screws including Plastic Fasteners.

In this April, NBK acquired Solid Spot LLC’s plastic fastener business and then, more various product lineup are available such as PEEK, RENY, PC, PVDF, PTFE, POM, etc.

NBK manufactures not only plastic screws but also low profile (low head), miniature size(less than M3), vacuum application, anti-galling, chemical resistance, non-magnetic, and more.

Flexible customization is available.

NBK America LLC 307 East Church Road, Suite 7 King of Prussia, PA 19406 Phone: 484-685-7500 https://www.nbk1560.com/en-US/

Assemble Faster with SLIC Pins Pin and Cotter All-In-One Eliminates Cotters, Clips, Nuts Speeds Assembly Time No Tools Needed Safer Retention, More Secure As Strong as Corresponding Cotters

The SLIC Pin from Pivot Point features a strong, springloaded plunger that acts as an automatic cotter. Upon insertion, the plunger automatically ramps down to pass through the application, springing back up to lock the pin in place. More consistent and easier to install, SLIC Pins eliminate the wasted motion to install a cotter, clip or nut. With separate pin/clip systems, clips can be mis-installed, forgotten altogether, or fall off later. The one-piece design of a SLIC Pin eliminates those risks, reducing product failures in the field and leading to a more consistent product. Manufactured on automated equipment, SLIC Pins are affordable, making them an ideal solution for optimizing high-volume assembly.

Tens of millions of SLIC Pins are installed each year, touching every industry and saving countless hours.

Explore SLIC in your application today.

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www.fastenerengineering.com

Pivot Point, Inc. Tel +1 800 222-2231 Email: mail@pivotpins.com www.pivotpins.com/SLIC

DESIGN WORLD

12/11/23 10:11 AM

DECEMBER 2023

A DESIGN WORLD SUPPLEMENT

ALSO INSIDE: Rare earths and EVs — it’s not about batteries

Reducing range anxiety: PAGE 48

How automakers are increasing EV battery voltages PAGE 42

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12/14/23 8:23 AM

EV ENGINEERING

How silicon-carbide technology can address high-voltage EV challenges?

By Anthony Schiro, VP Quality & Sustainability • Stephen Oliver, VP Corporate Marketing & IR • avitas Semiconductor

S

ales of new electric vehicles (EVs) in the US exceeded five percent of the total market for the first time in 2022, joining 18 other countries worldwide that have surpassed the same milestone.

Although EVs are achieving market acceptance that bodes well for future success, adoption must continue and accelerate. Changing to tailpipe-free vehicles is a pillar of governments’ plans to meet climate pledges under the Paris Accord and improve air quality in major cities.

Standing in the way of progress, the usability of EVs is a key issue for many would-be buyers. Charging an EV at home can be impractical for those living in properties without offstreet parking or allocated spaces.

Moreover, while today’s EVs offer a decent driving range to handle average daily usage, longer trips still require stops to recharge.

There’s also concern about the location and availability of suitable charging stations and the stop duration. Whereas a liquid-fuel tank can be refilled in a couple of minutes, a typical discharged EV battery requires about 25 minutes to recharge to 80% of its full capacity.

Driving range and charging times still need better solutions to strengthen

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the case for EVs and drive faster market adoption to satisfy targets on emissions and sustainability.

Higher voltage, greater efficiency One way automakers are advancing electric-vehicle architecture is by increasing battery voltages. Some prestige and high-performance EV models have voltages as high as 800 V. Increasing the voltage provides greater power transfer, enabling faster battery charging.

Additionally, a higher operating voltage means thinner and lighter cables can handle the power delivered into the charging and traction systems and lower “I2R” losses, contributing to a longer driving range.

While greater passenger EVs use 400 or 800 V, a new 1,250 V charging specification promises to cut the charging times of long-haul trucks, including the high-capacity Class 7 and 8 vehicles. Productivity is a major concern in commercial haulage. The Megawatt Charging System (MCS) has been proposed to ensure the fastest possible charging times — standardized as SAE J3271.

Currently, SAE J3271 is under development and specifies charging

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from 440 kW at 350 A and 1,250 VDC without cooling and up to 3.75 MW at 3000 A and 1,250 VDC with active cooling.

As a guide, charging at 1.6 MW for 30 minutes would deliver 400 miles of driving with a standard Class 8 tractor. The SAE J3271 specification standardizes aspects, such as the plug design, communications protocols, and safety requirements, providing interoperability between vehicles, charging stations, charging networks, and the electric grid.

Higher battery voltages could extend the driving range by about five to 10%.

Technology for the transition Raising EV battery voltages can lead to faster charging and greater driving range, but it also puts extra demands on the vehicle’s essential powerhandling functions. These include the traction inverter, onboard charger (OBC), and HVAC systems.

As battery voltages are increased to 800 and 1,250 V, silicon-carbide (SiC) technology is inherently better suited to these applications. SiC MOSFETs offer advantages, including

DESIGN WORLD

12/11/23 10:30 AM

What Does It Take To Keep Industrial Automation Alive?

LAPP networking technologies are the lifelines of automation systems, reliably transmitting the power and data that enable the seamless interaction of machines, devices and plants.

Using our in-depth expertise, we design powerful communication solutions that enable the most reliable connections on the market— meeting your toughest industrial requirements and keeping production lines running. lapp.com/us

lapp group – ev engineering december 2023.indd 5

12/11/23 10:31 AM

EV ENGINEERING

Table 1.

Planar, trench, and trenchassisted planar comparison.

smaller feature sizes, lower parasitic capacitances, and lower on-resistance in relation to their breakdown voltage rating (VBR) compared to silicon IGBTs or MOSFETs, the typical alternative.

The lower capacitances permit faster switching with lower losses, resulting in greater energy efficiency.

The lower on-resistance allows for fewer transistors in parallel, resulting in smaller module dimensions, lower weight, and a reduced bill of materials. SiC can also handle higher operating temperatures, and the devices have lower thermal impedance, which can help simplify the vehicle’s cooling systems while preserving reliability.

SiC in roadside chargers Roadside EV fast chargers must be upgraded to meet increased EV battery voltages, especially to ensure faster charge times. Accordingly, SiC’s device size and efficiency advantages make this technology an ideal fit for charging applications where high speed, reliability, flexibility, and space savings are critical.

Many chargers are becoming more intelligent to better manage

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smart infrastructures powered by renewable energy sources. In a world where grid-connected storage is essential to maintain stability, the value of a nation’s fleet of EVs connected to the grid is inestimable as a storage solution.

An EV with a 40-kW battery could satisfy the energy demand of an entire household. The vehicle could be recharged when necessary and ready for the owner’s next trip. Vehicle-to-grid (V2G) communication is a specification that enables smart charging systems to use an EV as a resource to help balance energy flow through the grid and keep pace with continuously changing supply and demand.

Trench-assisted planar-gate technology Although the performance advantages of SiC devices have been well documented, designing SiC MOSFETs for the real world involves compromises between performance, reliability, and manufacturability. Typically, the choices are between a planar or trench architecture.

Trench architectures can offer lower on-resistance per die area and faster switching performance. However, the

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manufacturing yield can be low, and the gate oxide thickness is difficult to control, often leading to device failures in the field.

Planar devices benefit from superior gate ruggedness and shortcircuit capability, as well as simpler manufacturing processes. There’s also scope for future generations of the technology to deliver additional improvements in die size and cell performance.

The GeneSiC MOSFET platforms stretch from 650 to 6,500 V, addressing a range of high-voltage, fast-charging systems. Patented trench-assisted planar-gate designs combine the established strengths of planar technology with fast switching capability, extended operating lifetime, and high manufacturing yield. Table 1 compares the relative merits of the three architectures.

With low RDS(ON) at high temperatures and low energy losses at high speeds, trench-assisted planar devices outperform alternatives, including trench-gate structures. Their extremely low RDS(ON) temperature coefficient is significant.

In datasheets, RDS(ON) is typically stated at 25° C, but conventional

DESIGN WORLD

12/11/23 10:21 AM

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EV ENGINEERING

The electrification of heavy-goods vehicles is also significant to the transition to climateneutral mobility. The US has committed to ensuring all new trucks sold will be zero-emission vehicles by 2040.

Replacing 100,000 40ton trucks with electric Figure 1. Lower RDS(ON) temperature equivalents on long-haul coefficient of GeneSiC MOSFETs. routes is expected to save 10 million tons of the call to reduce emissions by CO2 annually. developing diesel-electric drivetrains, To support these efforts, certain electric pumps, and generators. long-haul routes could be targeted to Finally, hydrogen fuel-cell change first — prioritizing those that Future trends technology is expected to have a role let vehicles cover long distances at a The future must contain more fastin future e-mobility. It can leverage constant speed, with MCS chargers charging locations if EV adoption is the energy efficiency, ruggedness, placed in specific locations along to grow. However, installing more fast compactness, and reliability of SiC the route.

This approach, which chargers can demand a significant power semiconductors in hydrogen could establish a minimum viable financial commitment to upgrade the production by electrolysis and in the infrastructure as a platform for further supplying utility infrastructure and electric powertrains of hydrogen fuelprogress, would give fleet operators could slow the rate of progress. cell vehicles. and vehicle manufacturers confidence A fast and relatively low-cost to make investments in zero-emission approach involves upgrading Level Conclusion haulage.

2 charging points by integrating an Automotive OEMs have demonstrated Off-highway applications, such as energy storage system to boost the that passenger and commercial EVs charger output. The storage is charged agricultural and construction vehicles, can be practical, reliable, convenient, are expected to transition to electric continuously from the same lowand cost-effective. However, further powertrains more slowly. Arguably, voltage infrastructure used to supply improvements in charging times are such vehicles cover less distance than the Level 2 charger and discharged critical to reduce range anxiety and passenger cars and long-haul trucks. quickly into the EV battery when However, leading brands are answering accelerate adoption. The latest 800 connected. and 1,250 V systems require 1,700 V or 3,300 V SiC FETs and diodes, which IN-CIRCUIT, HIGH-SPEED TEST must be efficient and reliable to meet critical needs for the migration to faster charging. EV devices can suffer from a significant increase in resistance at elevated temperatures. GeneSiC MOSFETs have been shown to operate with up to 15% lower RDS(ON) over the rated temperature range (Figure 1).

This reduces energy losses, leading to increased system efficiency. Also, reducing device self-heating can lower the case temperature by as much as 25° C compared to equivalent alternative SiC devices operated with the same gate drive and ambient conditions (Figure 2). The 25° C cooler operation translates into a device lifetime that’s three times longer.

Figure 2. Operating temperature reduced by 25° C.

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www.evengineeringonline.com

References • freewiretech.com • reuters.com/business/cop/us-aimszero-emissions-heavy-duty-vehiclesby-2040-2022-11-17 • man.eu/corporate/en/experience/ megawatt-charging-revolutioniseslong-haul-truck-transport-120000.html • mckinsey.com/industries/travellogistics-and-infrastructure/our-insights/ powering-the-transition-to-zeroemission-trucks-through-infrastructure • deere.com/en/engines-and-drivetrain/ diesel-electric

DESIGN WORLD

12/11/23 10:21 AM

Custom Prototypes and Production Parts for Electric Vehicles Machining Molding Casting 3D Printing Laser Cutting Assembly And More Work with our experienced automotive team to bring your biggest projects to life.

xometry – ev engineering december 2023.indd 5

12/11/23 10:32 AM

EV ENGINEERING

Figure 2. Researchers are developing alternatives to rare earth minerals, which would negate concerns over supply chain security, environmental damage, and sustainability.

Rare earths and EVs — it’s not about batteries

By Jeff Shepard

R

are earths are important in the manufacture of electric vehicles (EVs). Although there are sustainability challenges related to EV batteries, rare earths are not used in lithium-ion batteries. They’re necessary for the magnets that form the main propulsion motors. The batteries mostly rely on lithium and cobalt (not rare earths).

At the same time, the magnets in the motors need neodymium or samarium and can require terbium

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and dysprosium -- all are rare earth elements. The most common rare-earth magnets are the neodymium-iron-boron (NdFeB) and samarium cobalt (SmCo).

Let's review what constitutes a rare earth element, consider where NdFeB and SmCo magnetic materials fit into the landscape of available magnetic materials, and briefly examine the applications beyond EVs for rare earth magnetic materials. We'll also present examples of the efforts underway worldwide to minimize or eliminate www.evengineeringonline.com

the need for rare earths in highperformance magnets.

What’s rare about rare earths?

Contrary to their name, rare earths are neither rare nor earths. The 17 rare earths consist of 15 lanthanides, including cerium, dysprosium, erbium, europium, holmium, gadolinium, lanthanum, lutecium, neodymium, praseodymium, promethium, samarium, terbium, thulium, ytterbium, and the metals scandium and yttrium.

DESIGN WORLD

12/12/23 10:57 AM

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EV ENGINEERING

Permanent Magnet

Ba Ferrite

Ferrite

Sr Ferrite Alnico

Metal

Rare Earth

Bonded They’re all relatively abundant in the earth’s crust but are “rare” because they occur in relatively low concentrations compared with the ores for other metals. Metals like iron, gold, silver, copper, and others can be found in high concentrations in ores. While rare earths don’t occur in ores like other metals, their overall availability is three times that of copper, two times that of zinc, and 200 times more abundant than platinum or gold.

However, their low concentrations make rare earths much more challenging to acquire than other metals. They’re also relatively difficult to separate from one another and the ores in which they occur. The difficulty in mining and refining rare earths presents problems related to environmental damage and sustainability.

Where do rare earth magnets fit in?

Rare earth magnets are the strongest permanent magnets. They produce much stronger fields than other options like ferrite or alnico permanent magnets. For example, rare earth magnets can produce magnetic fields of 1.6 Teslas (T) or more.

At the same time, other materials are limited to 0.5 to 1.0 T. Metals, ferrites, and bonded structures are used to fabricate permanent magnets. Rare earth magnets are a

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Figure 1. Rare earth permanent magnets are a branch of metal permanent magnets. (Image source: Shin-Etsu Chemical Co.)

SmCo Nd2Fe14B

subset of metal magnets (Figure 1).

One challenge with rare earth magnets can be corrosion, especially for NdFeB magnets.

NdFeB and SmCo both make powerful magnets. The primary difference is their operating temperature range. Other than high opposing magnetic fields, high temperatures commonly demagnetize permanent magnets. NdFeB and SmCo magnets have different operating temperature capabilities and temperature coefficients.

NdFeB, the strongest available magnets, are typically room temperature up to about 180 °C. Above that temperature, SmCo magnets are superior. One reason for the excellent performance of SmCo magnets at high temperatures is their lower temperature coefficient. SmCo’s temperature coefficient is about 0.200.30 %/° C, while the corresponding specification for NdFeB is 0.45-0.60 %/° C. The temperature performance of these materials has a major impact on their use.

Not just for EVs There’s some overlap, but because of their different operating temperature capabilities and corrosion resistances, NdFeB and SmCo magnets are generally used in other applications.

NdFeB magnets are suited for use at up to about 180° C, where corrosion resistance is not a significant concern.

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SmCo5 Sm2Co17

Applications include: • Drive motors in EVs • Accessory motors in general automotive systems • Motors in industrial and commercial robots • Sensors • Portable electronics • Speakers and other electroacoustic devices SmCo magnets are better suited for applications with heavy loads or that operate at elevated temperatures like: • Locomotive traction motors • Marine and large industrial motors and generators • Motors in military and aerospace systems • Oil and gas production and exploration downhole equipment Stepping away from rare earths EV motors require high coercivity and the ability to maintain magnetization, even at elevated temperatures. In many instances, about 30% of the materials used in the magnets in EV motors are rare earths.

To improve the high-temperature operation of Nd magnets, terbium (Tb) and dysprosium (Dy) are added.

Unfortunately, Tb and Dy are highly costly and subject to severe supply chain risks. To address these concerns and performance needs, Toyota has developed a new Nd magnetic material that uses no Tb or Dy. In the new material, part of the Nd is

DESIGN WORLD

12/12/23 10:57 AM

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To learn more about the Allegro family of products and to explore available design resources, visit allegromicro.com

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EV ENGINEERING

replaced by lanthanum (La) and cerium (Ce), relatively low-cost and more widely available rare earths.

Toyota significantly reduced the use of Tb and Dy in the fourthgeneration Prius motor. The recent development eliminates the use of Tb and Dy, reduces the amount of Nb needed, and replaces the Nb with La and Ce. The new material is more sustainable and is expected to be used across a similar range of applications as the Nb material it replaces.

Cosmic magnets Researchers at the University of Cambridge are taking a different approach to eliminate rare earths.

They're developing an industrialscale process to make tetrataenite, an iron-nickel alloy with magnetic properties approaching those of rare-earth magnets (Figure 2).

Natural tetrataenite forms in outer space in a meteorite as it slowly cools over millions of years. The long cooling time gives the iron and nickel atoms time to order themselves into a specific stacking sequence that supports the fabrication of highperformance permanent magnets without rare earths.

The long cooling time nor the stacking sequence makes it impractical to produce tetrataenite on a large scale. The recently proposed fabrication method

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involves the addition of phosphorous in the right proportions to the iron and nickel matrix. The new formulation speeds the formation of tetrataenite by up to 15 orders of magnitude, enabling it to be produced in a matter of seconds instead of millions of years. The material is now being characterized to determine how its performance compares with NdFeB and SmCo rare earth magnets and to refine the fabrication process further to make it suitable for industrialscale operations.

MnBi-based permanent magnets Another proposed alternative to rare earth magnets is manganese-bismuth (MnBi) based permanent magnets.

Researchers from the Department of Energy’s Critical Materials Institute and Ames National Laboratory are developing a new method of fabricating MnBi magnets based on microstructure engineering. MnBi is a potential material for high-temperature magnets because of its increasing coercivity (H) with increasing temperatures up to 255° C. In general, the H of a permanent magnet is always lower than that of the material used to make the magnet due to defects introduced during sintering or other powder consolidation processes.

For most materials, the reduction in H is insignificant, but for MnBi, up to 70% of H is lost during powder consolidation.

The structure of the magnetization domains controls the H of a MnBi bulk magnet, and the significant H

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loss experienced during the powder consolidation process can be attributed to the inter-grain magnetic coupling. The grains in the MnBi bulk magnet must be separated with a nonmagnetic grain boundary phase (GBP) to achieve a high H. The research team engineered precise nanostructures by controlling the grain size, tailoring the GBP, and improving grain alignment.

Those enhancements greatly improved magnetic properties, including H for MnBi magnets.

Further development work is being undertaken with PowderMet, Inc. to design a commercially viable and large-scale process for fabricating high-performance MnBi permanent magnets.

Summary NdFeB and SSmCo-based rare earth magnets are important components in EVs and various industrial, commercial, and military-aerospace systems. They are significantly higher in performance compared to alternatives without rare earth content. The use of rare earths is fraught with concerns about supply chain security, environmental damage, and sustainability. As a result, numerous efforts are underway to develop alternatives to rare earth magnets with similar performance levels. EV References • sneci.com/blog/are-rare-earths-anissue-in-the-production-of-ev-batteries • ameslab.gov/news/improvingrare-earth-free-magnets-throughmicrostructure-engineering • cam.ac.uk/research/news/newapproach-to-cosmic-magnetmanufacturing-could-reduce-relianceon-rare-earths-in-low-carbon • global.toyota/en/newsroom/ corporate/21139684.html • en.wikipedia.org/wiki/Rare-earth_ magnet • shinetsu-rare-earth-magnet.jp/e/design/ index.html • idealmagnetsolutions.com/knowledgebase/samarium-cobalt-vs-neodymiummagnets

DESIGN WORLD

12/12/23 10:57 AM

Interconnects A supplement of Design World • December 2023

2023 Cable & Connector Reference Guide Rotary slip ring connectors — what are they for?. . ....... . . . . . . . . . . . . . . . . . . . . . . . . . . 54 How can connector sustainability be improved? . . ........ . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Rotary slip ring

connectors — what are they for?

Rotary slip ring connectors are important components in various applications like multi-axis robots in Industry 4.0, wind turbines for sustainable green energy, machine tools, medical systems, and more. This article considers how slip ring connectors differ from commutators, how mercurywetted, pancake, and wireless slip ring connectors work, and more.

JEFF SHEPARD

S

lip rings, split rings, and commutators Slip and split rings are both designed to maintain electric circuit continuity between fixed and rotary sections in a mechanical system. The difference is that a slip ring can transmit signals and or power between the sections, while a split ring reverses the direction of current flow as the rotary section spins.

A split ring is literally split into at least two pieces; in some designs, there are multiple splits in the ring. When split into two and used in a commutator, the split ring is alternately connected to the poles of a motor, reversing polarity as the motor spins. The split ring is connected to the motor poles with brushes. The combination of the split ring and brushes is called a commutator.

Slip rings are also called rotary joints, rotary electrical interfaces, rotating connectors, collectors, and swivels. They are available in various geometries and constructions, like a pancake and through bore designs (Figure 1).

Slip ring construction The most common slip ring constructions are based on mechanical connections with brushes on a stator that slide against conducting rings on a rotor. The brushes can be made from various conductive materials, and the selection of material is based on several factors, including signal bandwidth, the amount of power to be transmitted, quality of the signal or power to be transmitted, speed of rotation, environmental factors, and reliability requirements. The moving mechanical contacts often require monitoring and frequent maintenance. Environmental factors are often the most limiting factor in the performance of mechanical slip rings. In addition, the sliding contacts can generate vibrations and electrical noise that can reduce the quality of the transmitted signals. That can be especially troublesome in applications requiring real-time control, like robotics. Several other slip ring designs are available to meet the demands of specific applications.

Pancake (left) and through bore (right) are two common designs for slip rings. (Image: Wikipedia)

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Mercury-wetted slip rings Mercury-wetted slip rings replace the sliding brush contacts with a pool of liquid mercury bonded to the contacts. The mercury maintains a low friction and efficient electrical connection between the two sides of the slip ring. Mercury solidifies at about

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-40°C, which can limit the use of this design. In addition, mercury is a toxic substance and poses safety challenges.

Wireless slip rings Wireless slip rings transmit signals and power using magnetic coils on either side of the slip ring and produce contactless and frictionless transfers.

These designs are better-suited for harsh environments, requiring less maintenance than conventional moving mechanical contacts. Wireless slip rings can transmit higher frequency signals with higher quality and less interference, but they are limited in the power they can transmit. If power coupling is important, a traditional moving contact slip ring can usually transmit several orders of magnitude more power in the same size solution.

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FORJs can be challenging to implement and suffer from high signal attenuation if not precisely aligned in angular and axial directions. Misalignments can also result in rotational signal fluctuations.

Because of their sensitivity, using FORJs in industrial environments can be especially challenging and demand high levels of protection, increasing installed costs.

Inductive and capacitive slip rings Near-field coupling using electric or magnetic fields can also implement non-contact slip rings. In these designs, non-radiating capacitive and inductive circuit elements transmit data or power.

Capacitive slip rings use electric fields to transmit data. These solutions are robust, low-cost, and lightweight.

They also have excellent performance even when misaligned and can support data transmission speeds of Fiber optic slip rings several Gbps in harsh environments Fiber optic rotary joint (FORJ) is a type independent of rotational speed. of contactless slip ring designed for data Because of their robust and high-speed transmission only. FORJs are particularly performance, capacitive slip rings useful in high EMI environments and are used in time-sensitive industrial typically use 850 or 1550 nm infrared applications like robotics and are transmission of analog or digital signals complimentary with the Ethernet and can data rates of 50 Gbps or higher. fieldbuses.

Inductive slip rings use electromagnetic induction and are suited to different applications. Like capacitive slip rings, inductive designs are suited for industrial applications with high rotation speeds. In contrast with capacitive slip rings, inductive slip rings are better suited for power transmission rather than data transmission.

There are a variety of contact and contactless slip ring designs with a The blade pitch

This SiGe transceiver can support 60 GHz wireless slip ring designs.

(Image: Analog Devices)

control systems in wind turbines are a common use of inductive slip rings.

As shown, there are various slip ring technologies, each with a particular set of performance tradeoffs (Table 1).

Wind turbines and slip rings Three types of slip rings are commonly used in wind turbines.

• Hub slip rings, as noted above, are usually inductive designs used in large utility-grade turbines.

• Yaw slip rings enable the turbine head on small privately owned turbines to rotate as needed by the wind direction. These are often a type of contact slip ring.

• Generator slip rings are used to carry power in utility-grade turbines.

Robots and slip rings The slip rings used in multi-axis robots are more varied and can include over 200 circuits in complex designs. In addition, slip rings in industrial robots can be used to link coolant or other fluids between the fixed and rotating parts of the machine.

Hydraulic or pneumatic slip rings are often referred to as rotary unions.

In addition to transmitting electric signals and power, these slip rings support the flow of coolant, gases, water, or steam. Some designs include pressure regulation or sensors to monitor environmental parameters and the operating condition of the slip ring. Large hydraulic slip rings are also commonly used in heavy construction equipment like excavators.

range of performance tradeoffs. (Table: Analog Devices)

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60 GHz wireless data slip ring A millimeter wave data interface slip ring has been suggested using frequencies from 57 to 64 GHz for industrial applications. The silicongermanium (SiGe) transceiver was developed for small-cell backhaul systems but can also support industrial slip ring designs (Figure 3). Using an integrated synthesizer, the SiGe chipset can be tuned in discrete frequency steps of 250, 500, or 540 MHz from 57 to 64 GHz. An external signal can also be used to control the modulation, coherency, and phase noise needs of specific applications.

The transceiver includes support for modulation schemes like on-off keying (OOK), quadrature amplitude modulation (QAM), frequency shift keying (FSK), and minimum shift keying (MSK). It has a maximum output power of 15 dBm and a maximum modulation bandwidth of 1.8 GHz and can be monitored using an integrated detector. The chipset features adjustable lowpass and high-pass baseband filters, a low noise figure, and flexible digital or analog IF/ RF gain control.

The receiver signal chain includes an integrated amplitude modulation (AM) detector that simplifies the demodulation of signals like OOK that use amplitude modulation. While the transceiver supports several modulation schemes, OOK is especially suited for control applications like slip rings since it can be implemented without high-speed data converters, which can add to cost and power consumption. In addition, OOK does not require complicated modulation and demodulation stages and can support the low latency needed for realtime industrial control applications.

Slip rings are important components in various industrial, green energy, and medical applications. Many contact and contactless slip ring technologies include mercury wetted, wireless, inductive, capacitive, and FORJ. In For a list of references, addition to transmitting please scan the electric data and power QR code in rotating machines, slip rings send gases and liquids between the rotating

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HELUKABEL® USA, Inc. | West Dundee, IL | www.helukabel.com | sales@helukabel.com

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How can

connector

sustainability be improved?

Before it became fashionable, connector makers were at the forefront of sustainability. It started with replacing cadmium plating to meet RoHS requirements and soon expanded to using plastic regrinds and bio-based plastics instead of 100% new plastics for connector bodies. Connector makers have more recently embraced new, more sustainable materials for high-performance contacts.

JEFF SHEPARD

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his article looks at sustainable connectors from the outside in, starting with a review of sustainable plating for connectors, looks at improving the sustainability of connector bodies and housings, and closes by reviewing developments related to more sustainable and higher-performance contact materials.

Sustainable plating for connectors The initial RoHS regulations in 2003 jump-started interest in sustainability across the electronics industry. While most attention was focused on getting the lead out of solders, the connector industry had additional challenges, particularly eliminating cadmium and chromium platings. Cadmium was a popular plating for military, aerospace, transportation, and industrial applications that needed corrosion resistance and guaranteed performance in all weather conditions.

New metal connector bodies were developed using aluminum with various protective surface platings. These designs can provide multiple combinations of corrosion resistance, electromagnetic interference (EMI) shielding, and appearance choices, including matte colors. Among the commonly used alternatives to cadmium are: • Tin zinc plating was developed for military applications in extreme environments. It’s considered to be the highest-performing alternative to cadmium. It’s highly conductive (< 5 mΩ) and corrosion resistant (500 hours static/5 days cyclic salt spray). It has a matt grey, non-reflective finish and provides cadmium-level protection.

• Zinc nickel plating is a high-performance solution for industrial, construction, and transportation applications. It provides a high level of EMI shielding and is rated for 500 hours of static salt spray.

• Zinc cobalt plating is also used in the industrial, construction, and transportation industries but offers less corrosion resistance than zinc nickel. It provides a good level of EMI shielding for signal integrity.

• Black zinc nickel is a cost-effective alternative and provides long-lasting

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PCR and PIR regrinds Regrinds and bioplastics are two approaches to increasing the sustainability of connector bodies and other connector components. There are two approaches to regrinds: Post-consumer regrind (PCR) plastics are plastic materials like bottles collected from recycling plants for cleaning, processing, and grinding, then added back into the manufacturing flow.

Connector makers do not generally use PRC plastics.

Post-industrial regrind (PIR) plastics are recaptured from a manufacturing process.

PIR plastics include flashings and other waste plastic from the manufacturing process as well as rejected finished parts that don’t meet specifications. Some connector makers use 40% regrind material for various components like plastic housings (Figure 1). Using PIR plastics helps sustainability in two ways: it reduces the use of virgin material and the environmental concerns associated with producing that material, and it reduces waste from the manufacturing process.

Bioplastics Bioplastics are not necessarily biodegradable and are not necessarily made using renewable organic resources.

They are defined in three ways: • Made from organic macromolecules obtained from renewable biological resources like plants or animals and may or may not be biodegradable

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corrosion resistance to exposed connector surfaces. It’s used in aerospace, ground transportation, and marine applications. It offers the same level of environmental protection, operating temperature range, and electrical performance as cadmium.

Epoxyurethanic varnish plating provides high corrosion resistance and was developed specifically for railroad applications. It does not offer high levels of EMI protection and is not generally used where signal integrity is an important consideration.

December 2023

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Figure 1: These high-speed backplane connectors use 40% PIR plastic in the housing.

(Image: Amphenol)

• •

CONNECT TECHNOLOGY WITH CONFIDENCE

Made from petroleum resources and are completely biodegradable Made from a combination of organically based macromolecules and petroleum resources and may or may not be biodegradable

Bio polyamides Bio-based polyamide 410 plastic is available and made with at least 70% renewable materials from castor beans. This material combines the performance benefits of short and long-chain polyamides. Compared with conventional polyamide 66 (PA66, also called nylon 66), the bio-based alternative offers superior mechanical performance and moisture resistance while providing good aesthetics. The bio-based polyamide EcoPaXX is used in sealed and unsealed connector systems that meet USCAR 050 standards (Figure 2).

A 100% bio-based high-temperature polyamide has been developed specifically for connector applications.

It meets the International Sustainability and Carbon Certification (ISCC) requirements. ISCC is a globally applicable sustainability certification system and covers all sustainable feedstocks, including agricultural and forestry biomass, circular and biobased materials, and renewables. This material is an ISCC+-certified massbalancing solution and delivers the same characteristics, performance, and quality as the conventional material. Its production generates a carbon footprint up to 50% lower than the corresponding fossil-based plastic.

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This 100% bio-based hightemperature polyamide is designed for miniature connectors with high pin counts, pitches less than 0.3 mm, and wall thicknesses down to 0.1 mm. Its thermal specifications make it suited for lead-free soldering processes, and it’s a 30% glass-fiber-reinforced material designed to deliver high levels of strength and ductility.

Room for growth While the connector industry has been using bioplastics for several years, it’s still relatively early in the adoption process.

Overall, bioplastic production is only about 1% of the over 350 million tons of annual global plastic consumption.

The largest current application for bio-based plastics is packaging, which accounts for over 50% of the market.

The use of various types of bioplastics is proliferating. For example, biopolypropylene use is projected to grow by 6X in the next few years. Today, multiple electronics applications like connectors account for only about 2% of bioplastic use (Figure 3). There’s

Harwin’s connector products are proven to perform in extreme conditions, with shock, vibration and temperature range rigorously tested.

Figure 2: This sealed connector meets USCAR 050 standards and uses bio-based polyamide 410 plastic. (Image: Molex)

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December 2023

WITH OUR QUALITY, SERVICE, SUPPORT, AND HIGHLY RELIABLE PRODUCTS, YOU CAN DEPEND ON HARWIN.

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on an EV connector with 5N mating force and showed little to no wear at 5 μm thick. Despite being 4x thicker, traditional silver plating experienced deep galling wear and exposed the copper substrate. Key performance specifications of the nanostructured silver include (Figure 4).

• 220 °C operation • Low insertion force • Thinner costings provide increased wear durability Electronics applications are a tiny percentage of bioplastic consumption.

(Image: MDPI polymers)

plenty of room for growth in bioplastics (and PIR plastics) to improve the sustainability of connectors.

used, especially the gold, equivalent to saving an average of 7.8 million kg of CO2 annually.

Nanocrystalline metal contacts The use of a nanocrystalline nickel alloy in connectors enables a substantial reduction in the use of gold. Mining and refining gold has significant negative environmental impacts that can be calculated using a life cycle assessment (LCA). The LCA impact of gold has an equivalent impact of 800 kg CO2 per troy ounce of gold mined. The LCA impact of nickel is 0.4 kg CO2/troy ounce, while the LCA impact of the nanocrystalline nickel alloy is 0.2 kg CO2/ troy ounce. The low LCA impact of the nanocrystalline nickel alloy is a result of two factors; it can be used in thinner platings to achieve the same level of performance, and its fabrication uses 100% recycled tungsten.

One connector maker has replaced the gold contacts on some lines of its high-reliability connectors with nanocrystalline metal contacts.

Nanostructured metal coatings are easily integrated into connector manufacturing since they are deposited through a traditional electrodeposition process for interconnects. Replacing gold with nanocrystalline metals has reduced the environmental impact of the materials

Nanostructured silver Nanostructured silver has been developed for high-performance, highpower connectors in electric vehicle (EVs) applications. EV applications include charger connectors that need low, stable contact resistance and high durability and high voltage connectors in the EV drivetrain and power system that need higher temperature ratings.

Regarding durability, the nanostructured silver material is about double the hardness of pure silver. It was subjected to 5000 cycles of wear durability testing

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Like bioplastics, nanostructured nickel alloys and nanostructured silver are very early in the adoption process.

There are many opportunities to increase their use and further improve the sustainability of connectors.

Connectors have made much progress toward improved sustainability.

It’s not new, but it has been happening since the RoHS regulations were first announced. It began with replacing cadmium and chromium platings with more environmentally friendly and sustainable alternatives. Today, it extends to various sustainable plastics for connector bodies For a list of and housings and references, nanostructured metals please scan the QR code for contacts. There are numerous opportunities to continue increasing the sustainability of connectors. DW

Nanocrystalline silver (orange) has about double the hardness of traditional Ag coatings (blue) at various temperatures.

(Image: Xtalic)

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0

0

Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months

a. Total Number of Copies (Net press run) (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail®) Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. c. Total Paid and/or Requested Circulation of 15b (2), (3),telemarketing and (4)) (Include direct written (Sum request from(1), recipient, and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.)

Outside County Nonrequested Copies Stated on PS Form 3541 (include b. Legitimate Sample copies, Requests Over 3 years old, Requests induced by a Paid and/or (1) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541.

Premium, Bulk Sales and Requests including Association Requests, Requested (Include direct written recipient,Lists, telemarketing Internet reNames obtained from request Businessfrom Directories, and otherand sources) Distribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.) and d. NonreIn-County Nonrequested Copies Stated on PS Form 3541 (include Outside quested Sample copies, Requests Over 3 years old, Requests induced by a Sales Through Dealers and Carriers, Street Vendors, Counter (2) the Mail) Distribution (3) Premium, Sales Requests including Association Requests, Sales, andBulk Other Paidand or Requested Distribution Outside USPS® (By Mail Names obtained from Business Directories, Lists, and other sources) and (4) Requested Copies Distributed by Other Mail Classes Through the USPS Outside (e.g. First-Class Mail®) the Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4)) Limit mailed at Standard Mail® or Package Services Rates)

e.

31,520

Nonrequested Distributed Outside the on MailPS (Include Pickup Stands, Outside CountyCopies Nonrequested Copies Stated Form 3541 (include (4) Shows, Showrooms and Other Sources) Sample copies, Requests Over 3 years old, Requests induced by a (1) Trade Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources) Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4))

d. Nonref.

In-County Nonrequested Copies Stated on PS Form 3541 (include Total Distribution (Sum of 15c and e) quested (2) Sample copies, Requests Over 3 years old, Requests induced by a Distribution Premium, Bulk Sales and Requests including Association Requests, g. (By Copies (See Instructions to Publishers #4, (page #3))and other sources) Mail not Distributed Names obtained from Business Directories, Lists, and Outside h. the Total (Sum of 15f and g) Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Requested Limit mailed atCirculation Standard Mail® or Package Services Rates) i. Percent Paid and/or (15c divided by f times 100) Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, (4) Trade Shows, Showrooms and Other Sources) Electronic Copy Circulation 16. Publication 16. of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication. e. a.

Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4)) Requested and Paid Electronic Copies 17. Signature and Title of Editor, Publisher, Business Manager, or Owner

0

0

0

0

21,277

21,736

9,849

8,562

0

0

0

0

243

287

10,083

8,849

31,360

30,585

160

352

31,520

30,585

67.8%

71.1%

Design World

f.

Total Distribution (Sum 15cPrint and e) b.

Total Requested andofPaid Copies (15c) + Requested/Paid Electronic copies (16a)

6,610 27,887

Date

6,958 28,694

37,970

37,543

73.4%

76.4%

Total Requested Copy distribution (15f) + Requested/Paid Electronic copies (16a) g. c.

Copies not Distributed (See Instructions to Publishers #4, (page #3)) I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form d. or Percent who omits material information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil Paid and/ororRequested Circulation h. Total (Sum of & 15f and g) copies (16b divided By 16c x 100) sanctions (including civil penalties).

(Both print electronic PS Form 3526-R, September 2007 (Page 2 of 3) i. Percent Paid and/or Requested Circulation (15c divided by foftimes 100) X I certify that 50% all my distributed copies (electronic and print) are legitimate requests or paid copies.

17.

16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication.

December 2023

17. Signature and Title of Editor, Publisher, Business Manager, or Owner 18.

Pat Curran, Senior Digital Media Manager

Date

9/2023

I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

PS Form Form3526-R, 3526-R, September July 2014 2007 (page(Page 2 of 2 4)of 3)

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ad index – dw december 2023 v3 final.indd 63

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December 2023

63

12/11/23 2:45 PM

Technical Thinking

By Mark Jones

The long road to Lego sustainability Many readers of Design World will likely recall gifts of Lego, and maybe some of them will be giving Lego (curiously, a word that is both singular and plural) this season. Lego bricks, as we know them today, came on the market in 1958. Other shapes have been added. Electronic controls have been added. Characters have been added. Still, the bricks of 1958 and the bricks of today are interchangeable — a testament to the perfection of the design; Lego bricks endure. Lego is still on a quest to be more sustainable, a quest I both admire and yet see as unnecessary.

Thirteen cubic feet of Lego still reside in my basement, about one for each of my son’s Lego-consuming years. Lego were a significant part of his growing up. That’s why Lego’s quest to become more sustainable caught my attention.

The effort isn’t going well. I’m not happy about their failure, but I’ve found that the effort to replace the polymer as misplaced or over-hyped.

Bricks are made of ABS, acrylonitrile butadiene styrene, polymer. ABS is an engineering thermoplastic — tough, durable, hard, and with a nice shine. It holds its shape. It doesn’t cold creep, a trait necessary for maintaining the mechanical integrity of structures. The characteristic click you get when bricks are pushed together, what Lego calls “clutch power,” is hard to get with other polymers.

As good as ABS is, the environmental footprint is a downside. The three monomers all come from fossil resources. CO2 is emitted, about 3 pounds for each pound of ABS made.

In 2012, Lego announced a goal of

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technical thinking – dw december 2023 v1.indd 64

substituting sustainable alternatives by 2030. In 2015, it founded a Sustainable Materials Centre, a $150 million effort researching and developing sustainable materials for its products and packaging. In 2015, headlines announced Lego was moving away from plastic bricks, a horrible misinterpretation of statements about finding suitable polymers based on renewable resources. They never found a suitable alternative. Lego moved to recycled polymer, PET from bottles. As of September 2023, those efforts have ended.

I’ve followed their sustainability efforts with some skepticism. Bricks use around 100,000 metric tons of ABS per year. That’s about 0.8% of all ABS production, 0.03% of all plastic production. Lego bricks are almost an inconsequential plastic use. It isn’t a significant part of my footprint either.

Like most Americans, my footprint is house, car, food, and the other 8-10%.

I figure 1% is insignificant. Thanks to Lego fanatics on the internet and researchers giving an average footprint by zip code, I estimate our household would need to consume 62,000 ABS Lego bricks per year for Lego to be a 1% contributor — or eight 7541-piece Millennium Falcon sets, almost $7,000 per year. We were never close.

Offsets are common in sustainability, especially for CO2.

Saving 7 gal of gasoline offsets one Millennium Falcon set. Easily done, but there is something better than offsets. I want to improve end-of-life. Or, actually, not to end the life of Lego.

www.designworldonline.com

Rather than changing the material, Lego should change the use pattern.

Lego are indestructible. There is a limited number of shapes and colors.

They are set up perfectly for reuse.

Rather than make new bricks, Lego should clean, sort, and repackage sets.

No need to melt and reprocess the ABS, the bricks are interchangeable, unchanged over decades. Perfect for use again and again. With the bricks in my basement, and basements all around the world, Lego may never have to make another brick. We may already be past peak brick.

Lego is doing many things right. They are transparently telling the story of their journey to sustainability. They’ve reduced unnecessary packaging and streamlined operations. They employ lifecycle thinking to drive their decisions. But I’m pulling for a new paradigm, not a new polymer. Reuse is better than ABS replacement. DW

DESIGN WORLD

12/11/23 10:56 AM

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