Design World July 2015 by WTWH Media LLC

www.designworldonline.com July 2015

INSIDE: MOTION CONTROL: IP65 rating and what it means for your application PAGE 70

MECHANICAL: New material for radial shaft seals increases uptime PAGE 84

TEST & MEASUREMENT: 6 ways to benefit from EMC testing PAGE 90

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Insights Engineering education still on the move A few months ago, I wrote about the new paradigm of engineering education that’s happening at Olin College and the University of Illinois. I was pleased to receive so much positive feedback from across the spectrum. Engineers, manufacturers and educators all seem to be on board with the idea of making an engineering education more broadly based, with a focus on creativity and real-world problem solving skills. Dr. Gary Maul is the Director of Systems Engineering for Otterbein University, and he shared what this Ohio liberal arts school has done in creating a new engineering program, slated to start this Fall. Otterbein’s program exists in the liberal arts environment and is multidisciplinary in that it combines mechanical, electrical and industrial engineering. Students will have a good dose of liberal arts courses, including the new History of Technology course, as well as a series of writing intensive courses. Maul said the program focuses on design of products and processes and teaches students how to manufacture things—as well as how to design processes that manufacture things. “We focus on the ramifications of poor design, impacts of design on cost, quality and manufacturability,” said Maul. “Our core essence is on solving real world engineering problems by approaching them as a system. In each engineering course, we will have students work in teams to do a term design project. We want and encourage students to collaborate by both teaching others at times, and at other times learning from other students who are teaching them. I think you often learn more by teaching someone what you know.” Maul presents students with open-ended design problems, ones where opinions may prove to be wrong and do not correctly define the core issues at stake. Students draft a situation appraisal and then figure out what they need to know. Exercises are designed to make them think about information they need, how to get that information, and how much of it to get. Then they have to formulate their problem statement, come up with alternatives—all while under the constraints of time and money.

Do you think engineering education is changing quickly enough?

Pa ul J. Heney - Edi tor i al D i re ctor pheney@wtwhme di a.com

Comment on Paul’s blog on Pneumatic Tips, www.pneumatictips.com/blog

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July 2015

“They then have to actually solve their problem,” said Maul. “This means design and build. I think the building part gives students a sense of being real engineers and teaches them by letting them make mistakes and then teaches them to persevere to get a good result.” Industry, too, has a role to play. A traditional university setting isn’t ideal for many students, and trade schools and apprenticeships should be encouraged and supported—not just by parents and guidance counselors, but by local manufacturers across the country. I love what Gilman Precision is doing to fight the manufacturing skills gap. The Wisconsin company works with GPS Education Partners, a company that connects school districts with industry partners. Through the program, local high school juniors and seniors aspiring to pursue a technical career in the manufacturing industry are matched up with companies like Gilman. Students can gain industry credentials, employability skills and transferable post-secondary college credits; they engage in two hours of classroom learning, followed by working at their designated intern locations. Bosch Rexroth has been supporting work in this area, too. Thanks to a founding grant of $80,000 by the company, the CharlotteMecklenburg public school system has opened the Bosch Rexroth Advanced Manufacturing and Technology Center. The new 2,839-sq-ft facility will support a new Advanced Manufacturing Hub and provide students with hands-on experience using state-of-the-art manufacturing technologies. It includes the latest in metal-cutting and finishing technology, with multiple lathes, milling machines, saws and grinders, along with metrology and quality-control stations. Changing half a century’s worth of educational inertia in engineering and manufacturing isn’t going to be a quick fix. But change is coming—and for this country’s industrial future, it can’t come quickly enough.

On Twitter @ DW—Editor

6/30/15 11:40 AM

The Secret To Keeping Electronics Cool! NEMA 12 Cabinet Coolers

The NEMA 12 Cabinet Coolers for large heat loads up to 5,600 Btu/hr. are ideal for PLCs, line control cabinets, CCTV cameras, modular control centers, etc.

A bad choice could cost you thousands! Look Familiar? When hot weather causes the electronics inside a control cabinet to fail, there is a panic to get the machinery up and running again. The operator might choose to simply open the panel door and aim a fan at the circuit boards. In reality, the fan ends up blowing a lot of hot, humid, dirty air at the electronics and the cooling effect is minimal. If the machinery starts functioning again, the likelihood of repeated failure is great since the environment is still hot (and threatens permanent damage to the circuit boards). Worse yet, that open panel door is an OSHA violation that presents a shock hazard to personnel.

• Measures 8" (203mm) high • Mounts top, side or bottom • Enclosure remains dust-tight and oil-tight

NEMA 4 and 4X Cabinet Coolers

NEMA 4 and 4X Cabinet Coolers for large heat loads up to 5,600 Btu/hr. They are ideal for PLCs and modular controls. • Enclosure remains dusttight, oil-tight and splash resistant • Suitable for wet locations where coolant spray or hose down can occur

Type 316 Stainless Steel Cabinet Coolers

Type 316 Stainless Steel Cabinet Coolers for NEMA 4X applications are available for heat loads up to 5,600 Btu/hr. • Resists harsh environments not suitable for Type 303/304 • Ideal for food and chemical processing, pharmaceutical, foundries, heat treating and other corrosive environments

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The mini NEMA 12, 4 and 4X Cabinet Coolers for small heat loads up to 550 Btu/hr. are ideal for control panels, relay boxes, laser housings, and electronic scales.

High Temperature Cabinet Coolers for NEMA 12, 4 and 4X applications are available for heat loads in many capacities up to 5,600 Btu/hr.

NHP Cabinet Coolers keep a slight positive pressure on the enclosure to keep dirt from entering through small holes or conduits. For use in non-hazardous locations.

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“It took us three days to get a replacement computer cabinet and we didn’t want to risk another heat failure. Fans weren’t an option since they would just blow around a lot of hot air. Freon-type air conditioners like those on some of our other machines were a constant maintenance project of their own. We purchased EXAIR’s Model 4330 NEMA 12 Jeff Hauck, Lasercraft Inc. Cincinnati OH

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Cabinet Cooler System since it was easy to install and requires no maintenance.”

If you would like to discuss an application, Contact: 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247 / fax: (513) 671-3363

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6/30/15 8:36 AM

Te s c h l e r o n To p i c

Can’t innovate? Don’t blame the dunderhead syndrome The popular press is filled with caterwauling that bemoans a lack of technological innovation in the U.S. The idea that seems to have taken hold in the public’s imagination is that entrenched corporations often squelch novel ideas. According to the popular narrative, corporate managers look like either dunderheads or villains. They spout bromides about the short-term bottom line to a degree that somehow blinds them to spending money on promising new ideas that take time to blossom.

The manager obsessed with short-term results is a convenient stereotype to explain why businesses don’t invest in more cuttingedge technology. There’s also reason to believe that it is also completely wrong. The real culprit, surprisingly, might be the way industry does its accounting. This insight comes from Peter Martin, a vice president and Fellow at Schneider Electric. Martin describes his role at Schneider as that of a futurist who discerns trends and then helps his employer get in front of them. Martin’s experiences have led him to conclude that a key obstacle preventing many industrial firms from innovating is their own bookkeeping methods. To understand why, consider this scenario: Suppose your engineering team has come up with an idea that makes your production line super productive. But the improvements involve new technology that costs money. Being prudent, you pick one particularly troublesome station as a test case. The changes get made. Big success! Your team figures that over a year, they can add a half-million dollars to the company bottom line for each station that incorporates this innovation. With proof in hand, you approach upper management about going plant-wide. And that’s where the trouble begins. “There may be 40 process points in the facility and you’ve fixed one of them. But cost accounting systems are often set up to look at entire plants, not at individual

process units. Moreover, they only look at them monthly,” said Martin. “When you examine the operation through the eyes of the cost accounting system, you might see an improvement, but you won’t be able to tell the improvement is in the unit you fixed. The accountants will look at the whole plant and say it has improved a little bit, but they don’t know why.” This isn’t just a hypothetical example. Martin says he’s seen it unfold numerous times during the 40 years he’s been working with clients in industry. “The accountants who study the books will say they can’t attribute anything explicitly to specific improvements that have been made. The best they can say is that the plant had a good month, but that could have been because of better feed stock, a more competent machine operator somewhere, or from any number of other causes,” he said. The picture that emerges from Martin’s observation is that stubborn managers are less of an obstacle to spending money on technological innovations than accounting schemes rooted in the last century. “You need accounting software that shows the specific financial performance of individual units. And managers need to see it in real time, not monthly. Do that, and you’ll know how each single improvement drives the bottom line,” Martin said. “Fortunately, there is accounting software today that gives that kind of visibility.” And with this visibility, we might add, could come the end of the cliché of the dunderhead manager. DW

Le la n d Te sc h le r - Exec u t i ve Edi to r ltesc h ler@wtwh m edi a .co m

On Twitter @ DW—LeeTeschler 6

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HOW DO I KNOW IF I’M TALKING TO AN ENGINEER OR A SALESMAN? Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer? Our customers would. That’s why they collaborate directly with our world-class team of Smalley engineers—experienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox® retaining ring or constant section ring for your precision application.

Smalley wave springs reduce spring operating height by 50%, saving space and weight, ﬁtting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.

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THE ENGINEER’S CHOICE™

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l Contributors Spotlight Choose the best linear positioning device for your application

TONY KLIBER

BRIAN TAYLOR

Application Engineering Manager Schneider Electric Motion

Engineering Director of Precision Motion Control Nexen Group

IP65 rating and what it means for your application

Tony Kliber’s primary focus at Nexen is new product development for the precision motion control sector. In the next five years, Kliber said he would like to see more products that offer simple links between electrical and mechanical systems. Being involved in product development comes with its own frustrations; Kliber points to motion drive systems in particular. “In my experience, it seems selecting components and programming a servo drive is difficult for common users. There are so many dependent variables, it becomes overwhelming.” He also said he sees junior engineers relying too much on pre-made tools to do their work for them. “If you want to grow as an engineer … knowing the base math, concepts and logic behind what you are doing will allow you to grow faster.” Outside of work, Kliber’s two daughters (ages 5 and 2) keep him busy. “It’s amazing watching them grow and learn, especially when they join me in my other hobbies, like golf and car building.”

Purdue University graduate Brian Taylor says time is one of the biggest issues facing most engineers today, “specifically how to make the most efficient use of their day with all of the additional responsibilities now on their plate.” Taylor, who received his B.S. in Mechanical Engineering Technology, hopes to see engineers impacting energy conservation in a major way over the next decade. He points to solar panel development and transportation, the latter with respect to using renewable energy to drive vehicles rather than fossil fuels. If Taylor hadn’t become an engineer, he would have loved to have been a full-time musician. “I currently can say that I am a musician, and a professional one, as people do pay me to play. However, the pay does not offset the cost of living in Connecticut, so I need a day job!”

fun fact

fun fact Kliber would like to have dinner with the early American

settlers. “I think it is amazing that people got on a ship, sailed for three months to a new land, got off the ship with nothing, and found a way to survive in the new world!”

Designing slides into electronic enclosures

STEVEN M. ROBERTSON DUNSTAN POWER ByteSnap Design

Pre-compliance EMC testing: 6 ways your project will benefit Having graduated with a degree in engineering from Cambridge University, Dunstan Power has been working in the electronics industry since 1992. Of his college experience, Power said his coursework had little content that was relevant to real-world electronic engineering. “It was mostly advanced math, which, in reality, most engineers use very little day-today, and very little practical experience. That was some time ago, and I hope that courses have become more relevant.” In 2004, Power founded electronic consultancy Diglis Design, then in 2008, established ByteSnap Design with a former colleague. He cites job security as a major issue facing engineers today. “The days of cradle-grave jobs have gone and the market is much more dynamic. You need to keep on top of your skills to avoid becoming institutionalized.”

R&D Engineering Group Leader Accuride International Steven M. Robertson has been designing myriad industrial products for more than 42 years. As a child, he enjoyed trying to figure out how things worked. Robertson said he started college studying graphic design, but became more interested in the technical aspects of drawing and engineering technologies. Over the last 18 years, Robertson’s focus has been on developing and designing products for the electronic enclosure accessories market. Like Taylor, Robertson hopes our dependence on oil reserves will diminish over the next 20 years and renewable energy will become the norm. “By then, we should be able to tap fresh water reserves of the ocean, to considerably reduce the dependence on the everchanging weather and to provide consistent water supplies around the world.” When he’s not at work or home, Robertson can be found

fun fact running or cycling in the hills or streets around Orange

fun fact Power could not live without his electronic drum

County, Calif., or off-roading in his Jeep Wrangler with family and friends.

kit. “I can play in venues large and small without deafening the audience and the rest of the band. Though it isn’t as much fun as a ‘real’ kit!”

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Co nten t s |

July 2015 â&#x20AC;˘ vol 10 no 7

designworldonline.com

F E AT U R E S CONTROL 70 MOTION IP65 rating and what it means for your application IP ratings have very specific definitions. Here we explain exactly what kinds of water and dirt exposure IP65-rated motion components can withstand.

TEST & MEASUREMENT Pre-compliance EMC testing: 6 ways your project will benefit Adopting pre-compliance EMC testing removes the risk of product failure and avoids costly re-testing after design.

76 LINEAR MOTION

Choose the best linear positioning device for your application Reviewing the basics about the most popular linear positioning devices will help users properly specify them in their

ELECTRONICS Designing slides into electronic enclosures Equipment that usually sits in standard 19-in. racks has gotten heavier in recent years, and that complicates the task of selecting hardware for managing server electronics and test instruments.

applications.

84 MECHANICAL New material for radial shaft seals increases uptime

A reduction in design elements and a new material lays the foundation for radial shaft seals for roller bearings in steel mills. This cost-effective approach is a distinct advantage for manufacturer and customer in a price-sensitive market.

ON THE COVER Slides can handle 1U to 4U chassis in multiple rack configurations. Photo: courtesy of Accuride International Inc.

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CONTENTS JULY 2015_first page_Vs3.LL.MD(1).indd 12

2014

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HMI + PLC in One The Most Efficient Automation Solution By combining PLC and HMI functions in one, the FT1A Touch makes it faster and easier to build smart machines. This integration reduces initial design and maintenance costs by eliminating extra components and duplicate programming. Just one HMI+PLC unit optimizes efficiency and productivity by providing the complete functionality of a separate PLC and HMI system. For more details and to read our Tech Note, visit www.IDEC.com/Touch

Embedded USB Mini-B Port

USB-A Port For data logging, recipe data and performing program updates

Analog Expansion Cartridges Add up to two analog expansion cartridges for an additional four analog I/O

RS232C and RS485 ports • Serial and PLC communication • Driver to communicate with other PLCs

Relay or Transistor Outputs 10A contact relay output, 300mA per channel transistor output

Analog Outputs Two 0-10V DC/4-20mA analog outputs

Digital, Analog and High-speed Inputs • Eight built-in digital inputs of which two can be configured as 0-10VDC/4-20mA analog inputs • 4 high-speed inputs (up to 10kHz)



800.262.4332

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RJ45 Ethernet Port • Supports remote Ethernet communication and Modbus TCP • Driver to communicate with other PLCs

6/30/15 8:49 AM

Smart Products... Simple Solutions

3 Bezel Colors • Silver • Light gray • Dark gray

Screens • STN monochrome (740cd/m2) • 65K TFT color (400cd/m2)

Extreme Operating Temperature -20° C to 55° C

Flexible and Stress-free Programming • 5MB screen-editing memory • Over 7,000 symbol factory images

High Environmental & Safety Ratings • IP66f (water and oil tight) • NEMA 4X (indoor) and 13 • Class I, Division 2 for hazardous locations

www.IDEC.com/usa

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Con te n ts

7.20 1 5 56

D E PA R T M E N T S 4 Insights 6 Teschler on Topic 11 Contributors 18 Green Engineering

22 Engineering Exchange 24 Design For Industry 32 Design Notes 46 CAE Solutions 56 Internet of Things

64 Robotic Trends 111 Product World SIKO MagLine Absolute: ■

■ ■ ■

Measuring length of up to 20 m with a large reading distance Contactless and wear-free Accuracy up to 10 µm Simple and fast installation

120 Ad Index

visit website

SIKO OptoLine: ■ ■ ■ ■

High-precision, optical measurement Accuracy up to 5 μm Repeat accuracy up to 0.05 µm Large reading distance

open flyer

SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com

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July 2015

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AMETEKTIP 14152-PMC Solution City-9x10.875_Design World 02/20/15 12:11 PM Page 1

SOLUTION CITY

Air & Fluid Movement

Linear Motion Drive Systems & Motors

All roads lead to SOLUTION CITY Welcome to Solution City, where you will ﬁnd the largest selection of Precision Motion Control solutions for air and ﬂuid movement, drive systems, linear motion technology, and brush/brushless DC servo motors.

AMETEK's market leading, high-quality brands offer engineered solutions to match your speciﬁc application requirements. Whether your need utilizes existing technology or requires a customized solution leveraging our growing list of microprocessor based capabilities, we work closely with you to evaluate your application needs, and to assure you a fully compliant or tailor-made solution unique to your system requirements. To put your ideas for precision motion control into action, contact your local AMETEK technical sales and application expert, or visit us at ametekpmc.com.

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» Gree n E n g i n e e ri n g n Paul J. Heney • Editorial Director

Smaller robots help increase efficiency Comau has introduced a high-speed, 6-axis articulated robot that features a payload of 3 kg and a reach of 630 mm. The third robot within the Racer family, the Racer3 is the company’s response to the market demand for fast, cost-effective robotic automation within small- to medium-sized companies and emerging countries. With a streamlined design and brushed metal exterior, the robot unites speed with absolute precision and repeatability.

Built from high-strength aluminum, the Racer2 weighs 30 kg and can be easily

mounted on benches, walls, ceilings or on inclined supports. Preliminary prototype tests indicate that it will be the fastest in its class. Field-proven technology and enhanced dexterity allow for a focus on safety, design and product aesthetics. Features include: compact design, aluminum construction, exceptional stability and user-friendly control interface.

Racer3 can adapt to any environment, meaning that SMEs in virtually any

industry can easily automate, with extreme accuracy, precision and intelligence, even the most delicate manufacturing processes. It was created for general industry sectors, including food and beverage, electronics, plastics and metalworking. Rigid construction ensures higher precision and repeatability, whereas the hollow body construction optimizes the fluid transition of cables. Racer3 can be easily transported, guaranteeing maximum deployability.

Comau robotics.comau.com

n n

Variable speed drive pump enables energy savings for industrial machinery

DESIGN WORLD

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July 2015

Eaton’s Hydraulics Group has announced a new variable speed drive (VSD) pump solution that can provide up to 70% energy savings for equipment in the machine building, manufacturing, oil and gas and marine industries, depending on the machine duty cycle. The industrial pump solution, available in open- or closed-loop motion control configurations, reduces operational costs by allowing quieter machine operation, reducing or eliminating cooling needs and allowing for pump downsizing.

7/1/15 8:17 AM

WHEN SPEED MATTERS THE MOST. And Affordability More than 1,000 motion solutions to choose from, most with same-day shipping option. Design your own, today!

• Brushed and Brushless DC motors • Planetary and Worm gearboxes options • Integral All-in-One BLDC • Diameter from 30 to 75mm • Power from 10 to 450 Watts • Motor stall torque up to 400Ncm (580 oz.in) • Gearbox output torque up to 160Nm (120 ft.lb) • Nema 17, 23, 34 flange options

dunkermotor.com/express

Dedicated to differentiating our customers’ products Dunkermotor is a leading manufacturer of customized rotary and linear motion solutions providing low-risk product development, lower total system cost and faster time to market for original equipment manufacturers in the automation, medical, solar, packaging, semiconductor and transportation industry segments.

Dunkermotor 3-15.indd 19

1500 Bishop Ct - Mt Prospect, IL 60056 Call: 773-289-5555 www.dunkermotor.com info@dunkermotor.com

6/30/15 9:05 AM

» Gre e n En gine e r ing

Multi-Axis Communications Just Got Simpler. 1 READY. Use our free SMI™ software to auto detect motors. 2 SET. Set CAN addresses and baud rate. 3 GO. Send commands; start talking.

The solution can include one or more pumps, selected from an offering of PVM variable piston pumps, Hydrokraft variable piston pumps or VMQ fixed vane pumps. Together with the smart control of variable speed drives, the system can be controlled to match the precise load requirements of the current duty cycle. “Energy consumption plays a significant role in overall machine operating costs, and as energy costs increase, Eaton has worked to provide more efficient solutions without sacrificing safety or power,” said Wayne Wang, product strategy and planning manager, Industrial Product Portfolio, Eaton’s Hydraulics Group. “By combining the proven reliability and availability of Eaton’s Hydraulic and Electrical solutions, we are helping enable

more sustainable, cost-effective industrial operations.” Running pumps at a variable speed also reduces noise pollution, protecting operators hearing while meeting noise regulations. As equipment efficiency increases, oil coolers can be downsized, limiting the amount of oil used and extending the life of seals and oil. DW

Eaton eaton.com/VSD

WHAT DO YOU THINK?

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Depiction of Frequency Waves

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DESIGN WORLD

July 2015

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What’s Inside Matters The PITTMAN Difference ®

On the outside, this looks like an ordinary DC motor. In fact, this particular motor is not a standard off-the-shelf part, but designed exactly to a customer’s specific technical requirements. PITTMAN provided an experienced team of engineers to work directly with the customer to design the perfect motor to meet a demanding motion application… • • • • •

Special brush formulation for use in a very low humidity environment Bearing system to handle higher than normal axial loads Very tight balancing spec to minimize audible noise and vibration at high speeds Unique magnet charge pattern to minimize cogging at low speeds Specially chosen surface-mount components inside the motor to meet an aggressive EMC requirement

When evaluating DC motor choices, it’s what’s inside that matters.

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5 mechanical considerations for electrical engineers Trying to size and space the electrical components before the mechanics are defined can lead to wasted time and rework. Edited by Paul J. Heney, Editorial Director

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» Design for Industry

robotics

Automated handling of uneven stacks Fresenius Medical Care SMAD uses a smart system to handle uneven stacks of dialyzers. This system consists of a robot that uses two 2D sensors to detect the position of dialyzers and move them to a conveyor without human intervention 24 hours a day, 7 days a week. Fresenius Medical Care SMAD specializes in kidney disease treatment, offering a comprehensive range of services and products for patients with chronic kidney failure. Operations are primarily focused on the production of two main types of product: dialysis filters (aka dialyzers) and bags of dry or liquid concentrates. Concentrates are salts that are used to prepare dialysis fluid, which is similar in composition to blood plasma. The dialyzer production line at its plant in east-central France is equipped with the robot. “In 2009 we decided to automate our dialyzer handling unit, which is located between a conveyor system and a processing unit. Automating the unit was an obvious solution. The main challenge was that the dialyzers are stacked unevenly and their positions vary along three dimensions. We had to find a system that could recognize their positions,” said Mouloud Ifri of Fresenius Medical Care SMAD’s Manufacturing Dept. Automating the line was necessary for two reasons: it is installed in a controlled environment—problematic for human intervention—and it operated at high speed 24/7. The feed system consists of two conveyors, each with two rows of dialyzers. The robot is equipped with a tool that allows it to pick up two dialyzers per cycle. The tool is fitted with two Keyence LJ-G080 laser sensors, one per dialyzer, so that the dialyzers are correctly picked up one after the other. The robot thus simultaneously removes dialyzers from each stack on a conveyor. It takes dialyzers from the two conveyors in turn. When a row (diagonal) is emptied, the conveyor moves forward until the stack reaches the unloading position. The robot routinely “scans” the theoretical positions 24

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The main challenge in automating a dialyzer handling unit was that the dialyzers are stacked unevenly and their positions vary along three dimensions. An automation system needed to recognize the individual dialyzer positions. depending on the type of product. It uses the Keyence sensors to detect products and correct its pickup position accordingly. If no products are detected, the robot moves to a different stack. It also uses the sensors to correct its X- and Z-axes. To compensate for dispersion along the robot’s Y-axis, the robot’s tool is fitted with a homing cylinder for each type of dialyzer. The maximum height and slope of the stacks are always the same for the same type of product. However, these stacks may be uneven. “We first considered installing an industrial vision system. However, the cost and complexity involved led us to scrap that idea. We then looked at a 2D laser measurement sensor provided by a competitor, but found it to be complicated to implement.” Ultimately, the installation team chose the LJ-G080 sensor by Keyence. Its user-friendly settings menu means that experienced and novice users can configure settings easily and quickly. The setting support software (LJ-H1W) supplied with the device makes it easy to save and analyze data with a PC. Configuration is also made easy by several adjustment functions. For example, position adjustment ensures accurate measurements even when targets are not perfectly arranged or positioned. The tilt

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correction function simplifies installation of the sensor head and eliminates measurement errors. A number of functions make measurements to the surface properties of targets (shiny, dull, for example). â&#x20AC;&#x153;We also place high demands on the robustness and reliability of equipment,â&#x20AC;? said Ifri. The LJ-G sensor delivers reliable detection over time, offering repeatability of 1 Âľ along the Z-axis and 10 Âľ along the X-axis. It is protected inside an IP67 housing and withstands vibrations tested from 10 to 55 Hz, with an amplitude of 1.5 mm, for two hours along X, Y and Z. It weighs 350 g and has a detection range of 80 mm. DW

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robotics

» Design for Industry

Inductive sensors fit tight spaces Size and weight restrictions limit the kind of sensors that can be used in compact applications, such as robotic end effectors. The SuperShorty inductive sensor line fits applications with space restrictions. These sensors weigh about 0.7 g, and have diameters as small as 6.5 mm and lengths as short as 6 mm. The electronics are self-contained, making remote amplifiers unnecessary, and are placed in stainless-steel housings, making them suitable in a range of challenging applications. DW Balluff balluff.com

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» Design for Industry

semiconductor

Cables ensure power and control

Several processes in semiconductor Wafer Fab Class 1 Clean Rooms are operationally critical and need equipment that is absolutely reliable. When it comes to cabling, one option is flexible flat cables. The crystal-clear designs are free of halogens and contaminants, and are an alternative to PVC, Polyurethane and Teflon cables, especially in continuous motion and long-term flexing operations. The flat cables from Cicoil are made from a unique extrusion process that combines multiple power conductors; shielded signal pairs; fiber optics; Ethernet; coax; thermocouple wires and flexible tubing for air, wire placement or fluid transfer; and StripMount fastening strips to be placed in a single flat cable, precisely controlling the inner component spacing, jacket thickness and the overall cable shape.

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The durable outer Flexx-Sil rubber jacket is selfhealing from small punctures and will not wear, crack or deform during a lifetime of more than 10 mil flexing cycles or long term exposure to vibration, de-ionized water, cold temperatures (-65° C), alcohol, extreme heat (165° C), stress, UV light and many chemicals. Standard “off-the-shelf” cables are available, complete with connectors offered in 3, 6 and 12 ft lengths. These cables for semiconductor applications are UL Recognized, CE Conforming, RoHS & REACH Compliant, Class 1 Clean Room Rated and exceed the outgassing requirements of ASTM E-595. DW

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» Design for Industry

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» Design for Industry

machine tool

Simpler machine tool design A mechatronic design tool will help you size a motion system within a single platform. Finally, some companies are cooperating together to make it easier to design a whole system. Tolomatic and Rockwell Automation have announced that you will be able to specify electric rod actuators and rodless electro-mechanical actuators on Rockwell’s Motion Analyzer web-based software, making it easier to specify, design and validate complete motion control systems that use Allen Bradley controls. The mechatronic design tool, with its cloudbased architecture, promotes collaboration among mechanical, electrical and controls engineers to create prototype machines. The Motion Analyzer combines application requirements with product

ratings and specifications to provide solutions that exactly meet needs. Tolomatic’s featured electric rod actuators (ERD, RSA) can meet most budget and performance requirements. ERD electric actuators are a low-cost alternative to pneumatic cylinders. The RSA high-thrust actuator offers mounting flexibility. Tolomatic rodless electro-mechanical actuators (MXE, MXB) are available in both screw- and belt-drive designs and a variety of bearing styles and options. Products can be built-to-order in 15 days or less. DW

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Âť D e s i g n N o te s

Mike Santora â&#x20AC;˘ Associate Editor

Optical encoder takes over for LVDT Conventional servo-hydraulic test instruments use a linear variable differential transformer (LVDT), a type of inductive absolute encoder, to determine the linear direction of travel and position of the actuator. But when Instron was designing its ElectroPuls fatigue testing systems, it knew the limitations of LVDT technology would be problematic. ElectroPuls is driven by a linear synchronous motor and requires additional velocity feedback due to the challenges of driving linear motors with lower inherent damping than traditional rotary designs. While suitable for position control, an LVDT suffers from relatively poor signal stability, and therefore, cannot produce accurate velocity measurements. LVDTs are also susceptible to magnetic fields produced within a linear motor and exhibit increasing non-linearity over longer axes. Optical encoders, on the other hand, have better signal stability and higher accuracy, making them better in this application. The Instron design

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The Instron E3 000 uses a T-slot ta ble for regular and irreg ular grips and specimins

July 2015

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â&#x20AC;&#x192;

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» D e s i g n N o tes

team determined that an absolute optical encoder, capable of providing absolute position information without homing, would be the best solution for their bi-axial systems. The encoder offers several advantages over servo mechanisms that use optical linear incremental encoders in conjunction with an LVDT. The engineering team needed an absolute optical encoder that was compatible with BiSS serial communications, easy to set-up and install, and non-contacting to eliminate the friction and wear that leads to mechanical hysteresis errors. They chose Renishaw‘s RESOLUTE, which offers linear resolutions of 1 nm and speeds beyond 20 m/sec.

Instron’s E30 00 has a twin column configu ration with the actuator in the upper crosshea d and is electrically pow ered from a single-phase m ain supply.

“We previously used an LVDT to supply the absolute position feedback needed to commutate a linear motor, and an incremental optical encoder to provide the required measurement and control accuracy,” said Graham Mead, principal mechanical engineer for Instron ElectroPuls. The absolute linear encoder gave the design

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team functionality and accuracy from one device. The ElectroPuls E3000 linear-torsion machine requires both linear and rotary absolute encoders for the linear and rotational axes respectively. The linear position is provided by a RESOLUTE readhead and RTLA tape scale with ±5 µm/m accuracy and 5-nm resolution. A second RESOLUTE reading a 115-mm diameter RESA ring determines angular position, offering a resolution of 0.019 arc second and an encoder accuracy of ±2.5 arc second. The behavior of dynamic materials-testing machines must be precisely controlled with either strain feedback from an encoder or stress feedback from a load cell. Standards body ASTM International tolerates a deviation of up to 2% of the maximum applied load before a test becomes invalid. RESOLUTE’s high accuracy and excellent dynamic performance permit more detailed analysis of samples at failure, contributing to the accuracy of drawn conclusions. DW

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» D e s i g n N o te s

Mike Santora • Associate Editor

Step motor control ensures accurate scanning

The mPAT LAB Inverted Raman Microscope

Even the highest quality metrology equipment can’t truly shine without a motion controller that functions with the same level of precision. H2Optx’s mPAT LAB multiplexed Raman and Optical microscope system needed a motion control platform that was easy to use and would allow quick integration during the prototyping stage of the design cycle. H2Optx Inc. provides the pharmaceutical, food and fine chemical industries with multi-spectral, online measurement devices. The devices can be used in end product situations or as a device within a larger, more complex laboratory or production system. Because H2Optx is a small team of specialists working to develop products for highly specific industries, its ability to integrate components for a particular system quickly and efficiently is important. Specifically, its ability to move samples and then do a detailed scan of the samples depends on complex underlying motion control capabilities. The mPAT incorporates a laser ScanHead as well as an optional material handling accessory, such as either the company’s Pillerator or Powderator product. That means that a controller must work right out of the box, and the software must be easy to 36

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integrate into pre-existing system components. In addition, the controller had to have high levels of overall integration (like a four channel controller in a single, compact, printed circuit board). Raman microscopes are laser-based devices that are used to identify and quantitate samples by measuring and evaluating the scattering properties of materials. The underlying capabilities of a Raman Scanning Microscope are enabled by the ability to move an optical block that houses a laser, microscope, digital camera and spectrometer interface together on a three-axis stage. The three axes are driven by accurate and repeatable linear stepper motor actuators. The system is controlled using a personal computer over a standard USB port. Therefore, the H2Optx needed a controller that was USB based. Plus, it needed to handle multiple axes simultaneously. “The only solution

we found that would meet all of our needs was the AllMotion EZ4AXIS controller,” said company spokesperson Scott Tandy. To accomplish the scanning function, the controller had to have a flexible enough interface to allow it to execute pre-programmed actions on its own, without the PC involved. At 2.25 x 2.25 x 0.6 in. (57 x 57 x 15 mm), the EZ4AXIS is one of the smallest controller/drivers on the market— and one of the most powerful in its size. It is a fouraxis position controller with built-in power drivers. It also incorporates dual encoders as an integral part of the package. H2Optx required a controller with at least 16 microstep resolution and 1 A drive current. The controller provided these capabilities for four outputs (one more than was needed). In addition, the design called for the use of hardware limit switch capability, something that came as part of the controller package. The H2Optx design team was also happy

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with the way the controller easily integrated with other components of the system. Its flexibility helped make interfacing easier. Each independent axis functions through a 1 A (2 A peak) PWM chopper driver. According to Tandy, “AllMotion provided all of the motion control capabilities we needed in a compact package. We integrated the EZ4AXIS directly into our ScanHead design using it as a daughter board to our main printed circuit board. This allowed us to use all of the features of the controller, but pick and choose the connectors and interconnects that we wanted for our form factor.” As far as ease of use was concerned, H2Optx engineers found that the EZ4AXIS’ software was based on industry standard

serial interfaces. Thus, direct interaction with the product was easy to incorporate during the investigation and early prototyping phases of the design—all while using the software application that AllMotion provided. “For the final product integration into our Microsoft C#/.Net environment, the serial port interface meant that there were no additional software modules to integrate into our mPAT system software,” Tandy said. DW

The AllMotion EZ4AXIS controller is a cr itical component of th e mPAT microscope syst em. It is shown here mounted on the ScanHead elec tronics.

AllMotion Allmotion.com

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» D e s i g n N o tes

The total package: How to design a film wrapping machine with direct-drive technology

Guaranteeing packaging results every time, even when product characteristics vary and product types change often, is one of the greatest challenges facing a machine builder. This was the primary consideration for Alpenland Maschinenbau (ALPMA) when designing its new MultiSAN film wrapping machine. The machine packages round and rectangular soft cheeses, as well as cheeses in karospar, cylindrical and half-moon formats. “There are cheese makers today that make only a few types of cheese, but nevertheless change over their production every two or three hours because they produce every order by the truckload,” said Helmut Eitermoser, the designer of the MultiSAN. The reasons for smaller and smaller batches are typically the same as in other industries: customer-specific product requirements, shorter product life cycles and increasing product variety.

DESIGN WORLD

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ALPMA’s film wrapping ma

chine called the MultiSAN can process a range of products with no changeove r with use of LinMot linear motors.

Until now, cheese makers used packaging systems in which a mechanical master shaft with cam drives mounted on it drove the synchronous motion of the individual mechanisms. “These cam machines were, and continue to be, the right solution for packaging just one type of product. They are precise, cost-effective and durable,” said Eitermoser. Two similar format shapes—such as round and half-moon—and different sizes with the same shape can also be processed on these machines with a reasonable effort. This does, however, require a compromise; the packages for each product version are less than optimal. “When several different products are to be packed in a folded or wrapped package on the same machine with rapid changeovers, the cam machine reaches its limit. Reconfiguration

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or even machine replacement is required before a product changeover. For the MultiSAN, the ALPMA design team used direct-drive technology in combination with a virtual master shaft and electronic cams, which have completely replaced their mechanical counterparts. The envelope folds under the cheese, typical for wrapped packaging, are now produced by means of four horizontally mounted LinMot linear motors that each drive one shutter blade through a linkage. Once the cheese has been wrapped in the packing film by the machine, and has been fixed in place on a round plate by a gripper, the shutters press the protruding film together on the bottom of the product in rapid succession, thus producing the desired fold pattern. Another linear motor axis moves the cheese off of the round plate onto a belt that transports the cheese to the next station. For this specific application, the design team

suspected early on that only linear motors would have the power density that they needed. “Demo units have shown that rotary servomotors are not well suited for this task because they take up too much space,” said Eitermoser. He chose model PS01-23x160H-HP-R motors for the MultiSan. The motors have a diameter of 23 mm (stator)—not including the plug connection on the end—but nevertheless are able to produce a peak force of 130 N when coupled with the E1130-DP-HC controller. The matching sliders are available as standard products in many variants, for strokes from 20 to 780 mm. The version selected for the MultiSAN has a stroke of 120 mm. The space-saving form factor of the linear motor also allows the new design to take up the same floor space as the comparable version with a mechanical master shaft. The cycle time also match: both run at up to 80 cycles. The commonalties end there, however. To

create a much more modular construction, the ALPMA design team combined the mechanical unit with the shutter drives into one module that is used in several places on the machine. It is designed to function as a heat sink for the linear motors as well. These features all helped lead to a product with consistent and repeatable results every time. “We have also made use of the sensitive and direct reaction performance of the linear motors to give the operator an instrument for reacting to variations in product consistency,” said Eitermoser. “The responsible parties on-site can thus set their own parameters for various consistencies, so that the machine operator can adapt the machine settings to changes in product characteristics just by pushing a button.” DW LinMot linmot-usa.com

By using direct-dri ve techn the MultiS ology, AN has be en decoup mechanic led ally so tha t sensitive ponents c coman be fold ed back o foam clea u t of the ning area.

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Âť D e s i g n N o tes

Edited by: Mike Santora â&#x20AC;˘ Associate Editor

as elta Robot e Omron D th g in w s ie d o V ping meth erent stop it uses diff d n stop a mergency between e curtain). stop (light protective

How using a programmable safety rated controller can increase the life of your machine How do you stop your car as you approach a red light? Is it a gentle release of the gas pedal so it can coast, slamming on the brakes or somewhere in between? With both methods, each way of stopping has a practical purpose. Most people like to glide to a stop. Itâ&#x20AC;&#x2122;s easier on the passengers and it saves on gas and brake pads. However, sometimes you have to stop the car as soon as possible. The same is true with machines. For engineers there are other practical considerations when designing an emergency stop system than the obvious primary function. A normal stop allows the machine to glide to a smooth stop at the end of a sequence. In most cases, this will be done by a signal sent 42

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to the machine to let it know it should finish its task. The signal can be sent by the operator, usually with a black pushbutton. For times when an operator needs to deliberately stop the machine as quick and safe as possible, an emergency stop is used. This type of stop is performed using a red mushroom shaped device with a yellow background. Machines require at least one category 0 emergency stop, which is the immediate removal of power. On occasion though, the removal of power creates more hazards, so category 1 emergency stops may be suitable for additional emergency stop buttons. This is a controlled stop before the power is removed.

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Careful consideration should be applied before using a category 2 emergency stop, a controlled stop with the power still available. Because it’s quite possible that the operator may not be aware of the hazard, a protective (safety) stop uses a control system to stop a machine if anything accesses a hazardous area. There are many types of this technology including light curtains, noncontact switches, safety mats, bumpers and edges, area scanners and mechanical switches. Every machine needs to have an emergency stop. However, the machine does not need to have immediate stops with protective devices. The only way they can stop differently is if the controls are separated. Depending on the load, motor size and speed, the number of braking stops could be greatly reduced before the disk in the mechanical brake is worn out. It is difficult to separate the stopping method with relays because they are hard-wired and share the outputs. However, with a programmable safety rated controller, the logic can be separated so a signal can be sent to the machine during the activation of a protective stop device. This signal separation gives the machine a chance to stop on its own before the safety system “slams on the brakes.” Like the need for emergency stops themselves, some design considerations are necessary but easily overlooked. When adding any type of delay, remember to include the additional time to the safe distance calculation. When using a time delay, the length of time for the motion to stop may be dependent on the machine age, condition of contacts, speed, load, and motor size. Using the dynamic braking settings may also affect the machine’s stopping time. If no more space exists to extend the safety zone, a common solution is to use a guard interlocking switch. One advantage of considering a servo drive or inverter is the safe torque-off function. It has a faster response time than using the traditional force guided relays for the EDM (External Device Monitoring) since it has one less connection. For small systems, turning off the power through a breaker box may be a suitable substation for an emergency stop pushbutton. The breaker box must be located by the machine and easy to activate. According July 2015

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to the ANSI RIA 15.06-2012, section 5.6.4, stop control device(s) shall be placed near each start control device. It is important to reference the specific emergency stop requirements in your area. In the U.S., the primary emergency stop requirements are found in the NFPA 79: 2015 Edition (Electrical Standard for Industrial Machinery). The Canadian standards refer to NFPA 79:2015. ISO 13850:2006 (Safety of Machinery—emergency stop function— Principles for design) covers international standards.

Specific requirements just for emergency

The robotics standard, ANSI RIA 15.06-

stops include:

2012, section 5.3.8 states the system

• be continuously operable and readily accessible • red with yellow background • positioned so readily available and capable of non-hazardous actuation by the operator and others who may need to actuate it • positive mechanical action, direct opening (NC contacts) • (be either) stop category 0 stopping by means of immediate removal of power to the machine actuator(s) OR Mechanical disconnection (declutching) between the hazardous elements and their machine actuator(s), and if necessary, braking

shall: • have a protective stop and independent emergency stop • lead to a protective stop when entering the safeguarded space in automatic mode • have manually initiated emergency stop function. DW Omron omron.com

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Drainage system and detail of conic shape drain.

Around the clock solar power Thermal modeling enabled the optimization of a critical drainage system for Archimede, the first Concentrating Solar Power (CSP) plant in the world to use molten salt for heat transfer as well as storage, and to be integrated with an existing combined cycle gas facility.

Valerio Marra • Technical Marketing Manager • COMSOL

Situated on the east coast of Sicily, this innovative industrial demonstration plant uses Parabolic Trough CSP technology to generate electricity during sunny hours as well as under overcast conditions or at night. Jointly developed by Italian utility ENEL and the Italian National Agency for New Technologies ENEA, it began operating in July 2010 and is named after the mathematician and engineer Archimedes who lived in the nearby town of Syracuse. 46

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Archimede incorporates 30,000 m2 of reflective parabolic mirror surface in the shape of troughs. The sun’s rays are concentrated onto long thin tubes, which together make up a receiver pipeline running along the inside of the curved surfaces and stretching for 5,400 m. This pipeline contains a heat transfer fluid made of 60% sodium nitrate and 40% potassium nitrate, commonly

used as fertilizer. During the start-up of the power plant, this mixture is heated to at least 240° C (464° F) so that it melts and can pass into the tubes. Once it is molten, it is heated further by the sun and channeled to a dedicated steam generator, where it produces high-pressure steam that drives a turbine in the adjacent combined-cycle power plant.

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The molten salt advantage Mainly located in the U.S. and Spain, there are several CSP plants already in operation. They all depend on pipes filled with diathermal oil to absorb solar heat; older CSP plants can only operate in the daytime under direct sunlight. Newer plants have extended their operating hours through the use of molten salt as a medium for storing heat in large, well-insulated tanks. Using molten salt for heat capture as well as storage has several advantages over pressurized oil. Molten salt operates at 550° C (1,022° F) compared with oil at 390° C (734° F), so power output goes up, maximizing energy efficiency and potentially reducing the consumption of fossil fuels. The annual solarto-electricity conversion efficiency is more than 15% better than other CSP plants. Because no oil-to-salt heat exchangers are required, the solar field is completely integrated with the energy storage system and there is minimal heat loss. This means that the tanks are less than half the size of competing parabolic trough CSP technologies with the same storage capability, yet they provide seven hours of thermal storage. The cold storage tank of both technologies works at 290° C (554° F). The temperature of the hot storage tank in oil-based CSP plants is 390° C (734° F), a difference between hot and cold tank of 100°. The temperature of the hot

storage tank in the Archimede plant is 550° C (1,022° F), a difference between hot and cold tank of 260° C. Comparing the Archimede plant with oil-based CSP plants the temperature difference between the two storage tanks is 2.5 times higher. Salt is clean, and one big advantage is that once it has been cooled, it can be reused. Oil degrades, is flammable and, as a toxic substance, needs to be disposed of carefully. In addition, molten salt allows the steam turbines used in the CSP process to operate within the standard pressure and temperature regulations at which fossil fuel plants run. This provides the potential for conventional power plants to be integrated easily with CSP plants like Archimede.

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Conjugate heat transfer simulation Unfortunately, the advantages of molten salt also present a technical challenge: to maintain the salt’s liquid state. Daniele Consoli, project engineer in the Engineering and Innovation Division of ENEL, explained, “At 220° C (428° F) salt is frozen. It melts at 240° C (464° F), and for it to remain liquid, it must be kept at 290° C (554° F). When molten salt acts as the heat transfer fluid circulating in

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» CA E »Solu CA Et iSo onlut s ions

IR Thermography of the conic shape drain.

the tubes in which irradiation is concentrated, the pipes must be able to withstand constant heat up to 300° C (572° F) to prevent the salt solidifying and causing an obstruction. An electrical trace system is therefore required to preheat the pipeline and to facilitate the emptying of the circuit, which drains the solar collector.” Accordingly, the Research Division of ENEL chose to make the pipeline from a stainless-steel alloy to withstand extremely high temperatures. “This is an experimental power plant and there have been some critical points throughout the project,” said Consoli. “COMSOL Multiphysics has helped us to solve technical issues as they arose, for example when we needed to analyze temperature and heat loss throughout the drainage circuit and optimize both its geometry and insulation properties.” The team created a model of the drain within COMSOL Multiphysics and the results were quickly validated by a physical investigation of thermography and thermocouple measurements. “To begin, we undertook two kinds of simulation. First, we created a stationary

model and used it to determine the level of heating power that needed to be applied by cable to ensure that the temperature in all areas of the drainage system remained above the point at which salt solidifies. We carried out a 3D solid-fluid conjugate heat transfer simulation where both the conic drain part and the surrounding air were modeled. We considered heat transfer by conduction in the former, while both conduction and convection were taken into account in the latter. All the material properties were temperature dependent. We simulated heat loss in the remaining part of the drain by using COMSOL’s built-in library of local heat transfer coefficients. Thanks to such coefficients, we

saved both computational time and resources without affecting the accuracy of the simulation,” Consoli said. The team then created a second dynamic model to study the transient heating of the drain and check the time required to achieve the desired temperature. Another example of COMSOL application in CSP plant analysis has been the development of a model of the storage system to assess how, after validation, it could be optimized for plants of a larger size. This may incorporate several thermal bridges, which would have to be assessed to avoid the potential for significant and costly thermal power losses. Consoli explained how heat transfer was

Archimede project; Priolo Gargallo, Italy. 48

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» CAE S olut i ons

modeled: “We considered heat transfer by conduction along the thickness of the wall (steel, insulation, aluminium sheet) and the foundation of the tank. We took both conduction and convection into account for the fluid (molten salt) and convection and radiation for the surrounding air outside the tank.”

Reliable process operation Given the over 50 million Euro ENEL total investment in the Archimede project, it was not difficult for Consoli to propose a business case for COMSOL Multiphysics. “Being able to simulate plant operation related to design choices on critical components was extremely important. In the case of the drainage circuit, simulation may significantly reduce the risk of potential damage to the power

plant and the consequent costs in case of failures. COMSOL Multiphysics represented an appropriate tool for those analyses.” From the operating and maintenance point of view the drain represents a single point of failure. “If it failed, we would have to stop one branch of the plant from producing energy while we repaired the failure. Then we would need to follow complex procedures to reactivate the affected branch, a process that takes at least two working days. All this would result in the loss of man-hours, significant operational income, and above all, clean energy. In addition, being aware of the thermal stresses that the drain and the whole plant are subjected to, we can schedule the preventive maintenance in a more effective way.” According to Consoli, another way to

have sized the heating cables would have been through an iterative process based on experience and on monitoring the effectiveness of incremental changes in an empirical way. “With COMSOL we quickly discovered the exact amount of thermal power required and then validated the results directly.” The Archimede project has attracted great interest from utility companies within Europe and around the globe. “We were building the first power plant in world to use this technology and we needed to get the first plant right and then go on to improve it. There are many potential opportunities for solar thermodynamic technology and the next Parabolic Trough CSP may be much larger,” said Consoli. DW COMSOL comsol.com

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» CA E Solu t i o n s

FloTHERM XT includes EDA connectivity for better thermal management

The newest version of FloTHERM XT software offers advanced thermal management capabilities for electronic systems, printed circuit board (PCB) and packages of any geometric complexity. This software includes CAD-centric technology and a mesher that simulates complex geometries with ease, speed and accuracy. It also supports transient analysis, Joule heating, parametric studies, extended EDA integration capabilities and new modeling options, including a cutting-edge ability to represent copper in detail for complex PCBs. These capabilities suit thermal simulation of electronic devices used in a range of markets including automotive, transportation, consumer electronics, industrial automation, aerospace and defense. “We can now take raw mechanical and electrical design data for an electronics system through to a viable thermal model appropriate for advanced parametric analysis. The improvements offered by FloTHERM XT enable us to work more efficiently and to build and run models with a significant reduction of engineering time and effort,” said William Maltz, president and founder, Electronic Cooling Solutions. For thermal specialists and design engineers, this software provides early design virtual prototyping and advanced “what-if” analysis for improved product quality, minimial design iterations, and faster time to market. Key product capabilities • Transient analysis. Time-varying analyses across all industrial applications is enabled with the FloTHERM XT state-of50

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the-art solver and intuitive user interface (UI). • Component and board manipulation. Time is saved by importing any board and component layout and easily modifying data for position, size, orientation, shape and modeling level prior to transfer to the FloTHERM XT product. • Joule heating. Comprehensive analysis platform predicts current density, electric potential and associated Joule heating effects in complex electronics systems, PCBs and other high-power devices—a valuable feature for automotive and power electronics applications. • Parametric study. A new integrated environment for defining, solving and analyzing results for parametric variations of geometry, attributes (such as material, thermal) plus solution parameters significantly enhances the design optimization process. • EDA tool connectivity. A new ODB++ interface for non-Mentor Graphics layout tools supports Cadence, Zuken and Altium and helps users save time by providing increased user flexibility and use of existing EDA data. • Modeling options. PCB copper nets and traces are represented in full 3D detail, critical for higher-fidelity solutions or high-power applications using Joule heating effects for critical devices on a board. • Enhanced UI. Easy-to-use interface and enhanced functionality enables efficient use WHAT DO of the FloTHERM XT software for an improved YOU THINK? DW intuitive user experience. Connect and discuss this and Mentor Graphics mentor.com

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Siemens launches Solid Edge App Marketplace Siemens launched an online store that will help customers easily search for, compare and purchase partner developed apps for Solid Edge software. The Solid Edge App Marketplace mobile app provides a onestop shop for add-on solutions that extend the capabilities of Solid Edge. The open architecture of Solid Edge gives partners access to a product development platform to create apps that support the user community.

“Innovative features enabled by apps allow customers to choose how they want to extend their use of Solid Edge technology,” said Michelle Boucher, VP of Tech-Clarity. The Solid Edge App Marketplace allows customers to instantly find complementary partner apps to meet their specific needs. Customers will be able to research and compare a variety of apps, select the one that best meets their requirements and purchase the app online to start realizing value right away. DW

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Linear position sensors support finite element analysis of pipelines

To ensure drilling platform stability, elongation measurement sensors contribute data as part of a long-term finite element analysis of pipelines, derricks, moorings and other critical high-stress members on offshore oil platforms. These platforms must be constantly monitored to ensure their stability. These sensors are typically a type of LVDT linear position sensor made for offshore applications. Specific features include high accuracy and long-term reliability when operating in water. In addition to providing measurement from micro inches to two feet with repeatability and precision, some offshore sensors can operate for at least 20 years, even when exposed to seawater. One such 52

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sensor is the Macro Sensors Offshore LVDT Linear Position Sensor. Reliability is a demanded feature of these sensors in offshore applications because of the high cost associated with replacing underwater hardware. These LVDTs are hermetically sealed, constructed with a subsea connector and gold-plated pins, and rated up to 7,500 psi to survive and perform accurately when submerged in the ocean for indefinite time periods. Dependent upon ocean temperature and depth levels, the LVDT casing is typically composed of special alloy that supports longterm operation. As sensor housings and core carriers made from stainless steel do not survive well in shallow warm waters, the Offshore

LVDTs are made with exotic material, such as Inconel, titanium and Hastelloy, for pressure and corrosion resistance. LVDTs have no moving parts. DW Macro Sensors macrosensors.com

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New PCB design tool for SOLIDWORKS “We are now at a point where the line between electronic and mechanical design is blurred, and PCBWorks is the first PCB design product to address the need for electrical and mechanical design teams to collaborate in a natural way,” said Ben Jordan, product manager at Altium. PCBWorks is a PCB design tool specifically for collaboration with mechanical designers in SOLIDWORKS. It is available globally through a certified network of SOLIDWORKS resellers. With PCBWorks, the collaboration process between electrical and mechanical design teams is now a seamless process with linked design data between both environments. Designers can maintain their own distinct workflows with support from the following features: • ECAD/MCAD collaboration server. SolidWorks users can make changes to component placement, board shape and mounting holes on a PCB, and then push those changes to PCBWorks as a managed Engineering Change Order (ECO) to keep design data in sync. • Separate component lifecycles. Lifecycles for components can now be separately managed in their respective design

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» I n te rn e t of Th i n gs

How the IoT really affects manufacturing

Frank Blasé • CEO

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•

igus International

July 2015

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7/1/15 11:41 AM

When Size and Performance Matters Medical-Industrial

Recently, Editorial Director Paul J. Heney had the opportunity to tour the igus International Headquarters and speak with company CEO Frank Blasé. The tour included an opportunity to see the 350 injection molding machines that put out more than 3 million pieces per day. igus runs approximately 10,000 mechanical and temperature tests per year on its products, as well as chemical tests that are done off-site. There are 600 customer-specific tests on the bearings product line alone. The Internet of Things (IoT) appears to be new to many companies. However, if you have worked in manufacturing, the IoT is more of an evolution of data collection and connectivity that has been around for several decades. What’s new this time is using IoT to automate the processes that surround manufacturing—order entry, ERP systems and other parts of the total manufacturing system. Here are the comments from Blasé and how igus is using IoT concepts to further improve manufacturing.

DW: How do you personally see the Internet

of Things affecting igus?

Blasé: A little bit facetiously, on the one

hand, as we have been doing it for many years. Not all the aspects, not all digitalized, but part of what the Internet of Things means, according to us anyway, is that customers can order online any kind of configuration or any kind of one-off and get it, quickly. That has been part of our business … for decades, and also online tools started early, but we have to make huge efforts, and we are doing that. We invest in an unprecedented amount of IT right now, to digitalize the whole process. We call it “from contact to claim.” From the first contact that the customer has with us, on the Web, or we have with the customer, all the way to a possible claim, and digitalize everything in between, as much as is possible or adequate. [Imagine] making a CAD drawing that can be, should be, automated, with a few configuration tools; it should automatically go to the ERP system and then automatically go to the supplier, where automatically the CNC machine starts turning that part. We need to digitalize, quickly, and we have am ambitious plan for the next two years.

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We see three aspects of the IoT: the oneto-one online ordering, the smart factory and the smart products. For online ordering, we see ourselves quite well prepared. Smart factory, inside, we made a lot of preparations to do the one-to-one, and we need to digitalize more, for our customers. We have the cable developments, CAD 7 and so on, to make the data communication safe. Once it’s in motion, we believe, we can make some good contributions there. From the smart products point of view, we think that we will do more. We have some smart products, a chain that tells the customer if it has worn to a certain point, and the new Web-based control might be interesting, but we think that we can do more. We need the overall investment in IT, like the Big Data foundation, so that we can do something with data if we want to. It is so difficult to integrate a sensor into something, but the software and what IT does with it and tells the customer what to do with it, is, we believe, a big part of the investment. DW igus igus.com

July 2015

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» I n te r n e t o f Th i ngs

How to select wireless networks Like other wireless networks, wireless sensor networks eliminate the costly labyrinth of dedicated cabling to hardwire devices, enable flexibility in organizing operations, and expand opportunities for keeping tabs on plant-floor conditions and performance. Selecting the right wireless sensor network for your applications is still a challenge. To help manufacturers make confident decisions, the National Institute of Standards and Technology (NIST) has developed bestpractice guidelines for evaluating wirelesssensor-network performance and selecting the option that best meets requirements. “Our goal is to develop a tool that will enable manufacturers and their technology suppliers to design, assess, select and deploy secure, integrated wireless platforms that perform dependably in factory conditions,” NIST’s Rick Candell said during the International Instrumentation Symposium. Candell, head of NIST’s Wireless Platforms for Smart Manufacturing project, noted that several standards-based technologies have been adapted or developed to support industrial wireless applications. The guide will include benchmarking tests and metrics for comparing how well different technologies meet specific sets of requirements, he said.

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NIST is in the early stages of commissioning a wireless network test bed that will replicate a smart manufacturing environment. It will re-create conditions representative of a variety of industrial settings and support development of network-performance measurements and tests. The test bed also will be used to evaluate the usefulness of NIST network models and simulations. To ensure that the test bed accurately reproduces the messy and challenging realities of a variety of manufacturing operations—from chemical processing to aerospace—the NIST team is making a special request. They are asking companies to open their plant doors so that the researchers can characterize conditions and factors, such as heat, vibrations, reflections, interference and shielding obstacles that affect network performance. “We want to re-create the factory and network entirely in the lab,” Candell said. “To do that, we need to make measurements in the field to capture channel and environmental characteristics and to represent the current state of wireless activity in different types of manufacturing operations. We want to assess how the network performs and how the wireless network impacts factory performance.”

The NIST team has just completed gathering needed data at NIST’s own machine shop and at a U.S. automaker’s transmission assembly plant. “We would like to expand our measurement efforts from discrete manufacturing to a broader range of industries, including the process control industries such as oil and gas, chemical, and water treatment,” Candell said. DW NIST nist.gov/el/isd/cs/wpsm.cfm

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» I nternet of Things Analyzing Big Data One of the key developments to come out of IoT is delivering data analysis as a service. Siemens has launced Omneo Performance Analytics (PA), the latest application for its software as a service (SaaS) Omneo offering, which it obtained last year as part of its acquisition of Camstar. Omneo PA delivers product performance intelligence from Big Data analytics. It monitors data across the entire supply chain and customer experience, while analyzing billions of data combinations in seconds. By revealing the hidden intelligence that pinpoints the source of product issues, this service delivers proactive analysis for Big Data. “Using data from sources including field service, manufacturing, CRM, ERP and the Internet of Things, Omneo Performance Analytics enables companies to identify and resolve problems before they reach their customers—the ultimate goal of any business,” said Steve Bashada, SVP of Cloud Services, Siemens PLM Software. Omneo PA is the next evolution in product performance intelligence. It delivers on three major components in a big-data, cloud environment: discovery, monitoring and dashboards. By rapidly analyzing multiple combinations of all possible data sets, it helps create insights into Big Data that were previously unattainable. Discovery results clearly identify and display the highest contributing factors to data anomalies, so that every value chain decision creates the largest and most positive impact possible on current and future product performance. Companies can now answer questions they previously did not know to ask, saving valuable time and resources. The graphical monitoring capability in Omneo PA provides a complete view of product performance across the entire value chain and enables companies to consistently track current and emerging trends related to their products. Now fact-based, data-driven decisions can be made for the entire value chain. Omneo PA features a flexible, user-friendly dashboard workspace that users can customize with data analytics definitions and key performance indicators (KPIs). Definitions and corporate-wide KPIs are built as “modeling objects” with multi-level definitions, for easy re-use. This structure enables users to interactively explore custom data analytics and KPIs or schedule them for monitoring, and view the results whenever needed. “Omneo Performance Analytics goes beyond the limits of a traditional business intelligence tool to take businesses to the next level of performance,” said Rami Lokas, senior director, Omneo Research and Development, Siemens PLM Software. “By leveraging Big Data to monitor, discover and display global product performance for its customers, Omneo PA is already altering the landscape of product performance intelligence as we know it today.” DW

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» I n te rn e t of Th i n gs

GE offers an easier way to connect industrial IoT devices

GE has implemented and released a Global Discovery Server (GDS) based on Part 12 of the OPC UA standards. The GDS, used in conjunction with GE’s Proficy software, automatically discovers OPC UA devices on your network and connects to them; no configuration is needed. GDS automates the previously manual and complex processes associated with connectivity and certificate management—saving a significant amount of time and money. The technology supports both the push and pull of certificates. “We have been working closely with the OPC Foundation to help design this specification so that customers can reap the 62

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benefits of connected systems and the ability to manage asset performance,” said Jim Walsh, president and general manager of GE Intelligent Platforms Software. GE’s decision to standardize on OPC UA within its businesses provides a foundation for cloud-based systems and asset performance management. GE’s OPC-UA enabled devices include the PACSystems RX3i and RXi and controllers. Other GE products adopting the standard include: ADAPT3701, GE Oil & Gas’ System 1 condition monitoring software, 8 Series for primary or backup protection for underground and overhead medium voltage feeders, and 3

Series multifunctional feeder relays. “Companies around the world are working with multiple OS platforms across their organizations,” Walsh continued. “By standardizing on OPC UA, GE is alleviating the issues involved with multiple platforms, including Windows, iOS and Android.” “With hundreds of thousands of nodes needing to migrate from OPC DA to OPC UA, users are looking for tools to leverage enterprise connectivity and security in as close to a plug-and-play fashion as possible,” said Craig Resnick, VP, ARC Advisory Group. GE’s OPC UA-enabled software can also aggregate data from legacy systems and equipment to eliminate islands of information. Even for devices that are unaware of OPC UA, the GE server can still manage certificates and trust lists for those devices, using Proficy Agent, which acts on their behalf. DW GE ge.com

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»»

»R o b o t i c

T r e n d s

Software with standard models can now drive motion and robots Machine builders must deliver designs with more flexibility than ever. Standardized motion software helps them go beyond segregated component and drive purchases with efficient programming of even complex robotic movement.

Detlef Stork Technology Manager, Motion • Lenze

Today’s increasingly custom products are leading to smaller production batches, so production machinery is becoming more flexible. Robots are useful here because they’re not tied to rigid motion sequences. No wonder robots are on the rise in industrial manufacturing, especially in the packaging industry. The only catch is that it can be difficult to integrate robots (and their controls and kinematics) into larger automation systems. It’s still standard practice for machine builders to buy kinematic axes and program them from scratch, or to buy proprietary turnkey robots and add them after the fact. For the latter, builders must integrate the robot control with consistently compatible software and communications. In contrast, builders that use free kinematics must do copious programming. How does modular software for motion work?

Lenze drive and motion-control systems integrate robots with software using standardized modules represented by the boxed sketches here. The Feasibly Applicable Software Toolbox (FAST) modules use standardized interfaces that combine in myriad ways, even with a designer’s own software. Functions are scalable to meet the requirements of the task in hand.

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No matter a machine’s kinematics, the aim is always to produce motion in a multi-dimensional space—either by linear interrelationships (as in a gantry) or nonlinear moves (as from a delta robot). The application dictates which is suitable. Especially for Cartesian robotics, some manufacturers now offer software toolboxes with standardized and reusable software modules to let machine builders set up flexible robot stations more easily. They let builders treat machinery controls and motion functions holistically. The modules adhere to the technical specifications of PLCopen and IEC 61131-3 and include complementary functions for delta-robot controls, electronic camming, conveying, cutting and tensioning.

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Shown here is one setup that’s possible with Lenze’s FAST software. It is functionbuilding-block software that lets machine designers virtually assemble predesigned control modules. The software includes interfaces for camera systems that detect objects for the robot to handle.

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Once a designer picks a general kinematics model, the software runs on automation equipment (including drives and motion controls) from one manufacturer. So, on the hardware side, motion and robot control (traditionally separate) become one. That simplifies physical setup and programming so designers can focus on what specific robotic movements should look like. In the years to come, such hardware and software innovation will put robots in jobs currently done by specialized machines. In fact, modular software can already set multiaxis kinematics to automate tasks too big for standard robots. Machine flexibility reduces efforts in mechanics, electrical engineering

and programming … so small- and mediumsized machine builders can integrate robot kinematics into designs with kinematics tailored to the task at hand.

Breaking tasks down into motion constituents Consider technology modules for pick-andplace motion functions and corresponding coordinate-transformation functions for alternative kinematics (read: delta or Cartesian robots) based on PLCopen Part 4. The designer sets hardware parameters to define motion functions—including the coordinate system, material speeds and acceleration, radii, and rounding. Then the kinematics model

Lenze’s FAST software speeds the implementation, so machine builders can quickly assemble software for complete production lines like this one.

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» Robot i c Trends

Lenze’s FAST software speed implementation so machines builders can more quickly assemble software for complete production lines like this one.

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parameterizes the mechanical variables such as arm lengths and distances between parallel struts. In this way, designers can reference, traverse and commission a robot-automation cell without programming. Currently, there are kinematics modules for gantries, belt kinematics, articulated robots, SCARA robots, and two- and three-axis delta robots. Elements for all their tasks are in the technology and kinematics modules. So now, engineers only need to know what a motion task should look like and not how to program a robot to make those moves. What’s more, if the design team needs to add another kinematics system, they only need to mechanically integrate the design, replace the corresponding kinematics model and set the necessary mechanical parameters.

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» Ro b o t i c Tre n d s

Some software also has application templates (some quite specific) to implement modularized tasks in the controls. For example, OMAC versions of one template let packaging-machine builders implement applications in accordance with the PackML standard. The template accepts custom program components just as easily as technology modules. As mentioned, some modules let designers implement robotics through simple parameterization instead of programming a controller. Once the controller takes control of the other axes of the machine system and process, programming complex interfaces is unnecessary. In fact, motion-component manufacturers have offered application software for years with dedicated winding, cross-cutting, conveying, separating, grouping or sealing modules. Only recently have some added robotics applications based on PLCopen Part 4 … including those for pick-and-place moves through alternative kinematics … with other modules for more machine applications on the horizon.

Software modules for machines, too Standard hardware and software also support modularization of machines. Here, builders can use software to break down the complexity of tasks into parts. Then, standardized technology modules let builders create and reuse designs for less engineering to get to machine production. That boosts software quality, so there’s less need for testing as well. Ultimately, the standardized and reusable modules free programmers to concentrate on developing and testing special machine functionalities that give designs unique features to benefit end users. DW Lenze lenze.com

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IP65 rating

and what it means for your application IP ratings have very specific definitions. Here we explain exactly what kinds of water and dirt exposure IP65-rated motion components can withstand.

Brian Taylor Application Engineering Manager Schneider Electric Motion

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M o t i o n

C o n t r o l

Just like the mysteries surrounding Stonehenge, crop circles, who shot JFK, and what a self-respecting individual would actually do for a Klondike bar, some motion-control considerations cause significant consternation, confusion and debate. No application engineer really wants to deal with these grey areas of motion, but most are eventually forced to do so during one design or another. The most heavily debated topics include closed loop versus open loop versus hybrid technology; sinking versus sourcing I/O; and the load to rotor inertia ratio. Another grey area is the meaning of IP ratings for industrial motors and how they relate to specific applications.

To dispel some of this confusion, let’s define IP65-rated components and what they do and don’t mean for applications. That will give us an understanding of how to correctly apply these components.

photo : istockphoto.com

IP ratings: the true letter of the law Ranging opinions about the meaning of IP ratings is frustrating, but actual definitions are very specific. Published by the International Electrotechnical Commission (IEC) and detailed by IEC standard 60529, IP ratings—also known as Ingress Protection ratings or International Protection markings— rate the protection components provided by mechanical casings and electrical enclosures against intrusion (including body parts such as hands and fingers), dust, accidental contact and water. In other words, an IP rating indicates how well the enclosure of a device shields internal subcomponents. The ratings include two or sometimes three numbers.

IP number First position Second position Third position

Indicates protection from … Solid objects or materials Liquids (water) Mechanical impact (commonly omitted as not part of IEC 60529)

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>> This IP65-rated Lexium MDrive from Schneider Electric Motion is an integrated motor for machine builders to use in applications subject to tough environmental conditions. IP65 LMDs include sealed M12 industrial connectors for power, communications and I/O interface.

To get the IP65 rating, a component must withstand hosing from nozzles up to 30 kPa.

IP ratingâ&#x20AC;&#x2122;s first number: Denotes protection against solids Level Object size protected Effective against against 0 â&#x20AC;&#x201D; No protection against contact and ingress of objects 1 Anything larger than 50 Any large surface of the body, such as the back mm of a hand, but no protection against deliberate contact with a body part 2 Anything larger than 12.5 Fingers or similar objects mm 3 Anything larger than 2.5 Tools, thick wires, and so on mm 4 Anything larger than 1 mm Most wires, screws, and so on 5 Dust protected Dust protected Ingress of dust is not entirely prevented, but it must not enter in sufficient quantity to interfere with the satisfactory operation of the equipment, complete protection against contact (dust proof) 6 Dust tight No ingress of dust, complete protection against contact (dust tight)

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What IP means for applications Now consider the two larger tables that accompany this article. A component with an IP65 rating withstands solid objects (as indicated by the 6) and liquids (as indicated by the 5). So, an IP65 motor is considered dust tight. It also seals against water projected from any direction from a distance of 3 m through 6.3-mm waterjet nozzles for a duration of at least 3 min with pressure not exceeding 30 kPa. Could the authors of this technical specification be any more specific? Probably not. But after reviewing application needs, how does an engineer decide if IP65 is an adequate protection level? To begin, the engineer must consider if the motor will be used outdoors or need to be fully submerged. Also: Will it need to withstand washdown conditions?

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7/2/15 10:29 AM

Contrary to some opinions (or because of a general lack of understanding), IP65 specification does not certify that a product will operate in any of these conditions. To be clear: • IP65-rated motors are not certified for outdoor applications without additional protection against the elements • IP65-rated motors are not fully water submersible • IP65-rated motors are not food- grade components that satisfy washdown requirements. So then, what benefits do IP65 motors offer? Many. For example, some integrated motors with an IP65 rating combine motor, drive, controller, I/O, encoder and closed-loop performance to simplify integration and maintenance, improve efficiency, increase profitability and reduce time to market. Applications that benefit from such IP65-rated drives are numerous. These include packaging designs that convey various materials; form, fill and seal machines that dispense and seal product; liquid dispensing and pumping applications in medical and life-science devices; and printing and labeling machines … especially barcode and 2D label applications for tracking and traceability of medical devices. Other applications include 3D printers, assembly and test systems with three- and four-axis pick-and-place gantries, and machine tools that use waterjet cutting, laser cutting, and tool changers.

Testing to ensure IP65 protection Now that we understand IP rating standards and how they relate to the specific rating of IP65, let’s explore how manufacturers verify that components meet the criteria. In most cases, an independent testing facility places the component in a sealed chamber filled with blowing air carrying fine powder to ensure the component is dust tight. In another chamber, engineers position 6.3-mm nozzles at a distance of 3 m from the component to hit from all directions with powerful water jets (not exceeding 30 kPa) for 3 min. The facility certifies components that pass these tests. July 2015

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>> To get the IP65

rating, a component must also withstand a sealed chamber filled with fine powder.

IP rating’s second number: Denotes protection against liquids Level Protected Testing for Details against 0 Not protected — — 1 Dripping water Dripping water (vertically falling drops) Test duration: 10 min shall have no harmful effect Water equivalent to 1 mm of rainfall per min Test duration: 10 min 2 Dripping water Vertically dripping water shall have when tilted up no harmful effect when the enclosure Water equivalent to 3 mm to 15° is tilted at an angle up to 15° from its of rainfall per min normal position 3 Spraying water Water falling as a spray at any angle Test duration: 5 min Water volume: 0.7 L/min up to 60° from the vertical shall have no harmful effect Pressure: 80 to 100 kPa 4 Splashing of Water splashing against the enclosure Test duration: 5 min water from any direction shall have no Water volume: 10 L/min harmful effect Pressure: 80 to 100 kPa 5 Water jets Water projected by a nozzle (6.3 mm) Test duration: at least 3 against enclosure from any direction min shall have no harmful effects Water volume: 12.5 L/min Pressure: 30 kPa at distance of 3 m 6 Powerful water Water projected in powerful jets (12.5- Test duration: at least 3 min jets mm nozzle) against the enclosure Water volume: 100 L/min from any direction shall have no harmful effects Pressure: 100 kPa at distance of 3 m 7 Immersion up Ingress of water in harmful quantity Test duration: 30 min to 1 m shall not be possible when the Up to 1 m of submersion enclosure is immersed in water under There are caveats defined conditions of pressure and time 8 Immersion The equipment is suitable for Test duration is beyond 1 m continuous immersion in water under continuous immersion in conditions which shall be specified water. Depth specified by by the manufacturer. However, with manufacturer, generally certain types of equipment, it can up to 3 m mean that water can enter but only in such a manner that it produces no harmful effects

But not so fast. Though components that pass their tests satisfy the IEC standard, some manufacturers go further to replicate real-world challenges. Here, some use IEC standard testing for IP65 certification and then task quality engineers to continue to subject the components to extreme life-testing. So a line of IP65-rated components now for sale as standard product may still be under testing—and have an installation base in the thousands that verifies real-world performance. Consider a typical motor application. Applying an IP-rated motor in a system is no different than applying a non-rated motor, as both require the correct fit for the application to operate successfully. IP ratings do not negate the need to consider the device’s ultimate environment or possible needs for additional protection. However, if engineers work to understand IP ratings, they can make intelligent design decisions to select appropriately rated devices for applications that run as expected. DW

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Reviewing the basics about the most popular linear positioning devices will help users properly specify them in their applications.

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Linear drive systems have been used for thousands of years, as far back as the ancient Egyptians who used tree trunks to move heavy blocks of stones, providing the precursor to linear motion solutions such as ballscrews and roller pinion systems. Today, linear motion technology is used to support, locate, guide and move machinery components in a range of applications in the aerospace, machine tool, medical, factory automation and packaging industries, among others. While the basic requirements of linear motion technology are to provide load-bearing capability and accurate motion, other requirements are also important in many cases. The linear drive technology used in a product plays an important role in providing the functionality, performance, durability, energy consumption and other attributes that enable the product to outperform competition. Engineers can choose from a range of linear drive technology choices such as leadscrews, ballscrews, rack and pinion systems, belt drives, linear motors and roller pinion systems. It’s critical to carefully consider all of your options to avoid common problems such as low accuracy, backlash/vibrations, high cost, dirty operations, high maintenance, low load capacity, excessive noise, low speed and so on. A systematic selection process can

ensure that the linear drive technology is selected to match the requirements of the application. Selecting the right technology can also reduce design complexity, improve performance and reduce the overall cost of assembly.

Leadscrews Leadscrews use the helix angle of a thread to convert turning motion into linear motion. The large area of sliding contact between the male and female members of the thread generate relatively high frictional losses. The result is that leadscrews are less efficient and not as

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Li n e a r M ot io n

as accurate as ballscrews. Leadscrews provide relatively high load-carrying capacity, although typically less than ballscrews. A key advantage of leadscrews is low costâ&#x20AC;&#x201D; they are typically only one-tenth the cost of equivalent ballscrews. Leadscrews are available in a range of lead sizes, meaning that the lead can be selected to provide the right balance of positioning accuracy and speed. Leadscrews generally produce minimal noise as long as sufficient lubrication is maintained. However, they can be difficult to use in long-distance moves as the screw is typically unsupported between the two ends.

Ballscrews are available in rolled or precision ground thread versions. Photo courtesy of THOMSON

Ballscrews The ballscrew drive consists of a ball screw and ball nut with recirculating bearings that roll in the grooves formed by the screw and nut. The ballscrew distributes the load over a large number of rolling elements, resulting in a high load carrying capability. The use of a large number of precision rolling elements also provides high levels of accuracy. In addition, ballscrews provide low levels of friction. This translates into high mechanical efficiency and reduced power requirements. The duty cycle of ballscrews is quite high because they generate relatively low levels of frictional

heat. However, compared to other linear drive technologies, ballscrews tend to be expensive and they require that lubrication be maintained to provide reasonable life. Finally, ballscrews are prone to noise, caused primarily by ball recirculation.

Iron Core Linear Motors are designed with coils wound on silicon steel laminations to generate force with a single-sided magnet.Â Photo courtesy of Kollmorgen

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Belt drive systems Belt-drive linear motion systems with ball guides are typically selected when high speeds, high rates of acceleration and long stroke lengths are the most important criteria. Belt-driven, slide guided linear actuators offer somewhat lower speed and acceleration capabilities at a corresponding lower cost. Linear positioning accuracy of belt drives, as might be expected, is not as great as either leadscrews or ballscrews. The load capacity of both ball-guided and slide-guided belt drives is somewhat lower than ballscrews. Belt stretch and stiffness are other drawbacks. Belt-driven linear motion systems are generally capable of high duty cycles because they avoid concerns about frictional heat buildup in the bearing of a leadscrew or ballscrew. Additional advantages of belt-driven systems include the fact that they generate relatively little noise and that they require relatively little maintenance.

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Chain drives Chain drives convert rotary motion to linear motion through a series of chain links that mesh with a toothed sprocket and with a linear slide. Because they are metal, chain drives hold an advantage over belt drives. They also take up less space than belt drives and are not prone to damage by oil, grease, sunlight or age. Unlike belt drives, chain drives are also capable of operating in wet conditions. On the other hand, chain drives typically generate more noise and have a greater tendency to vibrate than belt drives and also provide a lower load capacity and service life than gear drives. Linear motors Linear motors are based on the concept of unwrapping a conventional rotary servomotor with the stator becoming a forcer and the rotor transforming into a coil or magnet rail. Linear motors make it possible to achieve direct linear motion without any rotary to linear transmission devices. Brushed linear motors use coils in the linear rail and magnets in the forcer. Brushes in the forcer contact a bar running the length of the motor to provide commutation. Both the windings and forcer are contained within the forcer of a linear step motor. The advantages of linear motors include high speeds, high levels of accuracy and fast response. The limitations of this

approach include high cost, large package size and generation of considerable amounts of heat. Linear motors also have a low capacity, similar to the comparison of direct-drive motors versus motors with a gearbox—the direct-drive motor must be significantly larger to get the same capacity.

Rack and pinion sets Rack and pinion gear sets consist of a circular gear called a pinion that engages the teeth of a linear gear called a rack to convert rotational motion to linear motion. Rack and pinion gears are commonly used as linear actuators in a wide range of machinery. For example, they are used to move the axes of CNC machine tools such as machining centers. Helical racks offer quieter running at high speeds and a higher load carrying capacity due to the higher tooth contact ratio. Lubrication is important to ensure long life for rack and pinion sets. Because rack and pinion sets have relatively few components, they help save time during installation and increase reliability. They also offer high levels of accuracy even over long travel lengths. The disadvantages of rack and pinion sets include their relative high levels of friction, which reduces their efficiency, increases power consumption and limits their life. Plus, rack and pinion drives need to run with clearance so backlash can be a major disadvantage. Roller pinion systems At first glance, roller pinion systems look similar to rack and pinion sets, but instead of spur gear teeth, bearing supported rollers engage the rack teeth. The rollers

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Li n e a r M ot io n engage a tooth profile designed to match the pinion’s path, providing friction-free meshing that allows the pinion to be pre-loaded into the rack, eliminating mechanical clearance. The rollers approach the tooth face on a tangent path and then smoothly roll down the face. Each tooth is precisely measured relative to the first, eradicating cumulative error and maintaining high positional accuracy. The resulting smooth rolling friction provides 99% efficient rotary to linear motion conversion. Due to the smooth way the rollers engage the rack teeth, the new approach generates minimal noise and vibration. The system is whisper quiet at low speeds and less than 75 dB at full speed. Positioning accuracy of roller pinion systems ranges from 30 to 80 µm. For instance, a given size product in a premium model may deliver positional accuracy of ±30 µm, a life expectancy of 30 million cycles/tooth and a maximum dynamic load of 14,000 N. For medium loads, a universal model can deliver ac-

CNC machine tools are a key application for linear positioning devices.

Technology comparison chart

Application Considerations

Belt Drives

Chain Drives

Rack/Gear & Pinion

Roller Pinion/Rack

Leadscrews

Ballscrews

Linear Motors

Accuracy

Low

Low-High

High

Low

Low-High

High

Backlash/Vibration

A Consideration

Near Zero

A Consideration

Near Zero

Acceleration

Medium

Low

High

Low

Medium

High

Speed

Medium

Low

Medium

High

Low

Medium

High

Load Capacity

Low

Medium

High

Low

High

Low

Length

Shorter

Long

Shorter

Moderate

High Wear and Short Life

A Consideration

Long Life

A Consideration

Long Life

Maintenance

A Consideration

Little to none

A Consideration

Little to none

Noise Level

Medium

High

Medium

Low

High

Medium

Low

Dust & Dirt Emissions

High

Moderate

Low to none

Moderate

Low to none

DESIGN WORLD

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Li n e a r M ot io n curacy of Âą50 Âľm for 5 million cycles/tooth and carry a maximum dynamic load of 750 N. The RPS system is capable of speeds up to 11 m/sec (36.1 ft) making it the second fastest mechanical linear drive system second only to linear motors. The roller pinion system requires little maintenance. The pinion consists of 10 or 12 needlebearing supported rollers that are sealed and lubricated for life. The rack is lubricated with high performance light grease at installation, then again every six months or 2 mil pinion revolutions. In special applications the roller pinion system can be run lubrication free as long as the speed is less than 30 m/min. Roller pinion systems are offered with both metal and plastic racks. Thermoplastic racks offer an alternative that delivers high corrosion resistance, high durability,

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low maintenance requirements, medium accuracy, and load-carrying capacity at a relatively low cost point. Thermoplastic racks are impervious to corrosion. They are made of a self-lubricating polymer so they can withstand dirty environments and outdoor operation without concern over failure due to the loss of lubricant. Their ability to run at full speed without lubrication reduces maintenance requirements and means that these systems can easily withstand washdown, outdoors operations and operation in coastal climates with salty air. All of these linear drive systems offer their own unique mix of advantages and disadvantages. To apply the correct type of linear motion technology in a particular application, the design engineer should carefully

UPDATED

consider the specific capabilities of each alternative. Selecting the right technology can improve performance, ensure long life and reduce the overall cost of the assembly. DW

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M echa ni ca l

New material

for radial shaft seals increases uptime

A reduction in design elements and a

new material lays the foundation for

radial shaft seals for roller bearings

in steel mills. This cost-effective

approach is a distinct advantage

for manufacturer and customer in a

price-sensitive market. Edited by: Mike Santora • Associate Editor

8,000 hours. About a year. That’s the max before seals for work rolls in steel plants need to be replaced. But the wind power industry, for example, demands a service life of up to 20 years or about 150,000 hours. So how do you satisfy the steel plant customers that are not prepared to pay for 19 bonus years of service life? From your customer’s standpoint, the requirements for a sealing system for work rolls in steel plants are as follows: 1 A reliable sealing effect during the desired period of operation 2 A self-retaining fit in the housing 3 Easy assembly that protects the housing 4 A cost-effective sealing solution 5 The option for fast delivery—even for special sizes—in case of repairs

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M ec hanical

Comparison of pretensioning elements for seal lips on radial shaft sealing rings

Avoiding high cost options is the first step for the seal manufacturer in the development of radial shaft seals. One example is the use of a steel ring to ensure the seal’s self-retaining capacity. This option is expensive and inflexible in its accommodation of different diameters. Moreover, the steel rings are more difficult to assemble and disassemble. In some cases, the seals have to be driven into their seat with hammer blows or levered out with special crowbars. Damage to the installation space, which involves costly repairs, is a possibility. Additional O-rings in housing grooves partly compensate for the poor static sealing effect of steel rings. Due to their cost, the current required pretensioning elements for the seal lip are not an ideal solution either. And in the event of the failure of these spring elements, mostly

Pressure: Shaft offset:

0 bar 0 mm

due to defective mounting, the bearings behind them may be damaged. Developing a new radial shaft seal to meet the special needs of the steel industry is an ambitious goal. Freudenberg Sealing Technologies produced such a seal and it is already being used in American steel plants and in Europe. Here’s how they did it. The key element

Compared to other applications in heavy industry, the expectations for longevity are low in steel plants. This was the driving factor behind the new design—the springless seal lip. In the project’s launch phase, however, it became clear that this kind of seal design could not be achieved with known materials. The development of a new elastomer material was needed.

Pressure: Shaft offset:

0.5 bar 0 mm

Pressure: Shaft offset:

Pretensioning elements are traditionally used at the seal lip of radial shaft sealing rings. They are either round springs integrated into slots, formed leaf springs or combinations of the two. The main reason for spring pretensioning is that current materials fatigue too quickly to produce their own stressing force over a long time period. Due to wear on the seal edge, it must also be continuously repositioned. The seal edge needs sufficient contact and pressure on the counter face to achieve the required sealing effect even with slight shaft eccentricity. In addition, this has to occur over the equipment’s entire operating life. Elastomer materials’ compression set is the most important variable affecting the potential for long-lasting elasticity. This material property is a measure of how

0.5 bar 0.5 mm

FEM analysis on the self-retaining ability of the RPM 41 in the installation space

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M ec hanical

CNC precision cutting equipment for basic rubber/steel rings

elastomers behave under long-term, constant deformation, under pressure and during subsequent relaxation. To achieve these material characteristics, it was essential to reduce this value to a minimum. The goal was to guarantee a high material elasticity over the required maximum lifespan of 8,000 operating hours. The developers could not allow other material qualities, including high wear resistance and joint strength, to be influenced by a change in the formula. There are already tried and tested formulas for the maximum wear resistance. The newly developed elastomer material walks this tightrope with good elastic capacity and excellent wear behavior. The material’s good joining capacity also provides the desired dimensional flexibility during the manufacturing of the sealing rings. Self-retaining ability in the installation space

As retaining elements, metal rings give seals a firm fit in the installation space but with the disadvantages previously mentioned. A selfretaining fit into the installation space is part of the specifications, even if no cover or flange 88

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is used. Once installed, the operation in the work rolls is nearly pressureless. As a result, the required retaining forces are limited. Pure elastomer and rubber/fabric designs are just as poorly suited to the seal’s selfretaining function in the installation space. After several series of tests and FEM analyses, it was clear that a special steel element in the seal’s interior offered an ideal solution. With no material parts on the outside, this meant maximum protection against corrosion. Also, simple assembly and disassembly spared the installation space due to a solid rubber encasing on the adhering piece for the seal with a flexible steel core. With some practice, the seal can be pressed into the housing seat by hand. For disassembly, two fingers are usually enough to pull the sealing ring out of the installation space in a single, obliquely inward movement. Despite this ease of assembly, the new shaft sealing ring sits firmly in the installation space at up to 0.4 bar of overpressure. Precision joining

Fast availability of customer-specific sizes was an important aspect in the specifications.

When it comes to work rolls in steel plants, this availability consists of approximately 15 common profiles in the typical diameter range of 200 to 1,100 mm (approximately). This is an enormous range of different options with several hundred potential combinations. And if the installation space needs to be revised, there are numerous special sizes as well as the typical one-tenth deviations between the metric and imperial dimensions. It is not recommended that this wide variety be produced with individual tools due to concerns about costs and tool procurement. Even a certain level of inventory of completed shaft seals at the customer’s or the manufacturer’s location did not come under consideration due to the wide range of options and high costs. The best option was a shaft seal produced on demand and within 24 hours when necessary, providing assistance immediately in the event of an unplanned equipment stoppage. At the same time, the made-to-order ring must be no more expensive than current solutions. In this phase of the development work, The Freudenberg design team’s experience with joining large sealing rings for the wind

July 2015

7/1/15 12:40 PM

power industry actually proved to be an advantage. What is possible in the rubber and rubber/fabric field was supposed to be transferable to an elastomer shaft seal with an interior steel element. For a precision joint, however, special devices had to be developed so intersections could be connected and perfectly aligned with one another. The intersections of the interior metal core had to lie precisely against one another so that the necessary pressure in the radial direction is maintained for the ring’s self-retaining ability. That is why a multistep process ensures the constant position of the steel core inside the seal’s adhering piece. A special cutting wheel handles the precise cutting of the ring, producing a plane-parallel intersection in the area of the elastomer as well as the steel core. The sealing ring is guided into a profiled carrier both during the cutting as well as the joining process, which uses butt vulcanization. CNC-controlled peripheral equipment regulates the high-quality level of the production process and ensures maximum reproducibility.

The result is offset-free convergence of all lines and edges and robustness at the joining point of 93%, which surpasses the required level of 75% of the strength of original elastomer material in its sigma 100 value. This means if the material were distorted to twice its length, the joint would show nearly the same strength as the original material. In its installed state, this has only limited importance. However, during the transportation and installation phases, it is expected to show no weakness. DW

Freudenberg Sealing Technologies fst.com

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Mobile Integration Pow er ed By

Precision joining using butt vulcanization and molding tools

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Pre-compliance EMC testing:

ways your project will benefit

Dunstan Power ByteSnap Design

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Adopting pre-compliance EMC testing removes the risk of product failure and avoids costly re-testing after design.

Electronic products, such as home appliances, computers, tools and wireless devices, need to be tested for EMC (electromagnetic compatibility). Across the globe, regions and countries have their own standards, such as the CE certification in the European Union or the FCC’s standards in the U.S. Testing is normally undertaken at the end of a project at a specialty lab. But when tests fail—what then? This is more common than you might think; it’s estimated as many as half of all projects fall at this final hurdle, with radiated emissions often cited as the main stumbling block. For product designers, the cost of failing compliance testing is a nightmare scenario. The most traumatic phase comes after you have built a product that meets market demands, you are confident that it radiates little energy and is not susceptible to outside interference, yet during the final EMC testing stage, the product fails. The cost of testing was already high, but re-testing will stretch the planned budget and slow down the entire project. Now the design engineers will need to investigate where the problem is coming from, at a stage in the project when the integration of all the components can make this difficult. Design engineers can avoid this scenario by building precompliance testing into a project from day one. In the software testing industry, there is a move to shift testing and introduce it earlier in the product development lifecycle. Likewise, this thinking is moving to the electronics industry—investigating emissions from your device during each major development stage is the best way to avoid costly re-testing and high failure rates.

What EMC testing actually entails Complete EMC testing involves a number of different tests, described below: Radiated emissions testing: This is carried out in a chamber or open field site. An EMC test receiver scans through frequencies up to a multiple of the highest clock frequency used in the device, recording the signal strength at each step. The test is designed to check for unintentional emissions that exceed a given pass band defined by the class of product.

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T e s t

M e a s u r e m e n t

An anechoic chamber, such as this one used by ByteSnap design for EMC testing, identifies radiated emissions from devices as well as a deviceâ&#x20AC;&#x2122;s immunity to electromagnetic interference.

Typical classes are for industrial and for residential/ commercial. The emissions criteria are more stringent for the latter; the device needs to be quieter. These scans can be slow, particularly if the board has high frequency components on it, as the scan has to run up into the GHz frequency range with a dwell at each step. If youâ&#x20AC;&#x2122;re wondering where the time goes in EMC testing, this is one of the main areas. Conducted emissions testing: Where the device has long cables attached or operates from the mains, those cables are passed through an LISN (line impedance stabilization network), RF current clamp or artificial mains network, and, again, frequencies scan to search for unintentional emissions. The frequency range is much shorter than for radiated emissions (say, up to 30 MHz). Radiated immunity: This is the reverse of the radiated emissions test and is carried out in an EMC chamber. Here, the UUT (unit under test) is subjected to a radiated field, which, again, scans through the required frequency band, from 30 MHz up into the GHz range. The UUT needs to be operating so that the tester can see if there are any failures at any frequency. This is slow and may require a lot of concentration from 92

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the tester, depending on how a failure would be spotted. For instance, at the most basic, you could be staring at a monitor attached to a camera in the chamber. The industrial field strengths are higher than commercial, so if your device was required to be quieter (commercial), it also isnâ&#x20AC;&#x2122;t required to operate surrounded by the same level of interference, and so it is easier to pass the immunity testing. Conducted immunity: If appropriate, the cables are subjected to conducted noise, scanned across the frequency band. As for the radiated immunity test, the device needs to be operating so that failures can be spotted. ESD testing: ESD (electrostatic discharge) testing is usually carried out last, as it can be destructive. The UUT is subjected to air and direct discharges to any exposed contacts and to the case itself. The device should be in an operating state and should recover to that same state, or be unaffected, by the discharges. Other tests: There are many categories of device and environment, such as commercial, industrial, military, medical, rail and automotive.

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their very different capabi

Consequently, there are many specialized tests carried out that are just called up for specific device types. For instance, for mains power devices, and those with long cables, fast transient tests and surge tests, both of which can be destructive, can be carried out. They may be simulating lightning strikes or other mains transients. For automotive devices, there are also extended power tests, such as load dumps and high and low voltage tests, simulating such events as a battery being disconnected while the engine is running or the battery being reversed. In our experience, the radiated and conducted emissions tests are the ones that fail most often, they are also time consuming tests, where if there is a failure, working around it and retesting is often a slow process. While we have seen failures in all of these categories, they are not all equal in terms of time to fix the issue. In addition to this, devices that perform well with emissions testing generally perform well at immunity testing also, and the reverse is the case, so by sorting out emissions problems, you are quite possibly also fixing potential immunity issues. To this end, the earlier you can catch these issues, the better.

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There are a number of advantages of pre-compliance testing:

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lifecycle accelerated through 1 Project early error detection The sooner product deficiencies are identified in the development process, the easier it is to rectify any shortcomings. It’s much more costly and time consuming to rectify issues after compliance testing than fixing them during the design stage. Pre-compliance testing allows you to focus on the areas that you have identified as potential causes for concern and find solutions for them early. Generally, the risk to a design failing is relative to how long you delay testing, so designers who schedule testing toward the end of a project are completely reliant on the design team’s skill and experience. Early analysis of the electronics can also help steer system decisions. Apart

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T e s t

M e a s u r e m e n t

from being about electronics, EMC is also about the system, and mechanical changes, such as adding EMI shields, coating boxes or adding EMC foam to fill any leaks/gaps in an enclosure, may be necessary. Take the example of the design of an Android tablet. This will have multiple features such as LCD, touchscreen, USB, Wi-Fi, Bluetooth and camera. These are positioned around the architecture of the core CPU and memory. Each of these sub-sections will emit some form of unintended electromagnetic energy, but hopefully all at acceptable levels. You would ideally test the core CPU with each section separately, and when a problem occurred, the source would be apparent. But the reality is that this is rarely a commercially viable approach. However, the use of development boards with pre-compliance testing can do some of this work at a lower cost. This highlights issues early on and allows for remedies to be implemented ahead of the final integration. This is not a substitute for the final testing, but may save some of the pain. In a similar vein, once the target hardware is available, partially populated boards can be used to isolate problem areas.

2 Test products early to compliance standards Using an anechoic testing chamber before formal testing can determine whether or not a design will meet relevant compliance standards. Specific standards call up specific measurement limits, and these limits vary widely. If you are not testing to the standard that you will ultimately be judged against, you may be either over or under-testing, or applying the incorrect frequency range. A spectrum analyzer and near field probe can be useful in finding emitters, once they have been identified as presenting radiation above the required limit, but less useful before a calibrated scan at a required distance. What may appear to be a problem at close range 94

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with a probe, can melt away in a chamber, and, of course, the reverse is also true. Testing to a known standard early on focuses attention on real problems.

your electronics design 3 De-risk project Early EMC testing can de-risk a project by determining many, if not all, noncompliance issues prior to submitting for formal testing. This is one of the ways the time taken on pre-testing pays back over the course of the project. The end design is much less likely to fail, saving the resulting costs and delays associated with board re-spins and excess test house charges. In addition to EMC, a chamber can be used to measure comparative signal strength for low-power radios to check performance over time, or the effect of modifications. Pre-compliance testing makes certification an overall less stressful experience.

testing means more 4 Integrated agile project development Stand-alone pre-compliance testing can be expensive, especially if a product doesn’t pass the first time, as subsequent rounds of testing will be required after design alterations. However, when testing is integrated into development, a testing chamber and expert advice is available during the entire project lifecycle. Design engineers that offer EMC pre-compliance testing as part of their services will be continuously on the lookout for areas of risk during product development. For instance, testing during development with evaluation or strip boards will provide the designer with the opportunity to add in preventative measures in the form of additional circuitry, such as signal bead filters, to prevent potential issues. Test houses typically charge time in half-day blocks, but often only a single RF emissions sweep is required to see

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if a problem is still there or is probably fixed. The maxim “if you haven’t fixed it, it isn’t fixed” can apply to EMC testing as much as software and hardware design. When you come up with a fix, it’s good to be able to try it out quickly before committing to a re-spin of a circuit board.

over-engineering for 5 Eliminate improved efficiencies Early EMC testing can save money by reducing over-engineering, ensuring that a product can pass compliance tests easily. Before a product is tested, it’s not known where the problems might occur. This can lead to counter-measures being added where they are not required, counter-measures that will be present for the lifetime of the product. As an analogy, Henry Ford used to send engineers to examine Ford cars in scrap yards to understand which components still had lots of life in them due to over-engineering. This helped his engineers to downgrade the specification on these components to achieve a cost saving. The equivalent can be done with EMC testing to optimize the BOM (bill of material) cost. As well as this having an electronic BOM cost impact, there is also an effect on the mechanical constraints (meaning the size of the board in all three dimensions). For a tight design, it’s crucial to optimize the EMC filtering, which can be large, at an early stage, as adding filtering in later on, once mechanical tooling is committed, may prove impossible. This is particularly the case with power line filtering using common-mode chokes or Pi filters.

uses of pre-compliance 6 Additional equipment As well as EMC testing a product, “looksees” can be carried out as obsolete parts are replaced or board layout changes. As CE marking is a self-certification process, this data can often be used to justify retention of the CE mark by reference

7/2/15 10:49 AM

to comparative measurements on the original unit. Clearly, this depends on the scope and type of any change. Similarly, tests can be carried out on comparative signal strengths of antenna configurations. For example, performance of one of our ZigBee products had markedly decreased on a recent batch, following the move to a new subcontract manufacturer. A new and old board were compared in an EMC chamber to determine the problem. It transpired that the stackup had not been followed on the PCB, resulting in detuning and losses. To minimize risk of EMC testing failure, at ByteSnap Design, we decided to set up our own testing chamber to allow us to make radiated emissions scans of customer’s products. This provides us with additional ability to eliminate many of the problems prior to formal testing by extending our scope for agile design. After all, adopting a smarter approach to testing can remove a high degree of risk of product failure, not to mention the savings in the bottom line over the course of a project. DW

ByteSnap Design bytesnap.co.uk

Personal CNC Prototyping - Product Design - R&D - Engineering Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line. To read more about this story, and to see what others are doing with their PCNC mills, visit www.tormach.com/design. PCNC 1100 Series 3

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PCNC mills shown here with optional stand and accessories.

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Designing slides

into electronic enclosures Equipment that usually sits in standard 19-in. racks has gotten heavier in recent years, and that complicates the task of selecting hardware for managing server electronics and test instruments.

Steven M. Robertson R&D Engineering Group Leader Electronics Enclosure Group Accuride International

DESIGN WORLD

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E l e c t r o n i c s

Mounting Rail

2907WB

1U Chassis 5U

Slide

Chassis Front

The 19-in. equipment rack has long been a standard for enclosures holding electronic instruments. The basic dimensions on these racks are spelled out in a specification document issued decades ago by the Electronic Industries Association. With this kind of history, you might think rack hardware from different vendors should all work together without much trouble. Unfortunately, this is not the case. One difficulty comes from factors that standards don’t specify. For example, a rule of thumb has long been that servers that fit in 1U enclosures (where “U” is a nominal EIA unit increment of 1.75 in. high) weigh about 25 lb. Today the average is closer to 60 lb, and 2U servers can hit 90 lb. To handle the additional weight, makers of enclosure hardware have had to beef up or redesign their equipment. Heavier chassis make it more difficult to meet safety standards such as UL 60950, which spells out stability tests as well as levels of steady and impact forces that equipment must be able to withstand. www.designworldonline.com

Electronics 7-15_vs6.LL.MD.indd 97

Here’s a typical 19-in. EIA enclosure and server rack with slides in a four-post configuration. This set up is commonly used for servers and to store electrical components, AV equipment and more. The slide shown (Model 2907WB) can handle 1 to 4U chassis in multiple rack configurations. This setup was fabricated by Magma.com, a developer and manufacturer of expansion systems for servers, desktops and portable workstations.

July 2015

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E l e c t r o n i c s

Enclosure glossary 1 Cabinet Width: the outside dimension (side to side) of a cabinet or enclosure 2 Panel Width: the outer dimension of the front mounting rails, which is greater than the clear opening between rails 3 Cable Carrier: accessory item to support and manage wiring behind a chassis when it is withdrawn or inserted into the cabinet 4 Clear Opening: the innermost dimension between the front mounting rails 5 Depth: the front to rear dimensions of a cabinet or enclosure 6 Chassis: a universal term for an electronics drawer; also known as the unit, drawer, module, device, stack equipment, system 7 Front Panel or Bezel: the front facade of the chassis 8 Cabinet Rail Upright: also known as mounting rail, column, strut, upright 9 Slide: mechanism that serves as link between the enclosure and chassis; also known as rail, glide, track, runner, chassis member or suspension. 10 Slide Mounting Bracket: attachment device between the slide and cabinet 11 Bar Nut: accessory used in place of hex nuts and washers 12 Mounting Holes: on cabinet rails, come in a repetitive series as follows: 1/2 in., 5/8 in., 5/8 in., 1/2 in. 5/8 in., 5/8 in., [12.7, 15.8, 15.8, 12.7, 15.8, 15.8 mm]

Slides can be quite versatile as in this setup where a slide is used to attach a chassis to an enclosure/server rack, but also to allow access to internal components within the chassis. This setup was fabricated by Magma.com, a developer and manufacturer of expansion systems for servers, desktops and portable workstations.

Makers of enclosure equipment have adopted several tactics to meet such requirements. In some cases, they have had to switch to higher-strength materials for structural elements. Another technique used for handling heavier chassis has been to equip 2U instruments with slides originally designed for 3 and 4U chassis. Racks have also gotten taller and deeper. A standard server rack is 7 ft high and can accommodate 42 units (42U) of rackmount equipment. Itâ&#x20AC;&#x2122;s possible to find manufacturers today offering enclosures up to 23 in. wide (particularly for telecom equipment) and 9-ft-tall 58U racks. Additionally, server racks are increasingly going to wider 435 to 438-mm chassis designs. Manufacturers such as Accuride have developed special profiles with a width of 7.2 mm to accommodate this demand. These super-narrow slides also have a low profile height that fits 1 and 2U chassis and will carry up to 77 lb. The products are available in partial extension and over travel to offer the access needed to service chassis. Depth wise, original 19-in. racks had a depth between 19 to 24 in. The most typical depth is now about 29 in., but it is possible to find racks with depths in the 40 to 50-in. range. Enclosure standards The EIA standard for enclosures (EIA-310) standardizes several important features of 19-in. racks that include theÂ Rack Unit (RU or U), vertical hole spacing, horizontal hole spacing, rack opening and front panel width. The specification also sets tolerances on each of these dimensions. But there are numerous rack dimensions not spelled out in the standard. For example, the standard doesnâ&#x20AC;&#x2122;t mention the types of holes permitted, rack mounting depth, front and rear space in the rack, and the possibility of obstructions between front and rear rails.

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All of these are subject to interpretation by equipment vendors. First, a quick review: Electronic instruments or servers that slide into the enclosure are generally each called a chassis. As previously mentioned, the height of a chassis is based on a nominal EIA unit increment of 1.75 in. (44.45 mm). Each increment is referred to as a U. The minimum measure of a chassis is 1U, with subsequent measures expressed as multiples of this unit: 2U (3.50 in., 88.90 mm), 3U (5.25 in., 133.35 mm), and so forth. The actual height differs from the nominal height. Equipment suppliers sometimes interpret the EIA standard loosely or ignore parts of it. For example, EIA-310 specifies that the horizontal spacing of the vertical rows of mounting holes should be 18 5/16 (18.312) in. (465.1 mm). Some racks don’t adhere to this dimension, complicating installation efforts. Some manufacturers use equipment mounting slots instead of holes to allow for variations in this dimension. Similarly, the EIA standard specifies that the rack opening between the mounting rails is, at minimum, 17.72 in. (450 mm). Racks that aren’t particularly deep, such as 2Post or relay versions, tend to have larger-than-normal openings. Ditto for many other racks with threaded holes. Racks having square holes tend to have an opening quite close to the minimum.

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Considerations for rack slides Indications are that traditional 1 and 2-U server formats will remain widely used for the foreseeable future. These enclosures frequently include slides that make it easy to move instruments around for maintenance or to change connections. But because enclosures can have different dimensions and still adhere to EIA 310, there is no such thing as a universal slide that fits all 19-in. racks. There are two main aspects to consider when designing slides into electronic enclosures: the cabinet construction and the chassis (or drawer). The attributes of these components affect the overall enclosure configuration and the selection of slides, brackets and cable carriers. Cabinets vary according to their intended July 2015

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E l e c t r o n i c s

Enclosure slides in recent years have become slimmer to accommodate the increasingly cramped quarters in server racks. The difference becomes evident when comparing the model 2907WB slide and an Ultra Slim model, which is a tenth of an inch thinner. Both are designed for 1 and 2U chassis.

use and the manufacturer. Each manufacturer may use different rail thicknesses, shapes, materials and placement. Because the slides mount to the cabinet rails and the chassis mounts to the slide, the variances in construction can significantly affect the enclosure design. It is helpful to review some of the major provisions for enclosures and dimensions spelled out in EIA 310. The standard dictates cabinets contain four or more rails (columns, uprights or struts). The enclosure may or may not have a surrounding skin. There are front rails, rear rails and optional mid-rails. There

is no limitation on overall cabinet height. A standard 17.72-in. (450-mm) opening is the minimum width between the rails. Rails carry a repetitive pitch pattern of mounting holes. Generally, cabinet rail construction methods fall into three groups: non-adjustable rails, adjustable rails and mid-rails. Non-adjustable rails provide a set distance from front rail to rear rail. Adjustable rails let the end-user relocate front and rear rails to an alternate distance from front to rear. Mid-rails are an additional set of rails, either adjustable or fixed, that provide an alternate mounting distance to accommodate short and deep slide lengths or varying chassis depths. Rails may alternately be referred to as columns, uprights or struts. Rails can also have different shapes. There are five shapes that are in wide use: 90Â° standard, return flange offset,

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1. DetermineTtype of EEIA 1.Determine ype of IA rail R ail Identifywhether whetherthe therack rack has hasround,tapped,or round, tapped orsquare squarestyle styleholes. holes. Identify

Type T ype 1

Type T ype 22 One option for slides is the ability to mount without the use of fasteners. The Accuride rotating bracket is designed to mount to square hole EIA racks without the use of tools. This bracket can also be used

R ound or Round or tapped tappedholes holesstyle style

Square style Square hole hole style

to mount to round and tapped hole racks using thumb screws.

2. Match mounting bracket 2. Mounting B racket to EEIA IA rail R ailtype T ype 4. Rack installation

The mounting bracket is reversible: T he mounting bracket is reversible: oneside sideaccommodates accommodatestapped tapped round holes, one oror round holes, the other side accommodates square holes. the other side accommodates square holes

Hole Side TThread hread Hole Side for TType for ype11

square hole rack installation: 6. RForack Installation

Align brackets desired vertical position on rack and 6a.Square holeto rack installation insert bracket spring-loaded pins into rack on holes. A lign brackets to desired vertical position rack and insert bracket spring-loaded pins into rack holes. The bracket will lock into place. T he bracket will lock into place.

SquareHole Hole Side Square Side for T ype22 for Type

3. RRotate correctPosition position 3. otate Bbracket racket totoCorrect Pressthe thebutton button bracket to rotate toappropriate the Press onon thethe bracket to rotate to the hole pattern, Lappropriate ock into position. hole pattern. Lock into position.

Press the the button button Press ononthe bracket the bracket

Rotate R otatetotoappropriate appropriate hole holepattern pattern

LLock ock into into correct correctposition position

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E l e c t r o n i c s

The EIA Unit dimensions: basically a U unit is 1.75 in. and U heights are a multiple of this figure.

return flange flush, U-shaped and extrusion. As previously mentioned, there are several types of mounting holes and locations. The mounting hole pattern is visually apparent on the front face of the cabinet column and often appears on other areas of the column as well. Generally, a given cabinet will use only one style. Different suppliers might use hole styles that include through-hole, countersunk hole, tapped hole and window/ square hole. Selecting the correct slide The best slide for a given use depends on physical parameters that include the height of the drawer, the cabinet rail construction and configurations, the weight of the chassis, the kind of mounting brackets used to mount the slide to the cabinet, the amount of chassis travel, whether there are accessories on the slide (locking, disconnect, hole pattern), the overall depth of the cabinet, and the chassis width. In particular, chassis width is critical and has been the single most important reason, along with chassis weight, that server slides have gotten thinner over the years. The anticipated chassis load will narrow the range of slide models. Recently, a relatively new IT safety test (UL 60950-1) and the amount of force it specifies for slide loads has greatly affected slide selection. Slide load ratings are based on dynamic loading, defined as continuous motion both

out and into the cabinet. Load ratings for slides in electronic enclosure applications are based on a number of cycles that vary from one vendor to another. Slides used in racks are seldom opened in real life, so vendors often specify low figures for cycle life. For example, some OEM enclosure slides have life requirements of as little as 100 cycles. In contrast, load ratings at Accuride are based on 2,000 cycles. Here, one cycle is considered to be the distance from fully closed to fully opened to fully closed in one motion. The cycle speed is generally based on 10 to 12 cycles per minute. Slide makers typically design in a margin of safety to handle overloads. For example, fully extended Accuride slides accept a static overload of twice the indicated load rating. The distance the chassis must travel (the relationship between the back of the chassis and the front of the cabinet) will help establish whether a two- or three-section slide will be necessary for a particular application. Two-section slides provide three-quarter travel. In other words, the chassis opens approximately three-quarters of the total slide length. Three-section slides offer full extension or over travel; the drawer opens the same amount or more than the length of the slide. The chassis length determines the slide length and corresponding travel needed. Adjustable brackets on these slides determine www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

Electronics 7-15_vs6.LL.MD.indd 103

the range of cabinet depths onto which they can install. On the other hand, cabinet depth can have an impact on the necessary slide length in slides that only have brackets with a limited adjustment range. Slides mount to cabinets by brackets. The mounting depth determines how long the bracket must be. Extension brackets can let a short slide mount on a deep cabinet. The slide is the connection between the cabinet and chassis; the slide will only move properly if the width dimensions are accurate. It is important to remember that adding mounting brackets can affect the functional space between the-rail-to-rail opening (450 mm) and the chassis width. Two crucial calculations, functional space and available space, determine the necessary slide width. Functional space is the area between the rail and the chassis side. It includes the overall slide thickness, the thickness of the extending slide member plus the bracket thickness. Available space is the area within the cabinet to mount non-moving portions of slides and/or brackets. Several factors help determine the optimal slide-to-chassis mounting position. For example, the mounting position must allow for the position of internal components (venting, fans, plugs, screws) inside the chassis. The chassis center of gravity also has an impact. The center of gravity should remain supported when the slide fully extends. In July 2015

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some cases, the chassis manufacturer may have a pre-designated mounting location, so there is no decision to be made. The overall U height is calculated using the bottom of the chassis as a reference. It includes the front panel or bezel, which may have a greater height than the actual chassis. In addition, the slide and bracket location must align with EIA cabinet pattern. The height of the slide should not exceed the specific unit height. The location of mounting holes on the sides of the chassis are usually known when the slide is selected, or the slide’s hole pattern is selected prior to creating a hole pattern on the chassis. The use or non-use of washers plays an important role in determining the fully closed position of the chassis relative to the cabinet front rails. If washers are used, the washer thickness dimension figures into the overall distance when determining the first chassis hole location.

Open Compute initiative Rack designs could undergo a significant change thanks to what’s called the Open Compute Project (OCP). Announced in 2011 by Facebook, the initiative aims to openly share designs of data center and server farm products primarily for the purpose of better energy efficiency. However, the OCP also covers standards for the mechanical mounting systems in server farms. Open racks have the same outside width (600 mm) and depth as standard 19-in. racks, but they are designed for chassis with a 21-in (537-m) width. This wider dimension lets more equipment fit in the same volume and improves air flow. Compute chassis sizes are defined in multiples of an OpenU (48 mm), slightly larger than the typical rack unit. The mechanical specifications of OCP were framed with the idea of making it easier for technicians to slide servers out of the rack, snap in new components, and get the unit

www.designworldonline.com

Electronics 7-15_vs6.LL.MD.indd 105

back up and running quickly. The mechanical standard also incorporates a power bus running down the back of the rack that lets servers plug into power connections; thus there are no power cables to manage. Because of the snap-out/snap-in nature of OCP server components, it’s likely that OCP servers will do away with some of the mounting and enclosure hardware common to equipment racks today. DW Accuride International accuride.com http://dwo.me/1RQIq9L

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The cure for spin coating An increasingly important use for UV curing compounds involves their use in spin coating, a method for coating substrates with a thin film. Often used in the semiconductor industry to create microlithography photoresists, spin coating has also been applied to the microfabrication of electrooptic, microfluidic and sensor components. Film thickness varies with the application but is usually a couple of microns or less.

» UV curing compounds are often used in spin coating applications,

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converted to chemical energy. This conversion process is 100% reactive in that it produces no volatile losses. It is essentially a non-polluting cure. UV-cure compounds also save energy on the factory floor. They do away with the need for ovens or other thermal curing equipment.

tough, durable, chemically resistant films on a variety of substrates—including silica and selected polyester films, especially pre-treated varieties. Neither compound is oxygen inhibited, which speeds cure times in ambient conditions. Both typically cure in less than a minute under commercial UV lamps. With appropriate post cure, both epoxies exhibit a glass transition temperature of 125° C, a high value for this class of materials.

Substrate versatility UV-cure adhesive products have gained traction in “high tech” industries such as electronics, optics and medical devices. The cure-on-demand capability has opened up in applications with complex assembly routines and the need to control the open time. DW

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Ethernet-connected motion controller Vena Engineering Vena.com PiMotion multi-platform, multi-language, secure Ethernetconnected motion controller with integrated linear amplifier offers complete control of the commutation waveform from the dual core FPGA. A 16-bit DAC on each phase drives the amplifiers. PiMotion runs on 24 to 48 Vdc with continuous output up to 3.5 A. Two analog inputs, auxiliary encoder input and 8 GPIO are available. With a cast aluminum case, in either panel or DIN-rail mount, this device is capable of continuous duty in an industrial environment.

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Pro duc t World High-torque dc motor

Touchscreen computer for hazardous environments

maxon precision motors maxonmotorsusa.com maxon motorsâ&#x20AC;&#x2122; EC-i 40 High Torque series of dc motors are equipped with three powerful iron-core internal rotor drives, each with a diameter of 40 mm. Ideally suited for applications in robotics, prosthetics and industrial automation, the motors feature high dynamics, a low cogging torque and extremely high output torque. The strongest motor in this series offers a maximum nominal torque of 234 mNm and is 56 mm long.

Sealevel Systems Sealevel.com The HazPAC R9-8.4 combines a RISC-based embedded computer with a bright 8.4-in. TFT LCD to create a wide-temperature, ruggedized, flat panel computer suited for a variety of HMI and control applications in hazardous area locations. The system carries the ETL electrical safety mark and is tested and certified for use in hazardous locations classified as Class I, Div. 2. Powered by a 400-MHz ARM9 microprocessor, the HazPAC R9-8.4 is available with 128 MB RAM and 256 MB Flash memory for maximum performance in embedded systems.

Harsh-duty photoelectric sensors AutomationDirect Automationdirect.com AutomationDirectâ&#x20AC;&#x2122;s new FM series harsh duty photoelectric sensors are IP69K-rated sensors in three-wire NPN or PNP styles and are available in 27 washdown models. Ideal for food and beverage applications, the 10-to-30-Vdc rectangular sensors are fitted with 316L stainless steel housings and are available in diffuse, diffuse with background suppression, and polarized retroreflective styles. The sensors have either an attached 2-m output cable, or an M8 or M12 quickdisconnect. All models have a selectable light-on/dark-on output setting; sensing ranges are available up to 10 m.

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Conveyor with pallet management Dorner Manufacturing Dornerconveyors.com With a unique pin tracking system to guide pallets through 90 turns, WE Series Linear Guideway Wide Series Ball Type.

and a fast belt change capability without the need to remove the conveyor from the system, Dorner’s 2200 Precision Move Pallet Systems are designed to increase efficiency and reduce downtime in various assembly automation processes. The pallets on this conveyor range from 160 to 480 mm. During operation, pallets move on twin dual strand timing-belt conveyors.

PG Series Linear Guideway Integrated Magnetic Encoder.

Electric brake Miki Pulley Mikipulley-us.com

MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

The compact and lightweight design of the BXRLE electric spring applied brake optimizes machine design efficiency. With accompanying voltage controller, power consumption is stepped down to 7 Vdc after a split second of 24 Vdc for brake actuation. The BXR-LE reaches a maximum rpm of 6,000 and has an ambient

HG / EG / RG Series Linear Guideways Ball and Roller Type.

operating temperature range of -20 to 60° C (-4 to 140° F). Its static friction torque ranges from 0.32 to 1.32 Nm (0.236 to 0.973 ft-lb).

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Pro duc t World Brushless dc motor and driver package Oriental Motor Orientalmotor.com

Open-frame stages Aerotech Aerotech.com PlanarDLA XY integrated,

Oriental Motor’s BXII Series Brushless Motor and Driver Package features speed control up to 4,000 rpm with a speed regulation of 0.05%. It is available from 30 to 400 W, in round shaft, parallel shaft gearheads

open-frame stages are optimized for applications where straightness and flatness of motion are critical. High-precision roller bearings, precision-machined surfaces

or the hollow shaft flat gearhead and electromagnetic brake options. The new driver features a digital setting directly on the face of the drive to use the built-in speed control, positioning or torque limiting functions with no additional control module required. The parallel geared type produces up to 610 lb-in. (70 N-m) of torque and the hollow shaft flat geared type products produces up to 970 lb-in. (110 N-m)

and non-contact direct-drive linear motors driving through the axes’ center-of-stiffness result in a positioning stage with straightness to ±0.5 µm and flatness to ±1.25 µm. The PlanarDLA enables high-throughput, high-accuracy processing with 2-m/sec velocities and 2-g accelerations. It is available in three positioning performance options. High-performance -PLUS and -ULTRA options enable accuracies and straightness values to ±500 nm and orthogonality to 5 µrad.

of torque.

High reliability angle sensors Novotechnik Novotechnik.com The Contelec brand of Vert-X 8800 Series of non-contact angle sensors have an 88-mm, stainless-steel housing base. Vert-X 8800 Series sensors measurement range is 0 to 360° with repeatability of 0.1° and linearity to ±0.1%. Analog and digital output versions include CANopen single and redundant, 0.1 to 10 V, 0.5 to 4.5 V, 4 to 20 mA and 10 to 90% of supply voltage. CANopen versions are CiA certified.

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Self-lubricating plastic bearing igus igus.com

LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

With the new iglide L500 material continuous rotational speeds of more than 16 ft/sec are possible, and the L500 material performs even under extreme environmental conditions,

KA Type Linear Actuator / SAR Ballscrew or belt driven, exible design.

such as temperatures ranging from -148 to 482° F, as well as media contact. The L500 material is characterized by its low moisture absorption and thermal expansion. These positive material properties allow the self-lubricating operation of electric motors, fans and ventilators, where sintered bearings were previously used.

KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

Linear and curved rail systems LM76 lm76.com Low-cost, SAIBO SB-LGV Straight and Curved Rail & Roller Block Systems are available in three widths and two styles to meet load requirements up to 7,200 N (1,619 lb). These low-profile linear and curved rail systems feature low noise, smooth travel, high speed, low weight, high accuracy, sealed radial low friction bearings, and

KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

easy installation into new and existing applications. They are available in lengths to 2,000 mm (79 in.) and curved sections with radiuses from 79.5 to 516.5 mm (3.13 to 20.3 in.) in 90, 180 and 360° sections. With operating temperatures of -40 to 120° C (-40 to 248° F), they are suited for use in robotics, laser cutting, wafer handling and other

AC Servo Motors.

precision applications.

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

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Pro duc t World Magnetostrictive position sensor

New line of motion systems ETEL Etel.ch

MTS Sensors mtssensors.com

ETEL’s DynX line of motion systems consists of three sizes of direct-driven

The RT4 is a linear position measurement solution that features two independent

linear axes, three sizes of direct-driven rotary axes and one high precision ballscrew-driven axis for vertical applications. The linear direct-drive axes feature high-precision, recirculating ball

sensor elements—each of which has a

bearings, high-accuracy optical encoders and iron-core motors with zero

measuring length of 50 to 2,540 mm (2

backlash, resulting in performance speeds up to 3 m/sec, accelerations up

to 100 in.). This fully redundant position sensing product employs a Synchronous Serial Interface (SSI), which means

to 5 g, bidirectional repeatability of ±0.5 µm at ±3 sigma, absolute position accuracy of ±2 µm after calibration, and position stability of ±50 nm. The rotary direct-drive axes are equipped with toothless motor

that data transfer is less susceptible

technology to provide zero backlash along with zero cogging force. They

to the presence of electro-magnetic interference. In addition, the IP68-rated enclosure protects against the threat

also include a high-accuracy optical encoder, allowing for speeds up to 391 rpm, bidirectional repeatability of ±1.5 arc sec at ±3 sigma, position accuracy of ±3 arc

of liquid ingress. The RT4’s detached

sec after calibration, and

electronics can be mounted up to 600

position stability of

mm (23.6 in.) away from the sensing environment allowing the electronics to

±0.2 arc sec.

be kept further from sources of potential harm. A temperature range that reaches up to 100° C (212° F) is supported for the sensor rod and interconnection cables.

MRI safe linear encoder Micronor Micronor.com With 100 µm resolution and 50 µm accuracy, the MR303 Linear Sensor is suitable for medical, MRI, robotic and industrial applications. The position sensor is immune to any electromagnetic interference, such as magnetic fields, lightning, high voltage and radiation. Being fabricated from non-ferrous and non-metallic materials, the sensor is also completely transparent to electromagnetic fields. These attributes allow the MR303 sensor to be safely used in and around the MRI bore and does not produce any imaging artifacts.

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Submersible pressure transducer

Compact positioning stage

BinMaster Binmaster.com

Velmex Velmex.com

The PT-500 submersible pressure transducer is a versatile level sensor that calculates level based on the amount of pressure being exerted on the sensor from the liquid above it. Made of 316L stainless steel, it can be used in a wide range of liquids including water, wastewater and a variety of chemicals. As it has a low current draw, the PT-500 can be used in remote locations and for battery powered applications. Lightning protection is built into the sensor, eliminating the need for a separate surge protector. The PT-500 installs simply by dropping it into the vessel.

The Velmex XSlide Assembly is a compact positioning stage suitable for either high-performance incrementing or scanning of smaller loads. Constructed with hard-coat anodized, aluminum dovetail ways and smooth motion PTFE bearings, XSlide Assemblies deliver rigidity for longer life and precise movement. XSlide Assemblies have a load capacity of 35 lb (15.9 kg) horizontally and 10 lb (4.5 kg) vertically. Straightline accuracy is 0.001 in./10 in. (0.076 mm/25 cm). Repeatability is 0.0001 in. (0.00025 mm). With a cross-sectional profile of 1.88 x 1.22 in. (48 x 31 mm), the XSlide stage comes in eight standard travel lengths from 2 to 30 in. (50 mm to 76.2 cm).

Infrared thermometer OMEGA Omega.com The OS499 Series are fully functional infrared (up to 760° C [1,400° F]) non-contact temperature measuring devices and compatibility with Type K thermocouples. They have dual lasers for better targeting and a built-in flashlight. Other features include: distance-to-spot ratio up to 30:1; mini thermocouple socket up to 1,400° C (2,552° F); emissivity adjustable from 0.1 to 1.00; and a Hi/Lo temperature audible alarm.

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SALES

Ad In dex All Motion ...........................................................4 Allied Electronics, Inc. ................................ 3,87 Altech Corporation ..........................................13 American Control Electronics ........................49 AMETEK PMC ...................................................17 AMETEK PMC/Dynamic Fluid Solutions........23 Anderson Metals Corporation, Inc. ...............43 Applied Motion Products, Inc. .......................27 Aurora Bearing Company ............................. 30 AutomationDirect ...........................................31 Baldor Electric Company ...............................45 Bimba Manufacturing Company .....................2 Bison Gear & Engineering Corp. ...................IBC C-Flex Bearing Co., Inc. ..................................51 CADENAS PARTsolutions ............................. 104 Canfield Connector .........................................54 CGI, Inc. ............................................................53 CS Hyde Company ......................................... 66 Del-Tron Precision, Inc. ...................................73 Delta Tau Data Systems, Inc. ...................... 102 Design2Parts ................................................112 Dunkermotor, part of AMETEK ......................19 EXAIR Corporation ............................................5 EZAutomation ...................................................1 FABCO-AIR ........................................................65 Firgelli Technologies Inc. .................................8 GAM ................................................................110 Graybar ..............................................................9 Helical Products Company Inc. .......................7 HELUKABEL USA .............................................33 Hitachi Cable America, Inc .............................57 HIWIN Corporation .........................113,115,117 IDEC Corporation ........................................14,15 igus ..................................................................59 IKO International, Inc. ....................................61 Interpower ...................................................... 60 ITT Enidine .................................................... 105 Lee Spring Company ......................................63 Master Bond ....................................................51 MFP Seals ....................................................... 34 Moog Inc., Animatics ..................................... 20 Nason .............................................................. 44 National Instruments Corporation ................41

NSK Precision America ..................................83 Omega Engineering, Inc. ...............................29 Omron Corporation .........................................75 Patrick Plastics Corp. .....................................47 PBC Linear .......................................................81 Peninsular Cylinder Co. .................................82 PHD, Inc. ..........................................................35 PITTMAN ...........................................................21 Proto Labs, Inc. ..........................................37,55 QA1 ..................................................................16 R+W ................................................................. 68 Rittal Inc. ...............................................100,101 Schneider Electric Motion USA ...........Cover,39 SEW Eurodrive, Inc. ........................................BC SIKO Products Inc. ..........................................16 Smalley Steel Ring Company ........................10 Sorbothane, Inc. ............................................ 20 THK America, Inc. .......................................... IFC Tompkins Industries, Inc. ..............................69 Tormach LLC ................................................... 95 Trim-Lok, Inc. ................................................. 26 US Digital, Inc. ................................................ 93 U.S. Tsubaki Power Transmission, LLC ........ 99 Vena Engineering Corporation ..................... 30 Visumatic Automated Fastening ..................67 Whittet-Higgins Company .............................25

Ad hes i ve Ti p Su p p lem ent

VP Sales Todd Tidmore ttidmore@wtwhmedia.com 512.626.8263 @wtwh_ttidmore

Regional Sales Manager Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

VP of EE Product Development Mike Caruso mcaruso@wtwhmedia.com 469.855.7344

Regional Sales Manager Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia

VP, Business Development Michael Ference mference@wtwhmedia.com 408.769.1188 @mrference General Manager Todd Christenson tchristenson@wtwhmedia.com 440.381.9048 @wtwh_todd VP, Business Development David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david Key Account Manager Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Regional Sales Manager Tom Lazar tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom Regional Sales Manager Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

Regional Sales Manager Megan Hollis mhollis@wtwhmedia.com 440.821.2941 @wtwh_Megan Business Development Michelle Flando mflando@wtwhmedia.com 440.670.4772 @mflando

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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THE BEST JUST GOT BETTER...

AC Runs Cooler & Longer Lasting than Traditional Right Angle Gearmotors AC and DC options available now 1/15 - 1/2 HP; 35-1780 in-lbs • AC MOTOR OPTIONS: 115V 1PH, 115/230V 1PH 230V 3PH Inverter Duty, 230/400-460 50/60HZ 3PH • DC MOTOR OPTIONS 720 frame size: 12V, 24V, 90V, 130V and 180V 725 frame size: 12V, 24V, 90V, 130V and 180V 730 frame size: 24V, 90V and 130V • Maximum power density means a compact profile without compromising performance • Ground gearing provides whisper quiet operation, low backlash precision • Latest hypoid gear technology ensures less friction/heat and extends product life • Versatile mounting interchangeability to easily upgrade your installed drives • Exclusive PowerSTAR® EP lubricant for extended life To learn more about PowerSTAR® right-angle gearmotors, please visit Bison’s NEW WEBSITE at www.bisongear.com or call 1-800-AT-BISON.

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Although independent research has proven that MOVIGEAR速 from SEW-EURODRIVE reduces startup and operating costs by 20-30%, actual case studies show that many users are experiencing 50% or more. MOVIGEAR速 also substantially reduces your inventory via its unique ability to replace several gear units of different ratios with a single unit. Yes...less really is more!

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