DESIGN WORLD JULY 2019

www.designworldonline.com

July 2019

inside: MOTION CONTROL: Getting to the point in

Chain and sprocket software parameters External force Chain mass

+ –

precision

p. 52

Belt software parameters Load mass External force +

–

Sprocket • Inertia • Diameter

Direction of motion

External force

Direction of motion

Rotation table software parameters

Linear-motor software parameters

Load mass

Driver • Inertia • Diameter

Belt mass

LINEAR MOTION: Offset Additional mass

Rotating inertia

Using software for Slide mass

+

designing and sizing motion-control systems

–

p. 56 Friction surface

• Direction of motion • External torque

Motor coil Direction of motion

Crank software parameters

Roll feeder software parameters

Connecting rod length

Press Force

Driven inertia

+

Friction surface

Tension force

ELECTRONICS: Crank radius

+

bad guys

p. 70

Direction of motion

Load mass External force –

+

–

External force

Crank inertia

Direction of motion

Driver • Inertia • Diameter

Load mass Friction surface

Rack-and-pinion software parameters

Ballscrew software parameters

Load mass Side mass Ballscrew • Pitch • Inertia

Wheel bearings +

Keeping out the

move telescope to new heights page 64

External force – +

Rack mass

Friction surface

Pinion • Pitch circle diameter • Inertia

Direction of motion

Direction of motion

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Creating a “wayback machine” for IT security Many people are familiar with the “wayback machine,” the useful internet archive at web.archive.org. But until now, there’s been no similar type of system for cyber security professionals. An attack may happen today and not manifest itself for months or years … by then, it’s impossible to do the sleuthing to figure out how the break-in happened.

Now Siemens is partnering with Chronicle to provide industrial monitoring and detection for the energy industry. Through a unified approach that will leverage Chronicle’s Backstory platform and Siemens’ strength in industrial cyber security, the combined offering is said to give energy customers unparalleled visibility across information technology and operational technology to provide operational insights and confidentially act on threats.

Research has found that while 60% of energy companies want to leverage analytics, a mere 20% are using any sort of analytics to do security monitoring in the OT environment.

What’s more, small and medium enterprises are particularly vulnerable to security breaches — they frequently do not have the internal expertise to manage and address increasingly sophisticated attacks.

At last month’s Spotlight on Innovation event in Orlando, Siemens Global Head, Industrial Cybersecurity, Leo Simonovich, and Mike Wiacek, co-founder and Chief Security Officer at Chronicle spoke about this partnership and its significance.

“To develop a continuous situational awareness of what’s happening in both the digital and physical worlds, we need to consume so many types of data — and in volumes that are almost incomprehensible. Being able to store this amount of information, let alone study it for those key links that may identify a cyberattack, is near impossible. But with Backstory, what was once impossible is now a reality,” said Wiacek.

“At its core, Backstory provides us with both visibility and context,” Wiacek said. “It’s a tool that can conduct in-depth forensic investigations ... we can look at behaviors ... to identify and understand unusual activity that could indicate an attack is underway.”

By identifying patterns, Siemens security analysts can build a picture of what’s happening, as well as the potential impacts. Then, the company’s OT specialists can build systems tailored for critical infrastructure and industrial technology and, when necessary, take action. In most cases, unlike what’s portrayed in James Bond movies, it doesn’t mean a system shutdown. Rather, it’s about developing options that balance operational safety and security constraints — and building the confidence to take a proportional and appropriate response, quickly and decisively.

“Needless to say, we are excited about this partnership. An old company partnering with a fairly new company … the whole idea, is to bring the best of technology, and to tackle this problem with expertise and domain knowledge from Siemens,” said Simonovich. “This is a massive problem and it requires innovative and scalable solutions.”

The partnership will help energy companies leverage the cloud to store and categorize data, while applying analytics, artificial intelligence, and machine learning to OT systems that can identify patterns, anomalies, and cyber threats. Backstory will be the backbone of Siemens’ managed service for industrial cyber monitoring. This combined solution enables security across the industry’s operating environment — from energy exploration and extraction to power generation and delivery. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com

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

(408) 460-1345

On Twitter @ DW—Editor

4

July 2019 www.designworldonline.com DESIGN WORLD

DW Insights 7-19_Vs4.PH.indd 4

7/1/19 8:11 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.

• 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 dust-tight, 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 applicat-ions 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

DON’T DO THIS!

It is an OSHA violation that presents a shock hazard to personnel.

The fan blows hot, humid, dirty air at the electronics.

Refrigerant panel air conditioners cause condensation and moisture.

When condensation is present, electrical components can begin to erode, resulting in severe damage.

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.

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NEMA 4 and 4X Hazardous Location Cabinet Coolers for use with classified enclosure purge and pressurization systems are available for all Class I Div 1 environments up to 5,600 Btu/hr.

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 nonhazardous locations.

• Maintain NEMA 4/4X integrity • Meet UL classified requirements • CE compliant

• Suitable for ambients up to 200°F (93°C) • Ideal for mounting near ovens, furnaces, and other hot locations

“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 Cabinet Cooler Jeff Hauck, Lasercraft Inc. Cincinnati OH System since it was easy to install and requires no maintenance.”

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Teschler on Topic Goal setting zaniness in corporate culture I once worked at a company where the people in the HR department seemed to be fixated on justifying their jobs. One way their fixation manifested itself was in a complicated and time-consuming goal-setting exercise foisted upon everyone in the firm. As I recall, we had to come up with goals that fit into categories such as operational, communication, strategic, and so forth. What this process actually boiled down to was taking the work you knew you were about to do anyway and squeezing it into categories that satisfied HR. In the minds of people in the HR department, the goals we came up with were supposed to be guiding our work.

In reality, I’m pretty sure neither we nor the people we reported to ever revisited them until goal-setting time rolled around again.

The process of evaluating our progress against our goals was equally silly. Supposedly, we were engaging in a thoughtful and earnest reflection about our accomplishments or lack of them.

But as in most companies, situations at ours changed constantly, and it was common for some of the goals we set

one week to be irrelevant the next.

So the whole self-evaluation process became super political. We devoted a lot of time to weasel-wording selfevaluations that said we hit our goals but were phrased in ways that didn’t seem arrogant.

When we didn’t meet a goal, explaining the reason why became tricky. We had to delicately delineate why certain things hadn’t gone as planned without giving company higher-ups an excuse to ex-out a costof-living raise for us, or worse.

All in all, we spent the better part of two weeks annually evaluating ourselves on numerous abstract goals that were meaningless shortly after we came up with them. More frustrating still, we had to pretend to company managers that we bought into the whole mess. The most pressing goal I had after completing one of these exercises was to have a stiff drink.

I once thought only the HR geniuses at my old company could come up with the kind of counter-productive goal-setting we experienced, but I was wrong. Marcus Buckingham, head of research at the ADP Research Institute, which focuses on workforce management, and Ashley Goodall, senior VP of leadership and team intelligence at Cisco, have examined heavy-handed corporate goal-setting

programs like the one I endured. They point out that no research exists showing that goals set for people from above stimulate them to greater productivity. In fact, they say, the weight of the evidence suggests that goals cascading down through levels of management do the opposite; they limit performance and slow things to a crawl.

Buckingham and Goodall claim that the only criterion for a good goal is that the person pursuing it must set it themselves voluntarily. To make voluntary goals meaningful for a company, management must ensure employees understand the things that matter most to the organization.

As the two put it, “Instead of cascading goals (and) instructions for actions, we …. need to give (team members) a sense of which hill we’re trying to take….The best leaders realize that their people are wise, that they do not need to be coerced into alignment through yearly goal setting. …These leaders know that in a team infused with such meaning, each person will be smart enough and driven enough to set goals voluntarily that manifest that meaning.”

We might add that organizations having team members able to set goals voluntarily also have far less need for meddlesome HR departments. DW

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

6

July 2019 www.designworldonline.com

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Technology Forward

Putting visualization to work According to recent research from Tacton, design engineers are turning increasingly to augmented reality (AR) to visualize product prototypes and test innovations.

In some instances, AR is used to make product changes on the fly. According to researchers, one of the benefits of using AR this way is to examine consequences of design changes. For example, if a design change is made to meet new standards, how will that change affect other parts of the design?

The goal is to reduce potential mistakes that could cost thousands of dollars.

AR helps uncover those consequences before products are built.

Tacton claims in its annual report “The Current State of Manufacturing,” that “companies are striving to embrace the digital revolution and leverage big data and AI to innovate faster and respond to customer demands.”

The company surveyed more than 100 large and mid-sized manufacturers worldwide with more than $250 million in revenue. In one example, the survey found that firms are using business intelligence and big data analysis to understand the market (50%), forecast revenues (48%), understand the customer buying process (30%), and optimize pricing (30%).

But AR visualization tools are also being integrated with CAD, ERP, CRM and Configure Price Quote (CPQ) systems in efforts to improve design and production workflows.

Companies surveyed believe that Smart Manufacturing/ Industry 4.0 are important and they want to implement initiatives to remain competitive.

The main obstacle is a lack of understanding and technical skills that is seen as hindering adoption.

Of the respondents, 70% said that Smart Manufacturing is important across industries ranging from automotive to medical technology.

However, only 41% responded that they had sufficient awareness and understanding of AR’s potential impact, and only 21% felt they had sufficient understanding to put a smart manufacturing strategy in place.

Close to 60% of respondents said they’ve made average or decent progress toward their goals, but more than 30% said they’ve made limited progress and significant action is needed.

These findings suggest that given the overall awareness of AR and visualization trends, most companies are coming up short in creating and implementing a strategy. They therefore risk being unable to catch up to the first movers whose strong competitive challenges may impact business revenues and long-term business viability.

So, what’s next in using AR and visualization to advance innovation?

56% of respondents believe that meeting customer demand for highly configured and custom products will drive the most value. 33% feel that increasing the speed of innovation and time to market will be extremely important.

Can AR serve as a catalyst supporting an alignment between sales, product and fulfillment processes, and manufacturering?

Send your thoughts to llangnau@ wtwhmedia.com DW

Leslie Langnau • Managing Editor llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

8

July 2019 www.designworldonline.com

Tech Forward 7-19_Vs2.LL.indd 8

DESIGN WORLD

7/1/19 8:05 AM

— The sign of reliability

For more than 100 years, ABB has developed a reputation for marketing, designing and manufacturing the most reliable industrial electric motors available. Azima, Inc. confirmed this in their Reliability Rating Report in which they stated that “ABB produces the majority of models scoring highest for reliability in 2018.”

When reliability counts, look for the sign of reliability from ABB. 479.646.4711 baldor.abb.com

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Green Engineering Paul J. Heney • VP, Editorial Director

Rooftop solar system greens up

electrical products manufacturer Schurter’s North American headquarters, standing amidst legacy oaks in Sonoma County, California, fosters a deep appreciation for the environment — something also echoed by its Swiss corporate parent. True to its green ethic, the company just completed installation of a 108kW rooftop solar energy system. The company’s CEO, Leonard Overholser, spearheaded this addition to the company’s green energy assets.

“Not only will the system reduce Schurter’s carbon footprint, it will also considerably reduce the company’s energy expense,” Overholser said. “A record-breaking year in 2018 made the decision easy, moving forward to allocate the funds for such an investment project. We are now in a position that allows us to re-invest that portion of the (energy) budget to more value added projects.”

Designed by Pure Power Solutions, a Sonoma county solar energy contractor, the system includes 290 QCell solar modules with optimizers that increase the efficiency of each module. The inverter is from SolarEdge. Using an innovative clamped racking system, Pure Power was able to clamp the solar racking onto the ribs of the building’s standing-seam roof, eliminating the need for roof penetrations.

The solar energy system is expected to generate more than 127,000 kilowatt hours of clean energy per year, satisfying an estimated 98% of the company’s energy needs and reducing the average cost of electricity to two and a half cents per kWh. Total lifetime energy cost savings is estimated at greater than $1.5 million.

The system will directly feed the company’s electricity needs, offsetting purchases from PG&E. When the system produces more electricity than the company requires, excess production will feed into PG&E’s infrastructure, earning the company a credit on its utility bill — and supplying green energy to other local users.

Schurter always envisioned a renewable energy footprint, since the solar boom rebirth in the early 2000s.

A perfect storm finally emerged: multiple years of higher than expected sales growth and lower upfront investment costs — coupled with dissipating state and federal tax incentives — pushed the shelved project into action.

“Because we are an electronics supplier who sell EMC components into the energy market segment, we saw firsthand the rise, fall and rise again of the renewable industry,” Overholser said. “We knew we had the golden opportunity to complete our long-term vision and we took it. We are extremely proud of this accomplishment.” DW Schurter Inc. | schurterinc.com

DESIGN WORLD

Green Engineering 7-19_Vs2.LL.indd 11

www.designworldonline.com

July 2019

11

7/1/19 8:15 AM

Contents 7 • 2019

•

vol 14 no7

•

designworldonline.com

64 52 _MOTION CONTROL

70 _ELECTRONICS

Getting to the point in precision

Keeping out the bad guys

A new concept for measuring precision aims to set a standard that promises to get at real-world levels of precision in motion control systems.

To keep hackers from wreaking havoc in industrial networks, modern industrial controllers employ measures that go far beyond ordinary firewalls.

56 _LINEAR MOTION

76 _TEST & MEASUREMENT

Using software for designing and sizing motion-control systems

New approach to frequency analysis on oscilloscopes

How software automates the choice of speed, torque, and inertia in servomotor offerings.

It has often been the case that optimizing scope settings to display a detailed view of an FFT results in a time-domain view that is suboptimal.

Not anymore.

64 _MECHANICAL How to move a space telescope up a mountain

With a construction cost of USD $1.4 billion, a lot was riding on just 28 wheel bearings each time one of the 66 antennas was moved into place on the ALMA project.

ON THE COVER

Tapered roller bearings help move a 66-antenna telescope 16,000-ft up the Chilean Andes. | Timken

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

2019

BRONZE REGIONAL AWARD asbpe.org

12

July 2019 www.designworldonline.com

CONTENTS 7-19_Vs2.LL.indd 12

DESIGN WORLD

7/1/19 11:24 AM

181231_AutoM_DW_US.indd Digi Key — PE 02-19.indd 13 1

12/14/18 8/7/19 3:45 3:40 PM

7.19 • contents departments 04 Insights 06 Teschler on Topic 08

Technology Forward

11

Green Engineering

18 Design For Industry 26 MC2 School 30 Design Notes

Fasteners

42

CAE Solutions

48

Internet of Things

84

Product World

88 Ad Index

Quick alternative to nutand-bolt assembly.

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www.fixtureworks.net 888.794.8687 CONTENTS 7-19_second page_Vs3.indd 14

14

July 2019

DESIGN WORLD

7/1/19 11:22 AM

RACI NG OU R WAY TO TH E

M OO N

MPD

MEMORY PROTEC TION DEV ICES

BEST SOURCE FOR LITHIUM COIN CELL RETAINERS AND BATTERY CAGES

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Reliable Power Connectors Handle Your Toughest Industrial Demands LAPP’s EPIC® Pin & Sleeve impact resistant connectors provide safe, secure connections even in challenging conditions—indoors and outdoors. They deliver protection from environmental conditions including dirt, moisture and water.

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EPIC® Pin & Sleeve connectors help prevent costly installation wiring errors.

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Senior Contributing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

DIGITAL MEDIA/WEB/ DEVELOPMENT

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick VIDEO SERVICES

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek Videographer Graham Smith gsmith@wtwhmedia.com DIGITAL MARKETING

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

Digital Marketing Director Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

CREATIVE SERVICES

Digital Marketing Manager Amanda Fourlaris afourlaris@wtwhmedia.com @wtwh_amanda

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Webinar Coordinator Halle Kirsh hkirsh@wtwhmedia.com Leadlift Onboarding Specialist Mike Ulanski mulanski@wtwhmedia.com @wtwh_mike

EVENTS

Events Manager Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen Event Exhibitor & Speaker Manager Michelle Flando mflando@wtwhmedia.com Events Marketing Specialist Christina Lograsso clograsso@wtwhmedia.com @wtwh_christina PRODUCTION SERVICES

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com

Higher Reliability smaller footprint

Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Julie Ritchie jritchie@wtwhmedia.com

New Ready-To-Use Cable Assemblies Now Available with Reverse Fixing Screw-Lok for Design Flexibility

Digital Production Manager Reggie Hall rhall@wtwhmedia.com

- Save time and money on tooling, training and testing cables

Digital Production Marketing Designer Samantha King sking@wtwhmedia.com

- Metal back-shells for maximum strain relief and RF shielding

FINANCE

- Up to 45% smaller and up to 75% lighter than Micro-D

Controller Brian Korsberg bkorsberg@wtwhmedia.com

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- Resists extremes of shock, vibration and temperature

Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

- Excellent out-gassing properties

2011 - 2018 2014 Winner

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Medical Design & OUTSOURCING DESIGN WORLD

Staff page 7-19_Vs1.indd 17

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July 2019

17

www.harwin.com/gecko-sl

7/1/19 8:24 AM

Design for Industry Food & Beverage

Hose fitting adds extra protection

W

With washdown solvents, food acids, and other chemicals, food and beverage equipment need

rugged equipment, especially for connections. The Series 696 HEC (Harsh Environment Connector) panel mount connector features a protective hose fitting that shields cable and single wires against external influences including UV exposure, extreme temperatures, and air pollutants, as well as shock and vibration. It can be retrofitted on existing binder Series 696 HEC connectors or purchased as a complete connecting component.

The binder Series 696 HEC was developed specifically for use in challenging environments. A 3-point bayonet locking mechanism and binder’s lightweight plastic design ensures that the connectors are resistant against climatic conditions, chemical substances, and other industrial hazards. It is IP68 and IPX9K-rated, providing further protection from temporary immersion in water and high-pressure washdowns. The HEC suits agriculture, chemical, food/beverage, chemical, and other commercial applications. DW Series 696 HEC features include: Available in 5, 8 and 12-pin versions.

Contacts: 4+PE, 8 (4+3_PE), 12 IP68/IPX9K rated Rated current: 32 A – 3A Rated voltage: 600 V – 60 V Contact plating: Ag (silver) Termination: Crimp UL, CSA, and VDE in preparation DW

Binder USA, LP www.binder-connector.us

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7/1/19 8:37 AM

Food & Beverage

Level switch keeps an eye on powdered and fine grained solids

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Tracking silo fill levels is easier with the Nivector FTI26 point level switch. It detects all types of powdered and fine-grained solids such as plastic granules, detergent, grain, sugar, spices, milk powder, animal feed and other dry materials. The switch can be installed at the top of a tank to indicate high level, or at the bottom of a tank to indicate low level.

Installed at the top, the device prevents the silo from overfill by switching to stop the filling process. When the point level switch is installed at the bottom of the silo, it avoids dry running and thereby protects pumps and subsequent plant equipment.

The capacitance device fulfills all hygienic requirements, such as 3A, EHEDG and FDA. It is also cleanable to protection class IP69. No additional or individual adjustments to different media are necessary.

The function of the point level switch can be checked with LED signalization without dismounting the device. In addition, the FTI26 is Industry 4.0 ready due to IO-Link communication. IO-Link reduces costs and complexity with an easy configuration of the devices via engineering tools.

Depending on the fail-safe mode selected and the level, the FTI26 activates when the point level is reached, in the event of a problem, or in the event of a power failure. DW

Endress+Hauser www.us.endress.com/fti26

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Design for Industry Food & Beverage

For hot and cold environments

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While standard HMIs often feature an operating temperature range from 0-55°C, the expanded temperature range of the GOT2507T-WTSD, from -20°C to +65°C, means it can be used in harsher environments without heaters in the lowest temperatures or fans and coolers in the highest. The temperature range can reduce operating expenses for the likes of food and beverage manufacturers and in power industry applications, as well as offering more flexibility for deployment in extreme temperatures.

Where use in direct sunlight is required, the GOT2507T-WTSD resists UV rays, while on-screen clarity--even under strong sunlight--has been enhanced through the use of a high brightness LCD panel and a special coating to eliminate glare.

Furthermore, since the structure of the front panel has been reinforced with a metal housing, the rugged model can be used in environments that are subject to shock or vibration.

Along with the increased strength and durability, users benefit from all the features and functions of the existing GOT2000 models. These include multiple communication interfaces, comprising of two Ethernet ports, wireless LAN interface, USB, RS232 and RS422/485. In addition to this, audible warning functions reinforce the information displayed on the screen and GOT Mobile provides real-time machine visualization using remote devices such as tablets, smartphones and PCs. All these functions help improve productivity and reduce the total cost of ownership for machinery. DW

Mitsubishi Electric | us.mitsubishielectric.com/fa/en

Linear and bearingless rotary encoders for motor feedback

Absolute and incremental magnetic measurement Contactless and completely wear and maintenance-free Extremely precise, even in the presence of contamination of the scale  Flexible sizing of measuring lengths and diameters  Easy handling, high positional accuracy of highly dynamic processes  Customized, individual PCB solutions  

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

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Packaging

Clutch brakes keep

packaging machines running

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The Posidyne X Class Clutch Brakes have Oil Shear technology to handle the common rapid and precise stopping, starting, reversing, speed change and positioning requirements of packaging applications – all without adjustment and nearly no maintenance. For applications with frequent start/stop cycles, these unique motion control devices allow higher cycle rates (as high as 300 cycles per minute), and a service life of 20 to 40 million cycles. With speed and precision, the value engineered X Class Clutch Brakes allow machine designers to run at higher cycle rates and quality levels or design new machines for higher performance at a reasonable cost. They suit many OEM applications including conveyors, packaging machinery, food processing, meat packing, dynamite/ gunpowder processing, production machinery, extruder cutoffs, palletizers, feeders, inserters, loaders, cut-offs, fillers, and more.

The Posidyne X Class has a Split Clamped Quill feature that reduces shaft and key/keyway damage to the motor shaft associated with competitive clutch/brakes. The split quill collar

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Design for Industry Packaging tightens the quill 360 degrees around the shaft and key for better connection.

Convenient options such as foot mounting kits, manifold mounted valves and optical encoders with closed loop positioning controls are available to fit most applications. The totally enclosed clutch brake is impervious to dust, dirt, chips, etc. With a washdown or marine duty option it is resistant to chemicals, coolants, caustic wash down, weather, and more, making them ideal for hostile environments.

It is available with an explosion proof actuation valve. A standard valve could also be remotely mounted in an explosion proof cabinet.

All Posidyne clutch/brakes have low inertia cycling components for efficiency.

They use less motor horsepower to accelerate the load, and less torque to stop the load. By reducing the motors’ high inrush currents and the associated TL Design Worls 2019 V2.pdf

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6/11/19

power factor imbalance, these clutch/ brakes offer energy savings in 24/7 manufacturing demands.

A simple actuation system precisely controls torque in the clutch and brake through air or hydraulic pressure control.

Adjustment for rapid or soft starts and stops is easy. Manifold mounted control valves reduce response times by eliminating hoses and fittings while providing a space efficient design.

The hydraulic actuation package includes a hydraulic pump, solenoid valve, regulators, and a filter. A heat exchanger can be added for additional cooling for unusually high loads or cycle rates.

In addition to transmitting torque, a patented fluid recirculation system helps to dissipate the heat from the friction surface to the housing where it is cooled.

The inability of the dry friction units to dissipate the heat out of the friction

Force Control Industries, Inc. www.forcecontrol.com

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4:21 PM

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Design for Industry Semiconductor

Single-chip front end operates

in the 24 to 45 GHz bands

T

The goal was to improve mmWave front-end performance.

This compound semiconductor wafer foundry is able to commercialize an integrated GaAs platform capable of producing single chip front-ends for 5G handsets and mmWave radio access networks. The mmWave GaAs platform, PIH1-10 technology combines an advanced 100GHz ∫t enhancement-mode pHEMT with monolithic

on a single chip. GaAs technology outperforms BiCMOS in every front-end function, and mmWave single-chip front ends realized in PIH1-10 can reduce array power consumption, simplify thermal management, and extend battery life in 5G user equipment while improving total cost of ownership for mmWave access points. DW

PIN and Schottky diodes for mmWave performance for all

WIN Semiconductors Corp. www.winfoundry.com/en_US/Index.aspx

front-end functions.

The core of PIH1-10 is an E-Mode pHEMT that provides the gain, power density and efficiency for mmWave transmit power amplifiers, and the noise performance needed in the receive LNA. This supply transistor can support Tx power levels of 30 dBm and Rx noise figure of 2.5 dB at mmWave frequencies. Furthermore, the integrated PIN diode provides mmWave Tx/Rx switch functionality with <1 dB insertion loss, enabling monolithic integration of all front-end functions

DESIGN WORLD

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Design for Industry O f f- h i g h w a y

Seal protects off-highway equipment in extreme environments

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In today’s off-highway industries, working in extreme environments

is routine. Whether cultivating water-covered fields, moving abrasive scree, clearing sand and mud after a flood or ploughing through hard, compacted soil, agricultural and construction machinery is frequently exposed to conditions that contaminate wheel hubs and undercarriage applications.

Such contamination and its related downtime was proving expensive to manufacturers and end-use customers alike. When Freudenberg Sealing Technologies analyzed customer warranty and failure analysis data, the challenge became clear: Despite the availability of its best-in-class Cassette-S3 seal, harsh operating conditions were outpacing the ability of the cassette seal to stop dirt ingress and fluid leaks. A solution that incorporated superior dirt protection, material durability and seal longevity was required.

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Freudenberg established a dedicated team of product engineers and sales managers from its plants in Italy and the United States to design and develop a new approach to off-highway sealing.

The resulting Cassette-S4 has since met performance benchmarks in off-highway mobile machinery applications.

Unlike its predecessor’s double-lip design, the Cassette-S4 uses a complex,

DESIGN WORLD

7/1/19 8:45 AM

HELUKABEL can tailor make custom cables to fit unique applications

three-component configuration that protects all functional parts – sealing lips, lip working surface, dirt exclusion lips, dedicated counter-surfaces and internal lubrication – in a single component that that reduces the number of parts to be managed and minimizes the risk of accidental damage during handling and assembly.

Shaft machining and surface finish requirements for the Cassette-S4 are lower than standard sealing solutions because cassette-to-shaft contact is limited to static sealing function. The Cassette-S4 leaves no wear traces on the shaft during operation and requires no rework or repositioning during service.

In addition, its “plug and play” installation concept is easier and safer to install and remove.

Comparative mud bench testing and extensive field validation show the Casette-S4 can last up to four times longer than the Cassette-S3. Its static sealing function relies on an outer diameter of rubber and metal and an inner diameter of rubber. Its dynamic sealing function optimizes the seal’s working surface and incorporates proprietary materials that are matched to working applications. The dirt exclusion function, manufactured from standard or stainless steel, incorporates five internal dust lips and provides lifetime internal lubrication. Cassette-S4 has no speed, temperature or pressure limitations as compared with the Cassette-S3. DW

FACT: Our cable specialists design & develop custom solutions which include: flexing cycles, temperature, torsion or tensile strength and chemical resistance.

Freudenberg Sealing Technologies | www.fst.com/en DESIGN WORLD

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July 2019

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Gearmotors Miles Budimir

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This month’s three installments of Motion Control Classroom focus on shock and vibration damping, stepper motors, and gearmotors.

A gearmotor is basically a combination of a gear reducer and an ac or dc electric motor, with the gears and motor combined into one unit. Most industrial gearmotors use ac motors, typically fixed-speed motors. However, dc motors also excel as gearmotors, particularly in automotive applications.

The gear reducers in gearmotors vary and include helical, bevel, and planetary gears. The physical configurations of gearmotors also varies — though inline, right angle, and shafted and hollow-shaft configurations are most common.

In the installment of MC2 featuring gearmotors, you’ll find resources covering the basics of gearmotors and gearmotor accessories as well as how to select the right gearmotor to meet your particular application’s requirements. You’ll also find information on gears and gearboxes, including the gearbox service factor and service class.

Check out these and other resources on motion components and systems at www.designworldonline.com/mc2.

Educational installment brought to you by:

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Vibration damping + shocks Lisa Eitel

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Vibration is mechanical oscillation (regular or otherwise) about some equilibrium. It’s prone to becoming problematic in motor-driven motion designs where there’s looseness, backlash, windup, uneven effects from friction, machine-assembly imbalances, or shock loading.

Recall that free vibration is when an assembly is moved or struck once and then left to oscillate. (Assembly-component materials and geometry dictate how such vibration behaves.) This vibration is inherent to motion systems — as is forced vibration in response to temporary or recurring displacement or loading of an axis or axes. Because most motion systems run off electric motors, oscillatory disturbances often originate at rotor output.

Noise is a manifestation of these vibrations that degrades the perceived quality of machines … and in many cases is an unacceptable byproduct of motion.

So as we explore in several Motion Control Classroom features, the ultimate goal for design engineers is to build and tune designs for minimal vibration (free or forced) and render unavoidable system vibration damped (dissipated) or isolated. That way, the machine can quickly settle back to equilibrium.

We also explore a phenomenon related to that of vibration — that of shock. Most problematic for its capacity to induce damage and excite system natural frequencies, shock is large and sudden change in acceleration (impulse) often from a hard stop or jam. It’s sometimes defined by the acceleration’s maximum value, duration, and motion profile … and in units of acceleration due to gravity or g.

Equipment able to minimize the vibrational response to cyclical inputs from external forces — as well as internally generated sources — last longest and performs best. That’s why designing motion systems that run smoothly and quietly is a key task for machine builders. So is keeping machine sections’ resonant frequencies higher than any vibration the system might see during operation. After all, when an assembly’s resonant frequencies are excited by vibration or shock loading, they cause maximum oscillation displacement … which are capable of maximum vibrational damage.

Educational installment brought to you by:

The challenge is that assembled electromechanical designs and their frames often possess dynamics complicated to predict upfront — and subject to slow change where gearboxes, bearings, and belts are part of the power transmission.

That means damping vibration, isolating oscillations, and absorbing shock loading with components specifically built for such tasks are often essential for successful operation of equipment with moving axes — and the avoidance of premature performance degradation (as when a servosystem loses the ability to position an axis with a given speed and accuracy) and failure.

These issues arise from cyclical stresses; mechanical wear and fatigue; hardening of surfaces or loosening of fasteners and joints; leaks; separations; and increasing levels of rattling and other noise.

In this installment of Design World’s MC2 we’ve written and collected more than a dozen references that detail the challenges of vibration; correct approaches for upfront analysis of shock and vibration during the early phases of motion design; predictive maintenance components to prevent and mitigate vibration; and incidents of vibration in bearings and other mission-critical components.

References include: Difference between passive and active damping What are gas springs? A technical summary Application-specific shocks and damping — especially for high-speed axes Wire-rope isolators and their alternatives The basics of dashpots and snubbers Access this and other MC2 installments at designworldonline.com/MC2.

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Stepper motors Danielle Collins

THEORETICAL STEPPER-MOTOR MICROSTEPPING

your application. We also go in-depth on microstepping — a common method for producing smoother motion and increasing resolution. And finally, you’ll learn when it makes sense to use a stepper motor in a closed-loop control system.

Find these and many more resources on motion components and systems at designworldonline.com/mc2.

CURRENT CURRENT CURRENT

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For motion applications that require good holding torque, high torque at low speeds, and relatively straightforward operation, stepper motors are often the best choice. Plus basic stepper construction gives these motors inherently high resolution and accurate positioning capabilities, so they’re suitable for open-loop operation.

For designers and engineers considering a stepper motor, design and performance options abound. Our Motion Control Classroom on stepper motors explains the differences between various stepper motor designs — including permanent magnet, variable reluctance, and hybrid types — and reviews the performance characteristics of each.

For example, you’ll learn which stepper-motor design is best for high holding torque, which design eliminates detent torque, and when to consider a linear stepper motor.

In this installment of MC2 you’ll also gain insights into best practices for selecting and operating stepper

THEORETICAL STEPPER-MOTOR MICROSTEPPING THEORETICAL STEPPER-MOTOR MICROSTEPPING STEPPER-MOTOR motors THEORETICAL and how to choose the best driveMICROSTEPPING scheme for

STEPPER MOTOR STATOR AND ROTOR STEPPER MOTOR MOTOR STATOR STATOR AND AND ROTOR ROTOR STEPPER B

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STATOR STATOR STATOR WINDINGS WINDINGS WINDINGS

TYPICAL FOR STEPPER STEPPERMOTORS MOTORS TYPICALSPECIFICATION SPECIFICATION CURVES CURVES FOR FOR STEPPER MOTORS TYPICAL SPECIFICATION CURVES

PULLOUT (mNm) (mNm) PULLOUT PULLOUT (mNm)

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July 2019

STATOR

www.designworldonline.com

WINDINGS Motion Control Classroom_7-19_Vs3.LE.indd 28 TYPICAL SPECIFICATION CURVES FOR STEPPER MOTORS

DESIGN WORLD

7/3/19 2:39 PM

Configuration made easy with the commissioning and service tool driveSTUDIO The compact GreenTech EC drives from ebm-papst with integrated K4 control electronics have already proven their flexibility in many applications. The driveSTUDIO software from ebm-papst makes it even easier to adjust to the individual requirements of each application.

Contact sales@us.ebmpapst.com or visit our website to learn more.

• Simple commissioning • Warnings • Conditioning monitoring • High cost savings

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Design Notes

How materials science is helping

microbreweries

Edited by Mike Santora • Associate Editor

To protect against flavor transfer, it is important to understand a variety of complex factors, including the material science of different elastomer types, the selection and development of the rubber compound, and the various test methods used to measure fluid and temperature compatibility with this compound. Materials need to stand up to myriad ingredients including fruit solids and a range of temperatures without affecting performance or altering the taste of the drink.

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Choosing a beer, soda, or sparkling water has never come with as many options as it does today. From the ever-growing microbrew and craft beer trend that brings us seasonal and special edition suds, to machines that allow consumers to create their own soda flavor on the spot, expanded options are all the rage.

With companies and breweries producing more variety and flavors, the facilities and machines that make this variety possible are under increased performance pressure. For example, many microbrew facilities have a fixed number of production lines producing multiple styles of beer because dedicated lines for each variety can be cost prohibitive. The syrups used in flavored waters and energy drinks and beverages blended from solids such as fruits and vegetables can present sterilization and cleaning challenges. Add in the need for proper regional food contact certifications and longer maintenance cycles, and companies can find themselves spending months chasing problems like flavor transfer, leaks, and other mechanical issues and material compliance approvals.

Freudenberg Sealing Technologies designs, tests, and supplies seals for the beverage industry that resolve these challenges. The company has a variety of globally certified sealing materials and testing capabilities to improve equipment performance, ease cleaning and sterilization requirements, and handle complex flavor and ingredient challenges.

“Flavors are rarely the same and the taste of a particular beverage is the identity for a company,” said Patrick Scheib, Freudenberg’s Director of Sales, Process Industry, North America. “Our goal is to protect this brand value by providing seals that have been tested for ingredient compatibility and flavor transfer.”

Freudenberg has three globally-certified sealing materials, the 70FKM727 low-temperature Fluorocarbon (FKM) material, the Fluoroprene XP family of highly fluorinated materials, and the 70 EPDM 291 material.

“Industrial drink processors and producers go to great lengths to ensure the purity of their beverages, whether they are fruit juices, varieties of mineral water, milk, beer, or wine,” Scheib said. “Extremely stringent hygienic requirements apply to filling systems and all their components, all the way from tube lines and connectors to seals to make sure that no dirt penetrates the filling operation and no fluids leak from the system.“ Moreover, the challenge doesn’t end in the production plant. At the point of sale, dispenser lines face similar issues. With many bars offering rotating taps with different offerings each season, or even each week, the materials used in the dispense system need to be tough to prevent flavor transfer from one beverage to the next. The materials also need to stand up to myriad ingredients, including fruit solids, and a range of temperatures without affecting performance or altering the taste of the drink.

“To protect against flavor transfer, it is important to understand a variety of complex factors, including the material science of different elastomer types, the selection and development of the rubber compound, and the various test methods used to measure fluid and temperature compatibility with this compound,” said David Clark, Central Laboratory Operations Manager, DESIGN WORLD

Design Notes 7-19_Vs3.LL.indd 31

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Freudenberg-NOK Sealing Technologies.

“When you account for these criteria in your testing, you develop a robust material that will perform well in whatever you decide to expose it to.”

Extensive laboratory testing, which includes Compressive-Stress-Relaxation (CSR), flavor transfer/retention, state of cure, and analytical testing, help create seals and components that achieve their intended function the first time and every time, Clark added.

As the beverage industry continues to expand and increase in complexity, so does the demand for precision and versatility from new materials. Clark continues, “There are also some functionality issues when we get into these microdosing type applications. They’re using technology used in the medical industry for dropping precise drips of medicine in a hospital. It’s that same kind of technology that they’re using because you need to get that ratio correct otherwise the flavor and the taste is off. If we have O-rings and on you’re conventional beverages it was a 5 to 1, if it swelled up a bit, a volume swell of 2 or 3%, that wasn’t a big deal. But now, if you have an O-ring that swells up 3% and it constricts the amount of syrup to go into the micro-dosing unit, now your ration is off. It’s critical. There are a lot of challenges.” DW

Freudenberg-NOK | www.fst.com

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Design Notes

Despite the popularity of common mode chokes, an alternative may be monolithic EMI filters. When properly laid out, these multilayer ceramic components provide excellent rejection of common mode noise.

Filtering out common mode noise

with monolithic EMI filters Edited by Mike Santora • Associate Editor

Many factors increase the amount of “noise” interference that can damage or disturb the functionality of electronic devices. Today’s automobiles are a prime example. In a single vehicle, you can find Wi-Fi, Bluetooth, satellite radio, GPS systems, and that’s just the beginning. To manage this noise interference, the industry typically uses shielding along with EMI filters to eliminate unwanted noise. But now some of the traditional solutions for eliminating EMI/RFI are no longer sufficient.

This issue is leading many OEMs to avoid options such as 2-capacitor differential, 3-capacitor (one X-cap and 2 Y-caps), feed-through filters, common mode chokes, or combinations of these for more suitable solutions such as monolithic EMI filters that have better noise suppression in a smaller package.

When electronic devices receive strong electromagnetic waves, unwanted electric currents can be induced in the circuit and cause unintended operations — or interfere with intended operations.

EMI/RFI can be in the form of conducted or radiated emissions. When EMI is conducted, it means the noise travels along the electrical conductors. Radiated EMI occurs when noise travels through the air as magnetic fields or radio waves.

Even if the energy applied from the outside is small, if it is mixed with the radio waves used for broadcasting and communication, it can cause loss of reception, abnormal noise in sound, or disrupted video. If the energy is too powerful, electronic devices can be damaged.

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POWER TRANSMISSION

RETAINING DEVICES & Sources include natural noise like electrostatic discharge, lighting, and other sources and artificial noise such as contact noise, leaking devices that use high frequencies, unwanted emission, and others.

Usually, EMI/RFI noise is common mode noise, so the solution is to eliminate unwanted high frequencies with an EMI filter, either as a separate device or embedded in circuit boards.

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EMI filters EMI filters typically consist of passive components, such as capacitors and inductors, connected to form circuits.

“The inductors allow dc or low-frequency currents to pass through while blocking the harmful unwanted high-frequency currents. The capacitors provide a low-impedance path to divert the high frequency noise away from the input of the filter, either back into the power supply or to the ground connection,” says Christophe Cambrelin of Johanson Dielectrics, a company that manufactures multilayer ceramic capacitors and EMI filters.

Traditional common mode filtering approaches include low pass filters using capacitors that pass signals with a frequency lower than a selected cutoff frequency and attenuates signals with frequencies higher than the cutoff frequency.

A common starting point is to apply a pair of capacitors in a differential configuration, with one capacitor between each trace and ground of the differential input. The capacitive filter in each leg diverts EMI/RFI to ground above a specified cut-off frequency.

Because this configuration involves sending a signal that is opposite in phase through two wires, the signal-to-noise ratio is improved while unwanted noise is sent to ground.

“Unfortunately, the capacitance value of an MLCC with X7R dielectric (typically used for this function), varies significantly with time, bias voltage, and temperature,” says Cambrelin.

“So even if the two capacitors are tightly matched at room temperature, with a low voltage, at a given time, it very likely that they end up with a very different value once time, or voltage, or temperature have changed. This mismatch between the two lines will cause the response near the filter cut-off to be unequal.

Therefore, it will convert common mode noise to differential noise.”

Another solution is to bridge a large value ‘X’ capacitor across the two ‘Y’ capacitors. The ‘X’ capacitor shunt delivers the desired effect of common mode balancing, however, with the undesired side effect of differential signal filtering.

Perhaps the most common solution and an alternative to lowpass filters is the common mode choke.

A common mode choke is a 1:1 transformer where both windings act as both primary and secondary. In this approach, current through one winding induces an opposing current in the other winding.

Unfortunately, common mode chokes are also heavy, expensive, and subject to vibration induced failure.

Still, a suitable common mode choke with perfect matching and coupling between the windings is transparent to differential signals and presents high impedance to common mode noise.

One disadvantage of common mode chokes is the limited frequency range due to parasitic capacitance. For a given core material, the higher the inductance used to obtain lower frequency filtering, the greater the number of turns required and consequent parasitic capacitance that defeats high-frequency filtering.

DESIGN WORLD

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July 2019

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Design Notes Mismatch between windings from mechanical manufacturing tolerance can cause mode conversion, where a percentage of the signal energy converts to common mode noise and vice-versa. This scenario elicits electromagnetic compatibility and immunity issues. Mismatches also reduce the effective inductance in each leg.

Regardless, common mode chokes do have a significant advantage over other options when differential signals (to pass) operate in the same frequency range as the common mode noise that must be suppressed. With a common mode choke, the signal pass band can extend into the common mode reject band.

Monolithic EMI filters Despite the popularity of common mode chokes, an alternative may be monolithic EMI filters. When properly laid out, those multilayer ceramic components provide excellent rejection of common mode noise. They combine two balanced shunt capacitors in a single package, with mutual inductance cancellation and

shielding effect. These filters use two separate electrical pathways within a single device attached to four external connections.

To prevent confusion, it should be noted that a monolithic EMI filter is not a traditional feed-thru capacitor. Although they look identical (same package and external look), their design is very different, and they are not connected in the same way.

Like other EMI filters, monolithic EMI filters attenuate all energy above a specified cut-off frequency and only selecting to pass required signal energy while diverting unwanted noise to “ground.”

The key, however, is the very low inductance and matched impedance.

With monolithic EMI filters, the terminations connect internally to a common reference (shield) electrode within the device, and the plates are

separated by the reference electrode.

Electrostatically, the three electrical nodes are formed by two capacitive halves that share common reference electrodes all contained in a single ceramic body.

The balance between capacitor halves also means piezo-electric effects are equal and opposite, canceling out. This relationhsip also affects temperature and voltage variation, so components age equally on both lines.

If there is a downside to these monolithic EMI filters, it is that they cannot be used if the common mode noise is at the same frequency as the differential signal.

“When this is the case, the common mode choke is a better solution,” says Cambrelin. DW

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Design Notes

User interface enhances monitor for critical medical environments Edited by Mike Santora • Associate Editor

Setra FLEX, a flexible roomenvironment control and monitoring solution, is used in hospital operating rooms, burn units, cleanrooms and other areas where regulating the indoor environment is crucial to help medicalrelated facilities reduce and prevent healthcare-associated infections.

Setra Systems is a manufacturer of pressure transducers, transmitters, capacitive pressure sensors, and acceleration-sensing devices. The products are used in HVAC/R, semiconductor, test and measurement, medical, pharmaceutical, barometric, vacuum, and other industrial markets.

Setra set out to revamp and improve its flexible room-environment control and monitoring solution, which is used in hospital operating rooms, burn units, cleanrooms, and other areas where regulating the indoor environment is crucial. Setra’s differential pressure transducers measure the pressure parameters in these environments, helping hospitals and other medical-related facilities reduce and prevent healthcare-associated infections. (According to the Centers for Disease Control, on any given day, approximately one in 31 hospital patients has at least one healthcare-associated infection.)

Improving the product, the Setra FLEX, required making some essential upgrades, especially to the user interface (UI). The challenge: both medical professionals and the operations personnel charged with monitoring the system had to be able to use the device without any prior training and without needing to consult an operator’s manual to understand how to use it. Ease of use was paramount. Further, the device required a UI inviting enough to appeal to architecture firms and real estate developers that would be willing to recommend Setra FLEX to their clients.

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Without its own in-house user experience (UX) team, Setra knew outside experts were needed to create both highlevel UI and UX design, and to develop the software, which was where the value of the Setra FLEX would lie. Being familiar with Integrated Computer Solutions’ (ICS) Qt development knowledge and their invehicle infotainment system (IVI) work for Intel, Setra enlisted the company for the project. Setra was looking for a solution with: ● ● ● ● ● ● ●

Information Architecture Interactive Prototype Gesture Interaction Spec Development-Ready Assets Iconography Visual Screen Comps Visual Style/Layout Specs

Setra envisioned its new product to be intuitive and easy to navigate by two distinct audiences without prior training.

That meant figuring out how to best configure the device, as well as how to present complex data in a way that could be read quickly and understood with ease.

ICS analyzed Voice-of-the-Customer data and created personas to help them understand what users are trying to accomplish, what goals drive their behavior, and how they make decisions.

In other words, provide the researchedbacked context that would make it possible for Setra to deliver a product that filled a real need and would be embraced by the target audiences.

From there, the ICS design team created wireframes to flesh out the ideas and help guide the decision making.

Throughout the process, the team kept both of the audiences (medical professionals, and installers, and maintenance workers) in mind to design and deliver a device that what would make sense to them.

The UX team also paid attention to the visual design, including the treatment of parameter badges, background colors, icons, alarms, and room status among other elements, to ensure it met the needs of both user audiences. Further, the team carefully designed the UI so critical status information could be easily read from a distance and detailed data up close.

The design of the navigation features a large condition banner and an array of parameters that can be shifted laterally by touch to reveal additional readings.

Emphasizing functionality and legibility, the ICS team incorporated the ability to view and analyze data from multiple rooms connected to the system. The design also incorporates creative use of gestures, such as swiping, to make it easy for users to navigate quickly.

With development and UX design complete, Setra FLEX was sent off for testing. The response was positive, reinforcing that the team was on the right path. Users were able to navigate with ease and found the interface attractive and informative without being too complicated — precisely the goal for the UI. DW

ICS | www.ics.com

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The Design Challenge: both medical professionals and the operations personnel monitoring the system had to be able to use the device without any prior training. © 2019 by AMETEK Inc. All rights reserved.

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Design Notes

Handling coupling complications in sliding vane pumps Edited by Mike Santora • Associate Editor

Since introducing Blackmer to its no-coupling concept (GNX with gearbox) NORD has become pump manufacturers primary gearbox supplier.

Tom Koren, the director of engineering at NORD Gear Corporation in Waunakee, Wis., approached a potential customer with a way to significantly improve one of its product lines.

He and the NORD sales team had been calling on them for years with little success, but the idea was so compelling that the company — Blackmer, Grand Rapids, Mich., a product brand of PSG, Oakbrook Terrace, Ill., a Dover company — is now a business partner, and has made plans to incorporate NORD’s concept into all of its Blackmer brand of pumps.

The idea? Eliminate the one component that causes the greatest amount of grief in a typical pump drive application — the coupling.

“For the previous five or six years, I’d been thinking about developing a hollow socket shaft design for our inline speed reducers,” Koren said. “So, when we heard Blackmer was looking at a redesign on one of its sliding vane pump families, it was an opportunity for us to present the no-coupling concept of directly interfacing their pump with our speed reducer. They agreed to test it, and here we are today as their main gearbox supplier.”

PSG product manager Geoff VanLeeuwen said there were several good reasons to adopt the hollow socket design. “Anytime you have two mating shafts, they must be kept in alignment — if not, you end up with additional load and possibly vibration that will reduce the life of that product,” he explained. “The problem with a traditional pump and motor arrangement is that a coupling is used to join them. Even a skilled technician needs a fair amount of time to get the different pieces shimmed, tweaked, and aligned properly. The effort is required not only during the initial installation but also whenever routine maintenance is performed.”

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The industry has been dealing with this aligned coupling challenge for as long as there’ve been electric pumps, VanLeeuwen noted. But as competition grows and skilled technicians become scarce, those responsible for plant operations often settle for a quick “eyeball it as best you can” approach to shaft alignment, accepting the fact that pump life will suffer as a result.

“Companies need to make money,” he said. “In a typical chemical plant or rail terminal, for example, you could be facing hundreds of dollars per hour of lost productivity if a pump goes down, and possibly far more than that. So, they’ll do whatever it takes to get up and running quickly. The problem of poor maintenance has a snowball effect.

Instead of spending a couple of hours to properly align a pump, suddenly you have a day or two of unexpected downtime when the coupling fails or the pump seizes, just because someone was rushed.

Our new GNX alignment-free pumps eliminate all that.”

Blackmer also made installation much easier. Because the new design is essentially plug and play, the amount of integration work required by the customer facility has dropped to nearly zero, VanLeeuwen said. “So instead of 15%of our pumps being sold as turnkey solutions, that figure increased to 72% last year.”

Blackmer is just getting started.

The first phase of their GNX- and GNXH-series rollout – now complete — focused on its 2- and 2.5-in. flange pumps. Using a NORD SK 771.1 gear unit directly coupled to a Blackmer heavyduty, self-adjusting sliding vane pumps, the self-contained units offer maximum flow capacities of 86 gpm (325 L/min) and 155 gpm (587 L/min) respectively.

Phases II and III (which VanLeeuwen expects will be completed over the next six months) will extend to the Blackmer larger frame 3- and 4-inch pumps, boasting up to 50 hp and 500 gpm (1,893 L/min).

NORD is also busy rolling out new products. NORD’s single-stage inline helical gear unit line (used with the Blackmer GNX- and GNXH-series pumps) will be expanded with three larger products — the SK 871.1, SK 971.1 and SK 1071.1. Each is available with NORD’s exclusive hollow-socket option.

The NORD gear unit series is suitable for virtually any high-speed pumping, mixing, or conveying application. Unlike the aluminum alloy construction of the smaller single-stage products, the three new gear units feature cast iron housings.

The NORD output torque ranges from 3,540 to 8,850 lb-in with gear ratios from 1.4:1 to 8.1:1 and a power range of 1.5 to 60 hp. Mounted by

The first phase of the Blackmer GNX and GNXHseries rollout — now complete —focused on its 2 and 2.5-in. flange pumps. Phases II and III will extend to their larger frame 3 and 4-in. pumps.

DESIGN WORLD

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July 2019

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Design Notes a choice of foot-mount, IEC flangemount (B5 or B14), foot/flange mount and NEMA standard output flange and shaft, the gear units provide the flexibility for customers to specify these drive solutions for countless applications.

These units replace NORD’s SK 41E and SK 51E. Plus, they’re interchangeable with other European-designed gear units.

Koren explained these and other NORD gear reducers offer a long list of standard features, including a robust one-piece UNICASE housing, Autovent pressure regulation, and high-strength, high-precision carburized gearing and high-capacity bearings.

For extreme shaft and bearing loads, customers have the option of upgrading to twin-tapered roller bearings and a higher-strength alloy steel shaft. Plus, for corrosive environments or where routine wash-downs are needed, NORD’s exclusive NSD TUPH aluminum

alloy surface conversion solution was developed as a cost-effective alternative to stainless steel gearmotors. (NSD TUPH is available for NORD’s single stage gear units through size 771.1) “What differentiates NORD from the competition are high-quality products, short lead times, and excellent customer support,” said Koren. “We’re probably not the least expensive supplier. But as illustrated in our relationship with Blackmer, our solutions are extremely innovative and we’re a good business partner.”

VanLeeuwen agreed, summarizing the relationship like this: “NORD was willing to dedicate time and resources to solve a specific problem faced by everyone in this industry.” He laughed.

“The ironic part is we didn’t really invent anything. People have been using motors, gearboxes and pumps for decades. What makes our solution

so effective is the way we paired them together. It’s been so successful that we’ve decided to gradually phase out all of our own gear units in favor of NORD’s.

As proven leaders, Blackmer and NORD offer the new industry standard for pump unit assemblies. It eliminates unexpected downtime and simplifies installation and maintenance tasks. Plus, installations benefit from noticeable improvements in uptime and ease-of-use. Welcome to the new normal of pump reliability.” DW

NORD | www.nord.com

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The latest version of Solid Edge software has many enhancements, including augmented reality, expanded validation tools, model-based definition and 2D Nesting. Solid Edge 2020 includes next generation technologies to enhance collaboration and digitalize the design-to-manufacturing process.

The software delivers augmented reality capabilities that enable users to visualize design intent in new ways, enabling enhanced collaboration internally, as well as with suppliers and customers during the design process. New validation tools have been integrated for conducting motion and vibration simulation, which can help customers reduce prototypes. The addition of Model Based Definition

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lets users completely define parts, assemblies and manufacturing instructions digitally from their 3D model. 2D Nesting capabilities have been added to optimize cutting patterns, reduce waste and costs, and accelerate manufacturing processes.

Solid Edge 2020 also delivers hundreds of core CAD enhancements such as new sheet metal capabilities, 3 - 10x faster large assembly performance, new data migration tools, and others across the portfolio. DW

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CAE Solutions More modeling scope available in MapleSim 2019

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From digital twins for virtual commissioning to system-level models for complex engineering design projects, MapleSim helps organizations reduce development risk, lower costs, and enable innovation. The latest release improves performance, increases modeling scope, and offers more ways to connect to an existing toolchain.

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Simulation is faster in MapleSim 2019 due to more efficient handling of constraints when preparing the model, resulting in more compact, faster simulation code without any loss of fidelity. In addition, models developed in MapleSim and then exported for use in other tools also run faster in the target applications.

New built-in and add-on components and expanded support for external libraries means that engineers can create more models, faster, in MapleSim 2019. The release expands the scope of models that can be created using pre-existing components, with additions to hydraulics, electrical, multibody, and more.

The MapleSim Engine Dynamics Library from Modelon is a new add-on library with specialized tools for modeling, simulating, and analyzing the performance of combustion engines. This component library is especially useful for representing transient engine responses, and can be used for analyzing engine performance, performing emission studies, controls development, hardware-in-the-loop verification of vehicle electronic control units, and more.

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CAE Solutions 7-19_Vs3.LL.indd 44

MapleSim 2019 offers advances in toolchain integration. Improvements include additional options for FMI connectivity, including support for variable-step solvers, as well as fixed-step, for running imported models in MapleSim and exporting models to other tools. In addition, the new B&R MapleSim Connector add-on gives automation projects model-based ability to test and visualize control strategies from within B&R Automation Studio, and to export simulation data for motor, servo, and gearbox sizing within SERVOsoft.

MapleSim is available in English, Japanese, and French. DW

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and AI-driven product development platform. The release expands on the number of solutions available for designers and engineers, under a single, open-architecture platform, to speed decision-making and time to market.

“We want to help our customers explore more ideas, better understand their designs, and improve profitability,” said James Scapa, Altair’s chief executive officer and founder. “Our development focus for HyperWorks 2019 was to increase the solve speed and functionality across our solutions for every stage of product development with optimization and multi-physics workflows for all manufacturing methods.”

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• Easy-to-learn fatigue life prediction

Altair HyperLife enables customers to quickly understand potential durability issues through an easy-to-learn solution for fatigue life under static, transient and vibrational loading.

The intuitive user experience enables test engineers to perform simulations with little or no training. HyperLife helps customers to confidently predict product durability in hours, complementing physical testing, which can take months.

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CAE Solutions • Efficient workflows for multi-physics

Altair SimLab is an intuitive workflow platform for simulating multi-physics problems. Automatic feature and part recognition can make simulation cycles more than five times faster. Design exploration is easier with synching to popular CAD tools. The multi-physics workflows feature deeply embedded solvers; including statics, dynamics, heat transfer, fluid flow, electromagnetics analysis, fluid-structure interaction, and electromagnetic-thermal coupling.

• Superior high-fidelity modeling

HyperWorks 2019 includes the most robust Altair HyperMesh version yet. New features enable the generation of the largest, most complex finite element models. The model build and assembly tools in HyperMesh make managing large, complex assemblies easier than ever. This allows CAE to keep pace with design changes by rapidly swapping new parts and assemblies into existing models, managing multiple configurations, mesh variants and part instances. The direct mid-mesh generation makes it possible to create shell meshes straight from solid geometry of complex castings and injection molded parts.

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• Enhanced user experience for fast concept modeling

The HyperWorks platform already includes Altair Inspire, Altair Activate and SimLab delivering class-leading solutions with intuitive and consistent user-interfaces. In this release Altair HyperWorks X is included with a new set of workflows for geometry creation, editing, morphing and meshing employing this same user experience. The easy-to-learn mesh morphing features of HyperWorks X will bring efficiency to teams working on simulation models early in product development. These workflows enable concept level changes to be made directly on an existing FEA model bypassing CAD generation and accelerating decision-making.

• Expanded non-linear solver functionality

Analysis with Altair OptiStruct is increasing at companies performing stiffness, strength and fatigue-life simulations; fueled by the significant process improvement it provides. The singlemodel, multi-attribute workflow enabled by OptiStruct delivers time and cost savings. Design decisions can be made faster by engineers performing linear, non-linear, and durability analysis - using one optimization-ready model. DW

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Internet of Things

Accelerate mmWave 5G wireless development

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Millimeter-wave 5G is an emerging technology with great potential. But it

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

The mmWave 5G chipset offers a high level of integration to reduce design requirements and complexity in the next generation of cellular network infrastructure. The chipset combines the beamformer IC from Analog Devices, up/ down frequency conversion (UDC), and additional mixed signal circuitry.

The chipset includes the 16-channel ADMV4821 dual/single polarization beamformer IC, 16-channel ADMV4801 single-polarization beamformer IC and the ADMV1017 mmWave UDC. The 24- to 30-GHz beamforming + UDC solution forms a

3GPP 5G NR compliant mmWave frontend to address the n261, n257 and n258 bands. The high channel density, coupled with the ability to support single- and dual-polarization deployments, increases system flexibility and reconfigurability for multiple 5G use cases, while isotropically radiated power (EIRP) extends radio range and density. DW

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Power over Ethernet injector delivers 60 W of power to end devices

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The INJ-0200G-60-24-T is an industrial high-power IEEE 802.3bt Type 3 Power over Ethernet (PoE) injector that is backwards compatible with previous IEEE 802.3af/at standards. By using multiple pairs of pins on the RJ45 cable, this industrial grade PoE injector delivers up to 60 Watts of power to end devices. Each port supports 10/100/1000Tx for both power in and data out.

The INJ-0200G-60-24-T is IP30 rated, DIN-rail mountable, and supports an extended temperature of -40°C to 75°C, making it ideal for outdoor or harsh industrial applications. DW

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Build sensor prototypes for IIoT networks

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MYTHINGS is a wireless IIoT connectivity brand and product family that will simplify and

accelerate the deployment of robust, scalable, and integrable Low Power Wide Area Networks (LPWAN). The MYTHINGS software platform implements MIOTY (TS UNB), and complies with the ETSI standard TS 103-357.

MYTHINGS was created to facilitate full-scale LPWAN deployments in demanding industrial and commercial environments. Because the MIOTY protocol is at the core of MYTHINGS, LPWAN networks can be implemented for long-range communication. The family has long battery life and high interference immunity.

The MYTHINGS Module is a pre-configured rapid prototyping module running the MYTHINGS Library – a small footprint and power-optimized source code for IoT end nodes featuring MIOTY software. Addressing the need for reliable and cost-effective sensor connectivity, the MYTHINGS Module will enable systems integrators, VARs, technology vendors, and companies in an array of industries to build their own sensor prototypes for IIoT networks, enabling fast, simple, and flexible testing and deployment.

The MYTHINGS Module complies with the mikroBUS add-on board open standard design. By specifying the physical layout of microcontrollers or microprocessors (mainboards) and compatible integrated circuits and modules (add-on boards), the mikroBUS standard enables easy, flexible hardware design and development with a growing ecosystem of standard development and add-on boards.

Leveraging a portfolio of more than 600 available mikroBUS click boards, businesses can mix and match the MYTHINGS Module with relevant sensors, interfaces, displays, amplifiers, and more to rapidly and cost-effectively build a customized end-node for a variety of use cases and deployments. DW

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Internet of Things

Accelerate AI at the edge

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This product line is based on NVIDIA technology from the AI edge to the cloud. On the edge, three AI edge products work with the NVIDIA Jetson platform: MIC-710IVA, MIC-720AI, and MIC-730AI for smart manufacturing applications.

These integrated systems allow AI application developers to rapidly create unique AI solutions based on Jetson.

For the AI cloud, the SKY-6000 series servers with NVIDIA GPUs provide highdensity solutions for the big data era. But these solutions resolve thermal issues from high-density GPU computing. The NVIDIA T4 GPU qualification shows that the GPU servers have better temperature control and thermal management. DW Advantech | www.advantech.com

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Performance and health monitoring of motors and loads Siemens and Veros Systems have interfaced Veros ForeSight technology with Siemens Large Drives for performance and health monitoring of motors and the assets they drive, all without installing any sensors on the rotating assets themselves.

The system uses MindSphere, the cloud-based IoT operating system, which allows users to connect products, plants, systems, and machines, and enables users to harness the wealth of that data with advanced analytics. SIDRIVE IQ in MindSphere is a digital platform for optimizing drive systems.

“Siemens envisions a future of using existing variable speed drives and other power distribution equipment to not only provide power to motors, but to continuously monitor industrial equipment performance and health,” says Scott Conner, General Manager, Siemens Medium Voltage Drives. Being able to monitor motors and equipment without the need for additional sensors

will accelerate the adoption of equipment analytics, reduce the cost/risk of unexpected equipment downtime, improve operational productivity, and help reduce global energy consumption.

Veros Systems, based in Austin, Texas, developed machine learning algorithms that learn how motors typically perform and alarm when they see an anomaly. Advanced technology employing artificial intelligence (AI) principles builds a model for how each particular motor and load (compressor, pump, fan, etc.) normally function across a range of operating conditions. Many types of developing mechanical and electrical degradations in the equipment subtly affect the motor’s current and voltage waveforms. Veros technology is designed to detect these changes and issue alarm messages providing early warning of developing problems. DW

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standard that promises to get at real-world levels of precision in motion control systems.

Bill Hennessey • CEO/Founder • ALIO Industries

Technological advancements often require a root and branch change in the language and nature of discussion associated with them.

Consider the case of electricity. When it became available in every home, it would have been unrealistic and not helpful if people continued to talk in terms of preferred candles rather than the relative luminescence and longevity of various forms of light bulbs. Likewise, when the automobile began to emerge and eventually replaced the horse and cart as the most efficient form of transportation, the discussion naturally switched from the best hay to feed the horse to the merits of different forms of internal combustion.

Without stretching this analogy to a breaking point, there is a similar shift in the area of motion control. Emerging new technologies push the boundaries of what is deemed possible in terms of precision to such an extent that the language surrounding the technology has to change, and the nature of the conversation needs to shift in order to differentiate this new technology from standard industry alternatives.

Over the last several decades, there has been more interest in hexapods to cater to the increased demand for micron and sub-micron level precision in multi-axis motion applications.

Hexapod motion control technology exists at the ultra-precision end of motion control, and it has become the best-in-class motion control solution for exacting industrial applications.

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The ALIO patented Hybrid Hexapod has a 3D point precision of less than 100 nm repeatability anywhere in its full work zone. With that information, users with a demanding metrology application can be extremely confident in their uncertainty measurement error quotient.

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M o t i o n

C o n t r o l

The burgeoning area of more precise motion control is driven by industry demand for technologies that will improve production processes. The emphasis from across industry is for smarter, smaller, and faster precision motion control and positioning equipment, and demand is especially high in areas like laser micro machining, micro assembly automation, optical inspection, semiconductor metrology, and photonics component test and alignment applications.

One key area of focus is how motion control process suppliers describe the level of precision achievable. Standard industry vernacular talks in terms of micron and sub-micron precision, but the idea of Point Precision is a new and more effective methodology of measuring and quantifying motion systems.

What does precision really mean?

Often times, the way the word “precise” is used in the motion control industry can be vague. Similar confusion surrounds terms like “resolution” and “accuracy” which are often deployed to imply that one’s product offers superior precision or accuracy.

In the area of motion control the focus should and must be on much more exacting criteria, by which we mean repeatability and accuracy. Also, what is often the case is that

Repeatability of a functional point attached to a linear or angular motion axis is commonly specified as a onedimensional linear measurement.

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SPHERICAL PERFORMANCE RANGE

TARGET POSITION

ISO VIEW

The concept of Point Precision incorporates all sources of error at any desired work location into a meaningful 3-dimensional value.

claims of precision for standard hexapods are based on best or ideal conditions, typically unidirectional one axis numbers.

These figures typically don’t factor in all of the six-axis error quotients or the backlash, which is the total error of all motion due to the compression and tension of each leg for every move. This can make claims about precision highly suspect. However, giving precision or accuracy figures with reference to terms such as micron, sub-micron, or nano precision provides more insight into the level of precision being claimed.

Point Precision: the basics The concept of Point Precision includes all six degrees of freedom of errors of each axis in motion, guaranteeing the precision point in the full work envelope.

Here’s how it works: Repeatability of a functional point attached to a linear or angular motion axis is commonly specified as a onedimensional linear measurement. However, the three-dimensional repeatability of a functional point (linear, straightness, and flatness repeatability) is critical for many applications. Characterizing the repeatability of a functional point in three-dimensional space at specified target positions can be achieved using existing methods and equipment. For example, 6D laser measurement system, laser tracker, straightedge, angular interferometer, etc.

However, the measurement uncertainty

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IMPERFECT REAL AXIS

may be too high, the equipment may be too expensive and too large, and with some methods and equipment, it may be too time consuming to measure the repeatability in three directions.

The concept of “point repeatability” is a measure of repeatability in three dimensional space and presents a simplified method for quickly characterizing this repeatability in three directions (X,Y,Z) using displacement sensors. The method enables characterization of repeatability of target positions at the nanometer level with appropriate uncertainty ratios. Test setup and equipment are common, cost effective, and can quickly be setup to test high precision angular and linear axes.

This method is presented for single-axis systems. However, the potential application to multi-axis systems is also noted because it captures statistically significant repeatability errors that are often neglected when a multi-axis system is characterized on a per axis basis.

Each axis of a motion system has errors in six degrees of freedom, and all error sources are statistically significant when characterizing the repeatability of a point in three-dimensional space. The test method is designed to be a simplified method focused on collecting the X, Y, and Z distributions of the repeatability data of a few target positions of a functional point attached to a stage.

So point repeatability can be defined as a measure of the ability of a motion system DESIGN WORLD

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Custom Engineered Linear Slides A representation of the X, Y, and Z repeatability components of a functional point attached to a motion carriage.

to sequentially position a functional point fixed to a stage to a target position with respect to a fixed three-dimensional reference frame.

Over many cycles, the test point locations will create a three-dimensional distribution of points and the shape of the distribution will vary from stage to stage or manufacturer to manufacturer. The point repeatability tolerance zone is the three-dimensional tolerance zone characterized by the X, Y, and Z components of the repeatability performance around a target position of a point repeatability test. The X, Y, and Z components are all presented so the actual tolerance zone geometry and distribution is known.

Summary There are numerous companies working in the area of micro and nano manufacturing providing industry with solutions that stimulate innovation and advance the chances of achieving success in ever more exacting precision engineering applications. They strive to provide technology solutions that facilitate greater precision, which is consistently demanded across industry.

ALIO has adopted a new approach to address the lack of clarity that exists specifically in the area of motion control solutions. Together with the NIST, the creation of the Point Precision standard will provide the future standard methodology of measuring and quantifying motion systems in the area of nanometer precision. DW

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M o t i o n

Using software for designing and sizing motion-control systems

Today servomotors abound. Thankfully the art of using speed, torque, and inertia to select from these servomotor offerings for specific applications has become quite automated.

N

Sixto Moralez • Regional motion engineer • Yaskawa America Inc. Drives & Motion Div.

Now, certain sizing and selecting software only requires that

design engineers enter a minimum of data to identify a plethora of servomotor products suitable for the motion design at hand. In this article, we illustrate how the process works by using one advanced software tool and walking through the steps of a specific example.

Motion system design Step 1: Mechanical selection Most machine builds can be modeled as basic mechanisms. Some software is preprogrammed to ask for the machine-axis mechanism type and then send the engineer to a set of fields to define its parameters.

Case in point: One common power-transmission device for linear motion is

the ballscrew. Most ballscrew-based designs employ a rotary servomotor that is coupled to the ballscrew by a flexible aluminum coupling. Then the linear drive moves a load carriage that slides on linear rails to move a payload back and forth. Let’s use this example through the remainder of this article.

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Chain and sprocket software parameters External force Chain mass

+

Belt software parameters

–

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Chain and sprocket software parameters

Load mass

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+

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–

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+

+

+– Sprocket Sprocket – + Driver Driver – • Inertia • Inertia Belt mass • Inertia • Inertia Direction of motion Belt mass External force Direction of motion • Diameter • Diameter • Diameter + – • Diameter Direction of motion Direction of motion Sprocket Direction of motion Driver table software parameters Direction of motion Rotation Sprocket • InertiaDirection Sprocket motion Belt mass Driver Sprocket ofparameters Linear-motor software Driver • Inertia Direction of motion Driver • Inertia • Inertia • Diameter Sprocket table software parameters Belt mass Additional mass Belt Rotation • Inertia • Inertia • Inertia Direction of motion of motion Driver •mass Diameter Belt mass • Inertia Rotating inertia Direction of Direction motion • Diameter • Diameter • Inertia Direction of motion Linear-motor software parameters Offset • Diameter Belt mass • Diameter • Inertia Direction of motion • Diameter Sprocket • Diameter • Diameter External force Slide mass Driver Additional mass • Diameter •Load Inertia Belt mass Rotation mass + • Inertia Direction of motion Rotating inertia table software parameters • Diameter Offset parameters – Rotation table parameters software • Diameter Linear-motor software parameters Rotation table software Rotation table software parameters Linear-motor software parameters External force Slide mass Rotation table Additional masssoftware parameters Linear-motor software parameters Linear-motor software parameters Additional mass Rotating inertia Linear-motor software parameters Load mass + Additional mass Offset Rotation table software parameters Rotating inertia Additional mass Offset Rotating inertia Additional mass Linear-motor softwareExternal parameters Offset force– Rotating inertia Slide mass Rotating inertia External force Slide Additional mass Offset mass Offset External+ force Slide mass Load mass Rotating inertia Load mass + External force Slide mass Offset External force Slide mass Load mass + – Load mass Load mass + External force Slide –mass+ –

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+

–

–

Friction surface

–

• Direction of motion • External torque

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Roll feeder software parameters

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+

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–

+

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+

–

+

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Ballscrew software parameters

+ + Connecting rod + –length

–

External force

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+

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• Inertia •Driver Diameter

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External force

Rack-and-pinion software parameters • Inertia Rack-and-pinion software parameters mass Yaskawa’s SigmaSelect Rack-and-pinion parameters Pinion softwareLoad Friction surface Load mass • Diameter • Pitch circle diameter

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– Ballscrew software parameters +

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–

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Loadsoftware mass is an efficient tool

• Inertia

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Rack-and-pinion software parameters External force

–

for selecting specific series

+ of motors to for an array Ballscrew External force – External force – + • Pitch motion system External–force+ Rack-and-pinion softwareof parameters Load designs. mass • Inertia Rack mass + –

It’s faster and more precise

+

• Inertia

Rack mass

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Load mass

Rack massdesign-engineering tasks

– Side mass Ballscrew using a trial-and-error + Friction surface • PitchPinion External force • Pitch circle diameter approach. Circled in red is Pinion • Inertia Ballscrew • Inertia – Friction surface Direction of circle motiondiameter Pinion • Pitch the ballscrew + Friction surface • Pitch Rackmechanism mass Pinion • Pitch circle•diameter Inertia Friction surface Direction of motion Direction of motion we use for our example circle diameter • Inertia• Pitch • Inertia Pinion Direction of motion Friction surface • Inertia calculations.

Direction of motion• Pitch circle diameter Rack mass Direction of motion

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Pinion • Pitch circle diameter Pinion • Inertia Friction surface motion www.designworldonline.com • Pitch circle diameter Direction ofJuly 2019 • Inertia Direction of motion Direction of motion

Friction surface DESIGN WORLD

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Total load and slide mass — entering data on ballscrew in the software Load mass

Side mass

External force –

Ballscrew • Pitch • Inertia

+

Friction surface

Direction of motion

System inertia calculator Ballscrew lead

Motion system design Step 2: Gathering and entering data Getting information from end users or potential customers can sometimes be challenging. However, design software gives engineers in this position the ability to visually see and enter data as it becomes available. Then the software automatically identifies which servomotors are capable of serving as the motion input for the application. Assuming our ballscrewdriven arrangement, these parameters include total load and slide mass, which is usually a combined number … but can be based on various parameters upon which

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separate load mass and slide mass values are based. Refer to the software screenshot titled, “Total load and slide mass — entering data on ballscrew in the software” for example values.

After entering these first values, the engineer should factor the inertia of the ballscrew into the design. If this isn’t given by the customer or manufacturer, use the software’s ballscrew inertia calculator to determine the inertia of the ballscrew.

Then the engineer should enter the lead of the ballscrew. This is the number of units (inches or millimeters) the ballscrew travels in one revolution.

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After inertia and lead values are set, the engineer should define the application’s move profile. Here, he or she enters the distance to move and in what amount of time — including any dwells or pauses. It is also good practice to enter a return move.

Motion system design Step 3: Selecting a motor With all the information entered, sometimes design software will return a sizable list of servomotors that are suitable for the application.

In this case, if cost is an issue (and it usually is) sort the suggested motor results DESIGN WORLD

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Selecting a motor that is suitable for the linear axis

Yaskawa’s SigmaSelect software lets engineers see the design’s cost factor in relation to the factor of safety. Note that a 10% increase in initial investment can give the application an additional 20% for its factor of safety. Also note that sometimes selecting a motor with only 6% higher cost than another option can provide more than twice the performance of the less expensive option.

Cost factor versus factor of safety

Allowable inertia

Speed and torque

Regarding the speed and torque values: If the application requires more speed but not a lot of torque, an engineer employing the above data should choose SGM7J or SGM7A motors.

Conversely, if the application requires more torque and not a lot of speed, an engineer employing the above data should choose an SGM7G motor. Some applications can have dimensional constraints; these would benefit from the specification of SGM7P servomotors.

Software determines whether a regenerative drive is required

SigmaSelect software will indicate if a design needs a regenerative resistor and what capacity should be selected. For more information on regeneration, please read Don’t forget these two things when selecting an amplifier for a servo-motion application on motioncontroltips.com.

The software will also prompt selection of a compatible power input and SERVOPACK amplifier (with analog-pulse capabilities and EtherCAT and Mechatrolink-III connectivity) for the application.

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M o t i o n Software-calculated move profile

For our example ballscrew-based design, the engineer enters load and carriage-slide masses as well as system inertia and ballscrew lead.

by the cost factor to find the lowest (initial) cost servomotor that will satisfy the application requirements.

Something else to leverage in some software is the ability to corollate the design’s cost factor to the factor of safety. In many cases, spending just 10% more on the initial servomotor purchase can give the application an additional 20% on its factor of safety.

Upsizing in this way allows for future scope creep — a common occurrence for motion systems.

Next, verify that the inertia ratio is at or below the allowable inertia ratio number. Refer to the software screenshot labeled “Allowable inertia” for an example of how these results appear — in this case, highlighted in green in the allowable inertia-ratio column. For our ballscrew-based design and motor selected in the screenshot, the design’s load inertia ratio divided by the servomotor’s motor inertia is 44% — which is great for the application.

Third, verify the speed and torque of the application is at or under the motor’s maximum allowable values. (Motor manufacturers offer different series of servomotors for different applications to make this step easier.) Note in the screenshot

labeled “Speed and torque” that our chosen motor’s speed and torque ratings exceed those of our application.

Motion system design Step 4: Account for power-transmission assembly additions Let’s say the motor chosen is an expensive servomotor. Remember, our sizing was done as a servomotor directly coupled to the ballscrew. But what if the application can accept the use of a gearbox with a 5:1 ratio? No worries because the design software is flexible and lets the engineer go back and enter new data. Let’s enter the following for the gearbox characteristics: Ratio (input to output) for 5:1 gear ratio in the software is entered as 0.2. Inertia can be in in.lb × sec2 or kg × m2 and efficiency is typically between 95% to 97% or so.

Then the engineer goes back to the motor selection to choose a different servomotor. Oftentimes this step will result in a selection of a smaller servomotor, because gearboxes multiply the torque by the ratio number; reduce the inertia by the square of the ratio; and help the design stay within the application’s speed constraints.

Adding a gearbox to the design

Choosing a servomotor for an application doesn’t have to be tedious. Yaskawa SigmaSelect software simplifies the process by requiring the entering of some data to yield servomotor suggestions to share with the end user. Engineers can even enter new data — as in this instance on a load editor tab where he or she may go back and insert gearbox characteristics if one is added to the machine build later in the design process.

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M o t i o n

Software outputs reports for sharing with OEM or end user

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Report generation with SigmaSelect software includes a simple PDF icon that prompts the output of a six-page report. Such design summaries are easy to share with OEMs and end users so they can verify all data.

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Motion system design Step 5: Regeneration and drive requirements Software from some manufacturers will indicate if a regenerative resistor is needed and what capacity should be selected. Some will also list compatible drives with sufficient networking and connectivity features.

Motion system design Step 6: Generating reports for sharing Most servomotor sizing and selecting software includes the ability to output full design reports to share with clients for data verification. DW Yaskawa America Inc. yaskawa.com/products/motion/sigma-7-servo-products

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Case-carburized bearings are highly resistant to shock loads and debris and have been used in modular transporters for decades.

Contributing significantly to the heavy haulers’ smooth and reliable operation, the bearings are engineered to meet the demands arising from the substantial kinetic and braking forces that can occur in a variety of steering positions during transporter operation — especially when traversing rocky, rugged terrain.

Case-carburized bearings are highly resistant to shock loads and debris and have been used in modular transporters for decades. Compared to through-hardened bearings (which have a brittle center and are more prone to crack failures), casecarburized bearings have a hard shell and a soft core, allowing them to absorb impacts better.

Most SCHEUERLE transporters have several wheelsets that allow the vehicles to negotiate tight angles and uneven surfaces while keeping the load horizontal. This functionality is achieved by the arrangement of the wheels — with knees to adjust the distance between wheel and platform and pivots to allow to turn the vehicle at the place. For the ALMA move, keeping the telescope antennas stable, upright and intact was critical to the success of the mission. Even a single failure of the pivot-and-knee bearings in the wheelsets could jeopardize years of careful planning and execution.

Engineers discussed how the unique operating conditions in the Chilean Andes demanded more than a standard bearing solution. As obstacles like rocks, cracks, and crevices could create significant shock loads on the way up the mountain, SCHEUERLE needed bearings that offered a high static capacity to handle the massive loads. Repeated trips to and from the maintenance center to the

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Figure 1: Enhanced finishing technology can result in up to four times improvement in bearing life versus standard bearings by smoothing and reducing the height of surface contact asperities.

Figure 2: Enhanced profile technology can result in up to four times improvement in bearing life by providing added, incremental support to edge-of-contact loading for more evenly distributed stress.

project site would also require a profiled bearing that could better resist premature damage and wear.

The P900 tapered roller bearing was specified for the ALMA transporters.

Manufactured from super-clean steel, these bearings have special finishes on the rollers, cones, and cups to reduce surface-related modes of damage and improve fatigue life (see Figure 1), as well as advanced geometry profiles to eliminate edge stress concentrations caused by high load or misalignment (see Figure 2).

P900 bearings are mainly distinguished by their surfaces’ multiple-radius dub profile (MRD). For this application the offroad demands on the ALMA transporters translated to high radial loads and lateral accelerations — stresses that could make precise wheel positioning difficult and cause standard bearings to fail prematurely.

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In response, the P900 bearings were customized to meet the requirements for a durable wheel-end solution that could conquer the steep climb. Each wheel’s pivot-bearing arrangement has a total load-carrying capacity of 18 metric tons.

The bearings are designed to scope with a 50% overload and lateral loads up to 9 metric tons. While under normal operating conditions these loads are extreme, they are frequent under the specific operating conditions of the ALMA transporters — hence the need for the special profile.

The transporters were eventually positioned with all 66 high-precision antennas and the bearings have continued to endure the chilly plateau-top conditions in the years since. DW Timken | Timken.com

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E l e c t r o n i c s

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Keeping out the

bad guys

To keep hackers from wreaking havoc in industrial networks, modern controllers employ measures that go far beyond ordinary firewalls.

A few years ago, viewers of a TV series called Mr. Robot watched the main character try to destroy mag tape backups held at a data facility that was portrayed as both well-fortified and remote. The idea was to raise the temperature of the storage room enough

Laura Dickinson | Wago Corp.

to melt the tapes. The plan called for connecting an ordinary Raspberry Pi computer board into the climate control system that would simply override climate commands from the building automation controller.

With the Raspberry Pi installed, the main character (Elliot Alderson) was able to access the HVAC system from an ordinary laptop with an internet connection using a real-life website called Shodan (www.shodan.io), a search engine that lets users find not just HVAC systems but also routers, servers, and other equipment connected to the internet. Shodan finds these unprotected devices by crawling the internet rooking for IP addresses with open ports. It can find computer-controlled HVAC systems if they’ve been plugged into a company web server that reaches the internet. (Conversely, Shodan won’t see HVAC systems operating on their own closed networks.)

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The Mr. Robot hack worked without a hitch. In fact, it came off so flawlessly that viewers probably wondered about the cybersecurity of real industrial networks. Can hackers or technical glitches compromise servers this easily?

Part of the problem is that the original development of widely used fieldbus protocols, which took place long before the advent of the internet, proceeded with no thoughts about security. Those systems were designed for ease-of-use and operational reliability which often led to the creation of vulnerable access points for external attackers.

But that doesn’t mean modern industrial networks can’t be rendered close to bulletproof. To get an idea of what’s possible, consider the security measures implemented by Wago’s PFC family of controllers. Security techniques that PFC100 and PFC200 controllers implement can serve as examples of the safeguards modern industrial networks can employ.

A few basic security terms might be worth explaining. TLS is an acronym for “Transport Layer Security,” which is the protocol that allows digital devices (such as computers and phones) to communicate over the internet securely without the transmission being vulnerable to an outside audience. Since last year, websites that process credit card payments have had to use the latest version, TLS 1.2.

A computer firewall is a software program that inspects each individual “packet” of data inbound to or outbound from a computer to determine whether it should be allowed to pass or be blocked.

Firewalls can also control what types of system functions and processes have access to networking resources. In that case, firewalls can use various types of signatures and host conditions to allow or deny traffic.

A VPN (virtual private network) is a service that lets you access the web safely and privately by routing your connection through a server and hiding your online

To keep hackers from wreaking havoc in industrial networks, modern industrial controllers employ measures that go far beyond ordinary firewalls.

“Our devices have security measures built-in that are unlike those of other products on the market,” Charlie Norz, Wago Automation Product Manager said.

“We have a built-in firewall to separate networks; in addition we also have builtin VPN that support two different types of VPN technologies that users can add to their controllers to enhance security.

When sending information to a cloud, for example, we also have a TSL 1.2 security that can transfer data via HTTP. So we add a lot of features right within the controller so that users don’t have to add additional components in their network.”

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actions. In operation, the VPN client (software) encrypts your data, even before your Internet Service Provider sees it. The data then goes to the VPN and from the VPN server to your online destination. The online destination sees your data as coming from the VPN server and its location, not from your computer and your location.

Data goes in encrypted form to your ISP then to the VPN server. The VPN server is the third party that connects to the web on your behalf. Thus the destination site sees the VPN server as the traffic origin, not you.

And no one can (easily) identify you or your computer as the source of the data, nor what

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you’re doing (in the case of a PLC, what data is transferred). And your data is encrypted, so even if someone does look at what’s being sent, they only see encrypted information and not raw data.

VPN protocols define how the service handles data transmission over a VPN. One of the most common protocols is OpenVPN. It’s based on SSL/TLS (SSL or secure sockets layer is the standard security technology for establishing an encrypted link between a web server and a browser.) and it’s an open-source project, meaning it’s constantly improved by hundreds of developers. It secures the connection by using keys that are known only by the two participating parties on either end of the transmission.

Getting back to the Mr. Robot hack, a VPN alone would probably have been enough to thwart the efforts of Elliot Alderson. But VPNs and firewalls are only the beginning of security measures modern industrial networks can implement.

Standard security measures, like firewalls, password protection and individual user rights, protect data within each location from unauthorized access.

Wago’s PFC100 and PFC200 controllers transmit data through onboard TLS 1.2 security protocols and also securely transmit data to the cloud.

A virtual private network extends a private network across a public network and enables users to send and receive data across shared or public networks as if their computing devices were directly connected to the private network. The Wago PFC controllers support the two common protocols that are used to set up VPN Connection, OpenVPN and Ipsec. (IPsec, for IP security, is a suite of protocols developed to ensure the integrity, confidentiality and authentication of data communications over an IP network.) This means there is secure communication over an insecure network.

An Open VPN connection can be applied straight from the PLC through data that is sent encrypted with the VPN directly on the PFC100 and PFC200 controllers.

Communication is secured by encrypted

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VPN connection using MQTT and other protocols.

MQTT (MQ Telemetry Transport) is a publish/subscribe, simple messaging protocol designed for constrained devices and low-bandwidth, high-latency or unreliable networks. The design principles are to minimize network bandwidth and device resource requirements while simultaneously attempting to ensure reliability and some degree of assurance of delivery. These principles make the protocol useful for Internet of Things connected devices and for mobile applications where bandwidth and battery power are at a premium.

To ensure information security and integrity during web access and data transfers, the TLS 1.2 encryption method is used as the standard for establishing secure HTTPS and FTPS connections, and the SSH protocol is integrated as standard for establishing secure shell and SFTP connections.

“TLS Security is used for transporting HTTP and is an industry standard for communication,” Norz said. “It is important when connecting data from a plant floor to the cloud. With our controllers we have the ability to publish and subscribe to MQTT brokers, which is becoming an industry standard for cloud technology and even more recently we have Sparkplug, which is also MQTT-based and through both of those protocols we are able to enable TLS security. If you are sending data, the data is encrypted so no one can read the data even if they capture the communications.”

With a standard integrated firewall, Wago’s PFC100 and PFC200 controllers protect against unwanted network attacks. There is no need for encryption via external components and protection through external firewalls. Firewall protection is out of the box without the addition of external devices.

Linux software is the foundation behind these security mechanisms.

Because the Wago controllers are based on a Linux system, the security is essentially built-in. The Wago controllers also have physical network segmentation via VLAN so application levels and management levels can be separated safely from one another.

A virtual LAN (VLAN) is any part of a computer network that is partitioned and isolated at the data link layer (OSI layer 2). VLANs work by applying tags to network frames and using them to create the appearance and functionality of network traffic that is physically on a single network but acts as if it is split between separate networks.

In this way, VLANs can keep network applications separate despite being connected to the same physical network. VLANs address issues such as scalability, security, and network management. Routers between VLANs filter broadcast traffic, enhance network security, perform address summarization, and mitigate network congestion.

“It is recommended by a number of industry organizations and security experts to separate networks in the event of a cyber hack,” Norz said. “If your network is separated within your facility the intruder will only have a certain access to part of the facility instead of the whole operation. So following good security standards, VLAN is just one of the many ways to engineer a defense in depth strategy.”

The traditional automation pyramid using conventional central controllers is gradually transitioning to new information and

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communication technologies like cloud services, OPC-UA (object linking and embedding for process control unified automation) with TSN (time sensitive networking), and flexible automation solutions.

Cloud connectivity solutions from Wago provide a high security standard and a secure path to the cloud.

With the quick development of the digital world, flexible solutions that can move with a company long term are necessary. Users have the option with Wago PLC Controllers of later upgrading controllers to match the requirements of the Federal Association of Energy and Water Industries white paper and the Federal Office for Information Security catalog if need be.

“People need cyber security because more companies are going through a digital transformation where they want to get more plant floor data into a cloud,” Norz said. “So when you are moving information over the internet then obviously your system is open to the internet which is an entry for hackers to compromise your system.”

In that regard, there’s a good chance any one of the security measures Norz mentions would have rendered the schemes of the Mr. Robot hackers moot. But that, of course, would have made for much less exciting TV. DW References Wago Corp. controllers www.wago.com/us/c/controllers-buscouplers-i-o

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T e s t

&

M e a s u r e m e n t

New approach

to frequency analysis

on oscilloscopes It has often been the case that optimizing scope settings to display a detailed view of an FFT results in a time-domain view that is suboptimal.

Not anymore.

The debugging of embedded systems often

New firmware enables simultaneous analog (left) and spectrum views with independent controls in each domain.

Gary Waldo • Tektronix

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involves looking for clues that are hard to discover when examined one domain at a time. The ability to look at time and frequency domains simultaneously can offer important insights. Mixed domain analysis is especially useful for answering questions such as: • What’s going on with my power rail voltage when I’m transmitting wireless data?

• Where are the emissions coming from every time I access memory?

• How long does it take my PLL to stabilize after power-on?

Mixed-domain analysis can help answer questions like these by providing views of time-domain waveforms and frequency domain spectra in a synchronized view. Until now, the Tektronix MDO4000C mixeddomain oscilloscope has been the only scope to offer

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T e s t

&

M e a s u r e m e n t

When debugging tasks demand it, Spectrum View lets multiple channels be analyzed simultaneously. Here, two channels show the startup of a clock signal from two different points in a circuit. Each of the two color-coded analog waveforms has a corresponding spectrum. Note that below each waveform is a small bar. This indicates the time at which the spectrum occurs within the time domain.

This spectrum time can be moved through the waveform to see the synchronized spectrum at any point in the waveform. In this example, the two channels show the startup of a clock signal from two different points in a circuit.

synchronized time and frequency domain analysis with independent control over waveform and spectrum views. It accomplishes this by incorporating a full spectrum analyzer with its own dedicated input channel.

There is a new approach that does not require a separate input channel but still provides similar time/frequency capabilities. It involves recently released firmware that unlocks an analysis tool called Spectrum View which takes advantage of patented hardware already in the instruments. With this tool, the scopes can provide simultaneous analog waveform views and spectral views, with independent controls

in each domain.

For more complex troubleshooting, instruments with the upgraded firmware can perform mixed-domain analysis on more than one channel.

Although spectrum analyzers are designed specifically for viewing signals in the frequency domain, they are not always readily available. Scopes, on the other hand, are almost always handy in the lab, so engineers tend to rely on scopes as much as possible. For this reason, oscilloscopes have included math based FFTs (fast Fourier transforms) for decades. And most modern With the time domain optimized using conventional FFTs, frequency domain detail is lacking on this spread-spectrum clock signal. In this screen shot taken from a TDS3000, the time-domain waveform is seen clearly, but FFT resolution is inadequate to see meaningful details.

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scopes let operators look at amplitudevs-time waveforms and amplitude-vsfrequency. So, what’s the big deal?

First, FFTs are notoriously difficult to use for two reasons.

For frequency domain analysis, spectrum analyzer controls like center frequency, span and resolution bandwidth (RBW) make it easy to define the spectrum of interest. In most cases, however, oscilloscope FFTs only support traditional controls such as sample rate, record length and time/div, making it difficult get to the right view.

Second, FFTs are driven by the same acquisition system as for the analog time domain view. This means that speeding up the time scale in the time domain reduces resolution in the frequency domain. As a result, with conventional FFTs, it’s virtually impossible to get optimized views in both domains.

In contrast, Spectrum View provides the ability to adjust the frequency domain using familiar center frequency, span and RBW controls. And because these controls do not interact with the time domain scaling, it is possible to optimize both views independently.

On-screen indicators (spectrum time) show the source of the spectrum on the waveforms. The ability to synchronize the two domains is useful for correlating signal activity on a board with EMI emissions, for example.

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Conventional FFT tradeoffs The challenges with conventional FFTs go well beyond ease of use. To illustrate the performance tradeoffs engineers must consider, suppose we have a tone at 900 MHz and want to view its phase noise out to 50 kHz on either side with 100-Hz resolution. Ideally, the spectral view should be set to a center frequency of 900 MHz, a span of 100 kHz, and a resolution bandwidth of 100 Hz. With a traditional scope FFT, horizontal scale, sample rate and record length settings determine how the FFT works and must be considered holistically to produce the desired view.

Horizontal scale determines the total amount of time acquired. In the frequency domain, this determines resolution. The more time spent acquiring, the better the resolution in the frequency domain.

To resolve 100 Hz, we need to acquire at least (1/100 Hz) = 10 msec of time. However, in reality we need to acquire nearly double that amount. In theory, FFTs are supposed to be applied to infinitely long signals. Because this isn’t possible, the beginning and end of the acquisitions introduce discontinuities (and thus error) into the resulting spectrum. To minimize discontinuities, the acquired record must fit in an FFT “window.” Most FFT windows have a bell or Gaussian shape where the tails are quite low and the center is high, meaning the spectrum must be primarily driven by the middle portion of the acquired data. Each window type has a constant associated with it. For this example, using a Blackman-Harris window type with a factor of 1.90 would require 19 msec (10 msec × 1.9 = 19 msec) of acquisition time.

Sample rate determines the maximum frequency in the spectrum, where Fmax = SR/2.

For a 900 MHz signal, we need a sample rate of at least 1.8 GS/sec. Using the analog sampling on the Tektronix 5 Series mixed signal oscilloscope as an example, we would sample at 3.125 GS/sec (first available sample rate above 1.8 GS/sec).

Now we can determine the record length, L. This is simply L = Time Acquired × Sample Rate. In this case, L = 19 msec × 3.125 GS/sec = 59.375 Mpoints record length.

Depending on the instrument, this record length may not even be available. Even if the scope has sufficient record length, many scopes limit the maximum length of an FFT

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T e s t

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M e a s u r e m e n t

FFT tradeoffs made apparent: Here, frequency modulation details are more visible with a slower time scale setting, but the time domain trace is now practically unusable.

because it is computationally intensive. For example, many previous-generation oscilloscopes have a maximum FFT length of approximately 2 Mpoints. Assuming you still want to see the 900 MHz signal (which requires the high sample rate), you’d have to acquire approximately 1/30th of the desired time resulting in 30 times worse resolution in the frequency domain.

As this example illustrates, setting up a desired view requires an appreciation of the complex interactions between horizontal scale, sample rate, and record

length. Moreover, the reality of finite record length forces undesirable compromise.

And observing high-frequency signals with good resolution in the frequency domain requires extremely long data records which are often unavailable, or expensive and time-consuming to process. Although some spectral analysis packages attempt to manage these tradeoffs, all oscilloscope FFTs to date face the limitations described above.

A new architecture Providing a way to perform spectral analysis

without running into the inherent tradeoffs of FFTs was a key design goal for Spectrum View. To understand how it works, note that digital oscilloscopes generally run their analog-to-digital converters (ADC) at the maximum sample rate. The stream of ADC samples goes to a decimator that keeps every Nth sample. At the fastest sweep speeds, all samples are kept. At slower sweep speeds, it’s assumed the user is looking at slower signals and a fraction of the ADC samples are kept. In short, the purpose of the decimator is to keep the Spectrum View enables optimized views of both time and frequency domains on the same screen.

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THE COUPLING.

FOR ACCURATE OVERLOAD PROTECTION

SK

record length as small as possible while still providing a sample rate adequate to view signals of interest in the time domain.

In the 5 and 6 Series MSOs, behind each FlexChannel input is a 12-bit ADC inside a custom ASIC called the TEK049. Each ADC sends high-speed digitized data down two paths. One path leads to hardware decimators which determine the rate at which time domain samples are stored. The second path leads to digital down-converters (DDC) also implemented in hardware. This approach enables independent control of the time domain and frequency domain acquisitions, allowing optimization of both waveform and spectrum views of a given signal. It also makes much more efficient use of the longbut-finite record length available in these instruments.

To illustrate the process, consider the 900-MHz measurement scenario mentioned earlier but with the hardware digital downconverter added into the acquisition process. The total time acquired still determines the resolution in the frequency domain. We also still need to apply an FFT window and acquire data for 19 msec. In the TEK049, the ADC sends digitized time domain data to a decimator to create the time domain waveform view, but it also sends the data to the DDC. As you might expect, the DDC has a profound effect on the required sample rate. The DDC shifts the center frequency of interest from 900 MHz to 0 Hz. Now the 100kHz span goes from -50 kHz to 50 kHz. To adequately sample a 50 kHz signal, we only need a sample rate of 125 kS/sec. Notice that by inserting the DDC into the acquisition process, the sample rate required becomes a function of span, not center frequency.

Record length is governed by the same relationship as before. Record length is now 19 msec × 125 kS/sec = 2,375 points. The data is stored as in-phase and quadrature (I&Q) samples, and precise synchronization is maintained between the time domain data and the I&Q data. Remember, in the case of a conventional FFT the required record length was 59.375 Mpoints. The down-converted record only requires 2,375 points.

Now we perform an FFT on the 2,375 point I&Q record to get the desired

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T e s t

&

M e a s u r e m e n t

Optimizing resolution of FFTs and time-domain waveforms High-speed 12-bit ADC

Time domain decimation

ADC

t

t

Signal Conditioning

t

t

Decimator

t

Digital down converters implemented on the custom TEK049 ASIC are what enable simultaneous waveform and spectrum views with independent controls in the Tektronix 5 and 6 Series MSOs.

Acquisition Memory

t

t

TEK049 ASIC

Digital DownConverter t

Frequency domain down-conversion

spectrum. This dramatic reduction in the number of data points creates several important advantages: • First, it greatly improves the update rate. And much longer timespans can be processed, thus providing a spectrum analysis with much better frequency resolution.

• Moreover, the desired frequency domain view can be captured without changing the time domain view in any way.

Toward more efficient system analysis Efficient embedded system analysis and debugging begins and ends with insight. How can you possibly figure out why a system isn’t working as expected without precise, synchronized insight into both time and frequency domains?

Clearly, you can’t, and engineers have long recognized this. But they have been constrained by limitations in conventional oscilloscope FFTs. A new oscilloscope architecture enabled by new firmware points the way to a number of significant advances.

It enables the use of familiar spectrum analysis controls

82

(Center Frequency, Span and RBW). It allows optimization of both time domain and frequency domain displays independently. It also enables a signal to be viewed in both a waveform view and a spectrum view without splitting the signal path. Further, it enables accurate correlation of time domain events and frequency domain measurements (and vice versa) and significantly improves the frequency resolution possible in the frequency domain. Last but not least, it improves the update rate of the spectrum display. DW References Tektronix Spectrum View, www.tek.com/product-features/spectrum-view-5-and-6-series-msos

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Product World Keyless shaft bushings Zero-Max zero-max.com These shaft locking devices rigidly secure shaft-mounted components into position. They are an excellent shaft-hub locking solution eliminating keyways which can weaken or cause excess wear to shaft components.

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Press model added to RSX extreme-force electric actuator family Tolomatic tolomatic.com The RSX press model (RSX096P) electric linear actuator increases the force range of the existing RSX product family to 40,000 lbf (178 kN) and is designed for force in the extend direction.

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Product World

Electric bench top press Bimba bimba.com The fully electric IntelliPress bench top press helps expand the possibilities of factory automation applications. This press complements existing hydraulic and

Roller and conveyor chains for industrial applications iwis iwis.com Inadequate lubrication and additional contamination can cause a reduction of chain performance to as little as 20% of its full potential, thereby reducing service life more than any other influencing factors. iwis antriebssysteme produces precision roller and conveyor chains for industrial applications in the field of general machine engineering, plant engineering, the packaging, printing and food industries, and conveyor technology. In recent years, the recognized chain specialist has conducted intensive research into solutions that prolong chain service life, as well as developing its own range of lubricants.

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Motorized, high-resolution pan-tilt stages OES oesincorp.com High resolution, motorized, pan-tilt stages have been added to the line of OES motion control products. These motorized Pan-Tilt Stages are available in two sizes. The PT60-1 Pan-Tilt Stage is a combination of two 60 mm (2.362-in.) rotary stages, and the PT100-1 is a combination of two 100 mm (3.937-in.) rotary stages, set at a 90° angle to each other. The rotary stages of each Pan-Tilt stage have a repeatability of 0.005O (18 arc-sec), a positional accuracy of 0.005O (18 arc-sec), and a resolution of 0.001O = 3.6-in. (10 Micro-steps per Step Motor Driver in use). These Pan (horizontal table)-Tilt (vertical table) Stages are suitable for scanning, testing, inspection, assembly, positioning, laser and micro-machining, pointing optics and cameras, and other applications.

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IP 65-rated distributed drive technology Beckhoff beckhoff.com Beckhoff Automation has announced the new AMP8620 supply module. The AMP8000 Distributed Servo Drive system provides support for the implementation of modular machine concepts. With the AMP8620 supply module’s IP 65 protection rating and consistent decentralization, the entire motion system can now be mounted directly on the machine. This configuration means drive technology can now be implemented entirely without control cabinets, resulting in maximum possible savings in terms of cost, materials, space, and installation work.

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Ad Index

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Encoder Products

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Company .................................40

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Trim Lok .......................................... 22

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July 2019

inside: MOTION CONTROL:

Chain and sprocket software parameters

Getting to the point in precision Belt software parameters

External force Chain mass

+ –

p. 52

Load mass External force +

–

Sprocket • Inertia • Diameter

Direction of motion

Load mass

Driver • Inertia • Diameter

Belt mass

Direction of motion

Rotation table software parameters

Linear-motor software parameters

LINEAR MOTION: Offset Additional mass

External force

FOLLOW US ON

Rotating inertia

Slide mass

Using software for designing and sizing motion-control systems

+ –

p. 56 Friction surface

• Direction of motion • External torque

Motor coil Direction of motion

Crank software parameters

Roll feeder software parameters

Connecting rod length

Press Force

Driven inertia

+

Friction surface

Tension force +

Crank radius ELECTRONICS:

Load mass External force –

+

–

External force

Crank inertia

Direction of motion

Driver • Inertia • Diameter

Load mass Friction surface

Rack-and-pinion software parameters

Ballscrew software parameters

Load mass Side mass Ballscrew • Pitch • Inertia

Wheel bearings +

Keeping out the bad guys

p. 70

Direction of motion

move telescope to new heights page 64

External force – +

Rack mass

Friction surface

Pinion • Pitch circle diameter • Inertia

Direction of motion

Direction of motion

JULY 2019 DW COVER_FINALFINAL2.indd 1

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