Design World February 2024 by WTWH Media LLC

www.designworldonline.com February 2024

INSIDE: LINEAR MOTION NEMA stepper motors update PAG E 2 9

INDUSTRIAL SAFETY

How IoT helps protect isolated employees PAG E 3 5

ROBOT REPORT

Cobot creates ‘cell manufacturing dream’ for plastics thermoformer PAG E 4 5

HMIs

in motion control PAG E 24

ALSO INSIDE:

EV ENGINEERING SUPPLEMENT PAG ES 55- 6 2

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Need Pneumatic Components? Everything you need at great prices, in stock and ready to ship

PNEUMATIC TRANSDUCERS STARTING AT

$380.00 (5520500)

NEW! Pneumatic Transducers starting at $380.00 (5520500)

Push-to-Connect Fittings starting at $3.75/5 pk. (PLUG532)

NITRA pneumatic push-to-connect fittings are easily installed and work well with flexible tubing to make sealed connections. • Threaded connections available with NPT, G-thread and BSPT R-thread types • Union-style fittings • Available in thermoplastic, nickel-plated brass, or stainless steel bodies • Configuration options include male straight (hex and round body), bulkhead female, long male elbow, tee reducers, and much more • High working pressure and temperature • Large selection of configurations • Threaded Elbow and Tee fitting bodies can be rotated after installation

Metal Work Regtronic pneumatic transducers convert an electronic signal into a regulated precision linear pneumatic output pressure. They offer high airflow capacity, excellent linearity, and a digital display that eliminates the need for a separate pressure gauge. • Compact transducer housing • 4-20mA, 0-5V, and 0-10V input options • RS-232 communication and keypad control • Settable minimum and maximum pressure range up to 145psi • Dual solenoid design eliminates continuous air consumption • 0-10VDC or 4-20mA output options • Two discrete outputs • M5, 1/8 NPT, or 1/4 NPT female process connection options

Flexible Pneumatic Tubing starting at $17.00/100 ft. (N532BLK100)

Strong, kink-resistant NITRA straight flexible tubing is available in a range of diameters and colors in 100ft packages or 500ft reels • Inch (up to 1/2in) and metric (up to 12mm) outside diameter tubing sizes • Multiple colors available including black, clear, and dark green UV stabilized • Straight polyurethane tubing • Straight nylon 12 tubing • Straight PTFE tubing • Straight bonded polyurethane tubing • Made in the USA

Research, price, buy at: www.automationdirect.com/pneumatics

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1-800-633-0405

the #1 value in automation

2/5/24 12:24 PM

Force that can hardly be restrained. The new DiaForce diagonal compact fans. The revolutionary fan concept combines the advantages of axial and centrifugal fans: – Up to 50% more air performance – Up to 6 dB(A) lower sound levels – Ideal for cooling-intensive IT applications – Optionally with integrated FanCheck diagnostic tool for calculating the specific remaining service life More information for your application: ebmpapst.com/diaforce

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2/5/24 12:25 PM

PRECISE. ROBUST. AVAILABLE.

ServoClass® Couplings • Zero-Backlash & High Torsional Stiffness • Engineered Performance for Reliable 24/7 Operation • Servo-Rated for Reversing, Positioning, Precision • Low Inertia / Low Misalignment Reaction Loads • Perfect for High Accuracy Actuator Systems • Engineering Assistance / Fast Delivery

www.zero-max.com 800.533.1731

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WHAT’S NEW FROM RULAND

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LARGE BORE DISC COUPLINGS • Bore sizes up to 1-3/4” and 45mm • Torque up to 1150 in-lbs (130 Nm) • Reduced vibration due to a balanced design • Double disc for increased misalignment

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INCH-METRIC RIGID COUPLINGS • Widest selection of standard inch-tometric bores with or without keyways • Supplied with proprietary Nypatch® anti-vibration hardware • One-piece style for easy installation • Two-piece style with a balanced design www.ruland.com | sales@ruland.com

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NEW!

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Thinking outside the bus I love learning about engineering colleagues who are innovating in new ways. Take the current issues with renewable energy. While strides have been made in solar and wind, the variability of these technologies often doesn’t match up with when power is most needed. That’s created much research over the years into ways to store power for the short term. One possible domestic solution may be hiding in a surprising place. Recently, I attended an event called Testival, hosted by Lincoln Electric in Cleveland. Testivals are conducted by CharIN, a global nonprofit seeking to bring the automotive industry together to create consensus on charging standards and best practices. Here, engineers discuss not just things like power, but other equally important issues such as data, billing, and privacy. “If you think about today’s market, [probably] less than 1% of the electric vehicles that will be sold are sold; 99% of electric vehicles haven’t been sold yet. What we’re doing here at these Testival events helps ensure that any charger from any company can work reliably and seamlessly with any vehicle from any company,” said Oleg Logvinov, Chair of CharIN North America and President and CEO of IoTecha Corp. Charging has been a one-way street for most EV owners in the U.S., but bidirectionality is on the horizon. Here, energy can be moved from the vehicle’s battery back into the grid, to power home appliances during a blackout, or elsewhere that power is needed. Logvinov points to fleets of school buses in the U.S. as a potential storage solution. School buses are perfect candidates for enabling bidirectionality because they run in the mornings and the afternoons. The rest of the time they’re stationary. They have fairly

Te c h n i c a l S u p p o r t

predictable routes and usage patterns. And they generally sit still in the summer. “Imagine that you have even a 100-kilowatt hour battery, but you have thousands of them,” said Logvinov. “It’s a huge energy storage opportunity — all of a sudden, we have the ability to take energy we are getting from wind and solar, store it there and when necessary, and release it back. All of a sudden, we solve one of the greatest problems that we’re facing today.” Bidirectionality adds another interesting thing to the mix. With an ICE vehicle, we’re used to dumping money into it. You buy a car, the value decays over time, and there are maintenance costs. EVs may now be able to become a grid stabilization resource by managing the load — and this could eventually earn the car owner money. “Utilities are willing to pay for the energy that you can either remove from the consumption or energy that you can get back. It’s pretty good currency. And all of a sudden, there are changes in mentality about being able to upgrade those assets,” said Logvinov. Logvinov discussed a test with a bidirectionally capable Lucid vehicle that was conducted just prior to the pandemic. A vehicle parked at Lucid’s office in Fremont, Calif., based on idle time and PG&E’s rates, was generating $5,400 annually, from 8:30 a.m. until 6 p.m. The utility would charge the vehicle with cheap energy rates during low demand periods and discharge when rates were more expensive, and demand increased. And $5,400 a year is significant; it means the vehicle is now an asset. Certainly, the payback will vary greatly depending on the geographic location and local rates, but this has the potential to be a game changer. DW

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

(408) 460-1345

On X (formerly Twitter) @wtwh_paulheney

insights – dw 02-2024 v2 final.indd 4

February 2024

www.designworldonline.com

DESIGN WORLD

2/5/24 11:16 AM

Technology Forward

Cybertruck — not Tesla’s best design

When the first deliveries of Tesla’s long-awaited Cybertruck began last November (and frankly even well before that point), it was widely panned across social media. People called it ugly, expensive or overpriced, even useless. Some of the funniest observations were that it looked like something a grade schooler would draw when assigned to design a vehicle; angular and boxy, as befits the aesthetic limitations of that age cohort. Looks aside, there are some useful lessons to be drawn here for design. It seems to me, at least, that the Cybertruck is a prime example of the failure of design. Let me explain. As many have pointed out, the biggest issue with the Cybertruck is safety. In fact, car safety experts have noted that the Cybertruck’s stainlesssteel panels are excessively stiff, which could cause more damage in collisions with other vehicles on the road, but also would pose a greater danger to cyclists and pedestrians. The many sharp edges of the stainless-steel body, which is touted DESIGN WORLD

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as being bulletproof, also pose an increased risk in collisions. Particularly at a time when the U.S. is seeing more pedestrian deaths on its roadways (where in other parts of the world pedestrian deaths are in decline), putting a vehicle with such clear safety issues on the road is a bad idea at best, irresponsible at worst. Apart from factors such as road design and behavior (both distracted drivers as well as pedestrians), a major factor in the rise in deaths is vehicle design. As a recent IIHS study found, vehicles that are tall and blunt, such as the everlarger pickup trucks we see on roads, are 43.6% more likely to cause death in a collision with a pedestrian. All of this leads to considerations of what goes into a good design. We can argue about the details, but a few basic principles seem fairly straightforward. These would be designing for functionality, reliability, safety, and manufacturability. Functionality may be the most obvious element – that is, does it function in a way that addresses the problem to be solved? The end product www.designworldonline.com

should have useful functions that the user needs or will make life easier or better in some way, and perhaps avoid unnecessary complexity; the much-vaunted “ease of use” that product marketers are apt to deploy to describe a benefit of their product. The designed product should also be reliable, with a solid useful life that’s realistic. So, no products that prematurely fail, for instance. And the design should take into account manufacturability; that is, designing a product or system that can be successfully manufactured, that doesn’t pose undue challenges to manufacturing. Combined with safety, a successful design would encompass all of these elements. In other words, it should be a good, useful, purposeful design that enhances the public good and makes life better for people. And in many ways, especially in safety and manufacturability, the Cybertruck falls short of these design principles. At the same time, this is not an argument against electric vehicles, nor electric trucks. Is there still room for such things as the Cybertruck? Perhaps so, but maybe as private fantasies of rich men. So let them tinker and design their speedy, bulletproof trucks and then go race them around in the desert or salt flats far away from public roads and cities with pedestrians and bicyclists and children and pets, where they won’t pose any risk to them at all. DW

Miles Budimir mbudimir@wtwhmedia.com On X (formerly Twitter) @dw_motion

February 2024

2/5/24 11:25 AM

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Contents 2 • 2024

•

VOL 19 NO 2

•

DESIGNWORLDONLINE.COM

ON THE COVER

Considerations for HMI in motion control

24 MOTION CONTROL Considerations for HMI in motion control

Open architecture HMI can provide benefits such as increased flexibility for motion control, leading to more efficient machine designs.

29 LINEAR MOTION NEMA stepper motors update Despite global supply and demand slowdowns, stepper motors are doing just fine, thank you.

35 INDUSTRIAL SAFETY The lone worker: How IoT helps protect isolated employees

Advanced wearable and monitoring technology provides real-time data, enhancing workplace safety and efficiency.

February 2024

toc (features + supps) – dw 02-2024 v1.indd 8

40 3D CAD Clinker coolers get an agile hybrid twist

Claudius Peters makes the machines that make cement. Applying agile processes to product design calls upon CAD systems to optimize those machines.

42 SENSORS When should passive or active RFID be used?

The main difference between passive and active radio-frequency identification (RFID) tags is the absence (passive) or presence (active) of an internal power source. Because of these primary differences, there are several secondary differences. Understanding these differences is the key to properly selecting the most appropriate RFID system for a specific application. www.designworldonline.com

SUPPLEMENTS FEBRUARY 2024

A DESIGN WORLD SUPPLEMENT

A Supplement to Design World • February 2023 www.therobotreport.com

Comparing EV battery cell charge and discharge rates

Cobot creates

What are the C-rate parameters?

CELL MANUFACTURING

DREAM

PAGE 56

for plastics thermoformer PAGE 46

45-54

55-62

2023

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NOW ONLINE!

2 .2 4 • CONTEN TS departments

Help us honor the companies that have provided the most leadership in engineering It has been a fascinating decade for all businesses, including manufacturers. We’ve seen the difficult supply chain issues brought on by the worldwide pandemic, along with a shortage of qualified workers and the strong reshoring trends in many industries. If nothing else, this helps to show how resilient manufacturers can be.

Insights

Technology Forward

Design For Industry

Design Notes

Ad Index

Technical Thinking

These companies represent the best and brightest, and they reflect the continued vision, integrity, and creativity of their design (and manufacturing) engineers. We think they deserve recognition from you, too. Vote online for one or more of the companies listed through October.

VOTE ONLINE leadership.designworldonline.com

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February 2024

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DESIGN WORLD

2/5/24 10:56 AM

DESIGN WORLD Follow the whole team @DesignWorld

EDITORIAL

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney Managing Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora Executive Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Senior Editor Rachael Pasini rpasini@wtwhmedia.com @WTWH_Rachael Associate Editor Heather Hall hhall@wtwhmedia.com @wtwh_heathhall

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VP, Creative Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Art Director Allison Washko awashko@wtwhmedia.com Senior Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel Graphic Designer Shannon Pipik spipik@wtwhmedia.com @wtwh_shannon

2023

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BRONZE REGIONAL AWARD

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February 2024

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Discover the beneﬁts of stainless steel 800-528-8650 info@eagletube.com ISO 9001 & ISO 13485

The many unique benefits of stainless steel make it a powerful candidate in materials selection. Engineers, specifiers, and designers often underestimate or overlook these values because of what is viewed as the higher initial cost of stainless steel. However, over the total life of a project, stainless is often the best value option.

What is Stainless Steel?

Stainless steel is essentially low-carbon steel that contains chromium at 10% or more by weight. It is the addition of chromium that gives the steel its unique stainless, corrosion-resisting properties. The chromium content of the steel allows the formation of a tough, adherent, invisible, corrosion-resisting chromium oxide film on the steel surface. If damaged mechanically or chemically, this film is self-healing, provided that oxygen, even in very small amounts, is present. The corrosion resistance and other useful properties of the steel are enhanced by increased chromium content and the addition of other elements such as molybdenum, nickel, and nitrogen. There are more than 60 grades of stainless steel. However, the entire group can be divided into four classes. Each is identified by the alloying elements which affect their microstructure and for which each is named.

Stainless Steel Grades and Applications 400 Series Martensitic – Typical grade: 410

Straight chromium (12 – 18%); magnetic and can be hardened by heat treatment. Typical use: Fasteners, pump shafts.

400 Series Ferritic – Typical grade: 430

Straight chromium (12 – 18%); low carbon, magnetic, but not heat treatable. Typical use: Appliance trim, cooking utensils.

300 Series Austenitic – Typical grade: 304

Chromium (17 – 25%), Nickel (8 – 25%); nonmagnetic, not heat treatable. Can develop high strength by cold working. Additions of molybdenum (up to 7%) can increase the corrosion resistance. Typical use: Food equipment, chemical equipment, architectural applications.

Precipitation Hardening – Typical grade: 17-4

Chromium (12 – 28%), Nickel (4 – 7%); martensitic or austenitic. Develop strength by precipitation harden reaction during heat treatment. Typical use: valves, gears, petrochemical equipment.

eagle stainless – dw 02-24.indd 5

• Fire & Heat Resistance Special high chromium and nickel-alloyed grades resist scaling and retain high strength at high temperatures. Stainless Steel is used extensively in heat exchangers, super-heaters, boilers, feedwater heaters, valves, and mainstream lines as well as aircraft and aerospace applications.

• Hygiene The bright easily maintained surface of stainless steel provides a modern and attractive appearance.

• Aesthetic Appearance Cleanliness is a matter of high importance. The easy cleaning ability of stainless makes it the ﬁrst choice for strict hygiene conditions, such as hospitals, kitchens, and food processing plants.

• Strength-to-Weight Advantage The work-hardening property of austenitic grades results in a signiﬁcant strengthening of the material from cold-working alone, and the high strength duplex grades, allow reduced material thickness over conventional grades yielding considerable cost savings.

• Ease of Fabrication

Modern steel-making techniques mean that stainless can be cut welded, bent, formed, machined, assembled, and fabricated as readily as traditional steel.

• Impact Resistance

The austenitic microstructure of the 300 series provides high toughness at elevated temperatures ranging far below freezing, making these steels particularly suited to cryogenic applications.

• Long-Term Value

In considering total cost, it is appropriate to consider material and production cost AND the life cycle cost. When the total life cycle costs are considered, stainless is often the least expensive material option. The cost-saving beneﬁt of a maintenance-free product having a long life expectancy.

• 100% Recyclable Over 50% of new stainless comes from old remelted stainless steel scrap, thereby completing the full life cycle.

2/5/24 12:28 PM

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Custom Retaining Rings and Wave Springs

Request Free Samples at 847-719-5900 or smalley.com

smalley – dw 02-24.indd 5

2/5/24 12:29 PM

Design for Industry SEMICONDUCTOR

Pioneering quantum computing cryogenic semiconductors The key to unlocking quantum computing’s potential for highperformance computing (HPC) and other fast-growing applications lies in the availability of control electronics capable of operating at cryogenic temperatures. Siemens Digital Industries Software is collaborating with sureCore and Semiwise to develop groundbreaking cryogenic CMOS circuits capable of operating at temperatures near absolute zero. The joint effort can dramatically advance performance and power efficiency for next-generation integrated circuits (IC) targeting

February 2024

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quantum computing, considered the leading edge in HPC research and development. Using Siemens’ Analog FastSPICE, Semiwise has developed cryogenic CMOS circuit designs featuring cryogenic SPICE models and SPICE simulator technology that can perform accurate analyses at cryogenic temperatures. The company is providing this intellectual property (IP) for sureCore’s revolutionary line of CryoIP, which aims to enable the design of CryoCMOS control chips seen as crucial for unlocking quantum computing’s commercial potential.

www.designworldonline.com

sureCore used Siemens’s Analog FastSPICE platform and Siemens’ Solido Design Environment software to construct analog circuits, standard cell libraries, and memory designs, including SRAM, register files, and ROM, using Semiwise’s cryogenic transistor models. The software showcased exceptional capabilities in handling foundry device models at cryogenic conditions, helping deliver efficient analog, mixed-signal, and digital circuit design and verification functionality without convergence issues. The result is a high level of accuracy and performance, setting the

DESIGN WORLD

2/5/24 11:29 AM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

When we develop new memory designs and their associated compilers, we need to run thousands of statistical circuit simulations to guarantee the yield and reliability of our IP stage for potentially groundbreaking advancements in quantum computing. sureCore is rapidly progressing towards its first CryoIP tapeout, leveraging GlobalFoundries' 22FDX PDK. "The critical storage element and the bit cell must essentially be treated as an analog circuit highly sensitive to process variability and mismatch,” said Paul Wells, CEO of sureCore. “When we develop new memory designs and their associated compilers, we need to run thousands of statistical circuit simulations to guarantee the yield and reliability of our IP." Siemens' Analog FastSPICE platform, powered by technology from Siemens’ Analog FastSPICE eXTreme platform, offers cutting-edge circuit verification for nanometer analog, radio frequency (RF), mixed-signal, memory, and custom digital circuits. It holds foundry certifications across all major foundries and is qualified across various process nodes, from mature to the most advanced. The platform also offers a comprehensive use model, including small signal, transient, RF, noise, aging, and multi-sim verification capabilities, with dropin compatibility with industry-standard SPICE-based flows. This all-encompassing solution boasts high performance, capacity, and flexible features. The Solido Design Environment provides a comprehensive cockpit for nominal and variationaware analysis and encompasses SPICE-level circuit simulation setup, measurements, regressions, waveforms, and statistical results analysis. Powered by AI technology, the environment assists users in identifying optimization paths to improve circuit power, performance, and area to facilitate production-accurate statistical yield analysis and reduce runtime compared to brute-force methods. DW

design for industry – dw 02-2024 v2 final.indd 15

February 2024

SHOELOK

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HARDENED TONGUE WASHERS

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RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

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Siemens • www.siemens.com DESIGN WORLD

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2/5/24 11:29 AM

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2/5/24 12:29 PM

Design for Industry M AT E R I A L H A N D L I N G & C O N V E Y I N G

Mobile conveyor platform bridges fixed systems and flexible AMRs Autonomous mobile robots (AMRs) can streamline material handling in manufacturing, logistics, warehousing, and more, yet many facilities rely primarily on conveyor systems. To serve as a flexible bridge between fixed conveyors and production lines, Interroll designed a light conveyor platform (LCP) to facilitate the handling of lightweight goods with AMRs from Mobile Industrial Robots (MiR). MiR’s AMRs are versatile robot platforms that accommodate top modules and other accessories to enhance functionality. Interroll’s LCP AMR top module is the newest certified application in the MIR Go partner program, the largest ecosystem of AMR applications with more than 160 top modules that seamlessly connect to the mobile robots. As part of its rigorous testing process, Interroll implemented the new LCP AMR top module with a MiR250 robot in its Center of Excellence in Sant Antonino, Switzerland. Specializing in producing techno-polymer injection-molded parts, the facility spans two floors, presenting a unique logistical challenge. Previously, material handling from production to

the logistics area required manual labor because no other logistics solution could offer the flexibility required for multifloor operations. MiR’s AMRs effortlessly navigate this multi-floor environment, autonomously using elevators to move between floors. To further optimize processes, Interroll uses MiR Insights, MiR’s cloudbased software that visualizes key performance indicators, such as distance driven, completed missions, and robot utilization rates. This software provides insights into high-traffic areas, enabling Interroll to enhance robot workflows and throughput. Since the introduction of MiR Insights in June 2023, the MiR250 operates an average of 22.3 hours per day, covering 65 mi (106 km) within the factory premises. Combining the MiR250 with the LCP AMR top module has significantly reduced manual handling and transportation times, allowing Interroll’s skilled workforce to focus on tasks requiring human expertise, creativity, and decision-making. The company anticipates a positive ROI due to increased efficiency and reduced labor costs. DW

Interpower®

Protection— New IP54-rated IEC 60320 Face & Plug Seal Kits

After passing UL’s Solid Particle Protection and Liquid Ingress Protection Tests per IEC Standard 60529 (Sec. 4.2, 13.4, and 14.2.4), Interpower’s C14 inlet Face Seal Kit as well as its Plug Seal Kit received an Ingress Protection rating of IP54 per UL’s test report. The IP “5” rating (solid particle ingress level), prevents corrosive dust and solid particles from reaching the terminals, which could create loss of electrical continuity and disable machinery.

Toll-Free Phone: (800) 662-2290 E-mail: info@interpower.com Business Hours: 7 a.m.–5 p.m. CST

Interroll • www.interroll.com • MiR • www.mobile-industrial-robots.com DESIGN WORLD

www.designworldonline.com

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February 2024

Order Online! 17

www.interpower.com

2/5/24 11:29 AM

HPUs ELECTRIC MOTORS GEAR PUMPS The US has many separate electric grids and there are differences in maximum and minimum voltages, but the small differences are enough to cause problems for a company. Gaudent Technology can design an AC electric motor with winding that covers the full range of the US electric grid thus minimizing problems.

CALL TODAY FOR YOUR CUSTOM SOLUTIONS: (219) 706-8521 gaudent ALA – dw 02-24.indd 5

2/5/24 12:29 PM

Design for Industry O F F - H I G H WAY

New onboard charger and electric filter boost heavyduty electrification Rapid charging is necessary to eliminate range anxiety for electric vehicles and mobile machines without charging access. Danfoss Power Solutions’ Editron division recently launched two new products to solve this problem and quicken the pace of heavy-duty electrification. The ED3 onboard charger with electric power take-off functionality was previously only available to Volvo Trucks. However, a product standardization project is underway, and Danfoss expects prototypes this year, with serial production to follow. Initially designed for on-highway applications, the ED3 will deliver 43 kW of charging power, the highest available in today’s market. This will allow heavy-duty electric vehicles to be charged overnight using readily available ac power outlets, facilitating quick deployment while minimizing infrastructure costs. The ED3’s high-power ac and dc electric power take-off will simplify integration for OEMs by pulling dc power directly from its main highvoltage battery to support up to 44 DESIGN WORLD

kW of power. It can also convert power drawn from the battery to ac in a single-phase or three-phase electrical supply to deliver up to 43.6 kVA. This means the ED3 can support any electric power take-off function for most auxiliary functions. Danfoss’ Editron division also launched the LCL1200/1700 electric filter. Specifically designed for offhighway applications, the filter is an accompanying component for the EC-C1700 electric converter the company released in 2023. The LCL1200/1700 filter acts as an active front end to convert energy from ac to dc grid or as a grid filter in generator applications. The LCL filter offers OEMs easy installation and design flexibility. When combined, the LCL1200/1700 filter and EC-C1700 converter will meet market demand for smaller, more sophisticated electric converters and enable easy access to full power grid connection. DW

After passing UL’s Solid Particle Protection and Liquid Ingress Protection Tests per IEC Standard 60529 (Sec. 4.2, 13.4, and 14.2.4), Interpower’s C14 inlet Face Seal Kit as well as its Plug Seal Kit was given an Ingress Protection rating of IP54 per UL’s test report. The IP “4” rating (liquid ingress level) prevents liquids from “splashing” into the terminals which may cause arcing and short-circuiting leading to fires or even electrocution.

Toll-Free Phone: (800) 662-2290 E-mail: info@interpower.com

Danfoss • www.danfoss.com

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design for industry – dw 02-2024 v2 final.indd 19

Interpower® New IP54-rated IEC 60320 Face & Seal Kits

Business Hours: 7 a.m.–5 p.m. CST

Order Online! February 2024

www.interpower.com

2/5/24 11:29 AM

Design Notes EDITED BY MIKE SANTORA

Fasteners help improve the view for the Einstein Telescope project Swedish specialist fastener manufacturer BUMAX has been selected to supply premium fasteners to ETpathfinder, an R&D facility at Maastricht University for testing and prototyping innovative concepts and enabling new technologies for the Einstein Telescope (ET). The Einstein Telescope is a nextgeneration underground gravitational wave observatory. The ET is being developed to be 100 times more sensitive than current instruments and is scheduled for completion in 2035. The telescope will enable scientists to study the precise structure of neutron stars, the birth of black holes, and the structure of the universe immediately after the Big Bang.

attenuation structures to isolate the test setup as much as possible from any noise from the outside world. The test setup resides in a vacuum to further remove vibrations carried through the air and minimize interference of air molecules with the optics and lasers. “Because we can’t use oils or lubricants in our cleanroom, regular fasteners just aren’t an option,” said Mathijs Baars, Mechanical Engineer at the Dutch National Institute for Subatomic Physics (Nikhef). “We investigated various fastener alternatives, including titanium-nitride coated fasteners, but BUMAX was the only solution that fully met our requirements while still being costeffective.”

Regular fasteners not an option The ETpathfinder equipment is currently being assembled in a cleanroom that includes a large vacuum vessel containing various optics and seismic

Anti-galling properties crucial BUMAX is supplying bolts, washers, and nuts in the BUMAX 88 stainless steel grade, which offers anti-galling properties. Galling is common with

regular stainless-steel fasteners and involves the fastener seizing up with the internal threads because of cold welding. In the ETpathfinder project, some parts may need to be disassembled and reassembled more than 100 times over the coming couple of decades. Any galling issues would have serious consequences for the project. “The worst-case scenario for us would be if a galled fastener were to weld with one of our custom-made vacuum parts as these would be very costly to replace,” said Baars. “This is why choosing fasteners with anti-galling properties is essential risk management for the entire ETpathfinder project — particularly in the vacuum chamber.” The bolts and nuts delivered to the ETpathfinder project are electropolished, receive kolsterised treatment, and are cleanroom packed. This is important to avoid particles from the nuts and bolts in the ETpathfinder

ETpathfinder illustration and diagram.

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DESIGN WORLD

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Efficient. Powerful. Dependable. The ETpathfinder R&D facility at Maastricht University for testing and prototyping innovative concepts.

cleanroom, and Kolsterisation increases surface hardness, further reducing the risk of galling. Cryogenic temperature resistance The ETpathfinder mirrors will be cooled to 8K (-265°C) when they are operational to ensure optimum performance. The mirrors are cooled to reduce thermal noise, which is the vibration of atoms that scales with that atom’s temperature. Metals typically become brittle at cryogenic temperatures, which makes them prone to sudden failure. However, these fasteners provide good resistance to cryogenic temperatures due to their high material quality, low impurities, and high-quality finish. Third-party tests have shown that BUMAX 88 fasteners retain excellent ductility even in temperatures as low as 0K (-273°C). DW BUMAX • www.bumax-fasteners.com DESIGN WORLD

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RATED SPEED 10 to 400 rpm

TORQUE 20 to 2,553 lb-in

GEAR RATIO 5:1 to 240:1

VOLTAGES 230/460VAC (inv-duty) 130 VDC BLDC

AC and BLDC Hypoid Gearmotors. Get high efficiency, high torque and smooth operation Compact and versatile hollow shaft design delivers up to 2,553 lb-in (173 Nm). 130VDC and 230/460 VAC models available now. Visit Bodine-electric.com for complete specs. bodine-electric.com | info@bodine-electric.com | 773.478.3515 (USA)

2/7/24 1:35 PM

Design Notes EDITED BY MIKE SANTORA

How to simplify seven-axis robotic system lubrication Seven-axis articulated arm robots are a good choice for operations looking to increase the working envelope of their six-axis robots while performing automated tasks with optimal speed, efficiency, and productivity. Despite the advantages that seven-axis systems offer, system maintenance presents challenges that can cut into those benefits. For example, lubricating the rack and pinion systems and linear guides that drive and support a seventh axis involves cumbersome lubrication equipment and processes, and installation is often difficult. In addition, the guides and rack and pinion have

different lubrication rates which can slow down a conventional lube system. Fortunately, adding a localized multipoint automatic lubrication system to the seventh axis of a robot can ease these burdens and deliver several benefits. Most significantly, a multipoint system properly lubricates the robot so it will function more efficiently and smoothly — ultimately improving productivity and reducing downtime. Automatic lubrication also improves safety by eliminating sudden movements that can otherwise pose a serious safety risk to human operators working nearby.

Adding automatic lubrication to a robot’s seventh axis is a smart investment. This article will describe how an automatic relubrication system was adapted with standard components to create a complete, multipoint assembly that installs easily onto a seven-axis robot. Redex USA develops and builds complete automatic lubrication systems for seven-axis robots. At the heart of each system is a multipoint automatic lubrication pump. Unlike conventional lubrication systems that require extreme pressure, filters, and long

A typical seven-axis system for robotic horizontal motion.

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DESIGN WORLD

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A Redex FlexxPump 400 lubricant delivery pump is the heart of an easy-toimplement multipoint lubrication system for seven-axis systems.

metal tubing, the Redex system uses a localized lubrication pump system with several distinctive features, such as: •

•

Multipoint lubrication. The pump can service as many as 40 lubrication points at specific locations on the machine. Polyurethane foam pinions and applicators. Thanks to its opencell architecture, the polyurethane foam can apply lubricants at their proper thickness to absorb excess lubricant. Progressive distributors. Each lubrication point receives the same amount of lubrication, and the lubricant gets to every lubrication point.

The Redex FlexxPump 400 is designed with a clear reservoir that can hold grease cartridges or oil. The bottom metal housing holds the piston pumps, which can deliver the lubricant at a rate of 0.15 cc per stroke and up to 1,000 psi pressure complete with builtin check valves. These characteristics ensure accurate control of the quantity and frequency of lubrication at each point. Users can control the FlexxPump in two ways: If there is a PLC on the seventh axis, each pump body can be activated with a 24V DC pulse of a specified duration. If the PLC is unavailable, the pumps can be controlled in a time mode. This

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specifies the time, in months, to complete one full cartridge of grease and the number of pump strokes — or the quantity of lubricant delivered — for each operating period. The FlexxPump also makes system monitoring easy by providing error signals for: • Pressure that exceeds 1,000 psi, in case there is a clogged line. • An empty reservoir, indicating it is time to replace the grease cartridge or refill it with oil. • Electrical error due to low voltage or other issues. Figure 3 shows a recent multipoint lubrication system assembly that was custom-built for a seven-axis robot integrator to lubricate a seventh-axis rack, pinion, and linear guide. It includes a Redex FlexxPump 402 automatic

lubrication system and a mounting bracket that was tailor-made to fit the robot system’s seventh axis. The system’s lubrication points were outfitted with open-cellular polyurethane foam applicators. Unlike felt devices, polyurethane applicators are suitable for higher-viscosity lubricants and greases thanks to their 76% open volume. The open-cellular polyurethane foam applicators consist of four linear guide lubrication rollers and one rack lubrication pinion. Although splitters are appropriate for this system, they sometimes dispense lubricant unevenly. FlexxPump’s progressive distributor ensures that the outlets apply equal amounts of lubricant. With this automatic lubrication system on the seventh axis, the machine builder can: • Apply the correct amount of lubricant to the lubrication point without the over and under lubrication that can otherwise occur with manual methods. • Achieve reliable articulated robot operation without costly downtime. • Avoid housekeeping issues often associated with conventional lubrication systems. DW Redex • www.redexusa.com

This complete multipoint automatic lubrication system uses standard lubrication components that are adapted for installation on a seventh axis.

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February 2024

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HMI CONSIDERATIONS FOR

IN MOTION CONTROL Ramey Miller • HMI Marketing Manager • Siemens

DESIGNING

industrial machines with motion control for manufacturing is a critical aspect of modern industrial automation. These systems regulate the movement of mechanical components, such as motors, actuators, and conveyors, within industrial machines. Motion control systems are pivotal in ensuring manufacturing processes' precision, efficiency, and reliability. The design of industrial machines with motion control is a multidisciplinary task that involves precision engineering, advanced control algorithms, sensor integration, and a focus on energy efficiency. Implementing these principles results in highly efficient and reliable manufacturing processes, contributing to increased productivity and quality in industrial settings.

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One key consideration in designing such machines is the need for precise and coordinated motion. This involves implementing advanced control algorithms that can synchronize multiple axes of movement to achieve intricate manufacturing tasks. Whenever precision tasks are automated in manufacturing processes, the motion control systems ensure that every movement is accurate and repeatable. Feedback from sensors, such as

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•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• • • • • • • • • • • • • • • • Open architecture HMI can provide benefits such as increased flexibility for motion control, leading to more efficient machine designs.

Modern manufacturers, especially in the automotive industry, need automation to stay competitive.

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February 2024

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Motion Control

Automation HMI, and the user interface and user experiene they deliver, are key to managing modern machines.

encoders and vision systems, allows the machine to adjust and optimize its movements constantly in real-time. This closed-loop control mechanism enhances the accuracy and reliability of the manufacturing process. Efficient energy usage is also a priority in designing industrial machines. Manufacturers can optimize motion control systems to minimize energy consumption. This not only reduces operational costs but also aligns with sustainability goals. The machine operators must monitor and control all these critical functions via human machine interfaces (HMIs). Insight and input – motion control HMI Considerations for user-friendly interfaces and programming flexibility are essential for motion control. Machine designers must include intuitive user interfaces (UIs) that streamline the user experience (UX), reduce onboarding and training costs, and enhance efficiency and

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safety. In addition, UIs must provide programming environments that allow customization for specific manufacturing requirements. The interface between human operators and industrial machines with motion control is a critical element in ensuring optimal performance and efficiency in manufacturing. Engineers face the challenge of designing these intuitive interfaces that facilitate seamless communication and control for operators, enabling them to interact with complex motion control systems effortlessly. An intuitive interface is user-friendly and accessible, allowing operators to monitor and control the machine with minimal training. Graphical user interfaces (GUIs) with clear visualizations of machine status, movement trajectories, and diagnostic information enhance operator understanding. Touchscreen displays and interactive controls contribute to a more intuitive user experience, reducing the learning curve

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for operators and minimizing the risk of errors. As manufacturing processes become increasingly diverse and customized, the need for adaptable programming environments becomes paramount. Engineers must develop software interfaces that allow operators to program and customize motion control parameters to suit specific manufacturing requirements. The software must also have the flexibility crucial in accommodating variations in product designs, production volumes, and process intricacies – which often means customization. Customizable programming environments empower operators to do more than modify motion profiles, adjust acceleration and deceleration rates, and fine-tune trajectories based on the unique characteristics of the products being manufactured. Truly customizable programming environments let engineers fully customize the interface to match the process. This adaptability is particularly vauable in industries with expected rapid product changes and short production runs. Integrating intuitive interfaces and customizable programming environments contributes to overall system efficiency and reduces downtime. Operators can quickly respond to changes in production needs, troubleshoot issues effectively, and optimize machine settings without requiring extensive technical expertise. This enhances operational agility and supports continuous improvement initiatives within the manufacturing environment. Designing intuitive interfaces and customizable programming environments is a pivotal aspect of motion control system development. By prioritizing userfriendly interactions and flexibility in DESIGN WORLD

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programming, engineers empower operators to harness the full potential of industrial machines, fostering efficiency, adaptability, and responsiveness in the ever-evolving manufacturing landscape. Optimizing HMI design — balancing cost-efficiency dynamics In the realm of machine design, a compelling dynamic emerges when weighing the option of a single industrial HMI for cost savings against the efficiency gains associated with more HMIs. Opting for a singular HMI minimizes initial costs, reducing hardware and software customization costs while simplifying the control interface. However, this streamlined approach may limit operational efficiency, as it often requires operators to manage diverse tasks on a single screen. Conversely, investing in multiple HMIs incurs higher upfront costs but provides the advantage of enhanced task specialization, real-time monitoring, and streamlined communication. The trade-off lies in finding the equilibrium between affordability and operational effectiveness, where a judicious investment in more HMIs can yield longterm efficiency benefits that outweigh the initial expenditure.

Designing machines with multiple HMI stations offers significant advantages in processing, handling, machining, and various other industrial applications but has often been costprohibitive due to the high cost of HMI hardware and customization. With more than one HMI station, each operator can focus on specific aspects of the process, improving overall efficiency. Even though more HMIs allow for enhanced collaboration among operators and promote better communication and coordination in complex manufacturing environments, the costs to scale these optimized solutions have led machine designers to use fewer HMIs in the machine design stage. In processing, having separate HMIs for different stages allows operators to monitor and control individual steps closely, ensuring quality and precision. For handling tasks, more HMIs enable simultaneous control of various material handling systems, reducing bottlenecks and optimizing throughput. In machining, where precision is paramount, multiple HMIs enable operators to simultaneously monitor different facets of the machining process. This real-time oversight enhances quality control and allows

Open architecture HMI allows high degrees of customization for any application.

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Motion Control

Engineering efficiency is enhanced by having intuitive user interfaces, as shown in this screenshot of a motion control HMI for a robotics application.

HMIs culminates in a harmonized system that maximizes operational effectiveness and cost-effectiveness in industrial machine design.

for quick adjustments to optimize production. Using more than one HMI in industrial processes enhances operational flexibility, promotes efficient collaboration, and allows for specialization, improving productivity and quality in processing, handling, machining, and other manufacturing operations. Cost-efficient open architecture HMI A strategic approach involves harnessing the benefits of a single higher-cost HMI endowed with a plethora of features, complemented by additional lower-cost HMIs with more specialized functions. The highcost HMI serves as the central hub, consolidating comprehensive control and monitoring capabilities into a single interface. This powerhouse can manage critical, overarching operations, providing operators with a holistic view of the system. Supplementing this with lowercost HMIs tailored for specific tasks introduces a layer of operational efficiency. These specialized interfaces can be strategically placed at critical points in the manufacturing process, allowing operators to focus on dedicated functions without the cognitive load of navigating an all-

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encompassing interface. For example, a dedicated HMI for quality control or material handling can streamline operations and reduce the risk of errors. Flexibility is enhanced (and machine costs reduced) by using openarchitecture HMI in machine design. Open architecture means that the HMI is compatible with various industrystandard hardware and commercially available software solutions. Open architecture HMIs use industry-standard networking and cybersecurity (UMC/ UAC), HTTPS encryption, and browserbased interfaces that allow for easy customization while offering features such as multi-touch displays that are familiar to operators, making them easy to onboard. This approach strikes a balance between cost-effectiveness and operational prowess. The design investment in a high-cost, featurerich HMI is justified by its ability to streamline complex operations and facilitate comprehensive control. Simultaneously, the judicious integration of lower-cost HMIs optimizes taskspecific workflows, enhancing efficiency and responsiveness. The synergy between the centralized, high-cost HMI and supplementary, task-specific

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Flexibility in designing efficient machines Employing multiple HMIs in motion control machine design yields a spectrum of benefits. A central high-cost HMI as the primary control hub offers a comprehensive overview of the entire system, and this centralized interface streamlines complex operations and enhances the machine's overall efficiency. Supplementing this with lower-cost open-architecture HMIs for specific functions optimizes task-specific workflows. Operators can focus on dedicated functions without navigating through an intricate interface, increasing operational responsiveness and creating competitive advantages in process agility. The judicious integration of these interfaces strikes a balance between cost-effectiveness and operational prowess, ultimately maximizing the overall efficiency of motion control machine design. Using openarchitecture systems ensures broad compatibility, easy customization, and scalability. This approach leverages the strengths of each interface, creating a synergistic system that delivers enhanced performance, adaptability, and responsiveness in industrial settings. DW Siemens • siemens.com DESIGN WORLD

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End users can buy step motors, couplings, and linear screw separately … though it’s increasingly common for OEMs to specify complete stepper-based actuator solutions.

NEMA

stepper motors update Lisa Eitel • Executive Editor

Step

or stepper motors are (like any other electric motor type) electromechanical components that accept electrical input to yield mechanical rotation of an output shaft. In a stepper motor, that input takes the form of specially sequenced electrical pulses that prompt discrete rotor and output-shaft turns — with the direction, size, and speed of those turns depending on the order, frequency, and count of the electrical pulses. Despite supply and demand slowdowns associated with the COVID pandemic, the use of stepper motors

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continues to grow around the world with the migration towards automation. In fact, according to P&S Intelligence market research, the stepper motor market (including permanent magnet, variable reluctance, and especially hybrid subtypes) will reach $3.7B by 2030. The smallest of these motors can cost as little as $20, though larger and more efficient (and rugged) variations are far more. Though a primary benefit of stepper motors is how they can be run open loop (even for positioning) there’s been an uptick in their use on closed-loop www.designworldonline.com

axes for a whole host of applications To be clear, traditional open-loop control continues to dominate stepper motor applications. (When the application is well-defined with predictable loads that don’t undergo significant changes, a properly sized stepper motor can provide very accurate and reliable positioning under open-loop control.) However, stepper motors run closed loop offer high performance and efficiency at high torque even at low speed — with short transients and other benefits over other motor types for servo operation. February 2024

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Advancements in stepper-motor design over the last two decades has also spurred their increased use in medical applications demanding top reliability and accuracy. No steppermotor subtype has seen more adoption than hybrid motors, though — as they leverage the benefits of older variablereluctance and permanent-magnet subtypes. The National Electrical Manufacturers Association (NEMA) is a trade association of U.S. electrical equipment manufacturers that (among other things) sets standards for electrical components — including standards for electric motor efficiency, sizing, servicing, rating, and safety. NEMA’s system of stepper-motor frame size standardization is used around the world and not just in the U.S., though many references express the motors’ dimensions as well as input and output values in metric. The NEMA system dictates the specifics of stepper motors to satisfy size 08, 11, 14, 16, 17, 23, 34, and 42 specifications. The vast majority of stepper-motor sales globally are of NEMA 17 and NEMA 23 motors,

with other frame sizes making up a small remaining percentage. The NEMA sizes indicate the dimension (square) of the motors as measured from one end (not lengthwise) so that: NEMA 11 stepper motors are 1.1 in.2 NEMA 17 stepper motors are 1.7 in.2 NEMA 23 stepper motors are 2.3 in.2 Nonformalized NEMA-derived size 24 motors are also available to use the mounting of true NEMA 23 motors but with a 0.15 in. more width to accommodate a larger rotor and stator capable of more torque output. Applications for these motors abound in all types of industrial equipment for packaging and labeling, retail vending machines, 3D printing, and robotic handling systems, as well as (for smaller NEMA sizes) consumer electronics and a growing array of medical equipment. The latter include powered orthopedic devices, ventilation systems, blood analysis equipment, and drug delivery machines. There is a caveat here, though: While NEMA standards support decent

interchangeability of stepper motors made by different component suppliers, shaft length can vary between them — as can proprietary coupling designs and mounting-bracket geometries as well as lead wiring and connector permutations To help machine builders avoid the headaches such variability can cause (and satisfy the many stepper applications requiring conversion of rotary to linear motion) myriad suppliers sell stepper motors pre-integrated in finished linear actuators. In fact, even these supplier-integrated linear actuators based on stepper motors are often designated by the NEMA size of the motor they include. NEMA stepper linear actuators in context Many NEMA step motors (especially NEMA 17 and NEMA 23) install on machine axes that necessitate the conversion of the motor’s rotary output to linear motion. In the past, OEMs and end users assumed all integration of such actuation — including the procurement of motor, coupling, and screw — and all their assembly. Today,

Shown here are NEMA stepper linear actuators on a robotic vision system in a phone manufacturing facility.

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www.designworldonline.com

DESIGN WORLD

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•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• • • • • • • • • • • • • • • • it’s more common for machine builders (whether designing for a few dozen axes or thousands of axes) to specify turnkey linear subsystems to free design time and focus on core engineering competencies. Of course, NEMA stepper linear actuators aren’t the only screw-based linear-actuator type around. With integrated motor and screw assemblies, the motor can be either a servo or a stepper type, and the screw can be a ballscrew or a leadscrew … although the most common configurations pair a leadscrew with a stepper motor or a ballscrew with a servomotor. Stepper motors for linear actuation include single and double-stack variations that run open or closed loop … with some actuators even incorporating programmable electronics if required. These linear actuators are named for the standard size-related designations of their motors … with (as mentioned) NEMA-17 and NEMA-23 linear actuators the two most common sizes. (Recent years have brought increased use of NEMA 34 stepper linear actuators as well.) In these actuators, NEMA 11, 17, and 23 motors pair with leadscrews in imperial or metric variations to yield linear resolutions to 0.10 mm or better — even to 0.4 mm while delivering forces to 1,000 N in some cases.

NEMA stepper linear actuator application. | Endurance Lasers

POWER TRANSMISSION-PART CONVEYING

PYRATHANE® BELTS

Stepper motors produce maximum torque at zero speed, and with open-loop control, they can hold a load at a precise location, because the motor doesn’t “hunt” for position. High motor torque for high linear force at low speeds NEMA stepper motors in linear-actuation applications produce maximum torque when the motor is at standstill … and continue to provide very high torque at speeds to 1,000 or 1,200 rpm. In contrast, servomotors often require a gearbox to multiply the torque and reduce the speed from the motor. But the addition of a gearbox reduces system stiffness by introducing backlash and compliance. Because stepper motors don’t necessarily require mechanical gearing to produce high torque at low

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pyramidbelts.com • 641.792.2405 • sales@pyramidbelts.com DESIGN WORLD

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3D printers are just one of many new applications for stepper linear actuators that have emerged over the last 15 years.

speeds, they also have an advantage in overall system stiffness for these applications. Holding a load in a fixed linear position Because they produce full torque at standstill, stepper motors can hold a load in place even against external forces — and run open loop. This is especially useful in: • Processing applications • Where loads are held stationary while some machining or assembly task is performed • While waiting for the next movement. Closed-loop systems can also hold loads, but because they constantly correct for any errors between the commanded and

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the actual position, the load is never truly at standstill, as the motor continuously hunts for its commanded position. Because there is no feedback loop to force position corrections, stepper motors with open-loop control can hold a load at a precise location without hunting. Need for speed (control) and quick integration The rotational speed of an openloop stepper motor is determined by the frequency of pulses delivered to the motor … which is what gives stepper motors inherently tight speed control. Plus the motor’s response to speed changes (changes in the frequency of supplied voltage) is practically instantaneous since there is no feedback loop to introduce processing delays. www.designworldonline.com

Without additional hardware required for feedback — particularly the sensor or encoder and related wiring — the upfront cost of an openloop stepper motor linear actuator is inherently lower than that of a closedloop stepper or servo-based linear actuator. Open-loop stepper control also provides cost savings due to its simple integration, with no need for parameterization and control loop tuning. While closed-loop control methods can indeed make stepper motors an attractive choice for linear motion applications previously reserved for servo systems, in many cases the choice between closed or open-loop stepper motor control still comes down to simplicity and cost. DW Linear Motion Tips • linearmotiontips.com DESIGN WORLD

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2/5/24 12:30 PM

Additive Manufacturing Users Group

2024 AMUG CONFERENCE March 10 - 14 | Chicago

For Users. By Users.

AMUG BUILDS THE

EVENT

YOU CREATE THE

EXPERIENCE

The AMUG Conference is where additive manufacturing users unite to share experiences and initiate collaborations.

Engage, share, learn and connect.

DON’T MISS EDUCATION Technical, Panel & Keynote Sessions

TRAINING Hands-on Workshops & Training Sessions

NETWORKING

COMMUNITY

Breakfast through Dinner

Users Supporting Users

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The 3D printing experience everyone raves about.

2/5/24 12:30 PM

•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• Pro Beton’s lone workers use the Wearin’ Brain to alert the control center when a fall occurs.

THE LONE Advanced

wearable and monitoring technology provides real-time data, enhancing workplace safety and efficiency.

Lone

worker practices are common these days, with an estimated 15% of employees reportedly working by themselves. However, working in isolated environments may also increase individuals' risk for serious injuries and death on the job. "Lone work can benefit both organizations and employees, allowing for more flexibility and greater use of resources, but this practice also comes with heightened risk for workers. According to a 2021 survey, nearly 70% of organizations reported a safety incident involving someone working by themselves in the past three years, and one in five of these incidents were described as 'quite or very severe,'"

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WORKER: How IoT helps protect isolated employees EDITED BY: RACHAEL PASINI • SENIOR EDITOR

said Katherine Mendoza, senior director of workplace programs at the National Safety Council (NSC). The NSC recently released a white paper through its Work to Zero initiative, “Using Lone Worker Monitoring Technology to Protect Workers,” to help employers identify and implement new solutions. The report assessed worker monitoring technologies, including fall detection devices, proximity sensors, mobile apps, and panic alarms, which can be ideal for lone workers in high-risk industries such as construction, mining, and agriculture. These technologies enable two-way communication, enhance hazard detection and alerting, and increase www.designworldonline.com

cost savings through more streamlined communication. Monitoring technologies advance with IoT As the global marketplace for monitoring technology rapidly expands, employers worldwide have unprecedented access to new safety solutions. For example, advanced wearables are building momentum with AI and IoT technology. In a recent news release, Switzerland-based startup Wearin’ developed a solution connecting the lone worker with a control center commissioned by Pro Beton, a concrete producer in Geneva. The device ensures safety for machine February 2024

2/7/24 1:52 PM

Industrial Safety

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operators and cleaners working on production sites during the day, night, and weekends. The solution comprises a physical and digital platform communicating with each other in real time. A device attached to the worker's vest, called the Wearin’ Brain, embeds three safety alert and detection systems: one to alert the control center via the Wearin’ SOS button that can be activated manually in the event of an accident; an inertial sensor that can automatically detect a fall (in case the alert cannot be raised manually); and GPS to pinpoint the worker’s precise location. Data and alerts are sent and collected via the cloud to the Wearin' dashboard integrated into the central monitoring system. The control center can then take appropriate emergency and rescue measures. "The reliability of the solution, in particular its advanced automatic fall detection system, makes the difference in securing lone working time and meeting the comfort and safety needs of our employees," said Éric Guillot, director of Pro Beton. "As they work alone in a noisy, high-risk environment, it's crucial for them to be able to rely on cutting-edge technology that incorporates all the necessary safety features so that the safety control center can intervene in a timely and appropriate manner in the event of an accident." As its name suggests, the Wearin’ Brain attached to the worker's vest is the brain of the hardware and software systems in the IoT solution, and the fall detection sensor minimizes the risk of false positives. “The critical problem faced by this type of system is the frequency of false positives and their impact on the worker. The detection provided by [less advanced products] is sometimes so unreliable that users, annoyed by repeated false alarms, end up disconnecting the system altogether,”

February 2024

DESIGN WORLD

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said Aurélie Balsa, embedded software manager at Wearin'. “Wearin's solution comprises hardware, firmware, and embedded algorithms. Based on data from our accelerometer and gyroscope, our algorithms reduce false positives to less than 1%, to the great satisfaction of users, who find it all the easier to adhere to this security system." As another example of advanced safety solutions, South American StraconTech, in collaboration with Abeeway and Actility, developed an innovative IoT device to increase worker safety at a major Peruvian mine site, Mina Justa. The team implemented a system and necessary infrastructure for real-time and historical tracking of people in blasting zones. With a concerning 29% rise in mining accidents due to blasts, collapses, and landslides, the robust people-tracking solution is a proactive measure to prevent such occurrences and ensure safer operations. The IoT-based worker safety solution is using Abeeway Smart Badges. These badges integrate with the LoRaWAN network managed by Actility’s ThingPark Enterprise platform. The solution employed StraconTech’s

custom-built application, developed and deployed on AWS servers. As they work alone The Abeeway Smart Badge is in a noisy, high-risk a portable multi-mode tracker in ID card format that can precisely environment, it's crucial and continuously track indoors and for them to be able outdoors. It is equipped with embedded to rely on cuttingsensors and uses GPS, low-power GPS, a Wi-Fi sniffer, Bluetooth low energy edge technology that (BLE), and LoRaWAN TDoA geolocation incorporates all the technologies. The Smart Badge offers various functionalities, such as SOS necessary safety panic alarms, notifications for danger features so that zones and restricted areas, safety the safety control evacuation monitoring, and location heatmaps for optimizing supervisor-tocenter can intervene worker ratios in large industrial sites. in a timely and LoRaWAN connectivity significantly reduces costs compared to other appropriate manner IoT connectivity technologies. It in the event of an has extensive coverage and offers accident. redundancy by design, secure AES 128 encryption, and intelligent traffic management suitable for openpit mining. With new format Longer lasting new rormat Belts, HEHT Split Spools_Layout 1 12/5/2 the cost-efficient LoRaWAN network, the company initially Longer Lasting Belts & Pulleys deployed 400 Smart Badges within two Round, Flat, Vee and Better than Poly-V belts and pulleys weeks. Lifetime Warranty

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Lone worker monitoring still needs humans Despite its many benefits, monitoring technology does not eliminate workers' exposure to hazards. Employers must still conduct thorough audits to mitigate risks and root causes, and they should schedule drills to train lone workers and leaders on emergency responses. Additionally, an enduring concern over worker and data privacy

challenges widespread adoption of monitoring technology. So, employers must maintain transparency on how their data will be used, stored, and encrypted. As for best practices, the NSC recommends the following guidance for selecting optimal solutions for an organization’s unique lone-worker needs:

Identify industry-associated workflow risks. Consider the ease of scalability and how new devices integrate with pre-existing technology. Use technology holistically to integrate it with other parts of the organization or address a range of hazards.

The NSC’s white paper builds on the Work to Zero Safety Innovation Journey to help organizations assess risks, identify technology solutions, and ready workplaces for implementation. Funded by the McElhattan Foundation, the Work to Zero initiative aims to eliminate workplace fatalities with intelligent technology. DW National Security Council • nsc.org Wearin’ • wearin.tech Actility • actility.com

The Wearin’ Brain below the worker’s right shoulder contains an SOS button, fall detection sensor, GPS, 10-hour battery, and LTE module for secure data transmission to the alarm center. | Wearin’

February 2024

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•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• 3D CAD

Using agile processes, Claudius Peters engineers created a web page with a simple CAD model so that customers could see how modifications to their machines would affect output. | Claudius Peters and Autodesk

Claudius Peters makes the machines that make cement. Applying agile processes to product design calls upon CAD systems to optimize those machines.

Clinker coolers JEAN THILMANY • CONTRIBUTING WRITER

get an agile hybrid twist

Once

used mainly to speed up software development, the agile method — which proponents say can slash product development time and costs — is making inroads into product development and manufacturing. The goal of an agile product development process is to explore as many design options as possible during the prototyping stage. “The idea is to find and qualify myriad ideas quickly. Computer-aided design software is a boon to the prototyping stage, where designers use CAD to quickly generate potential designs based on customer requirements,” said Thomas Nagel, operations director and chief digital officer at Claudius Peters, which designs and manufactures large materials handling systems for the cement and other industries. “Agile replaces the siloed work done by engineers for the past decades and calls for collaboration at all steps in the agile process.”

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Pioneered in 2001, the agile method is ideal for companies that want to develop products quickly. It allows for product development while simultaneously gathering requirements and information. The method calls upon a five-day “sprint” to quickly find a new product that can subsequently be designed and built. “The design sprint is an example of how you can define a new idea or fail efficiently in five days,” Nagel said. CAD software helps the “sprinters” isolate the best design within one day. And a feature in some CAD packages, which Autodesk calls “generative design,” is particularly useful here. “The feature generates several potential models based on design inputs and pairs well with the agile method,” said Nagel. “Essentially, designers enter their requirements, and the CAD package generates a number of designs that fit that parameter. Engineers then choose the best design to move forward with.” www.designworldonline.com

Cloud-based CAD packages allow engineers to collaborate and see others’ designs in real time. This is important for another part of the agile sprint, in which engineers bring their designs to the table and meet to discuss which ones to move forward with. When designers find a “viable” design — noting that it doesn’t need to be perfect or fully realized within the CAD software — they present it to a five-member team of professionals pertinent to a given field. If reviewers give it the thumbs up, the prototype is presented to the customer, who vets the product’s feasibility for their market. Only if the customer chooses to go forward do engineers get to work fully designing and detailing the product in their CAD system. “The idea is to find a prototype of a viable product, with no bells or whistles, then show it to your customer,” said Nagel. “Then you go through different iterations until you have a product that might be good enough to develop.” DESIGN WORLD

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•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• • • • • • • • • • • • • • • • But what if the product doesn’t get past the review stage? Or what if the customer doesn’t approve? The agile method allowed designers to “fail efficiently” rather than spending a lot of time designing a product that was bound to fail. “Get the failure over with and start the agile process again,” said Dave Martin, a configuration manager for Elroy Air, which develops autonomous aerial vehicles.

Replacing the waterfall Many engineering companies stick to rigid product development structures, such as the waterfall method. Traditional waterfall development is a step-by-step process like the automobile assembly line, where employees are situated along the conveyor line and add the individual part for which they are responsible. Eventually, the automobile can be driven off the line. But there’s a catch: The next step on the conveyor line can’t be taken until the previous step has been completed. “Think of a Gantt chart, where you have distinct, heavily planned sequential phases, such as concept, design, prototype, test, and product,” said Martin. “A design review gates each phase.” With the agile method, only a “realistic façade” is needed for customer testing. This is where CAD, and generative design, comes in. “You define how you will build the prototype and then get good, validated feedback from the customer,” said Nagel. “If the customer understands the meaning or purpose of your product, then it’s good enough to get the first feedback. The product doesn’t need to be ready or do everything you think. You’re just making a realistic approach.” Engineers use agile for more than physical products. They also create digital twins, 3D-printed prototypes, and virtualreality demonstrations.

football field — that cool molten rock, called clinker, from 2,550° to 212° F. The molten rock is then used to make cement. The first step for the company is to scan the cooler, and the next step is to upload the file. Nagel’s team uses CAD, BIM, and analysis tools on Autodesk’s 360 platforms. “We can upload this huge amount of data from all over the world directly to the BIM 360 platform. It could be a 20-gigabyte file from China, and the design engineer here in Germany can immediately start to work with this 3D scan,” said Lars Heidler, lead engineer at Claudius Peters. “Today, when we start a new project, we normally start with a 3D scan of the existing plant. Those contain huge amounts of data that need to be transferred,” said Nagel. “Then we take what could be called a hybrid engineering approach.” The engineers transferred the scans to Autodesk’s Navisworks simulation

software. They then edited the designs within the Inventor 3D CAD software, also from Autodesk. “All of a sudden, we could really measure and do everything,” said Nagel. This information was vital, of course, when implementing an agile sprint to update and perfect a part of the system. The team could collaborate internally, and everyone could look at the 3D models and compare versions. Engineers could also background themselves using the 3D model as they prepared for an agile sprint. DW

Claudius Peters | claudiuspeters.com

READ MORE ONLINE Scan to read the entire article online at designworldonline.com

Collaborating on a clinker cooler Could the agile method be used to make improvements to a vast structure? Claudius Peters found the answer when its engineers were tasked to modify a giant clinker cooler. Clinker coolers are huge industrial machines — about half the size of a DESIGN WORLD

February 2024

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2/5/24 12:04 PM

Sensors The main difference between passive and active radiofrequency identification (RFID) tags is the absence (passive) or presence (active) of an internal

When should

power source. Because of these

passive or active beRFID used? primary differences, there are

several secondary differences.

Understanding these differences

is the key to properly selecting the

most appropriate RFID system for a

specific application.

Passive RFID Since they have no internal power source, a standard passive RFID tag consists only of an IC and internal antenna. To operate, the passive RFID tag obtains its energy from the signal transmitted by an RFID reader. After reception at the tag’s antenna, the energy powers the IC, which generates a signal back to the RF system. This limited system places restrictions on the capabilities of the passive RFID based on operating frequency. Low Frequency (LF) (125-134 kHz) has an extremely long wavelength with usually a short read range of about 1-10 centimeters. This frequency range is not significantly affected by water or metal. High Frequency (HF) & Near-Field Communication (NFC) (13.56 MHz) is a medium wavelength with a typical read range of about 1 centimeter up to 1 meter. Ultra High Frequency (UHF) (865-960 MHz) is a short, high-energy wavelength of about one meter which provides a long-read range. While they can be read from an average distance of about 5-6 meters, larger UHF tags can achieve up to 30+ meters of read range. Because of their lower price point per tag, passive RFID tags are used for applications such as access control, file tracking, race timing, supply chain management, smart labels, and more.

February 2024

sensors feature – dw 02-2024 v2 final.indd 42

Passive RFID

Active RFID

Power Source

External (Reader provided)

Internal (Battery)

Tag Readability

Only within the area covered by the reader, typically up to 3 meters.

Can provide signals over an extended range, typically up to 100 meters.

Energization

A passive tag is energized only when there is a reader present.

An active tag is always energized.

Magnetic Field Strength

High, since the tag Low, since the tag powers from the emits signals using electromagnetic field internal battery source. provided by the reader.

Shelf Life

Very high, ideally does not expire over a life time.

Limited to about 5 years, the life of a battery.

Data Storage

Limited data storage, typically 128 bytes.

Can store larger amounts of data.

Cost

Cheap

Expensive

Size

Smaller

Slightly bulky (due to battery)

Table 1. Summary of key differences between passive and active RFID tags. Source: Difference Between Active And Passive RFID Tag Systems (tutorialsweb.com)

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2/7/24 2:11 PM

Active RFID With an internal battery as their power source, active RFID systems have three essential parts: a reader or interrogator, antenna, and a tag. The battery enables these RFIDs to have extremely long read ranges and large memory banks. The two main frequencies used by active systems are 433 MHz and 2.45 GHz. The longer wavelength of RFID systems that operate on the 433 MHz enables them to work a little better with non-RF-friendly materials like metal and water. There are two different types of active RFID tags: transponders and beacons. In a system with an active transponder tag, similar to a passive system, the reader initially sends a signal, and then the active transponder replies by sending a signal back with the appropriate data. Transponder tags are very efficient and conserve battery life when the tag is out of range of the reader. In a system that uses an active beacon tag, the tag will beacon or send out its specific information every 3-5 seconds. While active tag’s beacons can be read hundreds of meters away, to conserve battery life, their transmit power can be reduced to reach around a 100 meters read range. Active RFID systems are usually used in the oil and gas industry, shipping and logistics, construction, mining, and highvalue manufacturing. Table 1 provides a quick summary of the differences that may impact the choice of passive vs active RFID. DW

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February 2024

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Cobot creates

CELL MANUFACTURING

DREAM for plastics thermoformer PAGE 46

cover – robot report supplement dw 02-2024 v1.indd 111

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Cobot creates

CELL MANUFACTURING

DREAM for plastics thermoformer STEVE CROWE • EXECUTIVE EDITOR • THE ROBOT REPORT

Plastics contract manufacturer deploys UR10e trimming cobot for a fraction of the cost and lead time of a CNC machine.

hermoforming, a technology that is more than a century old, uses sheet plastic that is heated to become soft so it can be vacuum-formed in or around a mold. Excess plastic is then cut off to create final products with dimensions that range from a few inches to the size of a room. Over the years, 5-axis CNC routers replaced hand-trimming for most thermoformers. More recently, Juliet Oehler Goff, president and CEO of Los Angeles-based Kal Plastics, had watched her peers explore the use of large industrial robots to finish-trim molded plastic parts, but she wasn’t convinced. For a business like hers, the initial price

Kal Plastics CEO Juliet Oehler Goff watches as robot operator José Luis programs the UR10e cobot to trim thermoformed plastic parts. With no robotics background and minimal training, Luis programs the cobot using its teach pendant.

February 2024

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THE ROBOT REPORT

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point of industrial robots and their required safety caging was too high, not to mention the programming costs. “You end up having to have a skillset under your roof that’s very expensive. That’s a risk for a small business,” she said. After talking to colleagues, she heard behind the scenes that many of those who had tried industrial robots found that they didn’t work well for their applications and that they wouldn’t buy them again. Research leads to business results Goff is also a director and member of the R&D committee for the national industry association, the Society of Plastics Engineers (SPE) Thermoforming Division. In that role, she had been involved in numerous discussions about the state of robotics, particularly collaborative robotics, and their application in the industry. When Kal Plastics needed to replace a CNC machine that was nearing the end of its life, Goff was presented with an opportunity. She set out to research the use of cobots for her own business and agreed to share her findings at the organization’s national conference. As a contract manufacturer, Kal Plastics produces a wide range of parts with varying complexity and tolerances. Goff looked for low-hanging fruit for the initial cobot deployment: parts that presented safety or productivity issues with hand-trimming and could be produced on less-expensive equipment to boost competitiveness. Once she could prove the cobot worked, she knew there were other jobs that fit those criteria. “I did my homework and found that Universal Robots was the global leader in the collaborative robot space,” Goff said. “They came out and gave us a demonstration, and when I looked at the numbers, they were really attractive. I was looking at getting another five-axis CNC router, and at the time it would have been a $250,000 investment and I would have waited 12 months to take delivery. When I met with UR, I was quoted two weeks to get

February 2024

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the equipment, and the entry point was a quarter or a fifth of the cost.” During the course of her research, Goff hired Dan Sproles, a consultant and another director for SPE Thermoforming, to help improve overall operations. Since his initial skepticism, Sproles has also become a

champion of lightweight, cost-effective, and easy-to-program UR cobots. “If you’re a thermoformer that’s been in business for 50 years or five months, if I look at the cobot, it’s a perfect fit—because I can’t afford a new CNC, but I can afford this,” Sproles said. “And I can afford someone

The UR10e cobot is a “cell manufacturing dream” for Kal Plastics. The extended reach of the UR10e cobot, which is top-mounted on a gantry, means it can trim two parts per setup, cutting trimming time nearly in half compared to previous manual trimming.

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THE ROBOT REPORT

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Kal Plastics balanced two commercial routers on the UR10e cobot arm, using a saw blade and a standard router. who's going to basically take a tablet and program it. So your bang for your buck—it’s the robot.” “It would be foolish for other processors not to consider adding this to their operation,” Goff concurred. “They’d be really missing out on a smart business decision.” Inside the cobot cell Prior to installing the UR10e collaborative robot, the forming and rough trimming took place in the thermoforming cell, and then the parts had to be transferred to the CNC router in another part of the plant. The Kal Plastics facility is housed in multiple older buildings, so moving parts was disruptive and added production time. It also presented opportunities for damage or safety hazards as parts stacked up waiting in queues.

February 2024

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The initial task identified for the cobot is a complex trim of a four-cavity mold, in which one sheet of plastic is formed into four parts. The ability to install the cobot into the same work cell alongside the thermoformer inspired Sproles to describe it as a “cell manufacturing dream.” Formed parts come off the thermoformer and are immediately rough-cut to separate them. They are then delivered directly to the cobot, which can trim two pieces in each setup. The cobot takes nearly half the time of hand-trimming and provides greater accuracy and consistency. The deployment has two routers mounted on the robot arm—one with a standard router bit and one with a larger saw blade. The advantage is that the routers are the same commercial tools used for hand trimming. They www.therobotreport.com

are inexpensive and available offthe-shelf at any hardware store, so there is no expensive replacement or downtime due to tooling issues. Balancing the two heavy routers as they rotated around the part presented early challenges that were solved by mounting the robot arm overhead on a gantry to reduce pressure on the robot joints and improve accuracy. The efficiency of the new work cell has already paid off. “The robot has basically taken over all of the overflow that we had to do by hand,” Sproles explained. “In the past, we always had to juggle back and forth on the CNCs just to make delivery dates. We introduced the cobot: now there’s no more overtime and we can ship on time. I would say late shipments have dropped to less than one percent.” THE ROBOT REPORT

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It’s the right thing to provide a safe workplace environment, but it’s also a fiduciary responsibility to try to avoid having those incidents occur. So we’re always looking for ways to work safer, work smarter, work faster. Now that the cobot has been proven, Goff is looking forward to implementing newer, larger cobots in other workstations, and for processes beyond trimming. Ultimately, she would love to “form, trim, palletize, out-thedoor” from complete, automated work cells. Until then, the flexibility of the relatively lightweight cobot is an added bonus. Unlike a CNC, which requires a large dedicated space, permanent installation, and a three-phase, 480V power source, the gantry and UR10e cobot along with the fixture table can be moved anywhere in the plant as needed, as long as there is a standard 110V power outlet. Reducing costs and risks The cobot’s ease of programming was a big deal, said Sproles. “If I bought a regular CNC, regular robot, I’m going to spend thousands of dollars training that person, not knowing if they’re going to be here tomorrow.” The expense and risk of training workers in traditional programming are significant for small businesses, which are already facing difficulties retaining skilled workers in a competitive labor environment. With the UR cobot, José Luis, a Kal Plastics operator, learned the basics of programming using the free online UR Academy classes, which he could access in his native Spanish. He then attended two sessions of affordable, hands-on training. That was all it took for him to be able to create new programs, change tools, and make adjustments as needed.

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Luis recognizes that technology is evolving and his past skills will not necessarily be the skills he needs in the future, so he is eager for the opportunity to learn. He said, “My job is more interesting because the manufacturing process has really improved, and the robot provides me with a safer workplace.” Goff is thrilled to have a way to retain and advance her valued employees. “It gets your workforce excited because it’s different, it’s cool, it’s unique,” she said. “When you get someone who’s younger, who’s hungry, you want to find a way to satisfy their hunger and keep them interested and motivated.” She added, “It’s been a treat to watch José grow in this role, and elevate himself.” Luis is already scheduled for a master programmer class, where Sproles expects he will gain additional insight to make the robot cell even more profitable and repeatable, and to program it for any new jobs the company brings in. Necessity is the mother of invention Goff described California as a tough state for manufacturing. Challenges include high costs of labor, occupancy, and energy, as well as a regulatory environment that presents additional workforce challenges. “It’s a no-fault state for workers’ compensation injuries,” she explained. “It’s the right thing to provide a safe workplace environment, but it’s also a fiduciary responsibility to try to avoid having those incidents occur. So we’re

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always looking for ways to work safer, work smarter, work faster.” Along with those challenges, Goff is also dealing with labor issues that are common across the country: workers who are less interested in manufacturing jobs. Labor and safety were key drivers for Kal Plastics to become an early automation adopter. “Necessity is the mother of invention,” Goff stated. The job the UR cobot now handles used to be hand-trimmed. Sproles said, “In this plant, there are two people that can route parts. So if you brought in a job that had to be hand-routed, you’ve got those two people and you’re locked in because that’s all they can do.” Now those employees can be redeployed to safer, more valuable tasks, and production isn’t limited to the availability of those workers, giving the company better production flexibility. When Goff began her research, her workforce was afraid robots were going to replace their jobs. She told them, “Listen, you don’t get it, guys. I want you to be safe. I want you to work smart. I don’t want you to just rely on your hands; I want you to rely on your knowledge and skills. If we can get our work environment to a point where you’re more of a QC operator than a machine operator, that’s a win for everybody.” After working with the cobot, her workers’ attitudes have completely changed. Goff said, “Once everyone settled down and they saw how this thing worked, it was like, ‘Why didn’t we do this sooner?’” RR

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THE ROBOT REPORT

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FEBRUARY 2024

A DESIGN WORLD SUPPLEMENT

Comparing EV battery cell charge and discharge rates What are the C-rate parameters? PAGE 56

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2/5/24 10:24 AM

EV ENGINEERING

How do EV battery cell charge and discharge rates compare? By Aharon Etengoff • Contributor

he charge and discharge rates of electric vehicle (EV) battery cells affect the vehicle’s range and performance. Measured in C-rates, these crucial variables quantify how quickly batteries charge or discharge relative to their maximum capacity. This article discusses C-rate parameters, compares charge and discharge rates, and highlights the implications for EV drivers. It also explores various innovative technologies designed to improve EV battery cell efficiency. Understanding EV battery C-rates A one-ampere-hour (Ah) EV battery can charge from 0 to 100% in 60 minutes at a rate of 1C. Although a rate of 3C reduces this timespan to 20 minutes, frequent fast charging at high rates generates excess heat, causing damaging chemical reactions within battery cells. This decreases the battery’s state of health (SOH), reducing charge retention capacity and shortening operational lifespan. Lower rates, such as 0.5 and 0.2C, facilitate longer, safer charging cycles. Specifically, at a 0.5C rate, the battery charges 500 milliamperes (mA) over two hours, while a 0.2C rate extends this duration to approximately five hours. Ideal for overnight residential charging, EV drivers usually choose these rates to minimize thermal issues, mitigate mechanical stress, and extend battery lifespans. EV batteries typically discharge at higher rates for shorter durations. Even a brief discharge at 1 or 2C significantly boosts power output and acceleration. Frequent high

discharges, however, rapidly deplete the battery’s state of charge (SoC), especially during rapid acceleration or while climbing steep inclines. The SoC is the level of charge of an electric battery relative to its capacity. These discharges also adversely affect battery cell chemistry, reducing energy storage capacity and potential long-term performance issues. An EV’s battery management system (BMS) typically keeps driving discharge rates between 0.2 and 0.5C to reduce the likelihood of these effects. This ensures an optimal balance between performance, battery longevity, and safety. Comparing charge and discharge rates Understanding the similarities, differences, and complex interplay between battery cell charge and discharge rates is essential for EV drivers. These include: • Rate tolerance: EV battery cells generally tolerate high discharge rates better than high charge rates, maintaining performance with less degradation. However, if unchecked, frequent high discharges can still shorten battery life. • Thermal management: Rapid, high-rate charges and discharges increase the risks of thermal runaway and battery degradation. In contrast, slower charge and discharge rates usually result in a more manageable, gradual heat buildup. • Environmental sensitivity: Battery cells charge more slowly in cold temperatures due to decreased

February 2024

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•

chemical reaction rates while discharging faster in hot climates. Operational efficiency: Fast charging decreases battery efficiency over time, reducing energy storage, underused capacity, and a shorter battery life. Conversely, discharging at moderate rates maintains energy efficiency and improves overall performance. BMS: During charging, the BMS continuously adjusts parameters to prevent overheating and extend battery life. While discharging, the BMS prioritizes maintaining performance within safe operational limits.

Implications for EV drivers Frequent fast charging increases battery cell resistance and leads to charging inefficiencies, resulting in decreased capacity, longer charge times, and reduced range. This presents EV drivers with a trade-off between convenience and long-term cost. For example, fast charging is often used

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EV ENGINEERING

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during long road trips due to limited charger availability and time constraints, while recharging at slower rates is preferred for daily commutes or short road trips. Similarly, higher discharge rates facilitate rapid EV acceleration, responsiveness, and more dynamic handling. Over time, however, these benefits can be offset by battery cell degradation, adversely affecting driving range and performance. To mitigate these effects, an EV’s BMS typically reserves high discharge rates for specific situations, such as overtaking on highways, navigating steep inclines, or emergency scenarios requiring sudden acceleration. Future battery cell technologies Lithium-ion is the most popular type of battery cell due to its widespread availability, standardized manufacturing processes, and relatively high energy density compared to cost. There are several types of lithium-ion cells, each with unique advantages. The Tesla Model 3, for instance, initially used lithium nickel cobalt aluminum oxide (NCA) cells for their high-energy density until 2021. In China, certain Tesla Model 3 cars have transitioned to lithium-iron phosphate (LFP) cells, valued for their longer lifespans and improved safety. Emerging technologies are set to significantly improve EV battery cells’ charge and discharge efficiencies, including but not limited to lithiumion varieties. For example, solid-state batteries provide more capacity and support faster charging with minimal

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EV ENGINEERING

Summary The charge and discharge rates of electric vehicles, quantified in C-rates, directly impact range and performance. These essential variables determine how quickly batteries charge or discharge relative

1C Charge, 1C Discharge to their maximum capacity. While 2C Charge, 2C Discharge convenient, fast charging at high rates tends to generate Charge: 4.2V excess heat and Discharge: 3.0V 3C Charge, 3C Discharge Temperature: 23 C cause damaging chemical reactions within battery cells. Similarly, Number of cycles higher discharge rates boost EV A cycle performance graph of a lithium-ion battery at acceleration, different charge and discharge rates (1, 2, and 3C), responsiveness, depicting the relationship between the number of cycles and discharge capacity. (Original image: Battery University) and handling. These benefits are offset, however, by battery cell degradation over time. EV drivers should Scan the QR code limit frequent rapid charging for a list of references and discharging to maintain used in this article. optimal SOH. EV

Discharge capacity (mAh)

degradation risks, potentially increasing the driving range by five to six times. Similarly, liquid air batteries could boost an EV’s driving range from 300 to over 1,500 miles. Moreover, advancements in ceramic solid-electrolyte separators are helping to resolve fast-charging bottlenecks by replacing traditional graphite anodes with lithium metal. During tests, batteries equipped with these solid-state lithium-metal anodes retained over 80% energy after 800 charging cycles at 1C rates, equating to more than 240,000 miles for an EV with a 300-mile range.

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Ad Index Additive Manufacturing Users Group ............................................. 34 AllMotion ......................................................................................................4 Altech..............................................................................................cover,6,7 AutomationDirect ................................................................................. IFC B&R Industrial Automation.................................................................. 39 Bodine Electric Company...................................................................... 21 DigiKey Corporation..................................................................................9 Dorner ........................................................................................................ 36 Dura-Belt.................................................................................................... 37 Eagle Stainless Tube & Fabrication, Inc. ......................................... 12 ebm-papst, Inc. ...........................................................................................1 Faulhaber ................................................................................................IBC Gaudent ..................................................................................................... 18 Interpower .............................................................................................17,19 mk North America, Inc. ......................................................................... 43 Novotechnik ............................................................................................. 33 OKW Enclosures, Inc. ............................................................................ 27 Parvalux, by maxon ...............................................................................BC PBC Linear ................................................................................................. 16 Pyramid Inc ............................................................................................... 31 Ruland Manufacturing ............................................................................3 Smalley ....................................................................................................... 13 Spartan Scientific ................................................................................... 41 Whittet-Higgins ........................................................................................ 15 Zero-Max, Inc. .............................................................................................2

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Robot Report Supplement Harmonic Drive .................................................................................. 51,54 New England Wire & Tubing Technologies ............................. 53,54

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maxon ........................................................................................................ 49 Movu Robotics ........................................................................................ 47

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February 2024

2/5/24 11:12 AM

Technical Thinking By Mark Jones

We still don’t know everything about ice I recently saw my first icicle of the year. It was a small, wiggly thing. I know why thanks to some of the icerelated discoveries of the past year. In an example of curiosity driven research, the observation that icicles aren’t perfect cones led researchers to ask why. No one had explained why previously. Research showed impurities make ripples. It should follow that pure water would make perfect, smooth cones. It doesn’t. Mysteries remain. After centuries of living with icicles, there are still things we are just beginning to understand. More curiosity driven research is required. Reports of practical use of ice came out in 2023. Ice was touted as a sustainable, earth abundant building material. Multiple reports. All bring back memories of pykrete, the composite with ice as the continuous

February 2024

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phase. If it sounds like something out of MythBusters, it is. Material properties were confirmed. Adding sawdust to water and freezing it yields a material actually floated to be used in making an aircraft carrier in World War II. Today’s research harkens to pykrete, with new additions to the composite mix. Inorganic microparticles, polypropylene and basalt, and organic and inorganic nanoparticles are just some of the materials used to improve the mechanical properties. Ice is an ephemeral building material, one limited to climates where the refrigeration is natural. Even in naturally cold climates, warm weather threatens. Reconstruction is inevitable certainly dampening any sustainability claims. It is a practical use of a local, inexhaustible, albeit seasonal, resource. Other practical ice uses were reported, not for building but for human consumption. Starbucks announced it was changing the ice the company used. All ice for consumption begins its life as water injected into a cold vessel. Ice trays give us frozen chunks used without further processing: hard crystalline chunks. Nugget ice is different. A big frozen block is whittled into little chunks that are compressed to make ice nuggets or pebbles. The loosely aggregated collections aren’t hard. Breaking a tooth is nearly impossible. So is choking. Long popular with hospitals, nugget ice is spreading to Starbucks. Nugget ice is more satisfying to chew, at least according to most surveys, and offers some other

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advantages. The machines are more sustainable, using 40% less water and 15% less energy. Less water loss due to purging and more on-demand production underly the sustainability advantages. Starbucks may be moving on from big ice, but others embrace it. Camper English released The Ice Book, becoming the de facto ice expert of 2023. Much of the reporting centered on his work to make clear ice. The aesthetics of clear ice make it preferable, especially in high-end cocktails. Camper is certainly to be commended. He methodically experimented to find a way to make the big, clear ice he wanted. What he found was directional cooling. In order to get clear ice, you want the ice to grow from a single edge. Camper did something I’ve done many times. He rediscovered something that was actually wellknown. The adage I heard early in my career was “two weeks in the lab can save fifteen minutes in the library.” Clear ice wasn’t well described in either academic or popular press before Camper. It was, however, well described in the patent literature. Going back to at least 1973, directional cooling was known to make clear ice. There are several things to take away from the current fascination with ice. I’ll feel a little better munching on nugget ice, knowing it is slightly better for the planet. I’ll appreciate wiggly icicles more. I’ll also remember to check patent literature when seeking practical, technical solutions. DW

DESIGN WORLD

2/7/24 1:22 PM

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