DESIGN WORLD JANUARY 2020-MAIN ISSUE by WTWH Media LLC

January 2020

www.designworldonline.com

2020

Leadership in Engineering

THINK INSIDE THE BOX Exceptional designs deserve superior components. The developer of the original world-class linear motion systems, THK continues to redeﬁne industry standards and to meet an ever-growing range of needs. From aerospace and machine tool to packaging and medical, THK products play a vital role in the advancement of technology and capability.

To learn more, call us at 1-800-763-5459 or visit www.thk.com.

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One of the more interesting talks I heard over the course of 2019 came at the recent Power Transmission Distributors Association’s Industry Summit. Frank Abagnale, whose early exploits as a con man and check forger were detailed in the 2002 film Catch Me If You Can, spoke about his life and his lessons learned. Abagnale, who went on to work for the federal government, shared his thoughts on how to protect your personal information in today’s world of online scams. While a different kind of technical issue than the normal engineering topics we cover, I thought it worthwhile to share with you for the new year. Here are his top three suggestions: 1. Freeze your credit. Identity the is a real problem. Congress has passed a federal statute allowing for every American citizen to eeze their credit. Absolutely no fee can be charged. You can eeze it and un eeze it over and over. “It’s as simple as going to the Google box and typing in ‘how do I eeze my credit,’” he said. Abagnale explained that once you eeze your credit, absolutely no one can see your credit without your consent. If tomorrow you decide to buy a car, you go down to the car dealership and tell them you’d like the finance it for three years, want to get the best interest rate, and you will un eeze your credit to the dealership to run the credit. Then it’ll be ozen, and you leave the car dealership again. “I would highly recommend anyone with 16-year-old children or older to eeze their credit, too.”

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2. Don’t write checks for just anything. He doesn’t write a lot of checks anymore, and he’s careful where he does. If you go to the drug store tomorrow and write a check for $9, you’d have to hand the clerk the check. On the check is your name, address and phone number, your bank’s name and address, your account number at your bank, your routing number into your account — in other words, your wiring instructions. It also has your signature. And the clerk will likely write your driver’s license number and your date of birth on the ont of the check. “We live in truncation, which means you don’t get the check back,” he said. “You get an image of the check. The physical check goes to their warehouse for 65 days, where eventually they will destroy it. Anyone who would see it, in the meantime, could dra on your account.” 3. Don’t own a debit card. “I’ve never owned a debit card,” Abagnale said. “I have written many, many articles on debit versus credit. I’ve had three sons and have never allowed them to possess a debit card to this day, and they’re grown men. A long time ago, I asked myself a very simple question, ‘How do I remove 99% of my financial liability?’ And the answer is to use the safest form of payment that exists in the United States, and that is a credit card. Not credit debit card, credit card. Visa, MasterCard, American Express, Discover Card. Every day of my life, I spend the credit card company’s money. I never spend one dime of my money.” Abagnale said he uses a credit card to get his dry cleaning, pick up the groceries, get on a plane, etc. He explained that he does everything in his power to make sure no one gets his number, but if they do tomorrow, and they charge $1 million on his credit card, by federal law, his liability is zero. When he pays the bill every month or the minimum due, his credit score rises, and he continues to build his credit. “Alternatively, when you use your debit card, every time you reach for it, you expose the money in your account.” Sage advice for 2020 and beyond. Stay safe! DW

Te c h n i c a l S u p p o r t Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com

(408) 460-1345

On Twitter @ DW—Editor

DW.Insights.1-20_Vs2.LL.indd 4

January 2020

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DESIGN WORLD

1/14/20 12:42 PM

The Truth About Compressed Air! If you think compressed air is too expensive and noisy - read this. The facts will surprise you! Compare These Blowoffs

Drilled Pipe This common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. The initial cost of the drilled pipe is overshadowed by its high energy use. The holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

There are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application.

Flat Air Nozzles As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suffers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers offer flat air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air. Blower Air Knife The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and flat air nozzle, but was comparable to EXAIR’s Super Air Knife. The large blower with its two 3" (8cm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs. Costly bearing and filter maintenance along with downtime were also negative factors.

The goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

EXAIR Super Air Knife The Super Air Knife did an exceptional job

of removing the moisture on one pass due to the uniformity of the laminar airflow. The sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be dead-ended. Maintenance costs are low since there are no moving parts to wear out.

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

Blowoff Comparison Type of blowoff

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Drilled Pipes

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Blower Air Knife

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Horsepower SCFM SLPM Required

Sound Annual Purchase Approx. Annual First Year Level Electrical Price Maintenance Cost Cost dBA Cost*

174 4,924

$50

$4,508

$920

$5,478

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257 7,273

0.2

N/A

102

$208

$6,569

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$8,227

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$1,288

$1,500

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4.1

1,557

$650

$1,417

$300

$2,367

*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

Facts about Blowers Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of filters, belts and bearings.

Here are some important facts: Filters must be replaced every one to three months. Belts must be replaced every three to six months. Typical bearing replacement is at least once a year at a cost near $1000. • Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate effective airflows. • Poorly designed seals that allow dirt and moisture infiltration and environments above 125°F decrease the one year bearing life. • Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer.

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Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required.

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1/12/20 4:21 PM

Teschler on Topic Too simple for your own good: The benefits of being confused

Your last encounter with a textbook likely involved simple diagrams, bullet-point lists, and several other constructs designed to condense concepts and present them as simply as possible. It turns out that this dumb-it-down approach isn’t helpful for learning things and, in fact, might make learning more difficult. Neuroscientists who study learning now say people learn best when they are confused. Moreover, we are more likely to remember new information picked up in shorter bursts rather than through intensive learning sessions. Insights on the subject come om UCLA neuroscientists Robert and Elizabeth Bjork who say a counterintuitive technique called productive failure promotes rapid acquisition of knowledge. Here the instructor asks students to solve problems they have no clue how to handle. Only a er a lot of wheel-spinning and struggle is the correct method revealed. You’d be right if you suspected that stunts like this in a classroom might result in a bunch of ticked-off students. But introducing difficulties this way works better than making the learning process easy, the two scientists say. Also unsurprising is that few schools try to make use of such techniques though evidence of their effectiveness is mounting. A study of British Post Office workers illustrates the benefit of another idea that goes against common beliefs about learning. Workers taught to use letter sorting machines for just one hour daily over a long period got more out of the training than others who received four hours of daily instruction over a briefer interval. Interestingly, workers receiving the briefer training didn’t think much of it; they felt as though they weren’t mastering their tasks. But tests revealed they had picked up the basics 30% faster than the quickest learners among their counterparts who endured longer training sessions. Researchers say people benefit om learning in smaller chunks because doing so lets them forget some of what they learned in the last session, forcing them to work at relearning it. The process of forgetting and relearning strengthens your long-term recall. Those who spend longer chunks of time drilling don’t get the benefit of the more numerous forget/remember cycles. It turns out that most U.S. schools don’t like to try ideas that make things difficult for students (and ruffle the feathers of teachers), even if there’s evidence they work. But that’s not the case in East Asia, says David Robson, author of The Intelligence Trap and a former editor at the magazine New Scientist. Students in countries such as Japan appreciate that struggle is necessary in education, he says. There, even elementary school students are taught to discover new ways of solving problems for themselves and to consider alternative solutions. And they are encouraged to wrestle with problems whose solutions aren’t immediately straightforward. No wonder, then, that East Asian students score better than U.S. students on measures of critical thinking and evidence-based wisdom. So think back to the days when you stumbled out of your engineering classes confused and discouraged. Little did you know, though it didn’t seem so at the time, your instructors were actually doing you a favor. DW

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

Lee.Teschler.Column.1-20_V2.LL.indd 6

January 2020

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system. For example, a number of additive vendors announced AMspecific ERP and MES packages, so ware that helps users find the best use cases for additive manufacturing. Vendors are also focusing on easier to use design and development programs. These developments are part of a shi on the part of additive vendors to build an ecosystem. An open additive ecosystem means partnerships give customers greater control over their choices, one benefit of which is that it will deliver better costs. For a number of vendors and users, this development signals a growing recognition that additive manufacturing is really a group effort. Partnerships are making news. Another obstacle to adoption is quietly going away. That obstacle is vendor lock-in. Manufacturing customers have a long history of resisting proprietary equipment because their customers (such as aerospace and automotive) resist it. So, the days of forcing users to choose proprietary materials and technology are receding. And recognition is growing that the job of an additive manufacturing engineer is different om that of a typical manufacturing engineer. AM engineers are o en expected to have an understanding of materials, design and postprocessing for 3D printing in addition to the needs of traditional manufacturing.

The trend is clearâ&#x20AC;&#x201D;barriers to adoption are falling as vendors address specific issues (such as ease of use and affordability) and as vendors work to integrate additive more easily into legacy manufacturing systems. In fact, a number of companies report that they have more than doubled their use of industrial-scale additive in the last year. Additive will become a third option for manufacturing parts, and you will see this trend take stronger hold in 2020. According to some forecasters, 2020 will be the year we see additive as a full production system. DW

Leslie Langnau â&#x20AC;˘ Managing Editor llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

January 2020

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Green Engineering Paul J. Heney

• VP, Editorial Director

Where is secondary packaging going?

The key to more sustainable primary and secondary packaging involves two major approaches: recycle and reduce. The first requires that packaging materials are kept in constant circulation, being continuously reused. The second entails finding many different ways of using less and less packaging material in order to save on resources and avoid waste. “The greatest challenge for us is the processability of the packaging materials,” said Karl-Heinz Klumpe, packaging product manager for KHS in Kleve, Germany. “Shrink film made of recycled plastic demonstrates very different shrinking properties versus film made of new material. As an engineering company, we can’t provide all the answers ourselves but instead have to coordinate closely with the film manufacturers.” To this end, KHS is staging a number of workshops this year. These aim to find out how the percentage of recyclate in film — as stipulated by the new German Packaging Law, for example — can be increased. “You make a few changes to the chemicals or recipe of your film and we adjust the air flow or temperature accordingly,” said Klumpe. “Providing that there’s a standard of quality

January 2020

Green.Engineering.1-20_Vs2.LL.indd 10

which is accepted by the big bottlers’ marketing departments, of course. With film made of 100% recyclate, the shrink results aren’t yet satisfactory. Together we still have to work out how to close the gap here between recycling requirements on the one hand and the demand for packs of ever-increasing quality on the other.” Another avenue that film manufacturers are exploring is to reduce the thickness of their film. “The material’s getting thinner and thinner,” said Klumpe. “To provide the same stability the materials have to be more and more complex. This has its limitations when used for beverage packaging: below a thickness of 35 microns it’s possible that the price per kilogram for film then again rises. When it comes down to it, neither bottlers nor their customers want to pay for this.” www.designworldonline.com

What applies to plastics also applies to cardboard — chiefly when it comes to reducing the amount of material used. Paper factories are experimenting with thinner cover layers and lower ridges in the manufacture of corrugated cardboard. “The stability and durability are okay,” said Klumpe. “However, we have to answer the question of how suitable these materials are for use with machinery. What happens when the cardboard absorbs moisture? If the cardboard is thicker on the outside than the inside, it bends rather like a bimetal and can only be processed on machines with certain restrictions or not at all. What can we do to counteract this?” In terms of recycling, less attention is paid to cardboard than to plastic. Yet here, too, the reuse of DESIGN WORLD

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Green Engineering this material is an issue, for example in how far print can affect the recyclability of the paper. KHS is experimenting with new packaging materials. For instance, a manufacturer om Sweden recently approached the company with a newly developed, award-winning cardboard looking for partners for a market launch. “Our top requirement is that we can be sure that we can process the cardboard without any problems,” Klumpe said.

Constant process The packaging experts in Kleve are also in constant dialog with the manufacturers of adhesives and adhesive application systems. “Here, we explore how we can avoid having to heat the glue so intensely or how we can reduce our consumption of adhesive,” said Klumpe. “We’re now applying smaller and smaller dots of adhesive as opposed to the diamond shapes we used to use.” All told, sustainable product innovation is a constant process with both proven and new partners. The focus is always on the question of which approach can be adopted to save on materials, time and energy on the machines. One example of how energy can be saved is the shrink tunnel with porous gas burners. To heat the air, KHS decided not to use electricity as the energy transfer medium but to work directly with gas to prevent energy being lost during transport om the producer to the consumer. This saves up to 50% in energy costs and CO2 emissions are cut by as much as 60%. In the last few years, the company has also set standards in many other areas with its resource-saving packaging machines. Both fully-enclosed FilmPacks and nested and shi ed packs have done away with the need for stabilizing cardboard pads or trays. “ We don’t need any more cardboard at all here,” said Klumpe. “The taut film gives us a good shrink pattern and a sturdy pack.”

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In a countermove, the DisplayPacker has also been developed where large packs are placed directly onto cardboard trays without the need for an extra wrapping of stabilizing film. In 2018, the Nature MultiPack was launched to market as a six pack of cans by the Carlsberg Group under the name of Snap Pack. A few dots of adhesive developed specifically for this pack hold the cans together, and a stabilizing carrying handle make any further packaging material redundant. Once the new pack format has been fully rolled out, by completely eliminating the use of shrink film for cans, Carlsberg is set to make a plastics saving of up to 76% — more than 1,200 metric tons a year. Danone Waters first made successful use of the Nature MultiPack to launch its prestige PET bottle for Evian in 2016. “In the development of sustainable packaging we see ourselves acting as an interface between all those involved and the beverage industry,” Klumpe said. “We’re helping to develop new standards which marry ecological demands and legal provisions with bottlers’ economic interests.” DW KHS | www.khs.com

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

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Contents 1 • 2020

•

vol 15 no 1

•

2020

designworldonline.com

Leadership

148

| AdobeStock.com

Pages 227-421

84 _MOTION CONTROL

128 _MECHANICAL

156 _ADDITIVE MANUFACTURING

Motion controllers: Design from scratch or buy ready-made?

The eight best ways to wreck your coupling driven system

Multimaterial 3D printing manufacturers complex objects, fast

Here’s a look at the different types of motion controllers currently on the market, and the pros and cons of each. 92 _MOTION CONTROL Next generation electric actuators...

New smart electric actuators offer better efficiency, flexibility, and connectivity for a number of industries. 98 _LINEAR MOTION Boosting productivity with the right motor feedback

Key application parameters of precision, cost restrictions, and insensitivity to mechanical characteristics and environment dictate which technology is most suitable.

Here are the eight best ways to consistently sabotage or damage your coupling driven system (and how to avoid them in the future). 136 _MECHANICAL Understanding bearing system preload

We take a look at key considerations when determining how to best use preload for bearing system applications. 148 _ELECTRONICS Simpler debugging for Automotive Ethernet systems

With new additive technology, a multinozzle 3D printer can switch between multiple inks up to 50 times per second. 162 _PNEUMATICS How to build a pneumatics bill of material

Planning out all of the details — and remembering the small stuff — pays off when designing pneumatic systems. 172 _LEADERSHIP Leading by representing differences

What can an engineer do in the halls of Congress? And do we need more engineers there?

New techniques let engineers examine high-speed data traffic without garbling signals.

112 _INTERNET OF THINGS Trends in Internet of Things

Design engineers have a range of IoT and IIoT connectivity devices to choose om for their designs. 120 _3D CAD

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

2019

| AdobeStock.com

Implicit modelling for complex geometry

Implicit modelling is enormously powerful and offers huge potential for engineering design.

January 2020

CONTENTS.1-20_Vs2.LL.indd 14

BRONZE REGIONAL AWARD asbpe.org

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FEATURED MANUFACTURERS

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Design for Industry Aerospace

Electrically conductive PTFE-based

sealing materials for dynamic applications

While conductive elastomers are available, most of the materials are primarily for static applications. Conductive, injection-moldable plastic materials that exist have low flexibility and are less suited for sealing purposes and for installation in closed grooves. New materials, Turcon MC1 and Turcon MC2 meet the needs for conductive plastic sealing materials that will work effectively and reliably as seals and bearings in dynamic applications. With them, designers can take advantage of using a range of advanced PTFE-based sealing geometries and all the benefits that they offer in applications that require electrical conductivity through a hydraulic system or electric motor, for instance. Turcon MC1 and Turcon MC2 materials are polytetrafluoroethylene (PTFE) based electrically conductive materials. Virgin PTFE is a good insulator with resistivity around 2x10+17 Ohm-cm. For PTFE composites to conduct electricity, conductive fillers must be added, and these need to interconnect within the PTFE matrix. Historically, the only conductive PTFE-based materials were compounds with carbon filling above a â&#x20AC;&#x153;threshold value.â&#x20AC;?

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The fact that electrical conductivity was achieved in these original carbon-filled PTFE-based materials was accidental and electrical resistance was not the primary engineering requirement. Turcon MC1 and Turcon MC2 differ though, in that they have been specifically developed for electrical conductivity in dynamic sealing applications to optimize sealing performance. Electrically conductive sealing materials have some important applications: â&#x20AC;˘ In aircra , a worst-case scenario is that a plane is hit by lightning but less traumatic is the static buildup that occurs as a plane flies through the air. Electricallyvconductive seals in the landing gear, for instance, will ensure that electricity or static is safely dissipated. â&#x20AC;˘ Electric charge transfer through the gap between two components can cause sparks or stray current in machinery and systems, for example in electric motors. This can result in hardware pitting and carbonization of lubricant or grease. Use of an electrically conductive seal or bearing grounds the system by creating a clear path between two components, avoiding corrosion issues. â&#x20AC;˘ Sometimes intentionally a signal needs to be sent to or om a sensor in a system. This signal transfer can be achieved by using electrically conductive seals or bearings that will create a clear path for the signal, enabling system manufacturers to develop more complex systems incorporating aspects of artificial intelligence without adding electrical circuitry. Turcon MC1 is a medium-filled material for dynamic applications requiring medium to high conductivity, while Turcon MC2 is a high-filled material for dynamic applications requiring high conductivity. DW

Trelleborg Sealing Solutions www.tss.trelleborg.com

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January 2020

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Design for Industry Aerospace

Increasing robot flexing for plane assembly

Robot arms at work: the robots connect fuselage parts of an aircra with rivets.

| igus GmbH

Rivets are inconspicuous fasteners that hold the Airbus A320 aircra â&#x20AC;&#x2122;s metal fuselage parts together. But installing those rivets was a challenge. Previously, the task took weeks with workers fastening the rivets manually. So, a Spanish manufacturer of the Airbus fuselage turned to industrial LOXIN robots to tackle the job. However, those robots needed a few capabilities to handle the job. For example, the industrial robots needed more than just flexibility to reach every point of a fuselage. The robots had to master several work steps, including drilling, milling to riveting, all done with a precision of 0.2 millimeters. To ensure robot movement flexibility, LOXIN (ARITEX GROUP) relies on cable guides made of high-performance plastic manufactured by igus. The robots assembling the fuselage are helping Airbus increase production by 20% to catch up with demand. Airbus has sold approximately 6,000 jets, with another 8,000 on order.

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Safely protected: the cables for the tools on the end effector of the robotic arm are housed in black, three-dimensionally movable triflex chains and are safely guided by them. | igus GmbH The LOXIN 2002 automates the riveting process. The multiaxis robots work to the le and right of the raised fuselage. The robots are mounted on platforms that can be raised up to a height of several meters by linear units - similar to a forkli . Arriving at the right height, the heavy robot weighing tons, moves to the operating point with millimeter accuracy over six axes. It drills a hole in the metal, mills a recess for the rivet head, vacuums up the dust, applies a sealant and sets the rivet. Depending on the fuselage section, the robots must constantly change the angles and diameters during drilling, milling and riveting. Six axes move the head to any part of the fuselage. The tools on the robotâ&#x20AC;&#x2122;s end effector are connected to several energy, pneumatic, and data cables. And these cables must follow the contorted movements of the arm perfectly, even at high speed, without rubbing against each other or knocking against the sensitive surface of the fuselage. Otherwise, the result could be cable breaks and damage to the aircra . Igus offers a range of cable management systems including the triflex series. These are hose-like protective cages made of wear-resistant high-performance plastic, which follow even the wildest three-dimensional movements of industrial robots. Inside, the cables are securely fixed and protected against wear. To ensure that the triflex energy chains move as close to the arm as possible and do not hit the aircra , LOXIN uses the triflex RSE retraction system. If the robot arm returns to its original position a er a movement, the mechanical system retracts the chain. Round brackets, which are mounted on the arm, ensure safe guidance. The robot arm has full eedom of movement, without having the parts of the chain rub against each other or form loops. The igus energy chain has a better iction behavior than corrugated tube and will not break and cause a stoppage. And if a chain-link reaches the end of its service life, it can be replaced in a few simple steps. By using the triflex chains in conjunction with the triflex RSE retraction system, LOXIN has also been able

DESIGN WORLD

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January 2020

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Design for Industry Aerospace

A twisterchain protects the cables om the base of the robot arm to the first axis. The energy chain allows 540 degree movements. | igus GmbH

When SWaP matters most Connect with Confidence

to achieve better mobility of the robots, which can now simpli their work steps around the fuselage even more easily, saving valuable assembly time. Another product used on the robot arm is the twisterchain, an energy chain that protects the cables om the base of the robot arm to the first axis. The chain moves in a guide trough. If the robot arm turns, the chain folds as the upper run of the chain rests on the lower run. The chain allows a circular movement of up to 540Â° at speeds of up to 1 m/s. Since it also consists of high-performance plastics, it is wear-resistant. DW

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Design for Industry Aerospace

Inertial measurement systems for

the space market

Two all-silicon inertial measurement systems meet the specific demands of the small satellite and launch vehicle markets. The RMU30 combines below one-watt power consumption with performance that is comparable to larger and higher consumption fiber optic-based gyro systems. This is a small, lightweight, 3 axis micro electro-mechanical systems (MEMS) device incorporating three Silicon Sensing high performing sensor heads. The RMU30 does not have technology that is not relevant to the space environment for a motion sensing unit that is small and ultra-low power with precision inertial sensing performance. The IMU20 industrial grade MEMS IMU can withstand extremely high shock environments and has a dynamic range that makes it suitable for use on satellite launch vehicles. This device combines three of the developerâ&#x20AC;&#x2122;s gyros with MEMS capacitive accelerometers. DW

Silicon Sensing Systems www.siliconsensing.com

Silicon Sensing System engineers working on an RMU30 prototype. IMU20 delivers precision motion sensing in severe environments such as satellite launch vehicles.

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Design for Industry Food and Beverage

Edge computing can enable the smart factory

Manufacturing quality and productivity gains can be made in automotive, food and beverage and life science industries using the MELIPC solution. This real-time process so ware gives local diagnostics, predictive feedback and visualization for shop-floor analytics. Analysis algorithms for predictive maintenance and quality control are already on-board the MELIPC Series. In continuous production applications it can improve processes as well as adapting to variables. Efficiency is improved by generating a live predictive model, which can be updated and refined based on new demands om the process. A packaging machine in a food & beverage application for instance can predict issues and avoid mistakes, thereby improving quality. The MELIPC solution can recognize anomalies in machine status in real time by making use of artificial intelligence (AI). In an automotive paint shop for example, it can be used to prevent downtime. Detailed status information is reported back to the automation level so that machine operators can make pro-active early adjustment or maintenance interventions to maintain efficiency and increase availability.

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Processing data at the physical edge of operations can also improve data security and process integrity. In a life science application, the MELIPC solution can be used to store and analyse sensitive information on OT level, instead of it being sent up into the cloud. This also provides much faster real-timediagnosis while reducing IT in astructure cost and requirements. DW

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Design for Industry Medical

Pneumatic pinch valve optimizes

single-use batch production

The ASCO Series 273 Pinch Valve for the life sciences market is for single-use batch applications in bioreactor and fermentation tanks, tangential flow filters (TFF), chromatography skids and other drug discovery lab applications. The Series 273 features a pinch mechanism that remains firmly in place to provide better tube retention and eliminates breakage or damage to the so tubing. It also includes a safety guard to prevent exposure to moving parts, as well as a manual override feature that lets operators insert or remove tubing without actuating the valve during unplanned batch switching. Not only does this valve design keep operators safer, it also accelerates setup and makes unscheduled maintenance easy. A pneumatically actuated pinch valve, the Series 273 makes no contact with process media, features a high lifecycle and provides a reliable pinching force over repeated use. Available in anodized aluminum and 316 stainless steel, the series is suitable for peroxide

January 2020

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fumigation and includes a position indication option for valve on/off status feedback. Series 273 Pneumatic Pinch Valve specifications include: • 2-way normally open (NO) and normally closed (NC)

is also suitable for food and beverage production. The pinch valve can be actuated using ASCO Series 501 or the AV Series pneumatic valve manifolds and ASCO 580 CHARM electronics. DW

Emerson | Emerson.com

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• Valve position detection: open or closed The Series 273 targets single-use batch applications in the pharmaceutical and biopharmaceutical markets, but

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Design for Industry Medical

What will change in medical device packaging under MDR and ISO 11607 Britt Jones • manager of package testing services for devices, biologics, and combination products WuXi Medical Device Testing.

Regulators are setting a new bar for medical device packaging requirements to improve patient safety worldwide. Updates to International Organization for Standardization (ISO) standard 11607 parts one and two will require manufacturers to make important adjustments to packaging designs to comply. That’s on top of new Medical Device Regulation (MDR) requirements shaking up the European market.

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Updates to ISO 11607 hope to accomplish three objectives: • A device packaging’s physical integrity and sterile barrier system must be maintained. • Clinical staff need to have clear instructions on inspecting and opening packaging in a safe and sterile manner, now to be proven through usability studies. • Updated terminology aligns these regulations with others around the globe to help in establishing more consistent

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terminology, which makes it difficult to set expectations across borders. With the latest ISO 11607 update, consistent terminology has become a priority, including aligning with definitions specified in ISO 11139. Beyond harmonizing language, a goal in updating ISO 11607 is to keep devices sterile for patients. Clinical staff may have a hard time distinguishing sterile barrier systems in packaging, making it more difficult to maintain aseptic preservation of the device. The latest update requires device manufacturers to provide detailed instructions on how end-users should inspect sterile barrier systems. Not only will you need to provide instructions for inspecting the sterile barrier system, but you will also be required to include instructions on where to begin opening the packaging and how to open and present the device to the sterile field without causing damage or

expectations across borders. The overarching aim is to align ISO 11607 with the General Safety and Performance Requirements (GSPR) and the MDR. To ensure products gain approval om regulators in Europe, the United States and around the world, you may need to re esh your approach to packaging planning and test processes. Letâ&#x20AC;&#x2122;s review the rationale behind the updated requirements, the most important things to know in planning your packaging design, and how you can make sure your testing partner is up to speed on their end. Key learnings om the latest update Regulators are emphasizing standardization across markets. Until recently, thereâ&#x20AC;&#x2122;s been misalignment between how global standards committees and regulators approach TL Design World V1.pdf

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contamination. You must demonstrate to regulators that instructions are intuitive and clinical staff can properly execute with the given packaging design through a new usability evaluation requirement. To get your product to market, youâ&#x20AC;&#x2122;ll want to review terminology changes to ensure youâ&#x20AC;&#x2122;re using the preferred language, make sure your sterile barrier system is fully functional and provide and prove an effective set of instructions for opening packaging and presenting the final product into the sterile field. The process gets more complicated when attempting to both earn or maintain approval under ISO 11607 and align with the MDR. Testing and validation procedures While the ISO 11607 update strictly requires testing to the latest standard (including revalidation a er any packaging changes), testing will not

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Design for Industry Medical

always be necessary under the MDR. Your MDR submission may be approved without additional testing, provided you have sufficient justification to prove safety and compliance with the regulation. This doesn’t mean every device submission is approval-ready, but you may avoid this testing step in some instances. The reality is – especially when it comes to legacy devices – that many devices lack satisfactory evidence, so package integrity testing is important. Exact integrity testing needs will vary by device, but there are three methods that are most commonly used: Integrity and seal strength testing This method of testing is a key first step in understanding your packaging’s integrity and strength limitations. This testing determines the initial abilities of your packaging. As sterile barrier systems are a greater focus in the latest ISO 11607 update, physical integrity testing via bubble-emission, dye penetration and seal strength can be a stronger approach than microbial challenge tests, which may not provide the same level of sensitivity.

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Accelerated aging and shelf-life testing Aging and shelf-life testing is important to set expiration dates and understand shelf-life limitations, but you may need to make some of these determinations relatively quickly. While you wait for realtime data to become available, using an accelerated aging test can help fulfill requirements. To avoid unforeseen issues in storage or transportation, use retains om your sample lot to give yourself room to investigate these challenges when they arise. Distribution testing Simulated distribution can help plan for the worst-case scenario when it comes to shipping, handling and other unexpected obstacles your packaging could face. To demonstrate to regulators that you’ve considered all process failures (such as a puncture, abrasion or seal failure) during distribution, you’ll need to

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January 2020

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expose packaging to multiple hazards such as compression, shock and vibration. This performance testing may also include extreme temperatures, humidity levels and exposure times. A er your packaging has undergone these challenges, itâ&#x20AC;&#x2122;s time to measure the integrity of the sterile barrier system and the sterilized product. With the right stability and performance, your packaging configuration is ready for submission. Vetting your testing partner Outsourcing package testing and validation to an experienced partner can be worthwhile, especially if you are not familiar with the new testing requirements. However, not all contract research organizations (CROs) are created equally. As you vet testing partners, discuss aging capabilities, distribution testing and environmental conditioning. Take the time to understand the range of settings available for testing compatibility of package types and materials within accelerated aging. Distribution and transportation testing should be performed in-house by your testing partner to eliminate room for error that stems om additional handling and hazards if they outsource this function. Finally, itâ&#x20AC;&#x2122;s important to know if a potential partner can conduct environmental conditioning, as the data gained through exposing packaging to a variety of environmental elements will support your device packagingâ&#x20AC;&#x2122;s ability to withstand a worst-case distribution scenario. Ensuring your design history files and regulatory submissions will satis what regulators are looking for is a substantial but crucial task. Shortcuts in this process arenâ&#x20AC;&#x2122;t advised, as they could result in added costs, wasted resources and retesting. Take the time to understand the regulations and standards, find a trustworthy partner and dedicate the resources necessary to make sure your packaging is ISO and MDR compliant. DW

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Design for Industry Safety

Compact safety magnetic sensors The MC36C Series Compact Safety Magnetic Sensors are for safety-related applications, such as the monitoring of swinging, sliding or removable safety guards, which keep personnel safe om dangerous areas. The MC36C Series of magneticallycoded REED safety magnetic sensors monitor the position of sliding, hinged and removable safety guards, especially in dirty and dusty environments. Because of their wide actuation range, the MC36C magnetic sensors handle applications where great tolerances are required, such as with safety gates or doors which are imprecisely aligned. The MC36C Series are versatile and can work as standalone or in conjunction with a safety module to reach a safety category 4, according to the EN ISO 13849-1 Standard. These are some of the features which make these sensors flexible to meet various application requirements: • Compact size (36 x 26 x 13 mm) • Output configuration (2 NO or 1 NO and 1 NC), • Availability with 2m cable or M8 quick disconnect (le or right exit).

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Design Notes

Brakes, clutches, limit switches, and couplings help set the stage Edited by Mike Santora • Associate Editor

| AdobeStock

The 2500-seat Théâtre du Chatelet in Paris has undergone many restorations and upgrades since its original construction in 1862. In mid-2019, the theater re-opened after a 2 ½-year, 31 M€ renovation.

BC Caire, a French manufacturer of stage equipment, needed reliable and quiet powertrain components for new scenery winches at the Théâtre du Chatelet in Paris. The 2,500-seat theater has undergone many restorations and upgrades since its original construction in 1862. In mid-2019, the theater re-opened a er a 2 ½-year, 31 M€ renovation. The extensive effort included artwork and wall covering restorations, accessibility improvements, and energy-efficient electrical and HVAC system replacement throughout the building. Special attention was given to the backstage areas where new lighting systems and faster scenery moving systems were installed to bring the theater up to current

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standards. The elaborate mechanical systems were needed to allow more creative eedom to production designers and directors. Larger capacity motors and winches were installed to li heavier set decorations and large video screens at speeds om 1.20 to 1.60 m/s to accommodate faster scenery changes. Advanced electronic controls allow a single operator to maneuver 14 individual scenery li s simultaneously, at full speed, and full load. DESIGN WORLD

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Several Altra components were incorporated into the theaterâ&#x20AC;&#x2122;s stage scenery winch drive assemblies during the renovation.

The exceptional acoustics in the theaterâ&#x20AC;&#x2122;s large auditorium ampli the slightest sounds; it was critical that the new winch systems were quiet. The Combination Series 51 limit switches and largest concern was selecting a winch EZX tooth clutch assemblies were installed on braking solution that would provide each winch drive. These products are popular static holding and emergency stopping for theater applications worldwide. with no audible noise when braking. Series 51 limit switches feature a modular To meet the challenge, engineers design and use a patented planetary gear. Units specified Warner Electric ERS FENIX 10 offer a wide range of gear ratios (up 16,000 electrically-released brakes, specifically turns), a large number of switching contacts, designed for li /elevator applications. and easily adjustable cam discs. Other Altra Motion products were also The Stromag electromagnetic springsupplied, including Stromag combination applied EZX toothed clutch has been limit switch/tooth coupling assemblies specifically developed for use on stage hoisting and Huco Flex Ni couplings. applications. Units are typically mounted ERS FENIX 10 electrically released directly to Stromag limit switch housings. The brakes provide dynamic braking to backlash- ee units feature a form-fit crown prevent ascending winch overspeed and gear. In the open condition, the clutch acts as a also prevent unintended movement in brake for the geared cam limit switch. static park mode. The brakes provide Huco Flex Ni nickel bellows couplings quiet operation throughout their entire were also supplied. Units were mounted to life, which was a critical factor for this encoders to eliminate misalignment problems theater application. Units feature a single experienced by the customer. magnet and dual iction discs. The 10 Flex Ni couplings provide 12-1600 models supplied have a max rotation position torque rating of 1600 Nm with a Flex Ni couplings provide integrity. This is diameter of 274 mm. achieved through rotation position integrity. high torsional This is achieved through high stiffness torsional stiffness while still while still accommodating large amounts of accommodating lateral and angular misalignment large amounts of lateral and angular due to low spring rates in misalignment due these directions. to low spring rates in these directions. DW

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Design Notes

Harnessed energy supply systems help create new technology Edited by Mike Santora â&#x20AC;˘ Associate Editor

| igus GmbH

In the new production hall of DMG MORI in Brembate di Sopra, up to twelve MULTISPRINT machines can be produced simultaneously.

Machine tool manufacturer DMG MORI has developed a new automatic turning machine with multiple spindles for producing turned and milled parts in both boring and bar machining. Key components to the companyâ&#x20AC;&#x2122;s MULTISPRINT multi-spindle automatic lathes series are readychain harnessed energy supply systems om igus, the Germany-based manufacturer of motion plastics. The machine is the first to combine a multi-spindle automatic lathe with SWISSTYPE technology, and with a Y-axis on each spindle position. Customer requirements for modern turning machines have changed due to market dynamics and globalization. Machine tool makers now demand shortened processing and tooling times, reduced effort for process development and integration, and an ability to handle the increasing degree of complexity. The new MULTISPRINT includes nozzles for fluid power equipment, implants for dentistry, and sha s for motor vehicle manufacturing, which are just three of the components that can be made on high-tech machines. The result is a manufacturing solution for scalable requirements om initial series production to the high-volume production of complex workpieces.

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| igus GmbH

A look into the MULTISPRINT shows the complex energy supply system from igus, completely mounted on the spindle drum of the machine.

The combination of three types of machine technology enables the customer to engage in entirely new forms of production. There is maximum flexibility for the mass production of components with a diameter of up to 50 millimeters. The igus readychain, two meters wide and weighing 750 kilograms, powers the

machine. Among the first challenges for engineers was ensuring that the energy chain system fit into the housing of the machine. The system includes eight energy chains, 64 electric cables, and 73 hoses. The construction has a 1.8-meter-high body for rotation. Six linear energy chains for driving the spindles protrude

om the body like arms. Li ing the unit, which requires the assistance of two cranes, and connecting the readychain to the spindle drum, requires about two hours. During product development, technicians and engineers worked for nearly five months to design and assemble the machine, test it, and send it on its travels. It was finally unveiled at EMO in Hannover, Germany. The heart of the machine is the spindle drum with six spindles for the simultaneous machining of several workpieces. The main spindles in the drum can travel up to 180 mm.

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Design Notes The drum moves the workpieces to the tools quickly and precisely. It only takes 0.65 seconds for one of the six spindles to travel to the next position. For spindles to return to the starting position a er machining has been completed in the six stations, the drum must turn 300Â° in reverse. Despite weighing more than three metric tons, the drum completes the rotation in just one second. The rods are pushed out of the loader through the drum to get into position for machining. The drum in the MULTISPRINT rotates in a range of 300Â° and consists of two rotation systems. The outer system includes hoses with a bend radius of 160 mm. Twelve encoder cables and 12 servo cables are guided on the inner circle. For each of the six linear chains in the drum, there are two encoder cables and two servo cables. One of the servo cables supplies the energy for the linear movements of the main spindles in the drum, and one drives the spindle motor. They can move at a speed of 0.66 m/s and with a maximum acceleration of 10 m/s2.

| igus GmbH

The six energy chain systems can be plugged in individually due to distribution boards and are easy to maintain or modi . That feature was also one of the main requirements for the mechanical engineers that designed the product. In addition, the chains and cables of the readychain needed a relatively small installation space. It is important to ensure that the working space for the mechanical components behind the drum is as large as possible. In summer the of 2016, DMG MORI invited bids for the project and chose to collaborate with igus. The first meetings took place in January 2017, and two igus engineers visited Italy for a week. DMG MORI and

For installation of the harnessed cables in the energy supply chains and the metal guides, the technicians in Cologne need approximately 2.5 days.

Many technicians were involved in the development of the new type of machine. In the picture: Mirko Passerini, Fabrizio Corti, and Luca Milesi from Gildemeister Italiana and Volker BeiĂ&#x;el from igus (f.l.t.r.).

igus engineers shared ideas and solutions regarding the design and suitable cables and hoses for supplying the drum with energy, data,and fluid. Engineers had three months to develop the system. During development, the modularity of the individual components was paramount. The linear chain systems can be plugged in and the sheet-metal parts, for attachment to the machine, are made of several parts. This configuration facilitates the handling of the readychain on the customerâ&#x20AC;&#x2122;s premises and makes harnessing in the igus factory easier. Specialists needed a little more than two days to complete the final assembly of the chains with the harnessed cables and hoses. For fast production, it proved helpful that 95% of the readychain consists of parts directly made or procured. Assembly is also supported by the readychain rack, which is a metal ame with four different functions. It is an assembly tool for the connection of components and makes the entire construction stable. The rack fits onto the load bed of a small truck. On the customerâ&#x20AC;&#x2122;s premises, the rack enables easy plug-and-play connection of the fully harnessed energy chain to the machine. â&#x20AC;&#x153;Before delivery, the entire system was tested for weeks on end,â&#x20AC;? says Lukas Czaja, Head of Industry Management Machine tools at igus. A specially developed test stand simulates the movements of the multi-spindle automatic turning machine. In testing in a realistic environment used, the readychain has already completed more than 800,000 cycles without any problems. DW

igus | www.igus.com 44

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Design Notes

Linear guides for 5-axis milling application

Edited by Mike Santora • Associate Editor

THK’s Type SRS15 LM Guide installed in the Pocket NC

As components are growing smaller, developers are dreaming bigger. Reduced sizing and pricing of parts has opened the door to more innovations om engineers and inventors and is giving greater access to end-users. In 2011, recognizing the need for a compact 5-axis milling machine, Pocket NC founders Matt and Michelle Hertel started designing the Pocket NC. With backgrounds as a machinist and a mechanical engineer, the husband and wife team developed the first 5-axis milling machine designed for desktop use. They launched the Pocket NC on Kickstarter in 2015. The company solely manufactures, assembles, and distributes the Pocket NC om its 6,500 sq. . Bozeman, Montana facility. “In the past, the drive that controls the motors would have been as big as the machine and it would have cost significantly more. Today, the electronics that allow motor control are a quarter of the size and a small percentage of the cost,” explained Hertel. This is true of other Pocket NC components as well.

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THK’s Type RAU Cross-Roller Ring is used in the A and B-axis of the Pocket NC

Hertel specified THK LM Guides based on previous experience. “I had used mechanisms om just about every company out there and learned what components I like for various reasons,” continued Hertel. “Our decision to use THK linear guides was based on accuracy, ease of assembly, and how consistent they are om one rail to another.” With a rail as small as 7 mm, the Type SRS Miniature LM Guide is optimal for the Pocket NC application. The incorporation of Caged Technology, where a synthetic resin cage with a curvature that cradles each ball and separates it om the next, ensures smooth motion as well as increased speed and accuracy, low dust generation, and long life. The spaces between the rolling elements retain grease and act as a lubrication system for maintenance ee operation. The guides keep the balls om rolling against each other or falling out. Other LM guides created problems during the assembly process. With the Type SRS, the bearing cars could be removed and the linear rails installed with the balls remaining in place. The X-axis and Y-axis of the Pocket NC use two THK Type SRS9 LM Guides, while the Z-axis uses one THK Type SRS15 LM Guide. Pocket NC designed its machine with an additional component to further ensure precision. The RAU CrossRoller Ring is used for the rotary axes to provide stable and accurate rotation. Incorporated in the A-axis and B-axis of the Pocket NC, the spacer retainers of the micro-size roller ring enable smooth movement and high rotation precision. Using a 10 mm inner diameter and a 21 mm outer DESIGN WORLD

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January 2020

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Design Notes

The Pocket NC V2-50DA trimming a dental aligner

diameter, the Type RAU is more compact, lightweight, and rigid than a double row angular contact ball bearing type. RAU rollers travel on V-shaped raceways ground into the inner and outer rings. Alternating rollers are arrayed orthogonally so that one bearing can support loads and moments in any direction. Prototype labs make up 40% of the Pocket NC market, while the education industry makes up 50% of the market. Recognizing the value in a desktop milling machine, more and more universities are adding Pocket NCs to their manufacturing lab equipment list. “Engineering students don’t usually have access to full-size machines. The Pocket NC gives them access to, and experience with, using an actual milling machine,” said Hertel. Individuals make up the remaining 10% of the Pocket NC market. The Pocket NC operates with most common CAM so ware packages

and is available in V2-50 and V2-10 models, each with a 16 x 8- footprint. The Pocket NC V2-50 is suitable for fast, narrow, and deep machining. Applications include jewelry, medical, and dental, including prototypes. Some specifications: 1,000-50,000 RPM spindle speeds, tool diameters up to 1/8-in. (3.2 mm), ER11 collet, spindle runout 0.0005-in. (12.7 µm).

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The Pocket NC V2-10 is a lower-cost option. Also: 2,000-10,000 RPM spindle speeds, tool diameters up to ¼-in. (6.35mm), CHB (1/8-in., 3 mm, 4 mm) collet, spindle runout 0.000-in. (2.5 µm). DW

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Design Notes

Insert molding, especially on a vertical molding press, can hold tight tolerances while also offering design flexibility. These machines provide quicker cycle runs and the option of running up to twelve different molds on one machine at the same time.

Medical Sector sees opportunity with vertical injection molding Edited by Mike Santora â&#x20AC;˘ Associate Editor

The medical sector has embraced the technological advances recently seen in the plastic injection molding space. Insert molding, especially on a vertical molding press, can hold tight tolerances while also offering design flexibility. These machines provide quicker cycle runs and the option of running up to twelve different molds on one machine at the same time.

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Medical manufacturing and the medtech industry are constantly seeking fresh perspectives on healthcare device technology. Manufacturing advances like bookmolds continue to help the medical device companies bring safe and innovative solutions to patients.

These two benefits typically persuade medical device engineers to work with companies that offer vertical injection molding, rather than horizontal molding. Many of today’s new healthcare devices are made om a combination of thermoplastic resin and specialty medical components like cannula, tubing, wires, cables, stampings, and delicate sensors. Advances in molding technology have offered the ability to mold delicate components directly into the devices, rather than being incorporated later through machining, gluing, or ultrasonic welding. While this technology might not be brand new, the process has been reinvented with the use of book molds. The vast majority of vertical molding equipment on the market is configured

with the top half of the mold attached to the upper platen of the molding machine. The top then closes down with force onto the bottom plate. Traditionally, it is o en difficult to hold delicate inserts in place during the injection molding process (even more so with horizontal molding machines). The possibility for delicate inserts to be interrupted or misplaced is o en greater than what manufacturing managers would like to admit. The inserts loaded in the bottom half must be held securely in place so that when the top closes, neither the mold nor the delicate insert is damaged. Damage to the mold can be substantial, especially when the two halves close under high tonnage around steel or other

rigid materials — it is crucial to locate and secure components in place carefully during molding. Still, factors such as operator misplacement or shuttle/rotary table vibration can mean damage to the mold or the inserts. A solution that has helped eliminate these complications is using bookmolds mounted on a rotary table press. Bookmolds have become prevalent in the production of medical devices, specifically for medical injection molding. Book Molds differ om traditional molds as they are typically hinged to each other and open/close like a book (hence the name). These molds can be used on traditional vertical presses, but are commonly found on vertical molding machines with rotary tables.

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Design Notes Bookmolds are mounted to vertical clamp/vertical injection molding machines that have multi-station rotary tables. The molds consist of top and bottom mold halves that are connected by a hinge in the back so the top half can be li ed open. The hinge is the lynchpin of the mold and ensures each opening and closing is the same regardless of the type of machine it is on. Like conventional molds, bookmolds may have taper locks to maintain alignment between both halves and avoid shi ing. A tapered sprue bushing is located on the top of the mold so that when the mold is opened, the sprue and runner will remain in the bottom half. Ejectors are installed in the bottom half to li out finished parts along with the sprue and runner, so multiple cavities are o en well suited for bookmolds. A handle is o en mounted on the top half

for easy opening, which can be done either manually by the press operator, or with a stationary ramp. Medical manufacturing and the medtech industry are continually seeking esh perspectives on healthcare device technology. Manufacturing advances like bookmolds continue to help the medical device companies bring safe and innovative solutions to patients. Additionally, one service that benefits om bookmolds is overmolding. Overmolding is o en confused with insert molding as it is performed on the same injection molding machines. Overmolding vs. insert molding is less complicated than commonly thought. Overmolding is a subset of insert molding. All overmolding is insert molding, but it does not go both ways. There are many different preferences to what shops call overmolding and insert molding. Insert molding is o en when a

pre-produced part is inserted into a mold and receives a mold around it. Overmolding is a similar process, but it is typically when a part needs a second operation over the initial insert molding. It is still an insert molded product but referred to as overmolding. Overmolding vs. insert molding is also commonly referred to as “injection molding with a second operation,” or “insert molding with an overmolded sequence.” For a medical device engineer, the manufacturing process should always be at the fore ont of his/her mind as manufacturing costs quickly rise with the complexity of each part. The best way to keep manufacturing efforts efficient and affordable is to find a capable vertical molding manufacturer to help through the entire process. DW

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Design Notes

The importance of correct entry radius with shoulder bolts Edited by Mike Santora • Associate Editor The solution — introducing an entry radius and deforming the pre flanging area 80° — resolved the issues without impacting the material thickness and hence triggering any incremental material or assembly costs.

A er buzz squeak and rattle testing (BSR) analysis, an OEM discovered failures in its seating system. The issues included axial play in the seats and noise emanating om the seating system assembly. The OEM vendor reported that the issue was the seat mechanism of its Technymon MR-5 Sliding Bearing. The MR-5 Sliding Bearing in question is comprised of a zinc plate, low carbon steel, and thick PTFE tape. The tape prevents metal-to-metal contact and provides selflubrication. It is used in seating mechanism pivots including the upper and lower height adjuster pivots, folding pivots, the back-rest angle adjustment, (recliner mechanism) and the headrest. These bearings are designed to accommodate high static load, eliminate noise, and dampen vibration. They enhance the comfort level as well as extend the life span of the system components. But a er opening the seat mechanism for further inspection, the OEM also discovered that the bushing PTFE tape was missing. The absence of PTFE tape contributed to the axial play and direct metal to metal between the sha and the

January 2020

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Design Notes

The MR-5 Sliding Bearing in question is comprised of a zinc plate, low carbon steel, and thick PTFE tape.

backing layer of the low carbon steel, causing the noise. That’s when the company chose to incorporate Technymon MR-5 Bushings. As part of its investigation, the Technymon technical team visited the OEM’s site and collected the MR-5 Sliding Bearings, veri ing the PTFE tape adhesion test with steel. The team concluded that the integrity of the samples — its adhesion and dimensions — were acceptable. Next, the team analyzed the customer’s components, including the sha (shoulder bolt) and housing (link). A er exhaustive testing, the technicians concluded that the sha (shoulder bolt) was missing its entry radius, which was damaging the PTFE tape during the assembly of the bushing inside the housing (link). To address this performance issue, the

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ISO 9001 • ISO 13485

EAGLE STAINLESS Tube & Fabrication, Inc. team recommended incorporating an entry radius on the sha . A er this modification was introduced, the technical team revisited the OEM’s site and discovered that during the assembly process, the housing (link) fitment for the pre-flanging operation was faulty. Consequently, during the bolt tightening to fix the link with the seat mechanism sliding bearing backing layer, which is made up of low carbon steel, there was cracking at the pre-flanged area and damage to the PTFE tape. To address these issues, the OEM recommended replacing the material with a thicker low carbon steel backing to prevent cracking. Still, the Technymon team advised the client that this would increase the product cost. Next, the team noticed that the customer was assembling the 90° pre-flange forming in one step and recommended that it be changed to two steps, which would preserve the integrity of the material without compromising the PTFE layer. This solution posed an assembly cost increase. Finally, working with the OEM’s technical team, the Technymon technical team arrived at a cost ee solution: Deform the pre-flanging area with a maximum 80° deformation in one step, with the remaining deformation during the bolt tightening to be fixed at 90°. The problem arose when a heavy load was applied against the link surface on the sliding bearing, which resulted in uneven PTFE deformation. This uneven deformation caused the PTFE to tear, destroying the adhesion of the low carbon steel, and subsequently causing noisy axial play. The solutions — introducing an entry radius and deforming the pre flanging area 80°— resolved the issues without impacting the material thickness and hence triggering any incremental material or assembly costs. The OEM produced its seating system with the new solution. Subsequent BSR testing revealed that the changes had proved effective. DW

With the advanced technology and the expertise to deliver stainless steel exactly as you want it. Extensive tubing inventory Eagle stocks stainless, copper, brass and aluminum in metric, hypodermic and fractional tubing in an extensive assortment of grades. Cut-to-length tubing - Eagle can cut and de-burr any diameter in quantities from 1 piece to millions from lengths of .040” and longer with a standard tolerance of ±.005 on diameters of less than 1”. Closer tolerances are met quite often. Talk to us!

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CAE Solutions A look at version 5.5 of COMSOL Multiphysics

Elastic chain drive analysis in the Multibody Dynamics Module. Colors and arrows show the velocity and velocity direction, respectively, in the chain and sprockets.

In version 5.5 of COMSOL Multiphysics, the Design Module has an entirely new sketching tool for easier creation and more versatile parametric control of geometry models. New and updated solvers speed up a range of simulations. Two new add-on products, the Porous Media Flow Module and the Metal Processing Module, further expand the so ware’s multiphysics modeling power. Parametric sketching with dimensions The Design Module’s sketching tool makes it easy to assign dimensions and constraints to planar drawings for 2D models and 3D work planes. “We have carefully integrated the new dimensions and constraints tool in the Model Builder so that it becomes a natural part of the COMSOL Multiphysics workflow,” said Daniel Bertilsson, technology manager for mathematics and computer science at COMSOL. “The new tools for dimensions and constraints can be used together with model parameters in COMSOL Multiphysics to drive the simulation, whether for a single run, parametric sweep, or parametric optimization.” Acoustics simulations Ultrasound technology is becoming increasingly important in a range of applications spanning om process engineering and nondestructive testing to consumer electronics. New functionality based on the time-explicit discontinuous Galerkin method enables efficient multicore computations of ultrasound propagation in solids and fluids, including realistic materials featuring damping and anisotropy. The method also has low- equency applications, such as in seismology. The included multiphysics capabilities can seamlessly combine linear elastic wave propagation in a solid and

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its transition to a fluid as an acoustic pressure wave, and back again. The elastic wave functionality is available for users of the Structural Mechanics Module, MEMS Module, and Acoustics Module. The fluidstructure acoustics coupling is available in the Acoustics Module. For equency-domain simulations, a specialized solver for wave propagation analysis makes it possible to handle higher equencies (shorter wavelengths) using the finite element method. The new solver can be used to analyze enclosed structures such as that of a car cabin interior as well as other acoustics simulations. The Metal Processing Module The new Metal Processing Module makes metal phase transformation analysis accessible within the COMSOL Multiphysics environment for applications within welding, heat treatment, and metal additive manufacturing. “The Metal Processing Module makes it possible to predict deformations, stresses, and strains resulting om wanted or unwanted heat-driven phase changes in metals,” said Mats Danielsson, technical product manager at COMSOL. “The module

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Simulation of a packed bed latent heat storage tank, using the Porous Media Flow Module.

can be combined with any of the other COMSOL products for virtually any kind of multiphysics analysis that includes metal phase change. We envision users combining this with, for example, the Heat Transfer Module for the influence of heat radiation, the Ac/dc Module for induction hardening, and the Nonlinear Structural Materials Module for highly predictive analysis of material behavior.”

Shown: Rugged Melcher™ RCM500 Series

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The Porous Media Flow Module The Porous Media Flow Module gives users within, for example, food, pharmaceutical, and biomedical industries a range of transport analysis capabilities for porous media. The new add-on product includes functionality for single- and multiphase flow in porous media, drying, and transport in actures.

» Output Voltages : 12 / 15 / 24 V » Output Power : 60 / 150 / 300 / 500 / 1000 W » High Efficiency and High Power Density

Shape optimization of a sheet metal bracket using the Optimization Module. The structure is subjected to a bending load resulting in ridges in the optimal design.

» Input, Output and Auxiliary Connectors » Compliant to EN 50155, EN 45545 and AREMA

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CAE Solutions The flow models cover linear and nonlinear flow in saturated and variably saturated media with special options for slow and fast porous media flows. The multiphysics simulation capabilities are extensive, with functionality that includes options for calculating effective thermal properties for multicomponent systems; poroelasticity; and transport of chemical species in solid, liquid, and gas phases.

thickness optimization. A new smoothing operation for topology optimization ensures higher-quality geometry outputs that can be used for additional analysis and additive manufacturing. COMSOL Multiphysics now has general support for import and export of the additive manufacturing formats PLY and 3MF, in addition to the STL format that is already available.

Simplified Shape and Topology Optimization with the Optimization Module The Optimization Module offers simplified setup of shape optimization with new built-in features such as moving boundaries parameterized by polynomials and built-in support for shell

Nonlinear Shell Analysis, Pipe Mechanics, and Random Vibration Analysis A range of nonlinear analysis options are available for shells and composite shells, including plasticity, creep, viscoplasticity, viscoelasticity, hyperelasticity, and mechanical contact. The mechanical

Sound pressure field in a car interior solved with the finite element method at 7 kHz using a specialized solver for wave propagation analysis.

• Full diagnostic options for reduced machine downtimes • Open communication for high ﬂexibility • Innovative software solutions for easy conﬁguration, programming and visualization • High scalability for individual solutions • One system for safety and automation

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CAE Solutions contact modeling functionality has been extended to support any combination of solids and shells, including solid-shell, solid-composite shell, and membraneshell. Depending on the type of analysis, these improvements will be available to users of the Structural Mechanics Module, Nonlinear Structural Materials Module, and Composite Materials Module. For users of the Structural Mechanics Module, a new user interface for pipe mechanics provides functionality to perform stress analysis of pipe systems. The new functionality can handle a variety of pipe cross sections and can include effects om external loads, internal pressure, axial drag forces, and temperature gradients through the pipe wall. Users can now perform random vibration analysis to study the response to loads that are represented by their power spectral density (PSD). This allows users to include loads that are random in nature, such as turbulent wind gusts or road-induced vibrations on a vehicle. The loads can be fully correlated, uncorrelated, or have a specific usergiven correlation. The Multibody Dynamics Module provides new functionality for analyzing rigid and elastic chain drives with

Residual stresses in a spur gear after quenching, calculated using the Metal Processing Module.

automatic generation of the large number of links and joints needed for modeling chain drives. Compressible Euler Flow and Nonisothermal Large Eddy Simulations Users of the CFD Module will get new interfaces for compressible Euler flow and nonisothermal large eddy simulations (LES). In addition, the flow interfaces for rotating machinery now support the level set and phase field methods as well as Eulerâ&#x20AC;&#x201C; Euler and bubbly flow. The Heat Transfer Module comes with a new interface for lumped thermal systems, an equivalent circuit modeling approach for heat transfer simulations. Radiation in semitransparent (participating) media now supports multiple spectral bands, and a new open boundary

formulation for convective flow reduces solution time by 30%. Multiscale Wave and Ray Optics, Piezoelectric Shells, and PCB Ports The Ray Optics Module can be combined with the RF Module or Wave Optics Module for simultaneous fullwave and ray tracing simulations. This enables multiscale modeling, such as analyzing a waveguide beaming into a large room, where using a full-wave simulation would be computationally prohibitive. Combining the AC/DC Module and the Composite Materials Module, users can analyze layered materials with both dielectric and piezoelectric layers in thin structures.

Parametric optimization of fluid flow in a microvalve using the new sketching tool with dimensions and constraints capabilities available in the Design Module.

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A revolution in linear transport systems: XTS NEXTSTEP The XTS advantage circulatory movement flexible modular system individually movable movers

User benefits reduced machine footprint software-based changeovers improved machine flexibility increased throughput shorter time to market

www.beckhoff.us/xts Manufacturers around the world need to offer increasingly customized products â&#x20AC;&#x201C; with machines that deliver reduced footprint and improved productivity. Available now in the U.S., the eXtended Transport System (XTS) from Beckhoff answers these machine design challenges and more. In combination with PC- and EtherCAT-based control technology, the XTS features a high level of design freedom for machine builders to develop game-changing concepts for product transport, handling and assembly. A stainless steel hygienic XTS version is ideal for use in the pharmaceutical and food industries. Take your next step in machine design with XTS: total freedom of installation position compact design integrates directly into machinery freely selectable track geometries few mechanical parts and system components

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CAE Solutions In the RF Module, a set of new ports for vias and transmission lines makes setup much quicker and gives more control to the user for modeling of printed circuit boards. Efficient Distribution of Standalone Applications COMSOL Compiler enables you to create standalone applications based on COMSOL Multiphysics models with specialized user interfaces that have been built with the Application Builder. Compiled applications require only COMSOL Runtime — no COMSOL Multiphysics or COMSOL Server license is required. The latest version of COMSOL Compiler has a new compile option for generating minimum-sized files for easier distribution. When the user launches an application for the first time, where the new compile option has been used, COMSOL Runtime is downloaded and installed, if needed, om COMSOL’s website. Only one instance of COMSOL Runtime is needed for applications using the same COMSOL version. COMSOL Runtime has a size of about 350 MB and an application file can be as small as a few MB. DW

Simplified Engineering

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CAE Solutions

Link3D and Autodesk offer fully integrated additive manufacturing workflow so ware

Link3D, with the cooperation of Autodesk, Inc., offers a fully integrated Additive Manufacturing (AM) workflow system using linked Autodesk so ware to enable end-to-end traceability. Key benefits: • Autodesk Fusion 360 and Autodesk Netfabb users will be able to associatively queue manufacturing ready CAD models in Link3D’s production scheduler – including attached information like support structures or CNC tool path data. • Users of Link3D’s production scheduler with active subscriptions to Autodesk so ware will be able to send manufacturing-ready files to 3D printers using Autodesk’s build processor technology.

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www.designworldonline.com

• Link3D Additive Manufacturing workflows are enhanced through detailed manual control in linked Autodesk’s data preparation so ware at any process step. • Users of Link3D with active subscriptions to Autodesk so ware can get linked access to Autodesk’s leading process simulation so ware, helping to ensure predictability and stability of Selective Laser Melting and Direct Energy Deposition builds.

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â&#x20AC;˘ Granular versioning and access control enables a full traceability of production data and workflow information â&#x20AC;&#x201C; helping to ensure immediate quality standards compliance Currently, many AM users still operate multiple tasks manually. They manage their AM files on disks, generate support structures in a siloed system and manage print jobs with spreadsheets. More o en, users load files with a USB key directly to the printers without leaving a digital record. With this cooperative effort, Link3D Additive MES connects bidirectionally into Autodesk Fusion 360 and Autodesk Netfabb and can be used in the downstream production process to manually alter and control the data preparation at all stages. This helps ensure proper versioning and access control, while the cloud-based process helps to ensure that no local files are created at any preparation stage. With an integrated solution using linked Link3D and Autodesk so ware, organizations can enable the â&#x20AC;&#x153;Digital Threadâ&#x20AC;? by streamlining ordering, build data preparation, scheduling and downstream manufacturing processes. When users have build platforms prepared with Link3Dâ&#x20AC;&#x2122;s 2D/3D nesting tool, they can queue or launch models into Netfabb for build preparation with a single-click. Furthermore, users can then automatically schedule builds om Link3D. All generated data will be automatically stored safely within the system.

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CAE Solutions

Meshmatic optimizes CAD files for real-time visualization Meshmatic is a 3D optimization so ware that helps engineers prepare design files for real-time visualization faster. A challenge with many large and complex engineering files is having to manually clean and optimize them for 3D rendering or AR/VR development. Such tasks are o en repetitive and tedious, as well as prone to human error. Meshmatic is standalone so ware that automates tedious optimization tasks and helps companies save time when cleaning up heavy and complex design files for simulation and AR/VR applications. It works with applications such as Keyshot and V-ray or game engines like Unreal Engine or Unity. The so wareâ&#x20AC;&#x2122;s proprietary algorithms mathematically calculate the rotation, position, and scale of each of the 3D objects in a scene and groups them for duplicate instantiation or further modification. This method of calculation is useful for CAD conversions such as FBX or OBJ, with reset transformation. Meshmatic reads 3D data om common file formats such as FBX, OBJ, STL, Sketchup, STEP and more, and processes them as polygonal mesh without harming shape integrity. Multiple data clean-up tools help users efficiently reduce file complexity without compromising the quality of the visualization or accuracy of the data. In addition to its mesh, hierarchy clean-up and duplicate optimization tools, Meshmatic is equipped with data analysis tools to identi bottlenecks and errors in a file, which can be resolved with suggestive actions. The so ware also provides updates on file parameters such as file size, vertex count, face count, and more to help users track performance improvement during the clean-up and optimization process. DW

VRSquare | meshmatic3d.com

January 2020

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CAE Solutions

nTop Platform 2.0 overcomes the geometry bottleneck

The nTop Platform 2.0 is an engineering so ware that helps engineers simultaneously consider geometry, performance and manufacturability within a single, reusable workflow. This release includes support for prepackaged, application-specific nTop Toolkits. The so ware was developed to solve engineering problems where geometry is a bottleneck. It can handle complexity and iteration quickly and easily. The prepackaged Toolkits and authoring capabilities can be used to automate engineering workflows, delivering efficiencies and scaling an organization’s best talent across the enterprise. Teams can automate tasks that take hours, days or weeks with traditional design tools because of the ability to build reusable workflows. In addition to the Toolkits, nTop Platform’s authoring capabilities allow engineers to create their own proprietary toolkits, enabling secure knowledge transfer across the organization.

Lightweighting Toolkit

• • • 70

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Quickly and easily reduce the weight and maximize the performance of parts. Shell parts in seconds no matter how complex the geometry. Apply variable wall thickness to shelled parts.

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Architected Materials Toolkit

• • •

Engineer functional materials that perform at any scale—hundreds of unit cells, or hundreds of billions. Design with multifunctional requirements om the start. Structural, thermal, acoustics, or aesthetics; all with total control at any length scale. Optimize unit cells to create unique material properties to perfectly suit the application. Increase surface area while reducing weight. Turn geometric complexity into a competitive advantage.

Design Analysis Toolkit

• • •

Use fully integrated simulation capabilities to seamlessly analyze parts in a single, connected workflow. Drive geometric parameters directly om simulation results to achieve highperformance parts that meet functional requirements. Integrate with the simulation tools an organization already uses, including ANSYS, Abaqus, and Nastran.

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• • •

Discover new and innovative designs early in the product development cycle. Apply multiple loading conditions and optimize for a variety of performance criteria including stress, displacement, stiffness, and weight. Use automated geometry reconstruction tools to quickly generate instantly editable geometry.

Additive Manufacturing Toolkit

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Position, orient and prepare parts for additive manufacturing om a set of common build platforms. Add lattice support structures easily and quickly Slice parts avoiding error-prone STL files and export manufacturing data directly to machines

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CAE Solutions

Simufact improves metal additive manufacturing efficiency

Simufact Additive 2020 is for the optimization of metal-based additive manufacturing (AM) processes. It provides cost estimation of the build process, and improves interoperability with Materialise build preparation so ware and Renishaw printers to streamline manufacturing processes. Simufact Additive 2020 expands the scope of manufacturing simulation. In addition to designing and optimizing the build process virtually, users can estimate print job costs for single components or assemblies. The so ware also includes features for subsequent processes such as cutting, machining, drilling and grinding. This helps the user identi the best build variant by taking into account printing costs. Simufact Additive 2020 interfaces to Materialise using the 3MF industry standard 3D printing data exchange format. 3MF enables simple and reliable data transfer with thirdparty so ware and considerably reduces timely efforts for the model set up. Simufact Additive 2020 includes an integrated Renishaw QuantAM API for build job preparation and export, which provides the user an error- ee-data transmission om Simufact Additive directly to Renishaw printers. This function also improves productivity because the entire work process om design to printed part is possible within the so ware. More interfaces are under development to allowing easy connection to other printing machines.

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CAE Solutions This so ware release applies Adaptive Voxel Meshing technology to improve the simulation speed by automatically adjusting the voxel sizes in the part. Another release highlight, Hybrid Manufacturing helps manufacturers to combine Powder Bed Fusion additive manufacturing processes with conventional manufacturing. Simufact Additive 2020 makes it possible to define a given part upon which the printing will begin, including any internal stresses. Thus, stresses and distortions of the complete assembly, and all single parts can be investigated. DW

Hexagon | Simufact www.simufact.com/whats-new-in-v2020

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Internet of Things

Implementing IoT one step at a time

| AdobeStock.com

By: Don Eberly

The global metals industry expects to grow by 2.7-3.4% year over year. This growth is enabling companies to reopen shuttered mills, expand current plants, and build new ones while new companies enter the industry. As competition heats up, companies must continually seek new ways to heighten efficiencies and control costs. Executives at Kloeckner Metals Corp., one of the largest metal service centers in North America, are making strides by implementing technology that will bring about Industry 4.0 and digitalization. “The metals industry is a commodity-driven market and industry. It is extremely competitive. There are low barriers to entry and thousands of competitors. The only way to succeed is to find efficiency,” explains Matt Meyer, Vice President of Digital Innovation for Kloeckner Metals Corp.

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However, he says, “The traditional ways to derive efficiency have been exhausted. Many in the manufacturing and distribution fields have spent years trying to drive costs out of their organizations.” Meyer believes that implementing Industry 4.0 and digitalization will keep competitiveness high. By focusing on digitalization across the entire supply chain, Kloeckner Metals personnel work to extract efficiencies om the shop floor, shipping and receiving, inventory tracking and reordering, as well as manufacturing.

www.designworldonline.com

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1/18/20 2:23 PM

When technology and expertise come together Phoenix Contact’s expertise spans a wide range of applications so that you can make power, control, and network connections with absolute confidence. For bringing power to a device or power to a cabinet, discover the new capabilities within the popular M12 connector family – now capable of 16 amps with 4 positions plus ground. It’s a small size with big power from your trusted source, Phoenix Contact. Get amped!

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Internet of Things Defining Digitalization McKinsey & Company, a global management consulting firm, defines Industry 4.0 as â&#x20AC;&#x153;the next phase in the digitalization of the manufacturing sector, driven by four disruptions: The rise in data volumes, computational power and connectivity; The emergence of analytics and business-intelligence capabilities; New forms of human-machine interaction, such as touch interfaces and augmented-reality systems; and Improvements in transferring digital instructions to the physical world, such as advanced robotics and 3-D printing.â&#x20AC;? Kloeckner Metals takes a simpler view. â&#x20AC;&#x153;If you Google Industry 4.0, itâ&#x20AC;&#x2122;s all about the Internet of Things (IoT), machines talking to machines, and it sounds like a beautiful future place,â&#x20AC;? states Meyer. â&#x20AC;&#x153;We are more pragmatic in our definition RHAM-MKT QRAM PRINT Ad #1 2018-11-21 v1-0.pdf

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of the plantâ&#x20AC;&#x2122;s greatest challenges. The 166,000-square-feet facility houses thousands of SKUs of material, which are constantly on the move. It was challenging to keep accurate records of material movement. â&#x20AC;&#x153;We spent too much time locating one SKU,â&#x20AC;? Meyer says. â&#x20AC;&#x153;We put sensors throughout the factory and purchased Bluetooth tags, and put them on all products, finished goods, and raw material.â&#x20AC;? This produced a clear read on exactly where everything was located, saving time and energy. Today, workers locate SKUs within eight minutes, just three minutes shy of the companyâ&#x20AC;&#x2122;s original goal of five minutes. â&#x20AC;&#x153;It is a dramatic improvement made possible by strategic digitalization,â&#x20AC;? says Meyer. One challenge the team encountered was that of the reflectivity of metal

because [in the metals industry] there is a big gap between where we are today and this perfect world of Industry 4.0.â&#x20AC;? Initially, Meyer and his team will focus on applying Industry 4.0 for supply chain automation. â&#x20AC;&#x153;Itâ&#x20AC;&#x2122;s about employing technologies to drive efficiencies throughout the supply chain,â&#x20AC;? he says. The final phase of change will be on manufacturing. Tech for success The German-based distributor, which has operated in the U.S. since 1975, is beginning efforts at a factory in Tulsa, Oklahoma. A er examining the movement of material throughout the facility, the company began leveraging radio- equency identification (RFID) and Bluetooth technology to keep tabs on every piece of metalâ&#x20AC;&#x201D;at any given time. The move solved locating materials, one 10:54 am

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interfering with wireless signals. So, the team worked to develop a custom Bluetooth tag. Next steps involved continually optimizing the so ware to achieve required levels of accuracy. Kloeckner has since integrated RFID into every service center to better understand the flow of materials, personnel, and machines, while achieving greater efficiencies in maintenance and safety. The final phase of charge toward Industry 4.0 will be in its manufacturing facilities. Kloeckner hopes to put sensors on all equipment to better understand machine failure points and predict downtime. Meyers says, â&#x20AC;&#x153;These areas in production and digitalization will be powerful. We currently operate on years of experience to properly maintain equipment and reduce downtime.â&#x20AC;? This change will be slower and more capital intensive. Much of the equipment in the metals industry is older. â&#x20AC;&#x153;This equipment was built long before everything was wired up and there were outputs coming om the machines themselves,â&#x20AC;? Meyer says. The company has automated some processes on the factory floor; operators no longer must input job numbers, time of production, and other parameters into the ERP, for example. Workers also analyze data for predictive maintenance. While Kloeckner Metals isnâ&#x20AC;&#x2122;t quite at the intelligent factory level yet, it is on the docket. The plan involves the need to add sensors to equipment; pull data off the equipment; understand the data; and allow the machines to talk to one another. Once that happens, they can begin to automate processes between machines. â&#x20AC;&#x153;Kloeckner is a few years away om that world,â&#x20AC;? Meyer says. â&#x20AC;&#x153;Right now, weâ&#x20AC;&#x2122;re just trying to better understand the machines and how we focus our efforts for tangible results. Eventually, weâ&#x20AC;&#x2122;d like to use technology to allow one process to automatically drive the next process in the supply chain.â&#x20AC;? He adds, â&#x20AC;&#x153;That is really the goal of the intelligent factoryâ&#x20AC;&#x201D;machines talking to one another.â&#x20AC;? Meyer predicts automated ordering will be the next ontier. Most customers operate in a visual Kanban methodology. They keep three skids, and when they get down to one, they reorder using tablet computers provided in Kloecknerâ&#x20AC;&#x2122;s Parts Manager Program. Once machine-to-machine communication exists, the machines signal when it is time to replenish goods. â&#x20AC;&#x153;The future is to skip the ordering step and signal skids automatically, so that when a customer pulls a skid om storage to production, we automatically enter a replenishment order,â&#x20AC;? he says. â&#x20AC;&#x153;A lot of the big OEMs know this is the future, but getting there is the challenge.â&#x20AC;? DW

Kloeckner Metals Corp www.kloecknermetals.com DESIGN WORLD

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Internet of Things

Innovative EEG device helps you visualize mental activity and control IoT devices with brain waves

Backed by powerful so ware, the nūrio EEG device gives one an in-depth look at the activity of the mind anytime, anywhere. It uses AI algorithms that let users transform thoughts into commands to control things, such as IoT devices connected to the nūrio cloud. The proprietary architecture allows BrainComputer Interfaces to control most devices with internet connection. Nūrio is the world’s smallest wearable consumer EEG device. It simply slips over the ear like a headphone and provides consumers with app- and cloud-based command capabilities, comparable to Alexa Skills, but with just their brain waves – no voice commands required. According to the developers, Nūrio streams data collected om users’ mental activity via Bluetooth to any smartphone, enabling consumers to visualize their brainpower and gain health insights on the nūrio mobile app. Device data is instantly processed with the nūrio app, changing into streaming metrics about a user’s mental health/state such as attention, calmness and emotional levels. All metrics are derived om raw EEG data using in-house

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algorithms based on years of neuroscience research studies. The app can record the sessions of metrics which users can take to graph insights of attention during any focus-based task, calmness during meditation, or emotions during any type of performance or experience. Finally, nūrio uses machine learning to develop baselines of the users’ mental states to help alert them to changes over time. “We aim to provide the world with access to their mental data to help better understand the previously mysterious mind,” said nūrio founder and CEO Ian Rowan. “We’re entering a new era of leveraging the mind to control the connected world, no matter of a person’s physical abilities.” The other main component of the nūrio device is the ability to control internet-connected devices with the mind. Users can add compatible IoT devices to their profile, record approximately one minute of thoughts based on that object, and leave it to the powerful AI algorithms to process their future waves into actionable commands. A er set-up, the user can simply blink twice to trigger the device to begin recording a thought, then sent to nūrio servers which process the raw wave into the user’s device, and finally the device is triggered or the user is prompted to confirm a command with a blink based on configuration. All of this typically happens in under two seconds. As the wearables industry continues to proliferate, nūrio believes opportunity lies in looking at data om new angles to reveal insights into what’s going on in various parts of our bodies and using that information to optimize our health in new ways. The nurio idea was innovative enough to be the latest Protolabs Cool Idea Award winner for innovation in consumer technology. The award will help the developers of nurio keep costs down so that this technology can be accessible to the general population. With the award, nūrio has been able to significantly expedite production, putting the device on-track to come to market in mid-2020 for under $229 USD. Protolabs also helped manufacture the full plastic casing of the nūrio device with injection molding. In the future, nūrio will also work with Protolabs to produce its own essential electrodes via CNC machining once the design is complete. “Nūrio’s technology has the potential to completely redefine the quantified self and even tap into human capabilities that previously seemed impossible,” said Vicki Holt, President and CEO of Protolabs. “We’re proud to support such innovators who are giving people the ability to leverage their brain power in new and helpful ways.” DW

sales@hotwatt

Protolabs | protolabs.com

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Internet of Things

An easy way to implement ASi-5 The ASI4U-V5 ASSP is a silicon approach to fully implement the ASi-5 (Actuator Sensor Interface version specification version 5) standard for industrial network equipment. ASi-5 offers 1.27 ms cycle time, 200 m cable length and 96 slaves per segment. The ASSP delivers an easy-to-use fieldbus integration option for developers working with sensors, actuators, and other industrial equipment requiring easy and cost-efficient fieldbus connectivity. The new ASI4U-V5 ASSP features verified and field-proven firmware that reduces the complexity associated with ASi-5 implementations, allowing users to minimize design risks. The ASSP is fully backwards compatible with ASi-3 devices while incorporating the shorter cycle times, higher bandwidth resulting om the use of Orthogonal Frequency Division Multiplexing (OFDM), enhanced diagnostics, and state-of-the-art robustness associated with the ASi-5 standard. The ASSP also supports all bus topologies, including line, star, and tree. Users can take advantage of easy and cost-efficient integration with other industrial protocols such as IO-Link and HART.

Key Features of the Renesas ASI4U-V5 ASSP • The integration of up to 96 devices and operation down to 1.2 ms cycle time with less than 10ns jitter compared with 5 ms cycle times for ASi-3 solutions • Support for up to 200m cable and 16 data bits per transport channel • Diagnostics and event handling for industry 4.0 applications • Backwards compatibility with ASi-3 devices • Exceptional robustness against electromagnetic disturbers • Fully verified and field-proven firmware enables easy integration, as no further programming of the chip is required. Mass production is planned for March 2020. DW

Renesas Electronics Corporation www.renesas.com/products/interface/ industrial-network-transceivers/ asi4u-v5.html

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Ethernet/IP enhanced to integrate IO-link devices Enhancements to the EtherNet/IP Specification outline how to integrate devices built to the IO-Link Communication Standard into CIPTM architectures. The addition of this capability allows for IO-Link sensors and devices at the lowest level of the network to be better connected with EtherNet/IP controllers and devices at higher levels of the network. IO-Link to CIP connectivity reduces engineering effort and eases the acquisition of data and information, helping to meet the demands that IT/ OT convergence bring to the factory floor. IO-Link devices can now be recognized within EtherNet/IP without the end user having the burden of data conversion. From the perspective of EtherNet/IP, an IO-Link device is

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viewed as a native CIP device sitting on a (virtual) subnet. The IO-Link Master provides the CIP capability for the IO-Link device, transparent to the originating CIP application. All three types of IO-Link communication (cyclic, acyclic, and events) are mapped to CIP communication types. CIP to IO-Link communication is possible with an unchanged IO-Link master and device

specification that is standardized within IEC. Direct communication is enabled via translation between CIP originators and IO-Link devices through the intermediate IO-Link master. All IO-Link devices are treated as if they were CIP Connection target devices (I/O Adapters) on a virtual IO-Link subnet. DW

ODVA | www.odva.org

1/18/20 2:31 PM

Internet of Things

Connecting OT and IT infrastructure

One of the challenges for those engaged in digitalization is connecting shop floor operational technology (OT) with IT in astructure; om machine building to plant visualization, automation, networking, robotics and data processing. One step in optimizing OT / IT connectivity is processing and using the large amount of data made available by shop floor equipment, such as sensors and PLCs. Edge computing devices, such as the MELIPC series, demonstrates both capabilities. It offers edge computing functions combined with OPC UA compatibility. Data can be pre-processed locally and aggregated to create information locally and can seamlessly connect the shop floor with higher level IT systems such as MES and ERP platforms. This capability enables machine builders to offer services that can be adapted to suit many different IT environments and has already been demonstrated working with Oracle, SAP, IBM and Microso Azure. The technology enables predictive maintenance requirements and identifies anomalies to improve productivity or the efficiency of existing equipment.

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www.designworldonline.com

Another application using the advantages of OT/IT connectivity is web-based â&#x20AC;&#x2DC;so ware as a serviceâ&#x20AC;&#x2122; (SaaS) predictive maintenance tools which are under development. The OT equipment that is generating data includes the latest PLCs. For machine builders looking for increasingly compact control solutions, the MELSEC iQ-F PLC series offers fully integrated control om one unit. At the opposite end of the scale the MELSEC iQ-R PLC series enables total control over a larger machine or a complete production line. Highly dynamic motion control for up to 264 axes of movement by the iQ-R is made possible using CC-Link IE TSN. DW

Mitsubishi Electric Factory Automation eu3a.mitsubishielectric.com/fa

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More storage capacity for smart devices With 4Mbit capacity, the EEPROM memories let small devices capture and store more data through the serial SPI bus. This enables equipment such as smart meters to intensi data logging for managing grids more effectively and providing more user- iendly billing. Portable medical devices can log patientsâ&#x20AC;&#x2122; data to improve care quality, and consumer devices such as smart wearables can support more user features and greater precision. In these applications, the memoryâ&#x20AC;&#x2122;s low power consumption helps extend battery runtime. A range of applications in industrial controls and communication in astructure such as network switches can also benefit om these higher density memories. The M95M04 EEPROM memories combine their unprecedented data storage with excellent energy efficiency for budget-conscious applications. They offer one billion full-memory read-write cycles. Capable of writing 512 Bytes in 5 ms, the new devices enable fast system operation with low latency. M95M04 EEPROMs provide highdensity non-volatile storage for

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persistent data such as application code, calibration tables, and user parameters, as well as for intensive data logging. Offering a high density in small 8-pin SO8N and TSSOP8 packages, they are costeffective. These include EEPROM-emulation memories that combine a microcontroller and Flash, ferroelectric FRAMs, and magneto-resistive MRAMs, which consume more power and have narrower supply-

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voltage range than CMOS EEPROMs. M95M04 EEPROMs benefit om a power supply range of 1.8V to 5.5V, as well as 40-years data retention, and a state-ofthe-art 8-bump WLCSP chip-scale package option in addition to SO8N and TSSOP8 packages. DW

STMicroelectronics www.st.com/content/st_com/en

January 2020

1/18/20 2:33 PM

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Motion controllers: Design from scratch or buy ready-made?

Motion control is similar to chess in that it takes minutes to learn the rules (allowing the creation of very basic indexing systems) but years to master the ability to perform advanced motion control. This article reviews different types of motion controllers currently on the market, and the pros and cons of each. Jeramé Chamberlain • Manufacturing Engineer Manager • Nippon Pulse America

The main job of any motion controller is to command the motion of a mechatronic assembly, including any motors and other mechanical components such as actuators. Whether control is needed for a simple point-to-point positioning application or for multi-axis interpolated moves, choosing the right motion controller can have lasting effects on the final product. A controller with insufficient computing power or capabilities that fail to meet a machine’s motion control needs can degrade that machine’s performance and abilities. On the other hand, overly powerful or robust controllers can add unnecessary system cost. Choosing a motion controller can have its challenges because they range in complexity and capability — from very simple indexing systems to full-fledged motion control systems. Indexing systems deliver simple control

An indexing system is a category of controller used for simple position or velocity control with very few if any other features. Indexing systems for the most part have no (or very limited) acceleration control, which limits the number of set speeds and types of acceleration that can be employed. The key feature of the indexer is that they are very

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inexpensive, as they typically consist of a microprocessor with a limited amount of code. These simple systems have become very popular in the hobby and maker markets due to the availability of open-source software, which has made indexing a project easy. However, one disadvantage to using an indexing system is that, while generating a speed and direction command is simple to do by toggling outputs on a microprocessor, more complicated motion profiles need more time and experience to master. This is because indexing systems are not really intended to function as complete motion controllers. Indexing systems are commonly used for motors with integrated controller and drive, sometimes called smart motors. Indexers are also very commonly seen in single-axis motor drivers and some integrated circuit (IC) drivers. Motion control systems deliver multiple capabilities

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On the other end of the controller spectrum are full-fledged motion control systems. These controllers can operate motors at high speeds and allow multiple ways to adjust the speed. They employ inputs and outputs to monitor basic safety factors such as emergency stops, inhibits, end of travel limit, homing and a variety of other features. The inputs and outputs also allow for simple machine-control logic and advanced features such as multi-axis control, coordination of motion, pre-buffered movement, speed changes, positional offsets, and host of other advanced features. Full-fledged motion controllers can be lumped into two major categories — designed from scratch or COTS units.

Motion controllers that are designed from scratch are the most popular option for original equipment manufacturers (OEMs) who typically build controllers in large quantities. These controls are built from discrete components and a custom printed circuit board (PCB). Building their own systems allows OEMs to customize their controllers with only the specific features used by their equipment, which drives

www.deltron.com 86

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Designed-from-scratch motion-control units

January 2020

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C o n t r o l Nippon Pulse America will soon introduce a new category of powerful and ﬂexible

the component count (and ultimately, eventually, the cost) down, only using what is needed for a specific application. The major components or ICs used come in two basic categories:

• Application-specific ICs (ASICs) devices are designed to control motors and handle the intensive calculations involved in the profile generation, multi-axis coordination and many advanced features, as well as handle the safety devices involved in their operation. • General-purpose programmable devices (including CPUs, microprocessors, and FPGAs) are not solely for the control of motors but can be programmed for this use. These devices can also serve to execute other tasks related to the operation of humaninterface devices and other functions of the final device. The component cost for these two options are very similar. However, the ASIC device is regarded as a safer design choice, as the design and algorithm for motor control is time tested. Because the algorithms used by the ASIC device are encoded fully into the semiconductor device itself and don’t use a separate program, the algorithm can run much faster than a general-purpose programmed device. Also, there’s no way for a hacker to adjust the algorithm at a later date because it is a hardwired device that can’t be changed with programming. On the other hand, general-purpose programmable devices are more flexible due to the fact they can be programmed to do much more than just profile generation. Some general-purpose devices even offer “blocks of code” as basic motion indexers, which provide limited motion control capability. These blocks of code must be adapted by the developer to add the advanced features needed for each application. Because these are programmed devices, it is possible for them to be accessed and reprogrammed by hackers, so they are generally not considered secure. General-

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motion controllers to bridge the gap in the motion market. The secure, easy-to-

use hybrid IC is called the Commander core, and is built around the Nippon Pulse

PCL6045BL ASIC to combine the beneﬁts of COTS designs with the customizability of design-from-scratch ASIC and FPGA controllers. Commander will be sold as a readybuilt motion controller that eliminates the need to source components from additional

suppliers and will also be free from dependency on other components’ lifespans (and the huge revisions to products in the ﬁeld such lifespans usually entail).

For OEMs, the Commander core will serve as a cost-effective tool to allow

ramping up to higher-volume production with minimal design time and support. It will

reduce development time for the from-scratch motion controller segment, as systems can be quickly proven out with the Commander Development Kit, which includes a

development board and core module. The OEM can then incorporate the core itself into their ﬁnal custom PCB design.

The motion controllers will be suitable for use in 3D printing equipment • lab

automation • textile machines • printing presses • gaming machines • medical

imaging machinery • small robotics • CNC milling machines • welding equipment • semiconductor manufacturing equipment • and vending machines. This Nippon Pulse Commander motion-controller core (based on an advanced PCL6000series ASIC) will soon be released to market. With more than 6.6 million ASIC motion controllers sold worldwide, Nippon Pulse is the largest manufacturer of ASIC motion controllers in the world.

purpose devices run slower and are prone to interruptions from other processes, which isn’t an issue with ASIC devices. Both ASIC and general-purpose devices need supporting firmware and circuit designs, which also need an experienced programmer and an electronic engineer. General-purpose devices need a programmer that is experienced in setting up and designing the device being programmed. In addition, advanced motion control requires specialized engineering experience. Even with a full engineering team, designing a from-scratch motion controller can be very slow. The ASIC

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motion control device will let design engineering teams go to market faster, as the algorithm for the motion is already fully tested and ready to run. Because general-purpose device performance is driven by a market that is always looking for faster performance, they generally deliver a much shorter life cycle than ASIC motion control devices. Either way, the end of -life for an ASIC or generalpurpose device necessitates complete redesign.

Ready built off-the-shelf units

Ready-built or commercial off-the-shelf

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M o t i o n

(COTS) units are systems that have already gone through the design-from-scratch process described above, and the completed package is sold as a finished unit. In addition, the firmware and circuit designs are fully vetted and ready to use. These systems are usually sold as a standalone box, PLC, or PC boardlevel designs. The biggest market for these types of motion controllers is interdevice applications, and they are widely used by machine designers and smaller OEMs. Key advantages of standalone motion controllers include:

• Controllers that are simple to program often support one or more of the following industry standards: G-code, ladder logic, LabView integration (a form of Basic-style human-readable programming) as well as other easy-to-understand codes or even direct programming using buttons and an HMI display. • Often available with one or more standard communication interfaces such as CAN bus, EtherCAT, Ethernet, Powerlink, PROFIBUS, RS-485, SERCOS, and USB. • The ability to store and execute a standalone program without the need for a master device (such as a PC). Alternately, the standalone program can be integrated into a larger system, allowing a master device to send commands over an interface as described above. • Ready-built units are designed with an application or market in mind, and may incorporate standard connections, I/O, and axis controls that are common to the markets for which they were designed. The downside of off-the-shelf units:

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• Units have a set number of features and are not easily adaptable. This makes it difficult for them to be used outside of the market for which they were designed ... or to continue use as technology advances beyond the scope of the original control system. • Full-featured packages that are more flexible are very expensive, limiting their appeal for use in higher volume applications. In addition, not all features that come standard with the unit are necessary for every application — which means OEMs may be paying a premium for features that the application will never use.

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The path for an OEM to develop a motion controller design from scratch can be long and slow, and we have seen an uptick in the number of OEM manufacturers using ready-built motion controllers to prove out a design, because they are easy to program and get up and running. However, once the equipment has been designed around a ready-built motion controller, the system must continue to use the ready-built system, even with its higher cost, or else be fully redesigned to a custom, from-scratch system. Thereâ&#x20AC;&#x2122;s currently no product that bridges the gap between designed-from-scratch and COTS motion controllers. When we look at the market, thereâ&#x20AC;&#x2122;s a need for a full-fledged motion controller that is easy to use with a proven design, at a price point that is cost-effective for higher-volume applications. Even as a bridge from ready-made to design-from-scratch, an intermediary product would offer a quick avenue to custom-tailored control with a much shorter design cycle. The following individuals contributed to this article: Sacha Marcroft, Motion Group V.P. and Territory Manager at Western Automation Inc.; Brian McMorris, President at Futura Automation LLC; and Kevin McNicholas, V.P. Sales Channel Development at Allied Motion Technologies Inc. DW

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next generation

electric actuators get smart New smart electric actuators run on brushless dc motors, offering better efficiency, flexibility, and connectivity for a number of industries, including in process applications. Boris Wassmer • RTK Senior Manager, Engineering • CIRCOR

With no need for compressed air, early electric actuators could operate with less sound and less maintenance than the predominant pneumatic actuator. Of course, the standard pneumatic option offered its own benefits – performance in extreme temperatures, for example, and an elegant simplicity. As a result, the flow control industry has preferred pneumatic actuators, specifically in the American market, for decades. Now, the American market is changing. In the next four years, the market for electric actuators in the U.S. is expected to increase by 17% annually. This shift comes amid growing interest in interconnectivity, in harnessing the IoT and enabling Industry 4.0. While the electric actuator was once a replacement technology for a pneumatic option, next-generation electric actuators offer new capabilities that make them distinct products altogether. For instance, these new actuators can now connect to networks. The difference starts at the core of these devices; the motor. Brushless dc technology is making electric actuators more efficient, more adaptable, and more connected—and changing expectations for what an actuator can do.

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The RTK REact DC electric actuator uses a smart controller, seen atop the BLDC motor, to intelligently adjust speed in response to changing conditions. DESIGN WORLD

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How brushless dc motors work

Older versions of dc electric actuator motors used brushes to mechanically connect the rotating and stationary parts of the motor. The resultant friction is necessary for operation, but causes some undesirable outcomes. Brushes wear down over time and must be replaced. Also, sparking can occur, a danger in explosive environments. If pushed, the motors will overheat and damage components. Another more common option on the market, synchronous motors with ac power supplies, are brushless, but still present some meaningful limitations. For example, ac synchronous motors run at full torque and speed whenever engaged, so these models require downtime. They also lack so-called “smart” features. Next-generation electric actuators use brushless dc (or BLDC) technology. BLDC motors are engineered without brushes, instead using a smart motor management system to control rotation. With no space wasted on brushes, these compact motors can provide more power and torque in the same dimensions as their brushed counterparts. Without the friction, these actuator motors also require much less maintenance. Because there are no brushes to regulate rotary motion, and no alternating current to alternate magnetism in the motor, BLDC motors charge segments of the stator in a circular pattern to propel the rotor with a moving magnetic field. In order for the system to control the motor’s rotation, to “know” where to align the stator’s electromagnetic fields with the correct parts of the rotor, it gathers data on the speed and position of the rotor. To do this, embedded Hall effect sensors determine the relative position of motor parts. These Hall effect sensors enable intramotor communication nonexistent in other technologies. Essentially, they feed realtime information on the outcome of the controller’s decisions back to the controller. So, the system can detect a change in conditions by measuring how real outcomes differ from expected outcomes. For example, if changes to flow conditions cause greater resistance to the operation of the actuator, the Hall sensors will be able to sense that the rotor is moving at a lower speed than

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intended. Then, the intelligent controller will act on that information, accelerating electromagnetic rotations in order to make up for new conditions. This process is similar to how a driver would push down the gas pedal to maintain a car’s speed up an incline. Likewise, if flow conditions require less torque, the BLDC motor can reduce the amount of energy it uses. These “smart” motors can independently match speed and torque to conditions. As a result, BLDC motors can reduce energy consumption by over 60% compared to synchronous motors. Programming flexibility for flow control

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Additionally, because the BLDC motor’s sensors and controller are digital and not mechanical, operators can select the speed at which they want the motor to run. Synchronous ac motors are limited to one mechanically predetermined speed, torque, and supply voltage, and each motor requires its own capacitor. So, in order to change the speed of an actuator in a system, a synchronous ac actuator must be replaced with another built to run at the desired speed. For BLDC actuators, though, changing speed is a matter of programming, not replacement. Models can include switches to select a number of speeds. For example, the CIRCOR RTK REact DC actuators offer four speed presets that can be toggled by operators. The ability for a motor to self-regulate also serves as a maintenance prevention and safety feature. The REact DC is programmed with over-force limiting to protect the actuator. This flexibility is a desirable quality for process engineers. A system may call for an actuator at one speed with one supply voltage at a critical juncture. Before, a spare actuator matching those precise characteristics would have to be kept in stock. With BLDC actuators, one unit can offer four speeds and can operate with two different supply voltages. This means that operators can keep one BLDC actuator on hand as a backup component to cover the equivalent of eight distinct synchronous ac actuator types used in a process. A still greater benefit is the flexibility this provides engineers seeking to optimize a

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system. Engineers often install an actuator with a certain speed only to realize that the control loop does not function correctly. Now, with BLDC actuators, troubleshooting engineers can simply change the speed of the installed actuator instead of replacing it to get a process up and running. Networking smart actuators

Importantly, the internal communications of smart motors can be networked and monitored on system-wide scales. Smart actuators can sport LED lights to indicate actuating direction for easy maintenance, but operators no longer need to inspect each actuator by sight. This allows operators to remotely monitor temperature, number of strokes completed, running time, and actuator position, as well as flow direction and online/offline status for each actuator in a system. Then, operators can communicate with these remote units to make adjustments. This connectivity not only

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streamlines maintenance, as data can guide preventative measures before failures have a chance to occur, but can reveal data that can be used to make flow more efficient. The hardware of today’s BLDC actuator models enables connectivity now and in the future. Cutting-edge integration (for instance, REact DC actuators feature Profibus, and CAN-open integration) will surely be surpassed by future communication systems, and “smart” actuators will require little retrofitting to function in these new networks. In the context of market growth driven by the desire to connect, the flexibility of these new smart actuators reveals their most salient advantage here: whether one designs a network connected by USB to a central computer or to function with a mobile app using QR codes, the BLDC actuator is a programmable tool able to deliver efficient actuation force according to changeable parameters.

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While other actuators simply provide actuating force, BLDC actuators do that but also monitor and adjust that force independently and on an ongoing basis — and according to parameters selected and reselected by operators. These capabilities put this new generation into a class of its own, but the greatest value to this technology is its networkability. As process engineers consider new electric actuators, they should consider BLDC models to unlock efficiency and future-proof their systems. DW CIRCOR www.circor.com

January 2020

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Boosting

Productivity with the right motor feedback

Feedback options for linear motors and direct-drive torque motors abound. The most common employ optical, magnetic, capacitive, or inductive measurement. Here we explain how the key application parameters of precision, cost restrictions, and insensitivity to mechanical characteristics and environment dictate which technology is most suitable. Steffen Preg • CEO • SIKO Products Inc.

Machines operate most efficiently and precisely when their axes are well controlled. Encoders in particular excel where precise motion tracking is necessary. These can take the form of rotary and linear motor feedback built into the drive frame to measure velocity and motor position. The most suitable encoder type and model economically satisfies requirements for precision and ruggedness. Consider optical feedback — the subtype that’s been in the market longest. Optical-based feedback remains the gold standard for accuracy. Only since the early 2000s have magnetic, inductive, and capacitive offerings been commercially available for industrial applications. These other technologies don’t tend to deliver the accuracy of optical systems but are more cost effective and rugged and reliable where dust, liquids, vibration, and shock are involved. In fact, magnetic systems are particularly cost effective. As we’ll explore in more detail, motion axes with longer-than-average strokes benefit from the price advantage of magnetic-based feedback over other measurement technologies. While capacitive-based feedback is most economical of all (due to lower material costs) magnetic options have maximum robustness. That’s especially true for applications exposed to humidity — and implementation of

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This pick-andplace unit includes linear direct drives fitted with SIKO magnetic-based feedback for position detection.

capacitive systems requires complex and expensive protective housings. Motion applications with significant exposure to shock, vibration, dirt, or lubricants are inappropriate for fragile and sensitive optical-based feedback. The magnetic insensitivity of optical-based

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feedback does preclude other options where thatâ&#x20AC;&#x2122;s an issue â&#x20AC;&#x201D; especially on linear axes in the machine tool and medical industries. But the percentage of applications for which magnetic interference is an issue is quite small; typically, the magnetic field around an axis must be five times that of the magnetic feedback device to pose an interference problem. This is also quite

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rare as direct-drive and linear-motor manufacturers (for the sake of energy efficiency) have worked to make their motorsâ&#x20AC;&#x2122; fields as concentrated as possible in volume between the rotor and stator (or linear forcer and platen).

Basics of direct-drive motors Direct-drive motors are so called for how they directly connect to the load with no intermediate gear or rotary-to-linear mechanism. Rotary direct drives (also called torque motors) are increasingly

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Shown here from left to right are optical, magnetic, capacitive, and inductive solutions for motion feedback.

common in robotics. Linear direct drives (in the form of linear motors) are indispensable on positioning drives for machine tools and other axes needing top accuracy of path and constant velocity. In fact, linear motors impart a good force-to-mass ratio and unbeatable synchronization of axes. Most linear motors today include permanent-magnet arrays and a coil through which ac power is applied. The alternating field prompts the coil to advance through the varied magnetic field — or the other way around depending on what is fixed mechanically. Where the coil is integrated into a carriage, it moves along the magnet track while riding twin linear rails. In contrast, torque motors for rotary axes are suitable for applications needing high torque and precise synchronization. These rotary direct drives work just like any other motor, but as a rule include a hollow center through which cables, compressed air lines, and other design elements pass or mount. Both rotary and linear direct drives necessitate feedback.

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Motion-feedback requirements Motor feedback is catchall term for position feedback paired with linear and rotary systems employing a controller, drive (to feed electrical power to the motor), and the motor itself. In such setups, the measurement system communicates information about travel direction, velocity, and precision with the controller. Key measures of a motor feedback systems are accuracy and repeatability. Usually (though not always) longer axes tend to need less precision … and magneticbased feedback is often most suitable. As we’ve mentioned, another key measure of a motor feedback system is ruggedness. This parameter often precludes technologies altogether. Case in point: The copious water required to cool tools in glass working renders optical and capacitive measurement systems (so sensitive to humidity) inappropriate — and only inductive or magnetic solutions are viable. Besides these design objectives, another consideration for feedback is the motorto-controller communication in use … as well as whether the feedback system should be incremental or absolute. Incremental systems are sometimes far more accurate than other offerings; Incremental outputs are also faster for control purposes. However, they necessitate a reference position upon initial energization to ensure the motor starts from a specified position.

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Such reference travel is unnecessary for absolute measurement systems. SIKO absolute encoders offers both incremental and absolute operation to deliver the benefits of both types of feedback. Another consideration for rotary applications is the maximum shaft diameter, which can preclude certain feedback systems. Magnetic-based feedback options can handle large shaft sizes with an array of sealing options. Astounding motion-controller technological advances over the last 15 or so years have spurred demand for increasingly advanced motor feedback. That’s especially true for modern controllers that can now serve in cost-efficient systems that basically run motors in absolute steady-state conditions.

Open and enclosed feedback modules Open measurement systems are those without encapsulation or mechanical connection to the drive. These are most common, as they reduce part counts and give design engineers more installation options. In contrast, enclosed feedback systems encase the scale and sensor unit — for less adaptability but more ruggedness — including elements such as lip seals to prevent dirt ingress, for example. Such closed feedback systems are slightly more costly but indispensable in machine-tool builds and elsewhere. Most all magnetic, capacitive, and inductive feedback systems come in open versions — with the added benefit of contactless operation for no wear on the scale and sensor unit. Optical feedback offerings are also non-contacting, with one DESIGN WORLD

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Shown here are two schematic views of motor feedback solutions — on linear and torque motors.

exception — those designs with glass scales using a split mechanical housing for protection.

More about optical feedback Optical systems based on light and glass scales differ from those based on from epi-illumination or laser technology. These track position using the Talbot effect: When electromagnetic wave signals incident upon a surface grated for diffraction, that grating’s image repeats at regular distances somewhere away from its plane. Where employed for motion sensing, this brightness distribution is measured by a read head. The grid behind the sensor head is exposed to monochrome electromagnetic waves for wider light

Modern controllers are key to efficient drive engineering.

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distribution behind the grating. Resulting position values then go onward to controls as A, B, R digital-count pulses. As a rule, laser-based systems use a thin metal strip as the scale. Many such scales are flexible enough to allow winding or coiling. This is an advantage over rigid yet fragile glass scales. But glass-scale systems can be designed very precisely. Measurement accuracies to 3 µm or better are possible … and with such small error per meter of travel, glass-scalebased feedback excels on shorter linear axes. (Axes many meters long would necessitate prohibitively expensive transport and installation of long glass rods.) As mentioned earlier, a drawback of glass scales is their intolerance of mechanical impact, shock, and vibration. When used under such conditions, such scales require protective measures to prevent shattering. But the benefits of optical scales abound: The accuracy of many optical sensors reach ±5 mm and resolutions are to 0.05 mm. Opticalscale gradations (which partially define accuracy) are commonly to 20 mm. Then finer values are interpolated in sensor electronics and further processed by a system controller. High dynamics and the ability to return high-precision feedback with unbeatable accuracy, repeatability, and resolution even on very fast-traveling axes are key benefits of optical systems.

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Another advantage of optical systems is insensitivity to magnetic disturbances. Consider how linear motors generate electromagnetic fields capable of degrading the signals of magnetic sensors if the sensor head and tape are installed too close to the motor. Avoiding this issue with magnetic sensors is easy — by using a shield or maintaining a defined safety clearance between motor and sensor … but again, this is not a design concern at all with opticalbased feedback. Optical measurement systems do suffer from sensitivity to dust, oils, and fats in the environment — as well as condensation on the scale where high humidity combines with temperature fluctuations. Protective housings can indeed prevent dirt and condensation from settling on the sensor but incur added cost. Generally speaking, optical sensors cost about twice that of magnetic sensors … and the magnetic scale for an especially long axis might be about 60% cheaper than a comparable optical scale.

Magnetic measurement systems With magnetic measurement systems, the sensor travels sans contact over a magnetic tape (sometimes called a code strip) applied to a steel carrier a few tenths of a millimeter thick. This scale is magnetized with pole pitches to spur generation of digital signals when a read head passes over these magnetic poles and scans them. The read head recognizes the tape’s divisions and converts the resulting data into high-resolution path information for control electronics to use in adjusting servo commands.

Shown here is a highprecision glass scale with guided sensor head.

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Shown here is a high-resolution incremental magnetic sensor from the SIKO MagLine series. Engineers have used MagLine sensors on linear and rotary direct drives for many years. One exclusive variation from the SIKO product line is that of a magnetic feedback system that uses the motor’s magnets as the scale. Such designs must always be custom-designed and calibrated to the specific axis at hand — but that can be worthwhile where simplicity and eliminating additional cost for the scale benefit the overall design.

Consider one application — that of gantry drives with very long linear motors. Such designs must travel very quickly from one point to another but accuracy and precision requirements aren’t particularly strict. Here, one well-suited magnetic-sensing technology is that of a read head that uses the motor’s magnets as the linear scale. Magnetic systems (just like inductive systems, which we’ll explore shortly) are resistant to dirt, oils, and humidity. In fact, magnetic scales can even work in areas of a machine subject to oil baths. Magnetic-based feedback also withstands shock and vibration for applicability in the most challenging designs — on off-highway and mobile equipment operating outdoors, for example. Magnetic measurement technology also survives harsh applications such as stone and glass working. The flexibility of the magnetic tapes also means it can be shipped and stored coiled in rolls and then cut to size. Because the scale and even the mode of

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EXTEND operation are so resilient, magnetic sensing lets design engineers mount the scale and read head fairly far apart if needed — even to several millimeters. This isn’t possible with other systems … for example, optical systems have such a delicate grid structure that the distance between the scale and head should never exceed a few tenths of a millimeter. While inductive technology has scale divisions of one millimeter to also allow wider scale-to-head distances, its read electronics tend to be bulkier than those of magnetic systems. Drawbacks of magnetic systems are that they have lower absolute accuracy, resolution, and repeatability than optical designs. As mentioned, magnetic sensors are also sensitive to external magnetic sources of interference.

More on feedback based on capacitive means Capacitive-based motion feedback is based on interactions between two mutually chargeable plates. Position changes between a printed circuit board (PCB) scale and read head prompt the generation of an electric signal for use by a controller. Such feedback operation is applicable to linear motion but limited by scale length. That’s why capacitive-based feedback is far more common on rotary axes driven by torque motors. In fact, they’re often used where it’s too costly or complicated to integrate an optical glass scale into a motor shaft or rotor. The main strength of capacitive-based feedback systems is cost effectiveness. That’s because the materials in capacitive sensors are inexpensive. In addition, capacitive sensors are designed to fit on specific rotary motor types — though this also tends to restrict their use with only a few motor-construction types. The serious disadvantage of capacitive systems is their sensitivity to humidity. That’s why capacitive sensors are inappropriate for designs subject to washdown or where water is used to cool tools, for example. Deep dive on inductive-based motion feedback Inductive systems include etched scales just like optical systems. That means the reference gradient is also quite fine — though here the tape is made of steel. As with magnetic-based feedback, the scales can be quite long — so that 30 to 70 meters of coilable scale is common. The read head uses multiple small coils through which current is sent; current variations induced by traveling over the scale fields or slots form the signals from which relative movement or position is tracked. The accuracy and resolution of inductive-based motor feedback are comparable to those of magnetic systems. One key advantage of inductive systems is insensitivity to external magnetic fields. Inductive systems are slightly more expensive than magnetic offerings, mostly because inductive readhead electronics are more complex. The scales have comparable prices.

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Common uses for feedback in material-handling automation: Here the equipment requirements vary. Semiconductor handling might need a machine to quickly place DESIGN WORLD

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This is a capacitive scale in a compact design.

thousands of tiny components on circuit boards with repeatability to within hundredths of a millimeter. In contrast, a collaborative robot might need to move boxes containing fully finished smartphone over several meters to feed a conveyor with accuracy to within a rather forgiving Âą10 mm. Consider the mass assembly of smartphones. Myriad components must be assembled very quickly and efficiently. Typically, the PCB circuit boards are prepopulated with subcomponents, but the separate phone components must still be joined. Here, automated machinery must position parts to within 0.1 mm. That means inductive or magnetic systems are most likely to be used â&#x20AC;&#x201D; as the extremely high precision of optical systems is unnecessary here.

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Inductive measurement systems combine precision, high resolution, and repeatability.

In the same way, stone and glass working generate abrasive byproducts. But especially for window fabrication, relatively long linear motors must work quickly to efficiently transport tools between machining stations. High dynamics and fast adjustment of axes are needed — which means magnetic-based linear feedback is fairly common here. Back in the semiconductor industry, so-called depaneling machines separate relatively large PCBs into smaller circuit boards. Usually dozens of smaller PCBs are held together by crosspieces. Snapping apart the separate boards generates a lot of dust — making magnetic measurement technology useful here too. Magnetic systems are

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also very compact — making them more appropriate than some inductive systems.

Robotics: Virtually all motion-feedback systems work in robotics. Various options are combined with the increasingly common variation of robot arms that encapsulates all subcomponents and uses small to medium torque motors at each joint. But the customer-specific compact design of magnetic systems is especially suitable for integration into robot systems. Pick-and-place applications: Precision is paramount in the automated populating of PCBs. Components including

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Linear direct drives with magnetic motor feedback excel in glass-working applications. Contrast this task with the filling of PET bottles with mineral water in the food and beverage industry. Optical and capacitive systems won’t work here— but magnetic-based feedback will. Or consider the dustiness found in certain cardboardpackaging operations. Optical systems are out, but capacitive or magnetic systems may be appropriate.

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resistors, condensers, and microchips must be positioned exactly on the PCB before soldering. Optical and inductive systems are predominantly used for this purpose. But magnetic measurement technology can also be used if there’s low packing density and the design needs to be cost effective. Although the components used for populating PCBs are tiny and need precise guidance and positioning by the pick-and-place machine, magnetic sensors on some axes may be sufficient depending on the requirements for precision.

PCB working: Optical sensors are also used in semiconductor production and inspection

Magnetic motor feedback works reliably even in applications producing great quantities of dirt.

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Positioning tasks with particularly demanding requirements for precision (as on PCB wire bonders, for example) usually employ optical measurement systems.

High-speed pipetting machinery uses absolute feedback from SIKO Products.

Optical measurement

Precision

Absolute accuracy

Cost

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Repeatability

Resolution Mechanical impact • Shock and vibration

Resilience

machines. For instance, chips are often bonded with gold or aluminum wires in cleanrooms. On integrated circuits, electronic component connections are made approximately 1 µm into the board surface … so making these connections requires absolute precision leveraging the use of optical sensors — which are 100% free from hysteresis. Analytical and medical technology: Precision is a top design requirement for medical and analytical equipment. Patient-positioning benches for computer tomography (CT) imaging can use magnetic-based measurement technology on axes for adjusting height, inclination, and position. The tube of the CT — a large torque motor with a hollow shaft having an 800-mm or larger diameter — can also use a magnetic sensor. Absolute accuracy plays a minor role here; fast reproducibility and high repeatability matter due to the high dynamics when scanning the patient. But analytical technologies demand even higher repeatability. Here, magnetic systems work on some axes for liquid handling: Pipetting robots quickly grasp, transport, and dispense liquid vials from sample storage vessels in very accurate and small quantities. Accurate travel between stations is vital, as the individual samples are so close together. DW

Environmental and process considerations

Magnetic influences

Magnetic measurement

Capacitive measurement

Inductive measurement

High system accuracy to ± 2 µm and better

System accuracy to ± 8 µm

System accuracy max. ± 25 µm

High system accuracy to ± 3 µm

Very high repeatability

Repeatability to ±1 µm

Repeatability to 1 µm

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Trends in the

Internet of Things Proponents of IoT and IIoT continue to work on proving how this technology can make various processes more efficient and functional at lower cost. Design engineers have a range of IoT and IIoT connectivity devices to choose from for their designs. In 1999, industry finally settled on a name for the concept now known as the Internet of Things; even though examples of products with internet connectivity have been around since before the 1980s. Once multiple devices that could connect to the internet became available, the challenge shifted to what to make of all the data. We are still at that point, although artificial

Leslie Langnau Senior Contributing Editor

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intelligence algorithms and programs may help sort all of this out. In 2019, one of the larger trends associated with the IoT and IIoT was the digital twin. Forecasters now predict that by 2025, digital twins will be a $20 B market and will play a major role in the further adoption of IoT and IIoT. Digital twins should help address the challenges of what to make of all the gathered data. The digital twin concept is growing, according to forecasters, by customer demands for less asset downtime, optimized process time, reduced time-to-market, and improved operational efficiency. But proof of the value of digital twins is usually focused on how it helps maintenance efforts. An oft-sighted example is GEâ&#x20AC;&#x2122;s use of its digital twin Predix platform to help aviation clients dynamically optimize maintenance schedules of jet engines, as well as schedule maintenance shop availability. Forecasters tout how digital twins will grow in process support and service applications at a CAGR rate of more than 30% between 2020 and 2025. A few forecasters mention that digital twins will help inventory and supply chain management by reducing inventory and inventory carrying costs to free up working capital.

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Beyond maintenance applications

According to forecasters, a market showing strong growth for digital twins is the healthcare sector. Products in this market offer real-time monitoring and analytics through machine learning and help to streamline operations and processes in hospitals, improving the customer experience. For instance, a single MRI scanner produces an average of 800,000 log messages that tell how it is operating. Using digital twins to proactively and remotely monitor the MRI scanner can help to track and analyze these log messages for early warning signs of impending operational or technical issues. Another study* finds the global Clinical communication and collaboration market was valued at ~ US$ 240 Mn in 2014, and was expected to exceed ~ US$ 370 Mn mark by the end of 2019. The Clinical communication and collaboration market is expected to reach a market value of ~ US$ 1.3 Bn by the end of 2029. The healthcare industry is increasingly turning to digitalization in the form of smartphones, wearable devices such as bands, badges on patients’ arms, and other sensor-based signals. These devices have helped many hospitals improve their overall operational performance. This digitalization has led to hospitals developing custom Clinical Documentation Improvements (CDI). CDI can minimize a patient’s physical efforts because its clinical communication and collaboration feature enables patients, physicians and hospital staff to share medical reports with each other. These medical records and other patient related documents are loaded onto the Electronic Health Record (EHR) systems. This feature is helping drive the demand of clinical communication and collaboration solutions during the forecast period. A recent study segregated the clinical communication and collaboration market down to three levels: Tier-I, Tier-II, and Tier-III. Tier-I represents companies holding market shares above 12% of the clinical communication and collaboration global market. Cisco Systems Inc. and Microsoft Corporation are Tier-I companies in the global clinical communication and collaboration market. Tier-II represents companies holding market shares in the range of 6% to 12%. Companies, such as TigerText, Vocera Communications, Inc., and Jive Software, Inc., constitute the 2nd tier of the global clinical communication and collaboration market. Tier-III represents companies holding market shares below 6%. Tier-III of the global clinical communication and collaboration market constitutes companies, such as Intelligent Business Communication – AGNITY, PerfectServe, Inc., and Ascom, among others. Some of the key players identified across the value chain of the global Clinical communication and collaboration market include Uniphy Health Holding LLC; Everbridge Inc.; Microsoft Corporation; Jive Software Inc.; Cisco Systems Inc.; Intelligent Business Communication; TigerText; and Vocera Communications Inc., among others. IIoT and manufacturing

IoT and IIoT have been targeting the manufacturing sector for some time. Forecasters think the digital twin part of IoT and IIoT will reach more than 25% use by 2025. According to the World Bank, manufacturing globally DESIGN WORLD

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The LMP-1600G and LMX-1600G series of switches from Antaira Technologies are industrial-grade equipment that is Ethernet ready to fulfill various markets’ edge-level networking applications in harsh and outdoor environments, such as manufacturing automation, security surveillance, power/ utility, water wastewater treatment plants, oil/gas/mining, and transportation. These devices support high density Ethernet port connectivity, wide bandwidth, long distance data transmission, and have a superb reliability factor. The LMX-1600G Series suits applications needing to increase the number of port counts in automation equipment (UL Pending – 2020). The LMX-1600G series provides 16 one gig ports in a relatively small form factor for connectivity using only a fraction of the physical space required. This is a key feature for those working with NEMA enclosures or any application with size constraints. The LMP-1600G Series, like the LMX-1600G series, also provides 16 one gig ports for high port density applications but also provides PoE power on all 16 ports. The wide temperature rating and rugged enclosure design allows this device to be installed in environments without sacrificing the longevity of the switch. Both the LMX-1600G series and the LMP-1600G series are managed devices. Besides all the normal tools a managed switch provides, like port monitoring, alerts, and troubleshooting tools, these switches also provide multicast suppression (IGMP). This feature keeps multicast traffic going only where it is required without being broadcasted across the entire network; a need both automation and surveillance applications. January 2020

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Machine designers can use the Allen-Bradley ControlLogix CIP Safety I/O modules from Rockwell Automation to reduce panel space and setup time in applications that require high-density I/O. The modules provide local, in-chassis safety I/O for GuardLogix 5580 controllers, eliminating the need for adapters that require panel space and additional configuration time. If desired, the modules can also be used for distributed safety I/O.

The modules offer enhanced diagnostics, which can help designers build smarter machines. For example, faster safety reaction times can help improve productivity by allowing users to more easily identify faults, and by shortening the distance between a device and a hazard.

The modules also offer design flexibility because they can be used with all other standard ControlLogix I/O modules.

The Xcelerator from Siemens Digital Industries Software is an integrated portfolio of software, services, and application development functions that can be adapted to fit customer and industry-specific needs. It combines the full portfolio of Siemens’ software for design, engineering and manufacturing with an expanded Mendix low-code, multi-experience application development platform. The Mendix platform includes cloud and app services for digital engineering and Internet of Things (IoT) powered by MindSphere, the cloud-based, open IoT operating system from Siemens. The platform drives digital transformation by enabling anyone in the ecosystem to easily build, integrate and extend their existing data and systems. Xcelerator brings together and integrates many parts of the Siemens portfolio with embedded tools and databases that connect to existing Information Technology, Operational Technology and Engineering Technology environments. Capital software, from Mentor for example, has been embedded into NX software to allow experts across engineering disciplines to create new products collaboratively.

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The Xcelerator portfolio is comprised of multiple applications and solutions for Product Lifecycle Management (PLM), Electronic Design Automation (EDA), Application Lifecycle Management (ALM), Manufacturing Operations Management (MOM), Embedded Software and Internet of Things (IoT).

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The switch is designed with IP67 protection. Being compliant with IEC 60068-2-6: 5G standards further allows it to work against severe, continuous vibration. Thus, the switch is suitable for traditional machine tools, numerical control (NC), and computer numerical control (CNC) and DNC. LEESON® Extreme Duck® Ultra Motor with with fullbody encapsulation to keep what’s outside out

IEC 61131, was known as IEC 113, is an IEC standard especially for programmable controllers (PLCs). The EKI-2528I-M12 fully complies with the IEC-61131-2:2017 that specifies functional and electromagnetic compatibility and related verification tests, so as to be suitable for PLC and PAC applications and their associated peripherals. The high port density feature of the EKI-2528I-M12 makes it possible to support up to eight M12 port connections within a compact (62 x 25 x 194) housing. It is best for confined space since no extra room for wire deployment is required. Users simply need to screw it firmly on the wall or cabinet before enjoy the instant network communication service.

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The Evolution of Brewery Hoses

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Millimeter-wave 5G, from Analog Devices, is an emerging technology. But it can be difficult to design systems for it from the ground up, balancing system-level challenges in performance, standards, and cost. A new mmWave 5G chipset promises to simplify the design process, reduce overall component count, and help engineers accelerate the path to 5G deployment.

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The integration of the mmWave 5G chipset reduces design requirements and complexity in next generation of cellular network infrastructure. The chipset combines the beamformer IC from Analog Devices, up/down frequency conversion (UDC), and additional mixed signal circuitry. The chipset includes the 16-channel ADMV4821 dual/single polarization beamformer IC, 16-channel ADMV4801 single-polarization beamformer IC and the ADMV1017 mmWave UDC. The 24- to 30-GHz beamforming + UDC solution forms a 3GPP 5G NR compliant mmWave front-end to address the n261, n257 and n258 bands. The high channel density, coupled with the ability to support single- and dual-polarization deployments, increases system flexibility and reconfigurability for multiple 5G use cases, while isotropically radiated power (EIRP) extends radio range and density.

PID loop control capability (up to 8 loops simultaneously) has been added to the CLICK Series of stackable, Ethernet-capable micro brick PLCs. It can configure up to 8 PID control loops updating at 100 ms. CLICK PID control is streamlined with only the features that most users need, including direct or reverse acting control, pulse width modulated control outputs, bumpless transfer, anti-windup, auto-tuning, process variable alarms, process variable limits, control output limits and error deadband.

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The CLICK PID monitor gives access to and charts all PID parameters needed to test and tune the PID loops. An auto-tune interface sets up and initiates the auto-tuning feature.

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Design better devices â&#x20AC;&#x201D; faster.

Topology optimization of a heat sink.

Engineers from Fraunhofer IAPT used topology optimization and additive manufacturing to design a heat sink, a common component in many electronic devices. The topology-optimized design was then transformed into a simulation application to automate and customize certain design tasks. Now, engineers, designers, and manufacturers companywide are able to efficiently optimize intricate heat sink geometries and prepare them for 3D printing. The COMSOL MultiphysicsÂŽ software is used for simulating designs, devices, and processes in all fields of engineering, manufacturing, and scientific research. See how you can apply it to topology optimization and additive manufacturing processes. comsol.blog/3D-printing-optimization

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contributed to 16% of the total economic value in 2016. This steady growth of the sector is expected to further fuel the demand for digital twins to streamline and optimize the manufacturing process flows. The Asia Pacific digital twin market is projected to grow to around 30% between 2020 and 2025. The adoption of the IoT and IIoT is due to increasing internet penetration coupled with the proliferation of smartphones. Prominent automotive players in countries including Japan, South Korea, and India are contributing to the digital twin market growth as well. In 20172018, the retail shrinkage percentage of sales in the Asia Pacific region was estimated at around 1.75%, amounting to nearly USD 24 billion. To tackle the growing concerns related to inventory shrinkage, the uptake of the digital twin concept in the region should grow consistently over the forecast timeline. Some of the key players operating in the digital twin market are ABB Group, Ansys

Inc., Autodesk Inc., Dassault SystĂ¨mes, General Electric, IBM Corporation, Microsoft Corporation, Oracle Corporation, Robert Bosch GmbH, SAP SE, Siemens AG, and Wipro Limited. DW

Rockwell Automation Inc. www.rockwellautomation.com/ Siemens Digital Industries Software www.sw.siemens.com

Advantech | www.advantech.com

*Insights are based on reports by Global Market Insights and Persistence Market Research. Â

Analog Devices http://www.analog.com Antaira Technologies www.antaira.com AutomationDirect www.automationdirect.com/CLICKPLC

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Implicit modelling for complex geometry Dr. Jody Muelaner, PhD CEng, MIMechE â&#x20AC;˘ Muelaner Engineering Ltd Implicit modelling is enormously powerful and offers huge potential for engineering design. It is currently ready to apply in specific modelling tasks involving complex geometry. It is not yet clear whether it will be possible to fully implement it within the familiar parametric design environment, with constraintbased sketches used to define geometry. If not, it may remain a specialized tool.

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Additive manufacturing enables the production of highly complex geometries such as repeating lattice-like structures and organic shapes. This design freedom can improve performance in terms of weight, stress, fluid flow and heat transfer. However, modelling, editing and processing complex geometry files is challenging for the established CAD software. Letâ&#x20AC;&#x2122;s look at how implicit modelling can solve these problems as well as the challenges still remaining to integrate it into the design workflow. The Problem with Current CAD Software If youâ&#x20AC;&#x2122;ve ever tried modelling complex lattices in a typical CAD program, such as SolidWorks, youâ&#x20AC;&#x2122;ll know this is extremely challenging. When models have large numbers of features, the file sizes and rebuild times increase exponentially. Conventional CAD programs can also have difficulty with apparently quite simple models if they have features such as two fillets that overlap. When high feature counts are combined with these types of challenging geometry, model rebuilds become painfully slow at best and all too often they simply fail. The problem is the fundamental way that geometry is represented. All the major CAD programs use boundary representations (b-reps) to define solid geometry. B-reps use topology, such as vertices, edges and faces, which are defined by geometry such as points, curves and surfaces. For example, an edge is a bounded region of a curve and a face is a bounded region of a surface. DESIGN WORLD

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B-reps work fine for relatively simple geometry. Older CAD programs sometimes used Boolean operations to combine primitive objects such as cubes and spheres. B-reps are much more versatile, allowing profiles to be swept and lofted, solids to be shelled and so forth. However, when features are combined with fillets and blends, or large numbers of features are included, calculating the topology becomes exponentially more demanding on the computer. Many modelling operations involve combining simpler shapes with Boolean and blending operations. B-rep modelling has to calculate all of the new edges that are formed where faces intersect. For objects with planar faces the individual calculations are relatively simple, but the number of intersections increases by approximately the square of the number of faces. For intersections between curved surfaces the edges are complex splines, making the calculations considerably more complex. When faces are close to tangent, things get really difficult.

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C A D A cuboid can be defined by the implicit function. Any point on the boundary gives a function value of zero, negative values are inside, and positive values are outside, which makes the determination of whether a point is inside or outside simple.

Another issue with B-reps can be determining which points in the model are inside the boundary - the solid material. The method is to shoot a ray from the point in an arbitrary direction. If the ray passes the boundary an odd number of times then the point is inside the boundary. If the ray passes the boundary an even number of times then the point is outside the boundary. Since floating point arithmetic is used, rounding errors may mistakenly count boundary crossings when the ray is close to the boundary. There are also ambiguities such as when a ray is tangent to a surface or passes through a vertex â&#x20AC;&#x201C; it is not clear whether this counts as a boundary crossing, or as two crossings. Because of these issues, additional checks are required to ensure that b-rep modellers are robust. This makes them mathematically inefficient.

Performing Boolean operations to combine implicit geometry is also mathematically simple. Consider two solids added together in a Boolean union. For a point P to be within the combined solid, at least one of the two implicit functions must evaluate to less than zero. The combined implicit function is, therefore, simply the minimum of the two functions.

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The mathematical simplicity of Implicit Modelling Implicit modelling is a far more efficient way to model geometry. It doesnâ&#x20AC;&#x2122;t explicitly calculate any edges or vertices. Instead, a single mathematical function of x, y and z is used to describe a 3D solid. Consider the simple example of a cuboid centred on the origin.

The implicit function for the sphere is: FB(x, y, z) = x2 + y2 + z2 - 2

The implicit function for the combined solid is simply the minimum of the implicit functions for the two shapes: FC(x, y, z) = min(FA, FB) This simplicity of calculating geometry means that complex fillets and blends can be created reliably, and highly complex models This cuboid can be defined by the implicit rebuilt almost instantly. The below image function: shows fillets where a lattice joins a ring. The FA(x, y, z) = max(|x| - 4, |y| - 1, |z| - 1) fillets overlap in a way that would probably Any point on the boundary gives a function value fail in most CAD systems, but they have been easily created using nTopology implicit of zero, negative values are inside, and positive values are outside. Determining whether a point modelling software. is inside or outside is therefore very simple.

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There is no need to try to count how many times a ray crosses the boundary. Small floating-point errors will give the wrong answer only if the point is infinitesimally close to the boundary. Performing Boolean operations to combine implicit geometry is also very mathematically simple. Consider two solids being added together in a Boolean union. For a point P to be within the combined solid, at least one of the two implicit functions must evaluate to less than zero. The combined implicit function is, therefore, simply the minimum of the two functions. Imagine that a sphere, centred on the origin and with a radius of 2, is added to the cuboid.

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Distance fields – a powerful feature Another really useful property of implicit functions is that they actually give the distance from the boundary. A good way to understand this is to simply try some values in the function for a cuboid, used in the example above: FA(x, y, z) = max(|x| - 4, |y| 1, |z| - 1) The smallest value that this function can take is -1. This occurs for points down the centre of the volume. There is no upper limit to the value it can take, since you can travel infinitely far once outside it. Implicit functions make it really easy to calculate a distance field either inside or outside the boundary of any solid geometry. This makes it very easy to perform shell operations. It is even possible to create shells with varying wall thickness. Because implicit geometry is defined as a field, it can be modified by other fields. This enables highly efficient merging between different geometries, to create features similar to fillets. It is even possible to modify a geometry field using some other property, such as a stress field generated from an FEA study. In the below example, nTopology has been used to modify the diameters of beams in a simple diamond lattice, with the diameter increasing as the stress increases. It is also possible to do this with shelled solids, so that the wall thickness depends on stress. This can be a powerful method of optimizing structures that, unlike generative design, works well with cast or injection moulded components, as well as additive manufacturing. Implementation of Implicit Modelling A number of commercial software companies are offering implicit modelling packages. The field is currently dominated by smaller specialized providers such as nTopology, which has a suit of capabilities for working with complex geometry. Another notable start-up, Gen3D is currently focused on modelling flow paths for applications such as manifolds and heat exchangers such as the one shown below. The big players in the CAD world, such as Autodesk and PTC have started acquiring DESIGN WORLD

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Implicit functions can also give a featureâ&#x20AC;&#x2122;s distance from the boundary.

Implicit functions make it easy to calculate a distance field either inside or outside the boundary of any solid geometry. This makes it very easy to perform shell operations and you can even create shells with varying wall thickness.

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start-ups in order to gain access to this technology. Autodesk recently announced their Volumetric Kernel for Fusion360 which, it is claimed, will enable implicit modelling to be fully integrated within a parametric design workflow. At the moment, however, it is not possible to work directly with implicit models within any mainstream CAD system. Specialized implicit modelling software is instead focused on creating the complex geometry that conventional CAD struggles with. For example, you might import an initial design from your standard CAD package and then perform operations such as creating complex lattices, shelling complex components or creating intersecting fillets. The most obvious application is for light weighting structures using lattices for additive manufacturing. However, there are many other potential applications for complex geometry creation such as cast components with complex fillets and variable thickness shells. Many industrial designers are taking advantage of the capabilities to produce decorative grills. Implicit modelling software such as nTopology makes it extremely easy to create these types of geometry. Stress analysis using Finite Element Analysis (FEA) can also benefit hugely from implicit modelling. One of the most timeconsuming parts of analysis can often be cleaning up the geometry created by CAD software. Because b-rep modelling creates edges where any surfaces meet, there can often be thin sliver geometry at intersections and fillets. This can make even relatively simple parts difficult to mesh with high quality elements. Implicit models donâ&#x20AC;&#x2122;t have any of these issues giving the potential for painless creation of high quality meshes. This can, however, create its own issues as discrete surfaces may be needed to define boundary conditions. B-rep surfaces are therefore sometimes imported from CAD to enable boundaries to be defined. Gyroids and Triply Periodic Minimal Surfaces Triply periodic surfaces are an interesting type of geometry that is relatively new to the world of manufacturing, although they have been known to mathematics since the 19th century. These surfaces repeat in each of three dimensions, similar to conventional arrays. However, the arrays of intersections between each element are often problematic, with fillets at each interface quickly making models unmanageable. With triply periodic surfaces, there are smooth transitions between each repeating element, with the entire surface defined by a single implicit function. Within mathematics and the natural sciences, there is particular interest in triply periodic minimal surfaces (TPMS) which are minimal surfaces as well as being triply periodic. This means having zero mean curvature. Although structures used within additive manufacturing may be TPMSâ&#x20AC;&#x2122;, it is generally not important whether or not they are minimal surfaces. Because triply periodic surfaces can be defined by a single implicit function, they can easily be combined and blended with

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In this example of implicit geometry, the software program nTopology was used to modify the diameters of beams in a simple diamond lattice, with the diameter increasing as the stress increases. It is also possible to do this with shelled solids, so that the wall thickness depends on stress. This can be a powerful method of optimizing structures that, unlike generative design, works well with cast or injection moulded components, as well as additive manufacturing.

other implicitly defined geometry. They can also be modified by other fields so, for example, they adapt to stress, fluid flow or heat transfer requirements. These properties can make them enormously powerful from a modelling perspective. They also have many interesting mechanical properties although understanding these properties is still very much an area of active research.

Robust modelling enables greater reuse One of the benefits that nTopology is stressing is something they call their notebook. This is a way of recording the process used to create geometry, very much like the feature tree in parametric CAD. Variables can be changed and references to external files updated, before replaying the process. This can enable workflows and best

A number of commercial software companies are offering implicit modelling packages. One notable start-up, Gen3D, is currently focused on modelling flow paths for applications such as manifolds and heat exchangers.

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practices for capture, reuse and refinement. While nTopology’s notebook is conceptually similar to a parametric feature tree, the increased robustness of implicit models should make it more useful. While parametric model templates work well for simple standard parts, they are often unreliable for more complex products. This is often because topology such as vertices and edges are automatically created and assigned ID’s while the geometry is being constructed. When changes are made that affect the way features intersect, especially where fillets are involved, the number of vertices and edges may also change, resulting in different ID’s being assigned. Features that reference this topology therefore lose their references and the model fails. The designer is often faced with a choice between a lengthy debugging process and recreating the model from scratch. Implicit modelling

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doesn’t depend on these topology references and is therefore unlikely to fail when variables are changed. However, if b-rep geometry is referenced underlying topology may cause workflows to fail because of this dependence. Thus, implicit modelling is enormously powerful and offers huge potential for engineering design. It is currently ready to apply in specific modelling tasks involving complex geometry with the potential to be fully implemented in the familiar parametric design environment. DW

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M e c h a n i c a l

The eight best ways to wreck your coupling driven system Keeping a servo-driven system running at peak efficiency is no simple feat. Misunderstanding performance criteria such as misalignment, torque, or RPM can be all it takes to cause a critical failure. The following are the eight best ways to consistently sabotage or damage your coupling driven system (and how to avoid them in the future).

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1. Choosing the wrong coupling Unsurprisingly, one of the most effective and common ways to wreck your system is by selecting the wrong coupling. There are many factors a design engineer must keep in mind to avoid coupling failure. Balancing criteria such as torque, RPM, shaft size, tolerances, operating environment, and misalignment is paramount to selecting the right coupling.

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Servo couplings: jaw coupling, Oldham coupling, beam coupling, disc coupling, bellows coupling (from center clockwise).

2. Not identifying misalignment Most servo applications have one or more forms of misalignment. This issue is a primary concern, as misalignment can cause stress to system components such as bearings — not just to the coupling itself. Misalignment is often caused by a tolerance mismatch from the driving side of a system to the driven side. This can be caused by a variety of factors, including parts from different manufacturers, inaccuracies in assembly, system/motor movement during operation, system DESIGN WORLD

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component wear, poor mounts, and thermal shaft expansion. Each coupling style can accommodate different amounts of misalignment. Designers must understand the nature of existing misalignment to determine if a high misalignment coupling is needed at the expense of factors such as torque, or if corrective system adjustments are necessary before selecting a coupling.

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•• •• M e c h a n i c a l •• components. Even if the coupling is rated for high RPMs, greater speeds increase the effects of misalignment. For example, a disc coupling might accommodate slight angular misalignment at its maximum rated speed of 10,000 RPM without adverse effects on the coupling or system components but will cause damage at a speed of 15,000 RPM with the same misalignment. Designers must know the maximum operating speed the coupling will experience to select the right one. It is also important to understand how manufacturers determine ratings — with performance factors in isolation or everything at max.

Working properly: three types of couplings on shafts (from top to bottom): bellows coupling, beam coupling, Oldham coupling.

Misunderstanding performance criteria such as misalignment, torque, or RPM can be all it takes to cause a critical failure.

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3. Exceeding RPM recommendation System requirements determine speed and in precision-driven servo systems, it is possible to have speeds of 2,000, 5,000, 10,000 or even 25,000 RPM. Unfortunately, not every coupling can handle higher speeds, even if they are otherwise a perfect fit for the system. Exceeding the manufacturer’s RPM rating can cause coupling failure or damage to system

4. Not considering coupling wear Couplings are designed to be the wear element in most systems to protect more expensive components such as bearings and motors. Each coupling wears differently and will fail differently. Beam and bellows couplings will completely fail — stopping power transmission — when they reach the end of their service life. Disc, jaw, and Oldham couplings will lose zero-backlash but still transmit motion. Depending on the application requirements, one of these wear types may not be desirable. Additionally, designers must consider if the coupling requires maintenance or replacement when reaching the end of its service life. Beam, bellows, and disc couplings are maintenance-free and require complete replacement after a failure, whereas Oldham and jaw coupling performance can be restored by replacing the insert after failure. During the testing phase, designers

This bellows coupling has failed in a deep convolution closer to one hub than the other and represents what may occur in a misalignment situation. This type of failure can occur with an excessive degree of misalignment exceeding coupling design limits, or when the coupling is improperly installed and the misalignment (again within specifications) is not uniformly distributed across the bellows.

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•• •• ••

Even if the coupling is rated for high RPM, greater speeds increase the effects of misalignment. For example, a disc coupling might accommodate slight angular misalignment at its maximum rated speed of 10,000 RPM without adverse effects on the coupling or system components but will cause damage at a speed of 15,000 RPM with the same misalignment. can better understand the service life of the coupling and give a recommended PM schedule to best avoid unplanned downtime. 5. Installing the coupling incorrectly There is no faster way to undo the work of selecting the perfect coupling and optimizing system parameters than installing it incorrectly. For example, uneven torqueing of the screws, incorrect shaft penetration, installing off-center, and compressing or stretching the coupling can lead to failure or the premature wear of sensitive system components. The

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A failed spider. (fig. 1) Balanced holes for a balanced design. 1: Oldham coupling 2: jaw coupling 3: bellows coupling 4: disc coupling 5: beam coupling.

safest option is to follow the manufacturer installation instructions, especially when accompanied by videos. 6. Buying Generic Couplings Not all couplings are created equal, or for the same purposes. Some couplings are manufactured with common specifications, tolerances, and designs, such that they are nearly indistinguishable from many others on the market. This may be suitable for systems with limited performance requirements, but precision systems often require or benefit from couplings with additional capabilities. For example, balanced designs are not the industry standard for most couplings. In an application like printing, the reduced vibration afforded by a balanced design is a necessity — less precise couplings would cause banding and expensive waste or downtime. The five servo couplings pictured

A rigid coupling on a shaft.

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•• •• M e c h a n i c a l •• (fig. 1) all have balanced holes for a balanced design. 1: Oldham coupling 2: jaw coupling 3: bellows coupling 4: disc coupling 5: beam coupling. 7. Selecting the Coupling Late in the Design Process Far too often, motion control couplings are selected late in the design process. This can limit which coupling is used in the system and the performance it delivers. For example, a system requiring high torque and speed may need to use a disc coupling but ultimately have an envelope that is too small to fit a double disc type, forcing the designer to select a single disc type. While it may meet the speed and torque requirements, single disc couplings cannot accommodate parallel misalignment, meaning that the system will require greater precision during installation to eliminate the chance of parallel misalignment, likely adding cost and complication. Considering the coupling earlier in the design process would have likely eliminated this issue, saving time and money. To make the design process easier, manufacturers may have CAD, detailed product information, and technical support available on their website.

A beam coupling on a servo motor.

This beam coupling has failed near the center and represents what may occur in a torque overload condition. A torque greater than the coupling design limits was applied to illustrate this example. Beam coupling failure may also occur in applications with parallel misalignment because the single beam must bend in two different directions simultaneously, creating larger stresses in the coupling that could cause premature failure.

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8. Failing to Test One of the first rules of system design is always test. While everything may look correct in the design, it is hard to determine suitability until the coupling is run under common use conditions. Extensive testing before use in live systems can help maximize coupling and system performance. Manufacturers can assist in the design process with technical support and by providing product samples to ensure proper coupling selection. DW Ruland | ruland.com

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M e c h a n i c a l

•• •• •

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Understanding bearing system preload

Assessing proper preload is critical to maximizing bearing system efficacy and service life. Here, we take a look at some key considerations when determining how to best use preload for bearing system applications.

How?

What are the best methods for preload in a bearing system? Springs: The simplest method of applying preload is to use a wave spring. The spring acts on the outer ring of one of the two bearings. This outer ring must be able to be axially displaced. In Figure 1, the bearing arrangement comprises a preloaded, single-row, deep groove ball bearing at each end of the shaft. The preload force remains practically constant, even when there is axial displacement of the bearing as a result of thermal elongation. The requisite preload force can be estimated using:

F=kd where F = preload force [kN] k = a factor, described in the following text d = bearing bore diameter [mm] For small electric motors, values of between 0,005 and 0,01 are used for the factor k. If preload is mainly used to protect the bearing from the damage caused by external vibrations when stationary, then greater preload is required and k = 0,02 should be used.

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Fig. 1

Spring loading is also a standard method of applying preload to angular contact ball bearings in high-speed grinding spindles. The method is not suitable for bearing applications where a high degree of stiffness is required, where the direction of axial load changes, or where indeterminate peak loads can occur. Adjustment: Adjustment means setting the internal clearance or preload in an adjusted bearing arrangement during assembly. In operation, a certain clearance/preload— or only preload — range then arises. Axial preload in an adjusted bearing arrangement with single-row, angular contact ball bearings, tapered roller bearings, and deep-groove ball bearings is produced by displacing one bearing ring axially, relative to the other, by an amount corresponding to the desired preload force. There are essentially two principal methods to adjust preload: individual adjustment and collective adjustment. Individual adjustment: With individual adjustment, each bearing arrangement is adjusted separately using nuts, shims, spacer sleeves, crush sleeves, etc. Measuring and inspection procedures are used to ensure that the established nominal preload is obtained with the least possible deviation. There are various methods to obtain the required preload: • axial displacement method • frictional moment method • direct force method

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The method used depends on, among other things, the application design and the number of bearings to be mounted. Individual adjustment can accommodate enough tolerance stack-up so that if individual components are produced to normal tolerances, the desired preload can be achieved with a relatively high degree of accuracy. i) Axial displacement method: The axial displacement method is based on the relationship between the preload force and the elastic deformations within the bearing arrangement. The requisite preload can be determined from the preload force/axial displacement diagram (Fig. 2). This method of adjustment is frequently used when the components of a bearing arrangement are preassembled. The required preload, which is expressed as a negative distance, requires measuring total axial positive displacement (end play) of the shaft relative to a fixed surface. This is often done with a dial indicator. Shims, intermediate rings, or spacers can then be used to adjust axial displacement to the correct negative distance. The width of DESIGN WORLD

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Adjustment means setting the internal clearance or preload in an adjusted bearing arrangement during assembly. In operation, a certain clearance/preload range — or only preload — then the shims, intermediate rings, or spacers is determined by: • the distance between the shaft and housing shoulders • the total width of both bearings • the axial displacement corresponding to the desired preload force • a correction factor for the axial displacement to account for thermal expansion in operation and manufacturing tolerances of all related components, established by measuring the actual dimensions before mounting • a correction factor to account for a certain loss of preload as a result of settling and wear ii) Frictional moment method: This method is common in large series production because it is fast and can be automated. Since there is a relationship between bearing preload and the frictional moment in the bearings, it is possible to stop adjustment when a frictional moment corresponding to the desired preload has been reached. This can be done if the frictional moment is continuously monitored while setting preload. However, the frictional moment can vary from bearing to bearing, and it also depends on the preservative, the lubricant, and the sealing method.

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Fig. 2

iii) Direct force method: As the purpose

of bearing adjustment is to obtain a specific preload, it would seem sensible to use a method either to produce or to measure the force directly. However, in practice, the indirect methods of adjustment by axial displacement or frictional moment are preferred because they are simple and can be achieved easily and more cost-effectively. b. Collective adjustment: This method can also be referred to as “random statistical adjustment.” Engineers use this method so that the bearings, shaft, housing, and other components are manufactured to normal tolerances. The components, which are considered fully interchangeable, are assembled randomly. For tapered roller bearings, this interchangeability also extends to the inner ring assemblies and outer rings. To avoid high machining costs and the use of precision bearings, engineers assume that — given the limiting values of the tolerances — it is statistically improbable that the extremes of the tolerance stackup occurs. If, however, accurate preload is to be obtained with as little scatter as

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possible, manufacturing tolerances must be narrowed. The advantage of collective adjustment is that no inspection is necessary and no extra equipment is needed when mounting the bearings. Manufacturing: Single, universally matchable bearings: Universally matchable bearings are specifically manufactured so that, when mounted in random order but immediately adjacent to each other, preload within a predetermined range and effective load sharing will result without the use of shims or similar devices. The preload classes are GA, GB, and GC. Matched bearing sets: Bearings can be supplied as a complete bearing set consisting of two, three, or more bearings. The bearings are matched to each other during production so that when mounted immediately adjacent to each other and in the specified order, preload within a predetermined range and effective load sharing result without the use of shims or similar devices. The preload classes are GA, GB, and GC.

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How much?

What variables determine the proper amount of preload? The answer to this question varies on a caseby-case basis and depends on bearing type, size, and operating conditions. For general applications, the operating clearance range should be within the recommended zone shown in Figure 3. As seen in the diagram, the bearing life improves with slight preload. Still, excessive preload can have a sharp reduction in life due to increased load on the rollers, which in turn increases friction, damages the lubricant, and can cause high operating temperatures. Troubleshooting

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can have a sharp reduction in life due to increased load on the rollers, increasing friction, damaging the lubricant, and elevating operating temperatures. The variation between target preload value and actual preload value: When adjusting preload in a bearing system, it is

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also important that the established preload value, determined either by calculation or from experience, is attained with the least possible variation. To reduce variation when mounting tapered roller bearings, for example, the shaft must be turned several times so that the rollers are not skewed, and the roller ends are in contact with the guide flange of the inner ring. When the rollers are not fully settled into position, this results in a much smaller preload than the requisite value. The variation between design and test conditions: it is recommended to calculate the preload force and check if it’s appropriate by testing the application. Generally, it is not always possible to identify all influencing factors in operation fully during the design stage, and adjustments may be necessary. The accuracy of the calculated results depends on how closely the estimated operating temperature and elastic behavior of the associated components — most importantly the housing — match the actual operating conditions. The variation between ambient and operating temperature: During operation, if the shaft temperature is higher than

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•• •• ••

•• •• M e c h a n i c a l •• the housing temperature, the preload, which was adjusted at ambient temperature during mounting, will change. Thermal expansion: Thermal expansion of

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the inner ring in the radial direction leads to an increase of the preload. Thermal expansion in the axial direction increases the preload when the bearings are face-to-face, but is reduced for backto-back arrangements. Depending on the distance between the bearings, and provided the coefficient of thermal expansion is the same for the bearings and associated components, thermal expansion in both the radial and axial directions can cancel each other out so that preload remains unchanged for back-to-back arrangements independent of operating temperature. Stiffness: When selecting the preload for a bearing arrangement, the degree of stiffness increases marginally once preload exceeds a given optimum value. When exceeding this optimum value, friction and the resulting increase in heat can substantially reduce bearing service life. Excessive preload includes a risk that the operational reliability of a bearing arrangement is compromised. However, bear in mind that stiffness is also influenced by the elasticity of the shaft and housing, the shaft and housing fits, and the elastic deformation of all other components adjacent to the bearings, including abutments. Each of these factors has a considerable impact on the resilience of the total bearing system. The axial and radial resiliencies of a bearing depend on its internal design, contact conditions (point or line contact), the number and diameter of rolling elements, and the contact angle. The greater the contact angle, the higher the degree of stiffness in the axial direction.

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E l e c t r o n i c s

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•• •• •

Simpler debugging for

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E l e c t r o n i c s

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The Tektronix MSO 6 Series has an analog bandwidth of up to 8 GHz, a sampling rate of 25 GS/sec, and 12-bit resolution to accurately capture Automotive Ethernet signals.

Automotive Ethernet’s 100 Mb/sec data rate calls for an oscilloscope incorporating a bandwidth of at least 1 GHz.

Consequently, there is an industry wide move to Automotive Ethernet. Although the automotive standard originated in Ethernet, it incorporates significant changes at the physical layer to meet automotive needs. The first version of the standard was called BroadR-Reach and is being supplanted by the IEEE versions known as 100BASE-T1 (802.3bw) and 1000BASE-T1 (802.3bp). The standard being designed into most cars today is 100BASE-T1, which supports 100 Mbps operation in the noisy automotive environment. This data rate is significantly higher than that of traditional bus systems such as the CAN bus. Future designs will use 1000BASE-T1, at 10X the data rate. As signaling moves to higher data rates, so, too, does the need for comprehensive

Full Duplex MAC I/O (MII)

Examples of where signal integrity testing at the system level might bring benefits include: • TC8 (Technical Committee 8) signal quality testing • ECU component characterization and testing • Automotive Ethernet cable, connector, cable length and routing characterization and testing Full Duplex MAC I/O (MII)

Full Duplex PHY I/O

100 Mbps RX

MAC

System-level testing The OPEN (One-Pair Ethernet) Alliance has defined specifications for Automotive Ethernet encompassing components, channels and interoperability, and encompassing integration of ECUs, connectors and untwisted cables. To meet reliability requirements, testing must take place under the noisy conditions found within vehicles. This kind of testing, in turn, requires that testers characterize and visualize signal integrity and traffic at the system level under real-world conditions.

100 Mbps

PHY 100 Mbps TX

100 Mbps TX

PHY 100 Mbps

MAC 100 Mbps RX

Typical full-duplex connections on Automotive Ethernet: Master and slave devices can communicate simultaneously over the same link.

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• Electromagnetic susceptibility (EMS) testing or Gaussian noise testing • Bulk current injection testing • Production unit testing • Automotive system impact on Automotive Ethernet performance • DC motor on/off • Engine on/off • Automotive Ethernet system debug Ideally, you should perform signal integrity testing at the vehicle integration phase to select cables, determine optimal cable lengths and routing, check ECU performance in the presence of electromagnetic noise, etc. For visualizing the health of the system, an oscilloscopegenerated eye diagram is the most valuable tool. It also provides insight on the overall health of the physical layer (PHY) and can help identify errors caused by high temperatures or noise. Also, accurate timing measurements at the system level

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An Automotive Ethernet eye diagram containing master and slave signals typically looks like a garbled mess.

are critical for determining latency when using gateways that convert CAN or other traditional buses to Automotive Ethernet and vice versa. Automotive Ethernet’s 100 Mb/sec data rate calls for an oscilloscope incorporating a bandwidth of at least 1 GHz along with high sampling rates. For 1000BASE-T1, the

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necessary bandwidth is in the 2-GHz range. Ideally, the scope should come equipped with a PAM3 analysis software package having software clock recovery. These capabilities provide a better understanding of signal qualities for the validation and characterization of PAM3 designs having different cable lengths, noise conditions or ECU configurations.

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Traditional methods for separating Automotive Ethernet signals employ directional couplers spliced into the twisted pair, left. New software-based methods allow a simpler setup using just an inductive current probe and a differential probe, right.

Both full-duplex communication and PAM3 signaling, while vital to the performance of Automotive Ethernet, complicate the validation of ECUs under real world conditions. Most serial standards operate in a simplex mode, with only one device communicating at a time, or devote separate links to the transmitter and receiver. With Automotive Ethernet, however, the master and slave device communicate simultaneously over the same link. As a result, the signals from the master and slave overlay on each other. The master knows what data it has sent, so it can separate out the slave’s signal. The transceiver is designed to handle this situation, but it is virtually impossible on an oscilloscope to isolate the signal for signal integrity testing or protocol decode. To analyze signal integrity over a link and decode protocols in a real system environment, automobile designers must look at each link separately. This requires separating the signals before performing analysis. Currently, there are two methods for separating master and slave signals. The first, the traditional method, requires cutting the Automotive Ethernet cable and splicing a directional coupler in each wire of the twisted pair to separate and test the signals. Technicians must physically cut the cable to implement the test, which introduces accuracy problems. It is not easy to cut the cable, which

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makes this method less than ideal for most system-level testing applications. While this approach does provide access to the master and slave signals, it introduces insertion and return loss, which can make it difficult to determine if an error results from the additional hardware. And, while it is possible to remove the effects of the directional coupler, de-embedding (basically, removing the effects of the test fixture from the data) can amplify the noise in the system and degrade measurement and characterization accuracy. More recently, test manufacturers have devised software and probes to non-

intrusively separate the signals, allowing engineers to visualize the true signals with greater clarity. The connections involved consist of an inductive current probe monitoring one of the twisted-pair wires and a differential probe placed across the twisted pair. But there have been questions about whether this new method is more accurate than the old directional coupler technique. To compare the two directly, we first ran tests using the software-based method. We then cut the Automotive Ethernet cable and inserted directional couplers with SMA connectors. We used the same test conditions and compared the test outcomes. The eye diagram obtained using a directional coupler illustrates the impact of insertion and return loss. The max amplitude is just 100 mVpp as the directional coupler and the insertion and return loss close the eye diagram. In contrast, the software approach uses an algorithm to separate voltage and current waveforms from both the master and slave test points. This approach provides a much more accurate representation of Automotive Ethernet signals, helping to identify potential performance issues in less time and with greater confidence.

An eye diagram of a master signal, extracted from directional couplers, illustrates the impact of insertion and return loss.

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Software-based separation of Automotive Ethernet signals results in eye diagrams much cleaner than those generated from directional couplers.

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Peak-to-peak comparison A comparison of peak-to-peak voltages shows a significant amplitude difference between the two methods. When using the directional coupler, the amplitude was approximately 90 mVpp for the master and 85 mVpp for the slave. In comparison, the software approach had an amplitude of approximately 1.5 Vpp for the master and 1.45 Vpp for the slave. Thus the directional coupler reduced signal strength by 20 dB, a significant loss when evaluating edge cases. Test personnel must compensate for the insertion and return loss introduced by the directional coupler. The resulting deembedding process can be time consuming and challenging. It should also be noted that it can be challenging to cut the cable and install directional couplers when working in a real vehicle. In comparison, the software-based method as illustrated here shows the true signal without disrupting the system. This new Automotive Ethernet test methodology

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A comparison of peak-to-peak voltage shows a 20-dB loss due to the directional coupler.

will allow engineers to characterize signals faster and more accurately. This method overcomes many of the challenges associated with performing Automotive Ethernet signal integrity tests at the system level and opens up a wide range of new use cases that were once tough to perform. It is useful to review of few of the more advanced tests made accessible via the software-based method. For example, the 100/1000BASE-T1 specification defines a return loss measurement that requires a VNA. Automotive Ethernet test software allows the designer to perform return loss measurements using an oscilloscope, reducing the need for additional test equipment. A distortion test defined in the spec requires access to the ECU clock, which is often impractical. A special software correction method eliminates the need for the clock connection for 100BASE-T1 and 1000BASE-T1. Another portion of the spec defines a return loss test that determines how much Ethernet line impedance differs from the differential impedance specification of 100 Ω , because mismatches will affect hardware interoperability. A VNA can run this test but an oscilloscope equipped with the software solution can perform it as well, no VNA required. One last example is that of power spectral density (PSD) measurements. Built-in oscilloscope software computes the DESIGN WORLD

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spectra of an input signal. Post processing on the signal yields the PSD. The computed PSD is then compared with the specification using masks. DW References Tektronix Automotive Ethernet test solution datasheet, https://www.tek. com/datasheet/automotive-ethernettest-solution-0

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Because PHY frequencies are in the gigahertz range, test probes can cause line reflections and other distortions that can garble measurements. Tektronix recommends using its TF-XGbT Ethernet fixture and TF-BRR-CFD clock divider fixture to minimize distortion when making connections to Ethernet transmitter output and reference clock signals .

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MM3D is highly versatile, where the same basic design can be used to effectively print objects consisting of one or multiple inks in a fraction of the time currently required. | Wyss Institute at Harvard University.

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A D D I T I V E

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Multimaterial

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3D printing manufactures complex objects, fast With new additive technology, a multinozzle 3D printer can switch

between multiple inks up to 50 times per second.

3D printers are revolutionizing manufacturing

By Lindsay Brownell | Science writer Wyss Institute for Biologically Inspired Engineering at Harvard University

by allowing users to create any physical shape they can imagine ondemand. However, most commercial printers are only able to build objects from a single material at a time and inkjet printers that are capable of multi-material printing are constrained by the physics of droplet formation. Extrusion-based 3D printing allows a broad palette of materials to be printed, but the process is extremely slow. For example, it would take roughly 10 days to build a 3D object roughly one liter in volume at the resolution of a human hair and print speed of 10 cm/s using a single-nozzle, single-material printhead. To build the same object in less than 1 day, one would need to implement a printhead with 16 nozzles printing simultaneously! Now, a new technique called Multimaterial Multinozzle 3D (MM3D) printing developed at Harvard’s Wyss Institute for Biologically Inspired Engineering and John A. Paulson School of Engineering and Applied Sciences (SEAS) uses high-speed pressure valves to achieve rapid, continuous, and seamless switching between up to eight different printing materials, enabling the creation of complex shapes in a fraction of the time currently required using printheads that range from a single nozzle to large multinozzle arrays. These 3D printheads themselves are manufactured using 3D printing, enabling their rapid customization

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Rapid switching between inks is achieved thanks to special Y-shaped junctions in each nozzle (far left) that are precisely tuned to

“

prevent mixing or backflow of the inks during printing. The junctions can be multiplexed for larger printing jobs, and can be customized to account for materials with different physical properties (second from right). | Wyss Institute at Harvard University.

“

Because MM3D printing can produce objects so quickly, one can use reactive materials whose properties change over time, such as epoxies, silicones, polyurethanes, or bioinks, co-first author Jochen Mueller, Ph.D., a Research Fellow at the Wyss Institute and SEAS.

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and facilitating adoption by others in the fabrication community. Each nozzle can switch materials up to 50 times per second, which is faster than the eye can see, or about as fast as a hummingbird beats its wings. The research is reported in Nature. “When printing an object using a conventional extrusion-based 3D printer, the time required to print it scales cubically with the length of the object, because the printing nozzle has to move in three dimensions rather than just one,” said co-first author Mark Skylar-Scott, Ph.D., a Research Associate at the Wyss Institute. “MM3D’s combination of multinozzle arrays with the ability to switch between multiple inks rapidly effectively eliminates the time lost to switching printheads and helps get the scaling law down from cubic to linear, so you can print multimaterial, periodic 3D objects more quickly.” The key to MM3D printing’s speedy ink-switching is a series of Y-shaped junctions inside the printhead where multiple ink channels come together at a single output nozzle. The shape of the nozzle, printing pressure, and ink viscosity are all precisely calculated and tuned so that when pressure is applied to one of the www.designworldonline.com

“arms” of the junction, the ink that flows down through that arm does not cause the static ink in the other arm to flow backwards, which prevents the inks from mixing and preserves the quality of the printed object. By operating the printheads using a bank of fast pneumatic valves, this one-way flow behavior allows the rapid assembly of multimaterial filaments that flow continuously out from each nozzle, and enables the construction of a 3D multimaterial part. The length of the ink channels can also be adjusted to account for materials that have different viscosities and yield stresses, and thus flow more quickly or slowly than other inks. “Because MM3D printing can produce objects so quickly, one can use reactive materials whose properties change over time, such as epoxies, silicones, polyurethanes, or bio-inks,” said co-first author Jochen Mueller, Ph.D., a Research Fellow at the Wyss Institute and SEAS. “One can also readily integrate materials with disparate properties to create origami-like architectures or soft robots that contain both stiff and flexible elements.” To demonstrate their technique, the researchers printed a Miura origami DESIGN WORLD

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A D D I T I V E

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M A N U FA C T U R I N G

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structure composed of stiff “panel” sections connected by highly flexible “hinge” sections. Previous methods of building such a structure require manually assembling them together into stacked layers - the MM3D printhead was able to print the entire object in a single step by using eight nozzles to continuously extrude two alternating epoxy inks whose stiffnesses differed by four orders of magnitude after being cured. The hinges withstood over 1,000 folding cycles before failing, indicating the high quality of the transitions between the stiff and flexible materials achieved during printing. MM3D printing can also be used to create more complex objects, including actuating robots. The research team designed and printed a soft robot composed of rigid and soft elastomers in a millipede-like pattern that included embedded pneumatic channels that enable the soft “muscles” to be compressed sequentially by a vacuum, making the robot “walk.” The robot was able to move at nearly half an inch per second while carrying a load eight times its own weight, and could be connected to other robots to carry heavier loads. “This method enables the rapid design and fabrication of voxelated matter, which is an emerging paradigm in our field,” said corresponding author Jennifer A. Lewis, Sc.D., who is a Core Faculty Member at the Wyss Institute and the Hansjörg Wyss Professor of Biologically Inspired Engineering at SEAS. “Using our broad palette of functional, structural, and biological inks, disparate materials can now be seamlessly integrated into 3D-printed objects on-demand.” Importantly, current MM3D printheads can only print periodic (i.e., repeating) parts. But the team envisions that MM3D printing will continue to evolve, eventually featuring nozzles that can extrude different inks at different times, smaller nozzles for greater resolution, and even larger arrays for rapid, single-step 3D printing at a wide range of size and resolution scales. They are also exploring the use of sacrificial inks to create even more complex shapes. “3D printing is revolutionizing the manufacturing industry by allowing people to create without the need for expensive machinery and raw materials, and this new advance promises to dramatically improve the pace of innovation in this exciting area,” said

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The printhead can accommodate multiple nozzles, each of which can print up to eight different

materials. A series of branched channels distributes the “inks” to the nozzles. | Wyss Institute at Harvard University.

Wyss Founding Director Donald Ingber, M.D., Ph.D., who is also the Judah Folkman Professor of Vascular Biology at Harvard Medical School and the Vascular Biology Program at Boston Children’s Hospital, as well as Professor of Bioengineering at SEAS. DW

Wyss Institute for Biologically Inspired Engineering at Harvard University wyss.harvard.edu

Claas Visser, a former Postdoctoral Fellow at the Wyss Institute and SEAS, also contributed to this work. The research was supported by the Vannevar Bush Faculty Fellowship Program through the Office of Naval Research, the National Science Foundation (Harvard MRSEC), and the GETTYLAB.

MM3D printing’s unique 3D-printed printhead design allows

WHAT DO YOU THINK?

it to seamlessly switch between multiple different materials up to 50 times per second, greatly streamlining the process of printing complex structures. | Wyss Institute at Harvard University.

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Figure 1: It is easy to focus on larger items for a pneumatic installation, and overlook smaller but crucial components. | All figures courtesy of AutomationDirect

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P n e u m a t i c s

How to build

a pneumatics bill of material Planning out all of the details — and remembering the small stuff — pays off when designing pneumatic systems. Kevin Kakascik | AutomationDirect

So you have a big home project planned for this weekend, like building a deck. Earlier in the week, you stopped at the hardware store and picked up all the lumber and some necessary tools not already in your kit. Now it’s Saturday and you wake up early to get a jump on things before it gets too hot outside. The weather is perfect as you set out all the materials — only to spot you are missing deck screws. Sound familiar? You hurriedly drive to the hardware store, buy the deck screws, then return home and resume working. Another hour into your project, after cutting the lumber, you begin framing, only to realize you are missing joist hangers, requiring another frustrating round trip to the hardware store. How could you forget these small yet

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Usually, the tubing is remembered with the initial material order because designers plan for what is needed. However, an installation often runs short because the necessary lengths were not calculated properly to account for twists, turns, and tough-to-reach locations.

crucial items for your project? It’s simple — because they are small, they often times take a lower priority to the larger items. This syndrome of overlooking details is also quite common for industrial pneumatics projects. Designers plan the system, determine pressure and flow requirements, select control components, and focus on larger items like cylinders, Figure 1. Yet often times, some smaller but crucial components are missed. While these parts may be available at a local distributor, many pneumatics components aren’t for sale at the hardware store down the street. Having all the parts on hand can make the difference between getting a project up and running quickly or delaying the work and incurring additional costs. Let’s examine several pneumatic components that are oftentimes overlooked when creating a pneumatic system bill of materials (BOM). Tubing Flexible and durable tubing connects devices together by transporting compressed gas, usually air (but sometimes

nitrogen), Figure 2. Most pneumatic systems use some amount of flexible tubing unless they are entirely hard-piped. Some designs may use just one size and color of tubing, making it easy to stock the right material. But many installations need multiple tubing sizes, and oftentimes it is helpful to use various colors to identify functionality. Special tubing for extreme temperatures or added flexibility may be needed. For these and other cases, getting the right materials on hand is more complicated. Usually, the tubing is remembered with the initial material order because designers plan for what is needed. However, an installation often runs short because the necessary lengths were not calculated properly to account for twists, turns, and tough-to-reach locations. When an installation runs short on tubing, a local supplier may have enough of the right size and color in stock to match the already completed work — but this is a gamble compared to ordering enough upfront. When it comes to tubing, it pays to standardize as much as possible, over-order to some extent, and work with a supplier offering a comprehensive product selection. Fittings Fittings are used to connect tubing to devices or other sections of tubing, and they are typically threaded on one end and have push-to-connect or barb connections on the other, Figure 3. Because the fittings must accommodate various tubing and device sizes, many styles may be needed. Careful planning is required to ensure the correct sizes are ordered. Outside diameter of the tubing determines push to connect size, while inside diameter determines the type barb style fitting. Threaded size is very important because there are different types:

Figure 2: Pneumatic tubing is available in many sizes and colors.

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• National pipe thread (NPT), tapered • British standard pipe thread (BSPT), tapered R-thread • British standard parallel pipe (BSPP), straight G-thread • Metric versus United States (or British) sizes Beyond the size, each fitting must be selected with the right materials of construction based on the environment and operating pressure. Stainless or thermoplastic are options for push to connect fittings. Barb style fittings are usually brass. A missing or incorrectly sized or specified fitting can add days to a project schedule.

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Manifolds Pneumatic manifolds save space by distributing compressed gas to multiple devices — analogous to how power distribution blocks can provide an electrical supply to multiple loads. Manifolds make the most sense when there are many connections of a similar size needed in a location, all with

compatible pressure and flow requirements. While manifolds are not required and may not even be recommended for very small systems, they are low cost and provide a compact installation. Manifolds make for a neater and cleaner installation, and help avoid a spaghetti-like installation mess, which is hard to troubleshoot and maintain. As with other fittings, manifolds come in many different materials such as aluminum, nylon, polypropylene, and stainless steel. Various port sizes, quantities, and arrangements are also available. Planning is necessary to ensure there are enough ports, and also to provide plugs for unused ports. If an installation comes up short on manifolds, there may be a workaround using other fittings, but it won’t look as elegant. Manual shutoff and isolation/ lockout valves Manual shutoff valves can be used to isolate downstream devices from upstream air pressure, analogous to how an electrical disconnect switch de-energizes downstream loads, Figure 4. They can also be locked-

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Figure 4: Manual shutoff and isolation/lockout valves are crucial for any pneumatic system.

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out in the safe position just like an electrical disconnect. Shutoff valves can be used to isolate a system that won’t be used for a while, and they can also be arranged so users can de-pressurize an isolated system. Manual isolation/lockout valves operate similarly to basic manual valves except they bleed off downstream air pressure when closed. These valves are the pneumatic portion of an emergency stop circuit and can operate quickly. Per OSHA standard 1910.147, for all automated machinery the operating personnel must be capable of quickly relieving of all “hazardous energy.” Isolation/lockout valves are OSHA-approved for this purpose. Valves are necessary to properly supply, isolate, and de-pressurize pneumatic systems. They must be arranged so equipment can be locked out by maintenance personnel, who can then safely perform work without fear of equipment moving pneumatically. Each project needs all the valves on-hand and ready for installation so the equipment can be operated safely. Automatic soft start valves An automatic soft start valve is a three-way, two-position solenoid device that is installed upstream of all moving pneumatic equipment. When the machine requires air pressure, the controls energize the soft start valve, which has an adjustable ramp-up time to apply pressure gradually. This increases the life of pneumatic equipment and prevents any sudden mechanical movement that can cause noise, breakage, or injury. When de-energized, soft-start valves also act as a relief valve to quickly relieve downstream air pressure. Soft-start valves are usually installed in series with a manual shutoff valve, but they don’t satisfy the requirement for a manual shut-off valve or isolation valve. Only one soft start valve is typically needed per an equipment area, and they are not required but are a good design practice. The system can be plumbed to run without one, so it is easy to forget this device during initial designs. Exhaust mufflers Exhaust mufflers are some of the smallest, simplest, and least expensive pneumatic components. They screw directly into the exhaust port of control valves, shutoff valves, and isolation valves, reducing the noise created by the device exhausting air to atmosphere. Technically, exhaust mufflers are not needed for a system to function. However, they provide a more comfortable and safer occupational environment, and OSHA standard 1926.52 requires employers to protect their employees from continuous noises exceeding specified decibel levels for varying amounts of time.

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Specialty pneumatic fittings encompass many types of components.

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Specialty fittings The term “specialty fitting” or “special purpose fitting” is a catch-all for any functions that may be less commonly used for an application, Figure 5. Some examples are: • Small flow control restrictor valves, used to lower actuator speeds • Check valves to allow airflow in only one direction • Shuttle valves which shift to route the higher pressure from one of two inputs to the output • Bleeder valves with manual pushbuttons to bleed pressure trapped in part of a system

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These items are special in the sense that a designer may not typically use them, which is a good reason why they might be overlooked during design. However, many of these items can be difficult to source locally and should be carefully ordered in advance. Sweat the small stuff Projects of all types benefit from careful planning. For pneumatics projects, there are many components that may be overlooked or underestimated. These sometimes-forgotten components don’t always cost a lot, but they may not be readily available from the hardware store around the corner. Obtaining sufficient quantities of the right parts in advance helps keep installation efforts on time, within budget, and safe. DW

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Leading

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Engineering careers can take their twists and turns, and where they lead can be unexpected. Rep. Chrissy Houlahan, a first-term congresswoman from southeastern Pennsylvania, didn’t see herself walking the halls of Congress when she applied to Stanford to pursue a degree in engineering … she simply wanted to be an astronaut. Houlahan, who grew up in a military family — her dad and her grandfather were both P3 pilots — lived in a variety of places during her childhood, including up and down the East and West coasts, in Florida, Washington D.C., Rhode Island, California, and Japan.

Paul J. Heney | VP, Editorial Director

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‘‘‘

L e a d e r s h i p

That has to be part of success of building enterprises and organizations, to allow people to do what they’re good at it, and to recognize that you’re probably okay at some things … but you probably have a lot of people on your team who knew a lot more about certain things than you do,” she said.

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Those different living situations, as well as her father’s hard work, taught her a lot. In fact, Houlahan’s father was a refugee, so she saw the struggles of building a life from scratch firsthand: “It’s really important to have that lesson of what it means to come up from nothing.” “[Moving a lot] also taught me that everybody is the same, and yet everybody is different. In other words, having the opportunity to live in different places such as Japan and California and Florida and New England gave me an understanding of how even while all people have unique lives and perspectives, they always have a lot in common. And it’s especially important, now that I sit in government, to remember that — and not to have only lived in my own siloed part of the world.” Houlahan chose Stanford for a variety of practical reasons. She was finishing high school in Rhode Island while her family was stationed in Hawaii. Trying to head west was a way to get her closer to her family. Another benefit was that she had lived in the Bay Area before. “The Bay area was a place with which I was familiar. I was really an admirer of Sally Ride, and she went to Stanford — and I really wanted to be an astronaut,” Houlahan said. “Part of my thought process was that I needed to find a school that has engineering; Stanford obviously does. I needed something closer to my home; Stanford obviously was. I also need something having a ROTC program, because I wanted to be a pilot … and I thought the Air Force was a more likely possibility.” “If you talk to my parents, you’ll hear that I always wanted to go to Stanford. That’s probably true, but it also kind of satisfied all of the right requirements for me. It’s also a university that doesn’t have an engineering school. So you get into the school, and then you can major in whatever it is that you want. I thought that was a really nice thing as well.”

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Indeed, Houlahan was Air Force ROTC at Stanford … and after graduating and separating active duty, she went to MIT. There, a consortium of the military and the aerospace industry paid for her degree. “The defense contractors and the military got together,” she said. “Lean manufacturing in the auto industry, particularly in Japan, was kind of the thing back in the 80s and 90s, and our defense industry wanted to understand how to take those lessons from lean manufacturing in Japan and apply them to our defense industry. So, I got what amounted to a research assistant position to transition out of the military into MIT to work on that program. I was really, really lucky.” Full STEM ahead Houlahan served in the Air Force in active duty for three years and in the reserves for 13 more. She worked in both the private sector and nonprofit sector. While working as Chief Operating Officer for AND1, a footwear and clothing manufacturer, she was given company paid time off to do community service work — and she decided to work with young women in STEM programs. “As a young girl growing up, I was in a mostly male environment,” she said. “That’s because I was always interested in math and science … and then of course in college it was engineering … and then I was in the military. I was raised to recognize the importance of science and technology, but I also knew how hard it was to be the only girl in my classes, to be one of only 10 Stanford women who graduated with my degree, to go into the military and be just one of a handful of women who were engineers.” That only continued as Houlahan progressed in her career. “Then I was in a basketball apparel and footwear company where my job was to be the operations person, and my job was the technical part of the business. It was really important to me to try and help the next generation, including women and girls in STEM and STEAM as well as underserved communities in general. So, I spent my community service time on both of those things.” The day I spoke with Houlahan, she had just returned from an exercise hosted by Washington state’s Rep. Suzan DelBene, who (according to the Pennsylvania representative) is one of the other people in the House who thinks about things technical. The exercise let members of Congress learn and receive a certificate for coding.

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“I was walking back and talking to one of our technical staff members here — pontificating about the fact that I’m a Stanford and MIT educated engineer. I have three grown girls, and none of them were interested in engineering or technology, math or science. And I worked really hard in my house to could encourage my kids to think about those fields,” she said. “I had one female professor at Stanford and no female professors at MIT. Thirty years later when my daughter went to school, my degree had changed names but still only 10% of the students who graduated were women.” What advice does Houlahan have for young women? It’s pretty simple. “Don’t be so hard on yourself. Don’t negotiate with yourself and decide that you can’t perform a particular job or achieve a particular goal. I think women and girls assume they must be super-qualified and super-capable to do anything or to even try anything — and that mentality even applies to the concept of running for public office,” she said. Research into the female attitudes towards ambition tends to support this. “Women must feel as though they’ve checked every box and done everything required to be qualified. In contrast, guys are just like, ‘Sure why not? Why wouldn’t I be qualified to do that?’” Moving into elected office Houlahan was elected to Congress in 2018, representing Pennsylvania’s 6th district, which she describes as purple in political orientation. The district contains roughly 40% Democrats, 40% Republicans and 20% Independents, so a moderate voice is required to represent the voters there. “I call us farms and pharma,” said Houlahan. “We’re pharmaceutical towards the east and the city [Philadelphia], and farms, very rural, towards the west. We are the mushroom capital of the world, and we have a lot of dairy farms as well. What’s also cool about the district is you’ve got very suburban, frankly very affluent areas here towards the city, very rural, very farming westward of the city. To the north, still in my district, you have the city of Reading. A former industrial giant, Reading is now one of the poorest cities in the country. It’s a really, really interesting community to serve. I’m lucky. I have kind of a little American Petri dish.” She has been a passionate supporter of the Armed Forces Digital Advantage Act, which is basically a centralization of the HR process. It creates kind of an HR czar within the military who can think about career paths from people with technical backgrounds. “Very importantly for me, I thought there weren’t clear pathways for people with tech backgrounds [in the military]. We were trying to hire people in a more traditional and military way with skills that are very different than the skills of traditional military people,” she said. “We’re trying to figure out a way to centralize the HR process across the DoD so that when we were looking for cyber people or people with tech backgrounds or whatever, that you were actually thinking hard about what it is that you’re looking for from a specialty career area. And that you’re also centralizing it so that everybody’s not having to learn the same thing across the different parts of the DoD.”

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Houlahan said that one contributing factor to why she left the military was that she wasn’t able to visualize a career path for herself. “I couldn’t really look up and understand where I would be in 25 or 30 years. I couldn’t really understand — with a technical background and also as a woman — what it would look like to be here for a long time. If you’re looking at your career trajectory, you want to make sure you understand that. I think now it’s even more acute, that technology moves so, so rapidly and these skills are so much different than they were when I was a kid, that I think it’s really important to think hard about what the DOD looks like and how we hire people.”

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Engineering government Houlahan thinks that we need more engineers, more technical people serving in Congress. (Cambridge University Press lists 16 currently, out of 535 members.) “Do I think there needs to be more people with technical backgrounds in our government? Yes. Look at the things that we’re talking about — the accuracy of missiles that just dropped, for example: Was it intentional that nobody got killed? I would certainly like to know what kind of missiles they were using and what their accuracy was,” she said. “I’d also like to understand what it means to be a person who codes right now. It’d be helpful to have that knowledge.” “This morning, I had a meeting on biosecurity and synthetic biology. Who’s in that meeting? There’s me — and I’m certainly not an expert in synthetic biology, but at least I can pronounce those words.” Houlahan thinks that working familiarity of information technologies might be most helpful of all: “I think such knowledge is absolutely critical for legislators who are being asked to think about data privacy. In fact, I just had a meeting on data privacy; it would be really nice if we had more legislators with technical backgrounds on that.” Engineers are sometimes thought of as poor communicators. But Houlahan sees the issue differently. “There are definitely certain people who communicate in different ways — and having spent 30 years in industry now and seeing the spectrum of people, I actually value the way that engineers communicate … and I have considered myself to be an engineer whisperer in some ways,” she said. “I frankly miss the engineers with whom I had to work because I enjoy communicating in a more strategic and tactical way … and it’s harder for me to understand a lawyer, for example. I also appreciate the way that engineers think.”

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Leading and accommodating To describe her own leadership style, Houlahan explained that she sees herself as a sort of fluid engineer and tries hard not to be too rigid in her thinking. “That has to be part of success of building enterprises and organizations, to allow people to do what they’re good at it, and to recognize that you’re probably okay at some things … but you probably have a lot of people on your team who knew a lot more about certain things than you do,” she said. “I identify obviously as a woman, as an engineer, as a veteran — but fundamentally, I think that my bigger identifier is as an entrepreneur. And I think that entrepreneurial leadership or that kind of way of moving in the world has to do with the concepts that the best idea wins, the best team wins, and ideas can come from anybody and anywhere. You can find mentorship laterally, down, up. And you can provide mentorship that way, as well as leadership and guidance.” DW

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Silicone over mold cable assembly solutions ODU odu-usa.com The ODU silicone system solutions consists of connector, cables assembly over molding, and optional individual laser labeling. The new silicone over mold technology has a no stick-slip effect, which makes these solutions easy to clean, and has up to 500 autoclave cycles. It also creates bend protection and smooth transitioning over molding, making them suitable for applications in the medical industry such as endoscopy, surgical, and dental applications. Additional customer benefits include: liquid or solid silicone offering globally available, various standard over molding inserts, and halogen and latex-free solutions.

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encoder + module simplifies BLDC motor commutation setup Quantum Devices quantumdev.com This time-saving programming technology simplifies BLDC communication programming. It’s aimed at reducing production assembly and configuration time for OEMs that need incremental encoders to control the motion and position on axes in equipment they produce. Features: • A QM35 EZ-Comm low-profile incremental encoder with a full complement of commutation signals built into the base product • A handheld programming module supporting 4, 6, 8, 10, or 14 pole commutation to

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Industrial PC boosts computing power Beckhoff beckhoff.com The C6025 is a space-saving IPC that is designed to deliver the performance of the Intel Core i series in a fanless, small-form-factor device. The Intel Core i U processors, with low power requirements, have made this advance possible. Measuring 82 x 127 x 40 mm and combining high-computing performance with a fanless design, the Microsoft “Azure Certified” C6025 IPC is a suitable choice for automation and IoT applications where green, sustainable, IT is also a requirement. The Intel Core i U processors provide Core i performance capabilities yet consume significantly less power than other processors of the same series. The 8th Gen Intel Core i U processors used in the C6025 also offer an advantage typical of evolving PC-based

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Discrete Semiconductor Solutions for

Extreme Environments

Product World Ultra-cool heat sink family cools high-powered devices Advanced Thermal Solutions Qats.com ATS now has a family of heat sinks for cooling high powered CPUs, GPUs, FPGAs, and AI processors. This ultra-cool family includes active heat sinks with integral blowers and passive heat sinks that use available airflow to provide thermal management. The active heat sinks, dualFLOW, and quadFLOW are designed for use on moderate to high component density PCBs, including 1U and 2U boards. The sinks feature an aluminum or copper straight fin base with a powerful blower on top. dualFLOW heat sinks draw air from two opposite directions, and quadFLOW sinks pull air from all four linear sides. The fast moving, high-volume air helps maximize thermal performance on crowded boards and tight enclosures with insufficient airflow for passive cooling. All ultra-cool heat sinks fit standard Intel LGA 2011 sockets, (Socket R) square and LGA 2066 sockets (Socket R4) commonly used in high-end cloud and edge server applications. An optional backing plate is available for applications other than the Intel

Super Industrial : TM

Upgraded versions of standard commercial and industrial discrete semiconductor products.

LGA 2011 socket. The backing plate attaches beneath the PCB to avoid damaging the board when attaching the cooler.

spacellite : TM

Enhanced devices designed to meet the reliability and functionality specifications for today’s satellite applications.

1.631.435.1110 w w w. c e n t r a l s e m i . c o m

145 Adams Ave • Hauppauge, NY • 11788 • USA

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DESIGN WORLD

1/19/20 10:44 AM

1.800.463.9275

newark.com

Discover Over a Million

Engineering Products from Suppliers You Know and Trust 900+ new products each week

Custom services such as kitting, panel meters, enclosures, and many more! Market-leading online community of over 600,000 engineers

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Made Your Way and Made in the U.S.A.

Product World Absolute encoders with IO-Link interface Posital posital.com IO-Link is a low-cost, easy-to-implement, communications system. It’s designed to simplify connections between large-scale fieldbus or industrial Ethernet networks and sensor or actuator devices located on the factory floor. On one side of an IO-Link master gateway device is an interface to the plant-wide network, while the other side has multiple pointto-point connections to individual sensor devices. The IO-Link interface for end devices is simple, eliminating the need to support complex communications protocols at the sensor/ actuator level. IO-Link supports a variety of data types, including measurement data, device configuration instructions, and information about operating condition parameters such as temperature. IXARC encoders, based on magnetic measurement technology, are well-suited to IO-Link implementations. They are compact, easy to install, and provide reliable performance, even under harsh industrial conditions. Two versions of IO-Link connected encoders will be offered:

Cords for global markets—Interpower® manufactures them in the U.S.A. Cords can be made to your specifications. Wherever the market is, ensure that the end user has the correct means of connecting to the local mains supply with the correct cord. • • • •

single-turn (360° range, 14-bit resolution) and multi-turn (up to 1 billion revolutions). Singleturn variants can be converted to operate in incremental mode by making use of a different pin-out arrangement in the connector.

1-week U.S. manufacturing lead-time No minimum order or dollar requirements Blanket and scheduled orders available Same day shipments on in-stock products

Toll-Free Phone: (800) 662-2290 E-mail: sales@interpower.com Business Hours: 7 a.m.–6 p.m. Central Time

Order Online!

www.interpower.com

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DESIGN WORLD

1/20/20 8:32 AM

AZ Series

Hybrid Control Systems

Now With

AZ Series Family of Products

Rack & Pinion Systems

Compact Electric Cylinders

Electric Actuators

Rotary Actuators

EtherNet/IP is a registered trademark of ODVA, Inc.

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Precision Control for Your Operations

Product World High power density (HPD) outer-rotor brushless motor Allied Motion alliedmotion.com The KinetiMax HPD series is offered in compact stator-rotors sets. They are available in six frame sizes with three stack-lengths per size and three windings per stack length. The HPD series also features a large stator bore that allows cabling to easily pass through for applications such as robotic joints. Other features include: •

Compact frameless stator-rotor sets with outer-rotor design

•

Large diameter, short stack length

•

Large stator bore to allow cabling to easily pass through

•

High torque-to-weight ratio

•

Temperature sensor mounted on stator

•

Hall commutation board available

Clutches, Brakes and Motion Control Products Clutches and brakes for complete motion control, designed to meet exact specifications. From ultra-precise medical procedures to heavy equipment across a variety of industries – CJM is everywhere. • electrical, mechanical, pneumatic and hydraulic models • system design and integration • expert engineers working on every order

Engineering Solutions for Clutches & Brakes

www.cjmco.com Phone: 860-643-1531 291 Boston Tpke, Bolton, CT 06043

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1/19/20 10:55 AM

High-Speed Shielded

Micro-Coaxial Connectors

Delivering extremely small connectors, excellent signal integrity solutions and unmatched support.

High Frequency

Micro RF Connectors,

Cable Assemblies and Switches

High-Density

FPC/FFC Connectors

High-Density

Board-to-Board (FPC) Connectors

FPC/FFC Connectors

with Auto-Lock and Shielding Options

with Visual-Mating, High-Power and Shielding Options

www.i-pex.com IPEX 12-19.indd 199

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For Devices that require Reliability, High-Quality & Precise Performance Aerospace l Medical l Robotics l Commercial SDP/SI is the engineers preferred source for Mechanical Components

• Timing Belts & Pulleys • Precision Gearboxes • Gears • Couplings

Product World Linear position sensors Alliance Sensors Group alliancesensors.com The LV-45 series inductive, contactless, linear position sensor using LVIT Technology is now available. LV-45 sensors are specifically designed for measuring applications requiring rugged devices, whether measuring position of steam turbine valves mounted in a

Manufacturing Engineering Development We look forward to working with you.

paper mill head box or calendar roll stand, or even outdoors fastened to a building, bridge, or structure. The LV-45 series was designed after identifying the wants and needs of engineers in the industrial world. LV-45 Series linear position sensors can withstand the high

Years of Excellence

cellence

1950 - 2020

www.sdp-si.com

250 Duffy Ave., Hicksville, NY 11801 I 516-328-3300

vibration and severe shock environment found in steel, aluminum, and paper mills, as well as extremes in temperature and humidity found in most outdoor applications where many other types of linear position sensors cannot survive.

- 2020

Bearing Protection that Outperforms all Others Superior performance for maximum peace of mind. Helwig’s Bearing Protector extends the life of motors by keeping shaft voltage to a minimum. Prevents pitting and costly damage to bearings. The best choice for the motor industry.

•

• •

Easy installation One size fits all Reliable performance

• • •

Low maintenance Excellent conductivity Cost effective

Call 1-888-354-9914 or visit our website at helwigcarbon.com

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1/20/20 8:36 AM

NEW GENERATION

S E E U S AT S L A S , B O O T H # 4 3 8 a n d M D & M W E S T, B O O T H # 1 7 5 9

You’ve never seen

a solenoid valve like this before. TM

High Flow, Low Power, Low Leakage Across an Extensive Cycle Life The Lee Company is excited to announce a new generation of versatile and innovative 3-port solenoid valves. In a miniature 10mm package, the genvi™ solenoid valve platform features high flow capacity, low leakage and ultra-low power consumption. Designed using innovative manufacturing techniques, this new valve offers not only unmatched reliability, but also an economical price point suitable for molecular diagnostics, respiratory therapy, compression therapy, environmental analyzers, breath analysis and other applications where performance and reliability are paramount. When designing portable or stationary instruments, OEMs are often challenged with meeting aggressive size, power, and weight limitations, all without sacrificing the remaining elements of system-level performance. Each subcomponent is therefore pushed to offer improved performance within a smaller footprint. Featuring high flow and low power consumption, genvi solenoid valves are the solution. An extremely tight leakage rating reduces compressor demand and further underscores the valve’s ability to provide consistent long-term operation across an extensive cycle life. Custom valve solutions, supported by The Lee Company’s engineering experience in microfluidics, are also available to meet specific application requirements.

Innovation in Miniature ®

The Lee Company

2 Pettipaug Rd, Westbrook CT 06498-0424 8 6 0 - 3 9 9 - 6 2 8 1 | 1 - 8 0 0 - L E E - P L U G | w w w. t h e l e e c o . c o m W E S T B R O O K

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•

L O N D O N

•

P A R I S

•

F R A N K F U R T

•

M I L A N

•

S T O C K H O L M

11/21/19 9:32 PM AM 1/18/20 8:19

Product World Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone

Engineering Plastics High Temperature Tapes Silicone Rubber Products

Gearhead family with many gear ratios Faulhaber faulhaber.com This metal GPT planetary gearhead family is characterized by its compact dimensions, high torque, and fine graduations of the numerous gear ratios. It is robust and tolerates both frequent as well as sudden load changes. The gearheads operate with high efficiency, can be combined with many different motors, and enable various shaft configurations. The pure metal GPT gearheads achieve performance values comparable to more expensive technologies on the market like ceramic components. The gearheads are available with diameters of 22, 32, and 42 mm. The gearheads achieve top values for torque as well as for

Lineal foot films

speed. Compared to the predecessor models, the continuous input speed was more than doubled above 10,000 rpm and can support input speeds up to 20,000 rpm in intermittent mode. The 42GPT Series can sustain an intermittent torque up to 25 Nm while its length is squeezed down to 71 mm. The GPT gearheads are designed to be robust and tolerate continuous, abrupt, and sudden load changes. At the same time, they are significantly shorter than other models in the same diameter.

Slit to width rolls

die cut parts Slitting Die-Cutting Die-less Knife Cutting Adhesive Lamination Automated Sheeting Custom Belting

800-461-4161 sales@cshyde.com www.cshyde.com 202

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DESIGN WORLD

1/20/20 8:38 AM

ATOM DX encoder series ™

Performance in miniature

All-in-one: digital, miniaturization, quality, performance • All-in-one miniature encoder • Versatile metrology performance • Direct digital output • Compatible with the Advanced Diagnostic Tool (ADT)

For more information visit www.renishaw.com/atomdx

Renishaw, Inc. 1001 Wesemann Drive West Dundee, IL, 60118 T 847-286-9953 F 847-286-9974 E usa@renishaw.com

www.renishaw.com

Renishaw 1-20.indd 203 PD-6608-9016-01 Atom DX fullpage ad.indd 1

1/21/20 3:54 10/22/2019 12:36:05 PMPM

Spring Applied Brakes

From the world’s largest manufacturer of world-class electromagnetic clutches and brakes

Product World Position/displacement system for analytical and OEM applications

Electromagnetic clutches & brakes for virtually every application

For holding and stopping applications A wide array of standard torque ranges (1.75in/lbs - 880 in/lbs) Custom designed and manufactured for your application Manual release, zero backlash, and adjustable torque also available Inch and metric bores available 100 Randolph Road • Somerset, NJ 08873 Phone: 732-271-7361 • Fax: 732-271-7580 Website: http:ogura-clutch.com/spring Email: info@ogura-clutch.com

Kaman kamansensors.com The Measuring Division of Kaman Precision Products highlights the availability of its SMT 9700 position/displacement system, which provides high resolution noncontact position/displacement feedback of any electrically conductive target. The flexible SMT 9700 offers easy, cost-effective, performance customization that provides a good fit for customer applications and at significant cost savings for volume applications. The SMT 9700 system is a suitable choice for optics positioning in photolithography equipment, XYZ stage positioning in atomic force microscopy, and spindle position in precision grinding of bearing races.

Brushless Motors

The SMT 9700 uses Kaman’s eddy current sensor technology and provides nanometer to sub-nanometer resolution in a small package size. Available with 13 standard sensor options, the SMT 9700 system also enables users to customize sensor type and configuration, cable length, calibration range and offset, as well as performance attributes, linearity, bandwidth, and temperature.

• Hollow or solid shaft high performance housed and frameless • • • • •

brushless motors and matching drives for demanding applications. Sensorless or hall motors and drives for aerospace, military, medical, industrial, canned pumps, vacuum, extreme temperature applications. Custom drive programing and designs available. Standard or custom designs up to 98% efficient, up to 200,000 rpm. Highest power density in the industry. Slotless and slotted designs. Available with encoders and gearheads and separate or integral electronics. Quantities 1 to 10,000.

For technical assistance, mail@koford.com 937-695-1275 Data sheets at www.koford.com

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Motion Components

to Automate any Industry

Right Angle Precision Servo Gearheads with Single or DUAL Output Options

800-430-1439 diequa.com/dw

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full page print ad.indd 1

2/27/19 2:13 PM

Product World “Auto-In” 12 mm coin cell holders Keystone Electronics keyelco.com The demand for secured retention of the 1220 and 1225 12mm diameter Lithium Coin Cells has been met. These new “AutoIn” 12mm Coin Cell Holders are rugged and suitable for retaining cells securely under shock and vibration in high-density PCB applications. These new holders provide design versatility for surface mount applications using 12mm coin cell batteries in applications where the battery must be automatically inserted via a vacuum or mechanical pick-andplace device. The holder is polarized and has dual–spring, Gold-plated, Phosphor bronze contacts in a PA9T black plastic base.

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stom Gears

Product World Low friction bearing for improved lubrication Freudenberg Sealing Technologies fst.com Through a new “scoop” feature, the enhanced Levitorq

axial thrust washer’s design is able to collect and push d "Gear precision grade" lubrication under the washer for higher critical speeds and

of Gear precision grade

enhanced performance. Levitorq is part of the Low Emission Sealing Solutions

76 :1998

Gear precision Grade 1

(1973)

(LESS) product portfolio. 4 5

0 N4

TheN9 original Levitorq design was created to reduce weight, decrease friction, and improve thickness/flatness 9

control. It relies on the principles of hydrodynamic oil film technology and is designed to create a surface on which a 8 7 bearing can roll, or a load can be applied. Traditionally, thrust washers are made from metals, but this design alternative 9

in thermoplastic or thermoset materials allows engineers to replace heavy metal thrust washers. 9 8

erial table : corresponding materials of SCr415) is deﬁned as al of SCM415. ing (case hardening), SCM415 is normally used. ments for harder material, SNCM220 and/or SNCM420

s is determined by producti ardness value is inf

Largest selection of

ision grade table : equivalent grades are for ref pletely match each other.

Stock Metric GEARS in North America

15/05/21

14:20:18

Over 20,000 Stock Gears Available at www.khkgears.us 259 Elm Place, Mineola, NY 11501 Phone: 516.248.3850 | Fax: 516.248.4385 Email: info@khkgears.us

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Precision Gear Solutions for Automation

World Leader in Quality. World Leader in Delivery. World Leader in Service and Support. World Leader in Production Capability.

Economy Gearboxes

Performance Gearboxes

Rack & Pinion

Manufactured to Stock 50,000+ Units Per Month Production Capability Standard Lead Times 2-3 Weeks

Home of the FIRST and ONLY On Time or Its FREE Delivery Guarantee!

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Product World Compact cable for offshore connectivity HUBER+SUHNER hubersuhner.com The fire-resistant RADOX OFL (Oil & Gas Flexible Lightweight) cable solution provides the offshore industry with a safe way to reduce platform weight. With a lightweight and compact design, the RADOX OFL cables reduce weight and space by up to 60%. The cable’s small bend radius and thin wall — which is half the size of standard cables — reduces stripping time by 60%, making installation easier and quicker. This has the potential to save industrial and offshore facilities in structural design cost by overcoming space and weight restrictions. The RADOX OFL cable is fire-resistant and low smoke halogen free (LSFH), for use in harsh outdoor environments and offshore industrial applications. Core cables do not melt or drip in the event of a short circuit, minimizing emergency repairs and the potential for hazardous fume inhalation. The RADOX OFL cable is also oil, mud, and hydraulic oil resistant according to the highest standard NEK606 Cat. a-d.

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Reduce cable related downtime by 75% Defined bend radius. Built-in torsion stop. Split cavity for cable separation. Decrease downtime and improve production with the triflexÂŽ R multi-axis robotic cable management system

www.igus.com 1.800.521.2747 igus 1-20.indd 211

1/18/20 8:24 PM

Product World Specialty cleaning grease for wind power plants Klüber Lubrication www.klueber.com Klübersynth BZ 68-400 is a lubricant specifically designed to mitigate hot bearings in wind turbines. Hardened residues that accumulate on generator bearings can become a nuisance and prevent efficient operation. Most situations require cleaning by hand where the wind power turbines must be curtailed resulting in costly downtime. To minimize maintenance and help wind power plants operate at maximum power output, Klübersynth BZ 68-400 frees residues while protecting bearings and providing reliable lubrication against wear and corrosion. With this grease, rolling bearings can be cleaned while in operation. Klübersynth BZ 68-400 is compatible with several types of base oil, making it a versatile, high-performance, solution that can be used beyond wind turbines.

Micro PLC Mitsubishi Electric mitsubishielectric.com This is the company’s smallest and most powerful compact PLC to date — the FX5UC series Micro PLC. Its diminutive size is set to help machine builders and manufacturers pack more functionality into a smaller space — while also providing the web access and network connectivity demanded by the latest Smart Factory applications. Now re-positioned as part of the high functioning MELSEC iQ-F series, the new FX5UC model (the “C” denotes compact) is engineered to handle the increasingly sophisticated data processing and communication tasks demanded by Smart Manufacturing applications. More precisely, this tiny PLC now houses the same performance CPU as the FX5U model in a product as small as a micro FX3S.

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DESIGN WORLD

1/19/20 11:20 AM

Cleaner / Degreaser used in fda facilities for For use in fda inspected facilities

over 20 years

- just apply and rinse away - d99 is being used to replace hazardous solvents

- strong and environmentally safe

TIODIZE PROCESS TITANIUM ANODIZING FOR MEDICAL APPLICATIONS

TIODIZE TYPE ii bIOCOMPATABLE

INCREASED fATIGUE STRENGTH ANTI-GALLING INCREASED LUBRICITY

cOLOR ANODIZING bIOCOMPATABLE

VARIOUS RANGES IN COLOR EASILY IDENTIFY PARTS

pREVENTING FRICTION, WEAR AND CORROSION 5858 Engineer Drive • Huntington Beach, CA • (714) 898-4377 • Fax: (714) 891-7467 web: http://www.tiodize.com • tiodize@tiodize.com

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Product World Corrosion-resistant chemical tank cover Dynatect dynatect.com The ChemTank Cover is a corrosion-resistant chemical tank cover developed space-saving options. The cover is designed to accommodate a range of tank applications including chemical and surface finishing, anodizing, etching, plating, and cleaning. The cover system helps reduce heat-loss and evaporation. Its roll-up design offers easy manual or drill-drive operation. Productivity and ergonomics are a concern where wood, PVC, or metal static plates are considered cumbersome and time-consuming. This cover’s engineering team noted that they’ve seen much variation in process tank setups and layouts.

® 1-800-444-5366 www.lemo.com

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1/19/20 11:23 AM

DISPLAYS, TOUCH, EMBEDDED & MONITOR SOLUTIONS

DATA MODUL is a leading specialist in developing and manufacturing customized display solutions for industrial and medical applications. Visit us and discover our latest products and technologies.

TOUCH

DISPLAYS

In-house Optical Bonding

Leading Display Technology Partner

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TFT Displays Passive Displays OLED Displays Customized Displays Value Added Displays

EMBEDDED

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Projected Capacitive Resistive In-house Optical Bonding Optical HMIs

MONITOR SOLUTIONS

In-house Development

› › › ›

CPU Boards Embedded Box PCs eMotion LCD Controller Boards

In-house Design & Manufacturing

› › › ›

Monitors Panel PCs Video Walls OEM Services

Embedded Computing Design

DATA MODUL Inc. | www.data-modul.com | info.us@data-modul.com East Coast +1-631-951-0800

West Coast +1-503-885-1165

US Headquarters | 275 Marcus Blvd. | Hauppauge, NY 11788

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Product World Standard air bushings enable frictionless air cylinders New Way NewWayAirBearings.com These air bushings enable frictionless air cylinders. The O-rings in conventional hydraulic and pneumatic cylinders create significant friction. In measurements and test loading, that friction can be an issue. Instead of O-rings, the seal for the air bearings is the high-pressure air film generated by the bearing. With a 60 PSI input pressure to the bearing you could expect to generate 30 PSI in the air film. This pressure is usually used for bearing functionality, but it also doubles as a seal as nothing of a lower pressure will try to get into the gap, it would be like water running uphill. So, the air bushings are a great way to create frictionless air cylinders without hysteresis and can be used to apply loads on spinning objects while measuring the torque generated.

Tough, compact, angle sensors Novotechnik novotechnik.com/vx1600 The Vert-X 1600 Series of sensors measures angular position and have a housing base diameter of 16 mm. These sensors convert rotational angle into an analog or digital output. Measurement range is 0 to 360° with 14-bit resolution and repeatability of 0.1°. Available analog outputs are 10 to 90% of supply voltage and 5 to 95% of supply voltage. Digital interface options include SPI and PWM. The sensors are sealed to IP 65, life is ≥ 50 million movements, and MTTF is 668 years. Redundant versions of the Vert-X 1600 are available. A 6 mm D-Shaped shaft and two reinforced through-holes enable easy mounting. These sensors are suitable for industrial, medical, off-highway vehicle, and other applications with an operating temperature range of -40 to +125°C and will operate with up to 10 N axial or radial shaft load.

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DESIGN WORLD

1/19/20 11:25 AM

™

dESIgN SOLuTIONS

Design Solutions at your fingertips! Contact us for over 70 years of “in-house” design application and engineering expertise in:

• Stamping • machining • aSSembly • cnc • injection molding Our team is just an email or phone call away. It’s what’s on the InsIde that counts ® E L E C T R O N I C S

C O R P.

www.keyelco.com • design@keyelco.com • (516) 328-7500 • (800) 221-5510

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

TOF photoelectric sensors Omron automation.omron.com E3AS Series Reflective-Type Photoelectric Sensors combine accurate detection for diverse targets, exceptional sensing distance, environmental robustness, and compact size. These sensors are designed to help manufacturers manage varied and flexible production needs more effectively. Manufacturers are producing a broader range of products with shorter life cycles, making part detection a dynamic challenge. By maintaining stable detection without being influenced by varying sensing distances, colors, materials, or surfaces, the E3AS sensors make selection, adjustment, and maintenance tasks easier than ever, improving commissioning and operation rates. The E3AS familyâ&#x20AC;&#x2122;s sensing distance of 1,500 mm is five times longer than that of previous models, and the full sensing range of 50 to 1,500mm eliminates the need for manufacturers to select different sensors for each application. The time-of-flight (TOF) detection method ensures high detection stability regardless of the characteristics of target objects, making sensor selection and adjustment easier than ever.

Laser marking service for electronic enclosures OKW okwenclosures.com Laser marking of legends and logos is waterproof, smudge-proof, and durable. It is suitable for small machine-readable markings such as sequential QR codes or barcodes. Consecutive numbering can be carried out quickly, easily, and cost effectively. Using a laser to mark an enclosure provides a more resilient solution than printing because it physically changes the color of the surface. Dark and light plastic parts turn grey at the point of marking. Suitable materials for laser marking include ABS, ASA+PC, and ASA+PC-FR, polycarbonate, polyamide, (and PA GF) and aluminum. Depending on the materials involved, the following enclosure colors are good for high-contrast laser marking: off-white, pebble gray, light gray, lava, and black. OKW continues to offer photo-quality digital printing (up to 1,800 x 1,800 dpi) on surfaces with a height difference of up to 0.098-in. Like laser marking, the set-up costs for digital printing are much lower than those for traditional silk screen and tampo methods. This makes digital printing and laser marking suitable for lower volume production runs.

DESIGN WORLD

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Product World IoT for fill-level monitoring Pepperl+Fuchs pepperl-fuchs.com This is an IoT sensor with integrated ultrasonic measurement for determining fill levels. The data is recorded at regular intervals and uploaded to the internet along with the current geolocation. The autonomous wireless sensor is battery-operated and can therefore be used in mobile containers. With the Wilsen.sonic.level, Pepperl+Fuchs has developed a sensor concept that is suitable for use in a variety of different wireless networks. For example, there is a product version with a GSM(2G) interface for public mobile networks. Another version of the product has a LoRaWAN interface for using privately operated low power wireless networks. All of these radio interfaces are used to transmit sensor data to the internet. Depending on the wireless standard selected, an appropriate remote location is available on the internet for the incoming sensor data.

120W eighth brick fully isolated DC-DC converter modules Murata murata.com The 120-Watt IRE-Q12 series was designed specifically for industrial, railway, and transportation applications with system bus and battery voltages between 9VDC and 36VDC. The solution provides performance and efficiency through advanced power supply technology for fixed frequency switching architectures. The IRE-Q12 series offers fully regulated DC output voltage modules with 5V, 12V, and 24V, with up to 120W and an input voltage range from 9-36VDC. These features meet the requirements of EN50155 for 24V nominal battery voltages including brown out and transient conditions. Extensive testing ensures that the product can withstand the harsh environmental conditions typically found in railway and industrial applications. In addition to providing basic insulation with 2828VDC Input-to-Output isolation voltage, the fully encapsulated bricks are available with a standard or an optional flanged baseplate to optimize typical configurations for conduction cooling.

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DESIGN WORLD

1/19/20 11:27 AM

Metal Bellows Experts

Our engineering team focuses on your application and quickly responds with a custom design and high quality prototype or part. That’s why OEM manufacturers call us. Applications: • Actuators • Air Speed Measurement • Altimeters • Baromers • Oxygen Systems • Landing Gear Systems • Instrumentation, Temperature & Pressure • Medical Equipment • Semiconductor & High Vacuum

www.servometer.com

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Product World Adapter lock for spherical bearings Regal Beloit regalbeloit.com The Klamploc adapter lock for Sealmaster mounted unitized spherical roller bearings (USRB) was designed to simplify the installation process while improving shaft lock reliability. It accomplishes these goals with two unique design features. The first feature includes key installation steps that are written on the lock collar. Often, after bearings are removed from their boxes prior to installation, the boxes and the installation sheets get discarded by users. Or, the sheets might be reviewed ahead of time, but the installation specifications do not get memorized or are unavailable when needed at a job site. Because the Klamploc adapter has installation steps clearly marked on its collar, the installer can read the specs from the bearing itself. The second key design feature is a split collar with a cap screw to close the split. With the Klamploc adapter, there are neither parts to remove and then install, nor parts to bend on the bearing. Other market options require one or more parts to be removed before installation. This not only introduces additional non-value-

MAIN MANUFACTURING PRODUCTS, INC HYDRAULIC FLANGES AND COMPONENTS

added steps, but it also creates a situation where these parts, often small, can be lost. In addition to offering simplified final locking, the split Klamploc collar has a benefit unique to the industry. When tightening the collar cap screw, the split collar compresses and grips the adapter sleeve, which can provide additional clamp force to the shaft when combined with the properly set adapter lock.

MAIN’s ADVANTAGES QUICK

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www.MAINmfg.com/flg Phone: 800.521.7918 info@MAINmfg.com Grand Blanc, MI USA

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Power supply series expansion Rohde & Schwarz rohde-schwarz.com The R&S NGM200 power supply series extends the company’s current range of specialized power supplies. The R&S®NGM200 power supply series includes the single-channel R&S NGM201 and two-channel R&S NGM202, offering new features that make the devices suitable for developing battery-powered equipment operating at up to 20 V and drawing currents up to 6 A. The R&S NGM200 series offers performance and specifications to supply stable outputs with a minimum residual ripple and noise. Delivering up to 60 W of output power per channel, the R&S NGM200 power supply series offers floating and galvanically isolated output channels that protect against overload and short circuits. The R&S NGM200’s high accuracy and fast load recovery time makes it a suitable choice for challenging applications.

Inertial measurement systems for the space market Silicon Sensing siliconsensing.com The new RMU30 combines below one-watt power consumption with performance that is comparable to much larger and higher consumption fiber optic-based gyro systems. This is a small, lightweight, 3-axis micro electro-mechanical systems (MEMS) device incorporating three Silicon Sensing sensor heads manufactured at the company’s foundry in Japan. In the RMU30, engineers have stripped out all technology that is not relevant to the space environment to deliver a motion sensing unit that is small, and ultra-low power, with precision inertial sensing performance that can be tailored to specific satellite requirements.

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Product World IP65-rated step motors Applied Motion Products applied-motion.com This extended line of stepper motors with IP65 ratings are dustproof and resistant to water pressure impact, making them suitable for use in wet and dusty applications. Using advanced seal protection technology, the IP65-rated step motors feature sealed laminations, an oil shaft seal, internal corrosion-resistant film coating, gaskets for mechanical joints and an integral 10-ft. shielded cable that offers protection against the ingress of dust and resistance to low-pressure water jets. For improved protection in high-humidity environments, an advanced coating is available as an option. These IP65-rated step motors are available in NEMA sizes 23, 24, and 34. A double-shaft version is available with an optional IP65-rated encoder for applications requiring feedback.

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Actuator with electronic lock/unlock features Southco southco.com The AC-10-EM Actuator with electronic lock/unlock functionality eliminates the need for mechanical key access when connected to a remote access controller, such as a key fob, or to an existing control system, such as a button located within a vehicle’s interior. The AC-10-EM Actuator with electronic lock/unlock features a heavy-duty design and corrosion resistant construction, providing robust protection for outdoor applications including off-highway doors and specialty vehicle storage panels. With its recessed handle and flush mount paddle design, the AC-10-EM eases operation when opening panels and doors with a gloved hand, while reducing snag and catch points.

Stainless steel added to line of control valves Spirax Sarco spiraxsarco.com/us Stainless steel has been added to the Spira-trol line of modular control valves which ship in four days or less through the company’s Quick Ship program. The valves leave the factory preconfigured for the intended application, simplifying installation, and minimizing customer downtime. Spira-trol valves can accommodate more than 2,500 configurations, to meet the needs of almost any system or application. Unlike conventional valves with screw-in seats, Spiratrol valves have a quick-change, “clamp-in-place” seat that allows them to be modified to match changing plant conditions, rather than replacing the entire valve. No special tools are required, and there is no need to take the valve out of the line, which simplifies maintenance and avoids costly plant shutdowns.

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Back Page ADVERTORIAL

A Little Data Approach to Solving Big Data Problems By Derek Thomas Vice President of Sales & Marketing

•

Machine Automation Solutions at Emerson

Creating value om big data is top of mind for many executives across a wide variety of industries. These executives perceive the potential to substantially improve operations by creating insights into the terabytes of existing data stored in their organizations’ databases, with more data flooding in every second. Ironically, the best way to approach this problem can o en be to start with little data problems and insights before progressing to big data solutions. With big data opportunities come challenges, and perhaps the greatest is the sheer volume of data. There is o en a temptation to tackle the issue all at once, with mega-scale projects ambitiously gathering all the data om various sources into a data lake, either on premise, in the cloud, or a hybrid of the two. Once stored, this data must be cleansed to remove anomalies, and this is an ongoing process as more data floods. Another issue arises because big data o en comes with significant dilution of insights as data naturally starts to normalize and hide intricacies of events. During this process, it’s easy for a company to focus on the in astructure and technologies instead of the problem, which can lead to discouragement due to the complexity, cost, and scale of implementation. These and other issues can cause companies to lose sight of the goal, which is creating an acceptable return on investment by realizing operational improvements. Because big data and the tasks required to create value om it presents a formidable challenge, a better answer may be to consider a solution involving little data. For someone new to IoT, greatly reducing the field of view to a specific, defined source and need reduces the complexity and simplifies the search for a solution. This approach yields real tangible improvements and creates positive momentum by allowing users to find, solve, improve, and move on quickly. As experience and comfort increases, it becomes easier to scale to larger data pools because there is a baseline of insights to build upon. One of the main technologies for creating value om little data is edge computing,

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whereby data produced by field devices is analyzed by a field-located controller to generate insight. This information can be supplied to the right personnel, close to the source for appropriate action. In the past, this type of edge processing would have required the addition of a separate industrial computing device and so ware solution to store and process the data. This new device would then have had to be integrated with the existing controller and network, o en a problematic step due to the complexity of setting up and programming in two different environments, synchronization, lag/ latency, and other issues. But today, an edge controller can be used to perform both functions. The first is real-time control, much like a traditional programmable logic controller (PLC), and the second is data storage and analysis. Because both functions are performed in one device, there is no additional effort required to integrate two components. Once the edge controller stores and processes the data already being collected for real-time control, results can be transmitted to enterprise platforms such as MES, ERP, maintenance management, and other systems—both on premises and cloudbased—through the use of embedded connectivity capabilities. These higher-level platforms thus have better information to use in various ways to

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improve operations. Higher-level connectivity is simplified because an edge controller not only stores and analyzes data, but also supports embedded IT-compatible connectivity and security to communicate over standard networking technologies and protocols. Ethernet is of course the network of choice for most higher-level communications and is well supported by a typical edge controller, but this is not enough as various industrial Ethernet protocols must be supported as well. Common IT protocols must also be supported, as well as industrial protocols, such as PROFINET or WirelessHART. Cloud-based communications o en require their own lightweight protocols, such as OPC UA, MQTT or AMQP, so these must be supported as well. This article has introduced three new but related concepts for deriving value om big data: little data, edge processing, and embedded connectivity. Each of these concepts will be explored in detail in three subsequent columns, providing a roadmap for new applications and implementations to create value om the data available in industrial automation systems.

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1/21/20 8:58 AM

A d I n de x Accumold ..................................218 Ace Controls ...........................177 Aerotech ...................................191 Allied Electronics .......... Cover,30,31 AllMotion ...................................4 Altech Corporation ...............17,19,21 AMETEK Haydon Kerk Pittman .....65 Anchor Fluid Power ..............82 Anomet Products ..................154 Apex Dynamics, USA ...........209 AS-Interface Organization North America ...................39 Aurora Bearing Company ............................49 Automation24, Inc. ................9 AutomationDirect ..................1 Backer Hotwatt ......................79 Bansbach Easylift .................81 Bay Associates Wire Technologies, Inc. ............29 Beckhoff Automation ..........63 Bel-Fuse Inc. ............................59 Beswick Engineering ............118 Bimba .........................................179 binder USA ..............................110 Bird Precision ..........................180 Bishop Wisecarver ................101 Bodine Electric Company ...25 Bokerâ&#x20AC;&#x2122;s Inc. ...............................38 BRECOflex CO., L.L.C. ...........90 Bunting Magnetics ...............49 C-Flex Bearing Co., Inc. ........216 Cadence ...................................151 Canfield Industries, Inc. .......186 Carlo Gavazzi ..........................104 Carlyle Johnson .....................198 Central Semiconductor Corp. .....................................194 CGI Inc. ......................................61 Chieftek Precision .................6 CIT Relay & Switch ................188 Clippard .....................................11 CMT ...........................................166 Coilcraft .....................................51 Components Corporation ..186 COMSOL ...................................117 Cornell Dubilier Electronics, Inc. ................143 CS Hyde Company ................202 DATA IMAGE Corporation ...180 Data Modul Inc. ......................215 Del-tron .....................................86 Diequa .......................................205 Digi-Key .....................................15 Dorner ........................................89 Eagle Stainless Tube ...........57 Electrocube, Inc. ....................119 Emerson-ASCO/Aventics ....47 Emerson-Branson .................77 Encoder Products Company ............................190 EPLAN .......................................192 Exair Corporation ..................5 EZAutomation ........................27 Fabco-Air, Inc. .........................187 FAULHABER MICROMO .......IBC Festo ..........................................34

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Oriental Motor ........................197 Fischer Connectors ..............171 PBC Linear ..............................53 Flow Ezy Filters ......................210 Peninsular Cylinder ..............160 Fujipoly America Corp. .........178 Pepperl + Fuchs .....................106 Gluespec.com .........................69 PHOENIX CONTACT Harwin .......................................22 USA, INC. .............................75 HAWE Hydraulic .....................135 PI (Physik Instrumente) HELUKABEL USA ..................67 LP ..........................................73 Helwig Carbon Pilz Automation Products, Inc .....................200 Safety L.P. ..........................60 Hottwatt ...................................79 PM B.V. ......................................97 I-PEX Connectors ..................199 POSITAL-FRABA .....................144 IDEC Corporation ...................64 Pyramid Inc. .............................167 igus .............................................211 R+W America ...........................140 IKO International, Inc. ...........147 RapidDirect CO., Ltd .............94 Intech .........................................212 Regal Beloit Corporation .....115 Interpower ................................196 Renishaw ..................................203 ITT-Enidine ...............................224 ROLEC .......................................219 J.W. Winco, Inc. .......................170 Rota Engineering ..................206 Keystone Electronics RYCO Hydraulics ....................76 Corp. .....................................7,217 SCHURTER Electronics .......170 KHK USA ...................................208 SEW Eurodrive ........................BC Koford Engineering ...............204 SICK, Inc. ...................................183 Kuriyama of America, Inc. ...116 Siemens Digital Industries LAPP USA ................................87 Software .............................45 Lee Spring Company ...........165 Smalley Steel Ring ................105 LEMO USA ...............................214 Smart Products USA ............3 Lenze Americas .....................133 SMC Corporation Lin Engineering ......................126 of America ..........................207 LinMot USA Inc. ......................56 SONOTEC US Inc ...................127 Main Manufacturing .............222 Sorbothane .............................38 Maple Systems ......................146 Spirol ..........................................41 Master Bond ...........................79 Stock Drive Products/ maxon ................................... insert Sterling Instrument .........200 MEAN WELL .............................181 Super Swivels .........................189 METCASE .................................125 Tadiran ......................................37 Miki Pulley U.S. .......................12 The Arthur G. Russell mk North America, Inc. ........107 Co., Inc. ................................52 MOCAP ......................................167 The Lee Company .................201 Moog Animatics .....................71 THK America, Inc ....................IFC Motion Index Drives ..............109 Tiodize .......................................213 Murrelektronik .........................16 Tolomatic ..................................43 MW Industries Tormach ....................................96 Atlantic Spring ..................13 Trim-Lok ....................................33 MW Industries US Tsubaki ...............................123 BellowsTech .......................91 Veljan Hydrair .........................226 MW Industries Wago USA ................................169 Century Spring .................141 Weintek USA, Inc. ..................159 MW Industries - Helical ........193 Whittet-Higgins ......................35 MW Industries Yaskawa Electric America ..55 Servometer ........................221 Yates Industrial ......................48 Nason ........................................175 Zero-Max, Inc. .........................2 NB Corporation ......................23 NBK America LLC ...................95 New England Wire Technologies & New England Tubing Technologies .....................153 Newark, An Avnet Company ............................195 Newcomb Spring ...................142 Nippon Pulse Americas, Inc. ....................182 Nitto Kohki USA .....................176 FOLLOW US ON Novotechnik ............................145 NSK Precision .........................103 Ogura Industrial Corp. .........204 OKW ............................................185 Follow the whole team on twitter OMS Motion, Inc. ....................131 @DesignWorld Opto 22 .....................................139

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SALES Jami Brownlee jbrownlee@wtwhmedia.com 224.760.1055 Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Bill Crowley bcrowley@wtwhmedia.com 610.420.2433 Jim Dempsey jdempsey@wtwhmedia.com 216.387.1916 Michael Ference mference@wtwhmedia.com 216.386.8903 @mrference Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029 David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Courtney Nagle cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

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

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2020

Leadership in Engineering

Accumold ................................228 ACE Controls .........................229 Advantech .............................230 Aerotech .................................231 Allied Electronics .................232 AllMotion .................................233 Altech Corporation .............234 AMETEK Haydon Kerk Pittman ...235 Anchor Fluid Power ............236 Anomet Products, Inc. .......237 Apex Dynamics ....................239 AS-Interface Organization North America .................241 Aurora Bearing Company 242 Automation24, Inc. ..............243 AutomationDirect ................238 AVG EZAutomation ............244 Backer Hotwatt ....................245 Banner Engineering ...........246 Bansbach Easylift ...............247 Bay Associates Wire Technologies, Inc. ..........249 Beckhoff Automation ........250 Bel Power Systems (BPS) .................251 Beswick Engineering ..........252 Bimba .......................................253 binder USA ............................254 Bird Precision ........................255 Bishop Wisecarver ..............256 Bodine Electric Company ..........................257 Boker’s Inc. .............................258 BRECOflex Co., LLC ............259 Bunting Magnetics .............260 C-Flex Bearing ......................261 Cadence .................................262 Canfield Connector .............263 Carlo Gavazzi ........................264 Carlyle Johnson ...................265 Central Semiconductor .....266 CGI Inc. ....................................267 Chieftek Precision Co., Ltd. .............................268 CIT Relay & Switch ..............269 Clippard ..................................270 CMT ..........................................271 Cognex ....................................272 Coilcraft ...................................273 Components Corporation 274 COMSOL .................................275 Cornell Dubilier Electronics, Inc. ..............276 Coxreels ..................................277 CS Hyde Company ..............278

Curtiss-Wright / Exlar Automation ...........279 DATA IMAGE Corporation ......................280 Data Modul Inc. ....................281 Del-tron Precision, Inc. .......282 DieQua .....................................283 Digi-Key Electronics ............284 Dorner ......................................285 Eagle Stainless Tube .........286 ElectroCraft, Inc. ..................287 Electrocube, Inc. ..................288 Emerson-ASCO/Aventics ..289 Emerson-Branson ...............290 Encoder Products Company ..........................291 EPLAN .....................................292 EXAIR Corporation ..............293 Fabco-Air, Inc. .......................294 FAULHABER MICROMO .....295 Festo ........................................296 Fischer Connectors ............297 Flow Ezy Filters, Inc ............298 FluiDyne Fluid Power .........299 Fujipoly ....................................300 GE Digital ................................301 Gluespec.com .......................302 Groschopp .............................303 HARTING, Inc. of North America .................304 Harwin .....................................305 HAWE Hydraulik ...................306 HELUKABEL USA ................307 Helwig Carbon Products, Inc ...................308 Honeywell Intelligrated .....309 Honeywell Process Solutions ...........................310 I-PEX Connectors ................311 IDEC Corporation .................312 igus ...........................................313 IKO International, Inc. .........314 Intech .......................................315 Interpower ..............................316 IronCAD ...................................317 ITT Enidine .............................318 J.W. Winco, Inc. .....................319 Keller America Inc ................320 Keystone Electronics .........321 KHK USA Inc. .........................322 Koford Engineering .............323 Kuriyama of America ..........324 LAPP USA ..............................325 Lee Spring Company .........326 LEMO USA, Inc. ....................327 Lenze Americas ...................328 Lin Engineering ....................329

LinMot USA Inc. ....................330 Main Manufacturing ..........331 Maple Systems ....................332 Master Bond .........................333 maxon .....................................334 MEAN WELL USA, Inc. .......335 METCASE ...............................336 Midwest Motion Products, Inc. ..................337 Miki Pulley US .......................338 mk North America, Inc. ......339 MOCAP ....................................340 Motion Index Drives ............341 MTS Sensors .........................342 Murrelektronik .......................343 MW Industries Atlantic Spring ................344 MW Industries BellowsTech ...................345 MW Industries Century Spring ...............346 MW Industries - Helical ......347 MW Industries Servometer ......................348 Nason .......................................349 NB Corp ...................................350 NBK America LLC .................351 New England Tubing Technologies ....352 New England Wire Technologies ...................353 Newark, An Avnet Company .........................354 Newcomb Spring .................355 Nippon Pulse Americas, Inc. ..................356 Nitto Kohki USA ..................357 NORD Gear Corporation ...358 Novotechnik ..........................359 NSK Precision .......................360 Ogura Industrial Corp. .......361 OKW USA ................................362 OMS Motion, Inc. ..................363 Onshape .................................364 Opto 22 ...................................365 Oriental Motor ......................366 PBC Linear .............................367 Peninsular Cylinder ............368 Pepperl + Fuchs ...................369 PHOENIX CONTACT USA, INC. ...........................370 PI (Physik Instrumente) LP ..............371 Pilz Automation Safety L.P. ..........................372 POSITAL-FRABA ...................373 Prince Manufacturing ........374

Protolabs ................................375 PTC ...........................................376 Pyramid Incorporated ........377 R+W America .........................378 Ramco ....................................379 RapidDirect CO., Ltd ...........380 Regal Beloit Corporation ......................381 Renishaw ................................382 ROLEC .....................................383 Rota Engineering ................384 Rotor Clip ................................385 RYCO Hydraulics ..................386 Sager Electronics ................387 SCHURTER Electronics .....388 SDP/SI-Stock Drive Product ..............................389 SEW Eurodrive ......................390 SICK, Inc ..................................391 Siemens Digital Industries Software ......392 SIKO Products .......................393 Smalley Steel Ring ..............394 Smart Products USA ..........395 SMC Corporation of America .......................396 Solidworks ..............................397 SONOTEC ...............................398 Sorbothane ...........................399 Spirol ........................................400 STEUTE Industrial Controls .............................401 Super Swivels .......................402 Tadiran ....................................403 Technosoft .............................404 The Arthur G. Russell Co., Inc. ..............................240 The Lee Company ...............405 THK ...........................................406 Tiodize .....................................407 TLX Technologies ................408 Tolomatic ................................409 Tompkins Industries ...........410 Tormach ..................................411 Trim-Lok, Inc. .........................412 US Tsubaki .............................413 Veljan Hydrair .......................414 Wago ........................................415 Weidmueller ...........................416 Weintek USA, Inc. ................417 Whittet-Higgins ....................418 Yaskawa Electric America .............................419 Yates Industries ...................420 Zero-Max, Inc. .......................421

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