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July 2020
inside: ELECTRONICS: Making synchronous belts quiet and balanced
p. 62
TEST & MEASUREMENT: The importance of standardizing industrial bus cables
p. 68
FASTENER ENGINEERING: The design, materials, and stories behind the fastener industry
p. 72
Connectivity and IoT in motion and automation
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Why can’t we have innovation all the time? Recently, while listening to the excellent Freakonomics Podcast, one of the guests provided some great insight into our current situation. Marshall Burke, an Associate Professor at Stanford University explained that many times it takes an outside event to force society to move in directions that it had been technologically ready for, but not psychologically ready for. “Certain economic historians point to these critical junctions in history where it wasn’t slow change but something specific happened that set entire countries or entire economies on a different course,” Burke said in relation to the COVID-19 pandemic. “One idea is that these sorts of large-scale events could be critical junctures that cause us to change our behavior in ways that slow-moving changes in technology or slow-moving changes in preferences never do.” We’ve seen countless examples of engineers being innovative over the past few months. Manufacturing facilities have been reworked to produce ventilators or ontline PPE. Design teams have discovered (or rediscovered) Zoom meetings and the like. Engineers have refined processes to make them more efficient. Creativity has reigned. I had a fascinating interview with Deborah Jennings-Conner, who is UL’s Director of Global Life and Health Sciences Regulatory and Testing Assurance recently, and she hit on many of these points, too. “It seems when we’re in a normal situation, if someone has a new idea or a new idea about a product or a process, we can find 20 or 30 ways to say, ‘we could never do that.’ Or we might look at it next year,” she said. “But in this crisis situation, both at UL and what I’ve seen around the world, we have managed to quickly move forward on innovative, creative ideas and we have found a way to say yes. Not that we’re cutting any corners, not that we’re doing what we shouldn’t be doing, but we’ve managed to say yes to doing things the right way.” One of Jennings-Conner’s colleagues would tell her, “Make the right way the easy way.” And she pointed out that if we can have all of this incredible innovation in a crisis situation, why can’t we have that innovation all the time? We’re all looking forward to the day when we are finally past the COVID-19 crisis. But once we are on the other side, let’s make constant innovation the default setting, and not just the crisis setting. DW
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Teschler on Topic What you think you know that isn’t so
Ever heard of the K890 sub-machine gun? A a prototype came out during the 1950s, but there were hardly any made. The reason was its awkwardly shaped stock which made the gun difficult to shoot accurately. It also had a weirdly short barrel which also contributed to the difficulty in aiming. These problems forced the manufacturer to quit making the gun soon a er its release. The real problem with the K890 is that it’s a hoax. You could find a description of it on Wikipedia for more than five years, at which point Wikipedia editors figured out they’d been had. But the Wikipedia page for the K890 was so convincing that the gun was even mentioned in a paperback covering gun technology. Such are the dangers of relying on publicly maintained knowledge bases for information. Wikipedia now lists some 289 pages which were taken down when editors discovered they were bogus. They also have removed another 63 instances of fake facts om otherwise correct pages. Most of these could be classified as mischief because they concerned relatively silly ruses such as fake rock bands, imaginary movies, and made-up historical events. But you can also find Wikipedia hoaxes
in technical areas, ready to trip up unsuspecting researchers doing what they think is due diligence for projects that have potentially meaningful outcomes. Perhaps worse, some hoax Wikipedia articles have been picked up by credible media and treated as gospel. And it is relatively easy to be fooled by these scams. Reading through notes by Wikipedia editors reveals that a Google search on a bogus expression in Wikipedia o en turns up a list of sources that simply contain a verbatim copy of text li ed om the fake Wikipedia article. Those kind of search results may arouse suspicions in skeptical inquirers but may not set off alarm bells for naive users. Suppose, for example, you were researching acids and came across herzthiolate heptahydrolysic acid. If you didn’t pick up on the fact that its formula doesn’t make sense (NaO2H890− Mg4S2Ci2 Al2Si2He4Fe2CaN2C), you could spend a lot of time chasing your tail. Herzthiolate heptahydrolysic had a Wikipedia page for over 18 months before editors figured out it was a scam. And then there was V-Jay’s Verghjesles, or the V-Jazz, a “microprocessor controlled surround sound amplifier.” The creators of this fake product went so far as to list nonexistent components and specifications. What gave the entry some authenticity was that the suppliers mentioned--Texas
Instruments, Sylvania, and others—were real though the parts they were have supposed to supply were nonsense. The Wikipedia page was up for over four and half years. There are other problems with fictitious claims in articles that are otherwise accurate. For over two years, you could have found a statement that the PC Card, once called PCMCIA, was invented by Jacob D. Holm in 1986. In reality, the PCMCIA format arose 1989, instigated by Poqet Computer Corp. with help om Fujitsu, Intel, and other companies. And for seven years, Wikipedia would have told you that the history of Windows involves Chase Bishop, a computer scientist, who designed “the first model of an electronic device and project Interface Manager was started” in 1981. In reality, there was apparently no computer scientist by that name nor an “electronic device,” though Microso began working on so ware called Interface Manager that year. Most historians attribute the graphical user interface of Windows and the Macintosh to ideas conceived at the Xerox Palo Alto Research Center. All in all, it’s reader beware when it comes to Wikipedia pages. Most hoaxes get taken down quickly, but those that survive have good odds of staying in Wikipedia for a long time. DW
Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW_LeeTeschler
6
July 2020
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Technology Forward
Everything is connected “The information-sharing and collaboration required for Industry 4.0 maturity requires a daunting level of vulnerability, but as the global economy evolves, manufacturers must evolve with it,” says a recent survey, the 2020 Middle Market
Industry 4.0 Benchmarking Survey: manufacturing connectivity, om BDO, BDO USA. The study was done prior to the pandemic by Rabin Research Company, an independent marketing research firm. The report defines Industry 4.0 as “Machines paired with humans, services embedded in products, and products reimagined as services.” The key element in all of this is data, also referred to as the digital thread. The digital thread is supposed to be the foundation that will enable “autonomous decision-making and self-optimization.” But, no plug-and-play solution yet exists. The report finds the best available approach today requires weaving together multiple so ware tools and applications with complementary functions. According to the report, the future digital economy will be dominated by services and ideas rather than goods. Those who implement Industry 4.0 well will ultimately be
innovating the business model “in a way that fundamentally changes outputs, outcomes, and stakeholder relationships.” About one-third of manufacturers are implementing their Industry 4.0 strategies, up om 5% in 2019. The reasons behind this change include to modernize legacy IT in astructure (26%), drive employee adoption of digital change (25%), and drive operational efficiencies (21%). For these manufacturers, “the shortterm focus is on the bottom line, the long-term focus is on revenue growth.” One of the larger developments is exploring new revenue models. Subscription services still remain the top option, but product as a service, pay per use, and data as a service are gaining traction. Product-asa-service changes the value of a product om the product itself to its benefits; the service replaces the product. For example, instead of purchasing a car, a customer pays for the ride. Or instead of buying an exercise bike, the customer also buys a subscription to on-demand classes. Of course, a key element of Industry 4.0 is finding a way to monetize data. According to the report, the difference between data-as-a-service DaaS and SaaS
is that the data can be decoupled om a specific platform, though it doesn’t have to be. The value to the customer is in turning the data into meaningful information that can be published using an API, or using the data for predictive modeling. One of the top challenges with executing digital initiatives is cybersecurity. Some manufacturers not only face industrial espionage, they must also manage national security threats with their government contracts. Another challenge emerging involves implementation. The report shows that around 31% of surveyed manufacturers are implementing Industry 4.0 but without a strategy. About another third have developed a plan but have not implemented it yet, and the remainder are developing a plan. Data sharing is also still an issue. Roughly one-third are sharing up and down their organizations and with those they do business with. Data privacy as well as security are the main challenges here. For the design engineer, a key take-away is this: the next step for the digital economy is one “where the physical and digital worlds are tightly integrated. Goods will still be manufactured and sold—they’ll just be paired with services.” DW
Leslie Langnau • Managing Editor llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting
8
July 2020
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Green Engineering Paul J. Heney
• VP, Editorial Director
Taking blade testing to the extreme
Inside the DTU Large Scale Facility, Moog and its partners designed and installed equipment for the three test stands. The 25 m and 45 m test stands are shown here.
Each year, roughly one out of every 200 wind turbine blades fail. Those failures pose a twofold concern for turbine owners. First, when a blade fails, there’s unplanned downtime and potential insurance issues. Second, how can blade manufacturers and turbine owners and operators feel confident that the blades on their turbine are tested adequately? Researchers at the Technical University of Denmark (DTU) Large Scale Facility, part of Department of Wind Energy and the Villum Center for Advanced Structural and Material Testing (CASMaT), believe they have answers. The test facility, built by the Danish Building and Property Agency, opened in 2017 on the DTU Risø campus. Scientists there focus on developing new, advanced test methods to gain a better understanding of failure in large structures.
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For the wind turbine industry, testing and certi ing blades to established standards is mandatory. “But the current version of these standards is om 2014, and it’s based on experience when turbines were much smaller,” said Dr. Kim Branner, senior research scientist and head of the Structural Design & Testing Team for DTU Wind Energy. “The standard requires a static test in four different directions and fatigue testing that makes the blade swing in
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“Testing is an essential element to succss in the wind-energy field,” said Branner. “Moog understands that.” two directions, exciting the blade at its natural equency.” According to Branner, those testing methods aren’t robust enough to mirror what happens to a blade in service. Today’s standards, he said, only test certain parts of a blade, while in reality the loads in the field are much more complicated. Branner and his team are undertaking projects to load blades in more realistic ways and to do it faster than conventional testing. The wind industry wants faster test methods, especially since bigger blades (of up to 100 meters in length) have a natural equency that’s slower. Current industry testing standards would require a manufacturer to wait up to a year to know if its blade passed the test. DTU had a vision to develop a facility with the capability to test large-scale blades and other industrial components to help manufacturers reliably and efficiently replicate field conditions. A er soliciting proposals and securing funding om the Danish government for
the project, DTU picked Moog in the U.K. and its technical partners T A Savery and Qualter Hall. Moog’s expertise in aircra structural testing and range of precision control systems, actuation products and engineering support services, which includes modelling and simulation capability, appealed to DTU’s team. Moog had already developed actuation devices specifically engineered for wind turbine blades. “Testing is an essential element to success in the wind-energy field,” said Branner. “Moog understands that.”
The challenges of a large-scale test facility DTU and Moog began thinking through what kind of equipment they would need to carry out more advanced tests, including bi-axial equency tests that load a blade in different directions at the same time. From the outset, there was little if anything about the project that could be solved with commercial offthe-shelf solutions.
Moog initially undertook simulation and modelling work to demonstrate vthat its designs could meet DTU’s specification. For instance, one DTU requirement was to excite a wind turbine blade in two directions at the same time, with three test stands (ranging in size om 15 to 45 meters) running simultaneously. By comparison, the wind industry’s standard blade test involves exciting a single axis, one equency at a time. The requirement for three stands operating at once was a desire by DTU to use the facility to the fullest, which gives customers and DTU greater flexibility in testing. “In research, we’re trying to go in new directions all the time, and it’s important to have equipment that offers flexibility,” said Branner. “We had to have a set of equipment we could use in many ways.”
Designing a solution Moog’s expertise with closed-loop servo control and actuation helped it create a testing facility underpinned by a digital closed-loop control system and application so ware. To provide DTU with testing flexibility, Moog and its partners designed and installed test equipment to be used with the three test stands, which can take 15 m, 25 m and 45 m blades. Moog engineers carried out the installation and commissioning of the
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Green Engineering
Installing mass resonance exciters on a test blade at the DTU Large Scale Facility.
Moog continues to support DTU’s work via a project in which researchers hope to see what the future holds for a working wind turbine blade. By developing sensors to embed in a blade, DTU wants to know if it can predict damage.
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suite of test equipment and provided training and ongoing support for DTU staff. The Moog scope of supply for the three blade test stands included the hydraulic power plant and distribution network, six hydraulic winches for the static test and a combination of eight mass resonance exciters (MRE) and linear actuator assemblies for dynamic test work. The solution also included all pipe work, hosing and actuation devices, control system electronics and application so ware. “Much analysis went into how the MRE would work, the equency and how DTU would like it to perform,” said Graham Wood, Managing Director with T A Savery. “This was not a contract in which the customer simply said make A, B and C and that’s that. Moog won the DESIGN WORLD
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contract, and then began a great deal of technical research, modelling and hardware design.� In designing the facility’s equipment, Moog goal was to give DTU the latitude to conduct an array of tests. For example, if researchers wanted to use a test bay to conduct a dynamic test on a blade, the hydraulic system would accommodate wide pressure fluctuations. If the next test required a static one with winches, DTU could set the hydraulics to meet a very low flow. “DTU can literally select what they want, without being constrained by the equipment,� said Kevin Cherrett, business segment manager for Systems and Services with Moog’s Industrial Solutions & Services group. To design the winch assemblies, Moog tapped U.K.-based Qualter. The work included discussions about the type of rope, safety factors and mounting a hydraulic manifold on the winches, so DTU researchers can angle the winches depending on a configuration of 2, 4 or 6 load points. Competing blade-testing designs use enormous towers with winches that facility managers move with a fork truck for horizontal static testing. DTU’s winches load the blade vertically, so researchers can perform a static test to extreme loads with six winches loading a blade at six positions, while pulling the test specimen toward the floor and mimicking an extreme wind load experienced in a 100-year storm. The tip of a blade in the DTU facility can move up to 14 meters, while the root of the blade moves a few centimetres. DTU wanted a facility wherein gravity and the test direction were the same. The advantage to testing a blade vertically versus sidewise with a tower is that with the latter configuration researchers have a tower that will bend during a test; this makes it difficult to control load position, plus taking up a lot of facility space when not in use. With regard to designing the MRE, Wood and Cherrett explained that the concept was well established. But what they undertook was to develop a more robust version of that concept with flexible tools gra ed onto it. DESIGN WORLD
Green.Engineering.7-20_Vs3a.indd 13
“One of the challenges of fatigue testing is ensuring you’re fatiguing the test specimen, not the equipment performing the test,� said Cherrett. “We carried out extensive tests and modelling and simulation to predict the life of the equipment; we analysed each component for life expectancy.� In designing the actuation for the MRE, Moog included hydraulic actuator designs it had used for the aircra industry. Within the MRE is a standard Moog actuator building block that excites the blade. The weight of the MRE was also of concern to DTU because similar devices manufactured by test houses included manifolds and piping that added mass. Working with DTU, Moog created a control manifold made om high-strength aircra aluminium that DTU could mount anywhere. “For every customer, with these types of systems, we seek to engage in a service level agreement, support package, preventive maintenance and tech support,� said Cherrett. “Our definition of tech support is not just a one-off exercise; we’ll be with DTU for the duration of the use of the equipment.� Moog continues to support DTU’s work via a project in which researchers hope to see what the future holds for a working wind turbine blade. By developing sensors to embed in a blade, DTU wants to know if it can predict damage. “Moog’s technology is helping with this because we will embed sensors in test blades with built-in defects and monitor how the damage grows,� said Branner. “The Moog exciters will put realistic loads on the blades.� Branner sees the project helping blade makers build better blades but also creating a digitized twin of each blade that a wind farm operator could use to model what a blade’s future state might look like. If all goes according to plan, someday a wind farm control centre could predict a blade fail before it happens. DW
WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online
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Contents 7 • 2020
•
vol 15 no 7
•
designworldonline.com
Engineering
68 46 _LINEAR-MOTION CONTROL
62 _ELECTRONICS
Connectivity and IoT in motion and general automation
Harnessing waste heat for electrical power
Machine designs are evolving with wireless connectivity, Ethernet-based networking protocols, cloud-based operations, open programming, and various forms of edge computing.
A supplement of Design World
The design, materials, and stories behind the fastener industry.
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72-107
Solid-state devices that convert heat to energy have a reputation for being inefficient. New materials may eventually change the equation.
68 _TEST & MEASUREMENT Helping to see the light
Advanced interferometry techniques help overcome some common pitfalls when measuring thin, parallel optics
ON THE COVER Components with IO-Link function use unifying software, standard physical connectors, and cables to give systems a simple way for feedback. 4WRPEH valve and HEDE10 pressure switch image courtesy Bosch Rexroth.
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
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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
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
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Machine Tool Components
7.20
• contents departments
Spring Plungers
Clamps
Workholding Grippers
04
Insights
06
Teschler on Topic
08
Technology Forward
10
Green Engineering
18
Design For Industry
28
Design Notes
36
CAE Solutions
42
Internet of Things
108 Product World 112 Ad Index
Fixturing Accessories
Rollers & Bumpers
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EDITORIAL
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney Senior Contributing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Executive Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora CREATIVE SERVICES
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Design for Industry Food & Beverage
Putting food and beverage processors in touch with their operation Cory Hovanetz • Senior Account Manager • Teguar
The last few months have been challenging for the food and beverage industry. While this sector is facing the usual demands om the regulators and the market, these manufacturers are also trying to fulfill their role as an essential business while COVID-19 courses throughout the world. The industry has to deal with workforces depleted by the virus while striving to bring product to market. To deal with production, while management is continually looking over its shoulder at the CV-19 threat, more touchscreen computers are finding their way into the systems, equipment, and workstations on the processing plant floor. Given the appetite for data in this industry to maintain production and the health of workers, touchscreen computers will enable a plant to capture information om connected devices, send it through the system, and make realtime decisions along the processing and packaging line. These devices afford a high
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level of HMI (human-machine interface) for better management and response of the process. Controlling the impact of COVID — Food/beverage processing plants have become hot spots for outbreaks of the virus. Therefore, strategies in these facilities will require data for managing workforce density on the work floor, while maintaining productivity goals. Many workplace routines already involve RFID/barcode scanners upon entrance to the facility, to read employee badges. Other forms of touchless employee check-in now being used include thermal imaging and facial recognition. Recording these data requires workstation-embedded touchscreen computers with high processing power and modularity. Supply chain management and traceability – Traceability in the food and beverage industry can avoid costly recalls and blows to company reputation. A good portion of the food supply chain exists beyond the plant. Strategically positioned touchscreen computers track the processing path, as product makes its way om the point of origin to the consumer. The data that touchscreen computers capture either on-site or outside of the factory, allows management to increase their supply chain visibility to make adjustments in their process as needs occur. Processing regulations – The Food Safety Modernization Act and other government mandates have set high standards for food processing. Processors are marshaling touchscreen computers, so management can determine the weak points in their operation and take proactive corrective action. Predictive maintenance – Unplanned downtime and asset failure have always been an issue in food/beverage processing and a constant threat to production. These concerns are even more so now during COVID, with processing facilities working overtime to meet consumer demand. With touchscreen computers tracking the performance of the equipment they monitor, these devices enable root cause analysis of maintenance incidents leading to higher uptime, asset utilization, and on-time production. Management can avoid premature service and unnecessary shutdowns. The devices can also enable the usage of advanced technology such as IoT, AI, and blockchain. The right devices for the food/beverage environment: Touchscreen design – Touchscreens help save space in food manufacturing environments. Rather than installing waterproof peripherals, such as a keyboard, mouse, and scanner, which can require special cables and waterproof junction boxes, touchscreen computers can incorporate these tools. The touchscreen also allows portable devices, such as rugged tablet PCs, to be smaller and more mobile.
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Design for Industry Food & Beverage
Touchscreen designs can be either resistive or capacitive (PCap). Processes can use resistive touchscreens with thick gloves, PCap touchscreens can be used with thin latex gloves or bare hands. In humid environments where there might be condensation on the screen, resistive is preferred, because light water spay or condensation can interfere with PCap, but generally not with resistive. Ruggedness — Depending upon the product, food and beverage processors may use touch screen computers in areas with temperature extremes, om low-temperature, chilled operations, to high temperature, cooking or heating processes. Throughout these facilities, operations equently wash down equipment, so there is exposure to water and even high-pressure streams. Most food manufacturing specific touchscreen computers are fanless and fully sealed, as well as IP69K and NEMA-4 rated. Particularly crucial for many food/beverage environments, manufacturers have developed computers with sealed junctions on the back of the device, to protect against moisture. This addition allows the computer to accommodate more cabling options. Adaptability – For touchscreen computers to take their place along the processing/packing line and interface with IIoT configurations, they need to allow plug-ins om a number of devices, such as printers, scanners, scales, and RFID readers. In challenging times, such as these, manufacturers may need to quickly shi their operations to meet new consumer demand and heightened safety requirements. Having a computer with the ability to integrate a new peripheral or accommodate an expansion card can help quickly implement new processes and protocols. Whether it’s a pandemic, food recall, food shortage, or other challenge, touchscreen computers heighten the food and beverage industry’s ability to adapt and respond. DW
Teguar teguar.com
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Design for Industry Food & Beverage
Level switch flexibly adapts to different media
Design for food and beverage production is increasingly facing the need to meet individual customer requirements. Conventional measurement systems are unable to cope with the different media characteristics involved. But the level switch CleverLevel PL20 makes processes more flexible and eliminates additional efforts because it no longer matters what is in the tank. The level switch, especially when it comes to applications in the food production sector with changing recipes or batch production, is a self-learning sensor that automatically adjusts to the different media. This ensures maximum flexibility with minimum set-up times. Its compact design and low installation depth has only a minor impact on the process and thus ensures maximum food safety. CleverLevel detects every type of medium, whether liquid, pasty, viscous, or solid. The level switch does not have to be parameterized to a medium, but flexibly adapts to the medium at hand. This way, even adhesions such as those that equently occur with pasty materials can be reliably masked. With its optional 4 ‌ 20 mA analog signal, the PL20 offers several additional advantages for increased efficiency of production processes.
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With an additional optional 4 ‌ 20 mA analog output, the PL20 can help differentiate the media within the process or evaluate the cleaning process. The graphic evaluation of the measurement is aided by the FlexProgrammer, which ensures a transparent process. The sensor can be easily and quickly integrated in already existing systems through the analog interface. At the same time, the large selection of process connections and adapters allows the flexible and easy integration of the sensor. DW
Baumer | www.baumer.com/cleverlevel
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Food & Beverage
Linear motion system improves flexibility
Food and beverage manufacturers are constantly under pressure to package a wider variety of products in more types of packaging without compromising productivity. One way to accomplish this is through the use of the iTRAK 5730 small- ame intelligent track system uses independent cart technology to support smart, flexible and efficient machines. Independent cart technology offers several benefits over traditional gear, chain and belt conveyors, including unlimited machine flexibility, better traceability and increased uptime. By using magnetic propulsion, the individually controlled carts can quickly start and stop with high precision, which reduces machine wear and is energy efficient. The technology also quickly manages changeovers using preconfigured move profiles that can be implemented with the push of a button om an HMI. The iTRAK 5730 system has a small footprint. It has a 50 mm minimum pitch suitable for primary packaging applications, such as flow wrapping, DESIGN WORLD
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end load cartoning, and form-filland-seal pouching. The system also easily integrates into a manufacturer’s architecture, providing analytics that help optimize energy use, monitor parts wear and reduce downtime. In addition, the iTRAK 5730 also offers integrated safety. Features such as safe torque off, Safe Stop 1, a SIL 3, PLe safety rating and the ability to create safety zones help increase confidence in machine safety. Safety zones, for example, can increase safety without compromising productivity by allowing motion to continue outside of the safety zone, even a er a trip inside the safety zone. Furthermore, simulation capabilities let users calculate throughput on the iTRAK 5730 system. Users can also create a digital twin that can be used to virtually design, commission and demonstrate the system, and to virtually train workers. Standard object-oriented libraries also can help create a consistent user experience and accelerate time to market. DW
Rockwell Automation www.rockwellautomation.com July 2020
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Design for Industry O f f- H i g h w a y
Lithium-ion battery pack integrated into lift truck
The Hyster J60XNL breaks new ground as the first counterbalanced li truck engineered around a fully integrated lithium-ion battery pack. “While counterbalanced li trucks with lithium-ion power are available, they come in the form of battery box replacements,” says James Nielson, Product Manager, Hyster Company. “We took a different approach. The J60XNL is designed om the ground up to take advantage of the form factor of lithiumion battery power, eeing space in the operator compartment and reducing truck weight for significant ergonomic and efficiency benefits.”
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emissions in operation and no gassing during the charging process, making it a strong choice for operations subject to high hygiene standards, like food, beverage and pharmaceuticals. The battery can also communicate with the truck and adjust performance based on operating temperature, allowing the J60XNL to operate in a wider range of temperatures than other lithiumion products. DW
The li truck weighs more than 700 pounds less than the equivalent leadacid battery powered model and has a lower center of gravity for improved acceleration and maneuverability while reducing energy consumption. The integrated lithium-ion design offers more space under the operator seat to provide increased eedom to position feet during operation. The li truck brings all the benefits of lithium-ion power to a counterbalanced forkli , including efficiency gains, no battery maintenance requirements, consistent power delivery and long battery life. Opportunity charging and the ability to fully charge in approximately one hour make lithium-ion power a suitable solution for heavy-duty applications. The lithium-ion battery technology is FDA compliant, with zero TL Design World V1.pdf
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Hyster Co. www.hyster.com/north-america/en-us
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Design for Industry Semiconductor
Multi-object ranging for next-gen
industrial electronics applications
Multi-object ranging for next-gen industrial electronics applications The VL53L3CX is a FlightSense ToF ranging sensor with patented histogram algorithms that allow measuring distances to multiple objects as well as increasing accuracy. The VL53L3CX measures object ranges om 2.5 cm to 3 m, unaffected by the target color or reflectance, unlike conventional in ared sensors. This allows designers to introduce new features to their products, such as enabling occupancy detectors to provide error- ee sensing by ignoring unwanted background or foreground objects, or reporting the exact distances to multiple targets within the sensor’s field-of-view. The ST patented histogram algorithms increase cover-glass crosstalk immunity and allow real-time smudge compensation, preventing external contamination om adversely affecting the ranging accuracy of, for example, vacuum cleaners or equipment that may be used in a dusty industrial environment. Ranging under ambient lighting is also improved.
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In addition, the VL53L3CX’s linearity increases short-distance measurement accuracy enhancing wall tracking, faster cliff detection, and obstacle avoidance in equipment such as service robots and vacuum cleaners, markets in which ST has already enjoyed considerable commercial success. Like all FlightSense sensors, the VL53L3CX features a compact, all-in-one package design that eases integration in customer devices, as well as low power consumption that helps extend battery runtime. ToF sensing suits a variety of applications, including more reliable occupancy detection in buildingautomation and lighting controllers, smarter proximity sensing in IoT endpoints, more convenient autowakeup in portable devices, and more robust user detection in automatic sanitary equipment. With their high accuracy and fast response times, ToF
sensors also enhance the performance of all devices requiring precise movement control, typically robotics and indoor drones. DW
STMicroelectronics www.st.com/vl53l3cx-pr
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Design Notes
Streamlining the ventilator
manufacturing process Edited by Mike Santora • Associate Editor
Parts loaded in the machine. | courtesy of Staub Precision Machine
CERATIZIT USA has joined forces with several companies to make ventilators.
The company’s experience
in the carbide production process allows special-purpose tools to be developed for user-specific applications. Staub Precision Machine recently chose CERATIZIT reamers to perform a finishing operation of high-precision holes to size. The reamer was a solid carbide PCD tipped (polycrystalline diamond) with a through-tool coolant diameter of .626in. +.0005 -.0000. The material cut was aluminum, and the production run quantity was 2,500 parts per week. In addition, Staub designed and machined
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two tombstones as well as collets. There were 33 parts on each of the four sides of the tombstone in the machine, and Staub made 132 parts at a time. The machine was running at 4900 RPM and 78-in. per minute feed. The hole was only .250-in. deep, taking less than a second per hole to ream. Additionally, the hole was .616-in. before reaming, leaving .010-in. of stock www.designworldonline.com
allowance. While the hole has a .0005in. tolerance, the reamer cuts the same size every time with a high mirrored finish (See photos 1 and 2). The close collaboration between Staub and CERATIZIT team was facilitated through Abrasive Tool. Located in Buffalo, New York, the company is a distributor of tooling solutions. Jay Janca, distributor sales engineer, supplied Staub Precision DESIGN WORLD
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POWER TRANSMISSION
RETAINING DEVICES & maintenance & assembly tools
Machine with the reamers, helped process the part, and coordinated delivery of several other parts. Along with Tony Staub of Staub Precision Machine, the two started this project on a Thursday evening in his garage with a set of drawings and a part he needed to make for a ventilator client. Through Janca, he reached out to Chuck Somerville, CERATIZIT sales engineer, and told him about the project. Tony, Jay, Chuck, and the staff at CERATIZIT worked on confirming tool details. An approved drawing was created by the beginning of the week and the reamers were shipped on Friday of the same week and in production the following Monday. This was just over a week a er the initial discussion. Staub machines run unattended for maximum productivity 24/7, so the team worked to make the process as smooth as possible. Another two companies that joined CERATIZIT in the manufacturing of ventilators were Blackhawk Industrial and another manufacturer of precision metal components. As Blackhawk distributes CERATIZIT products, the company helped connect CERATIZIT with their customer. Blackhawk Industrial is an industrial distributor in Brunswick, Ohio. The machining process performed by their customer company involved machining adapters. To ensure that the tool holding device could accommodate various types of cutting tools, CERATIZIT reamers were used to create a hole for better positioning.
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A close-up of the part with the holes being reamed. | courtesy of Staub Precision Machine
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Design Notes
The Fullmax reamer. | courtesy of Blackhawk Industrial
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Different cutting tools in the adapter were used on multiple machines. The tool involved was number 52M.57.0497, known as Fullmax - DBGU - Ø4,97 +4µ. The material cut was stainless steel. The ventilators had to fit in a precise location; thus, dowel pins were used to locate the mounting brackets to the mobile unit. In this process, five reamers were used to provide a true position diameter. The tool diameter of the reamed blind hole in stainless steel was .1958 +/- .0005. There were three holes in each bracket, and over 10,000 brackets were made. Blackhawk’s customer blends old world cra smanship with cutting- edge technology. Capabilities include precision turning, grinding, milling, automated assembly and inspection, semi-automated assembly, manual assembly, and wire EDM. Additional capabilities are CNC machining, Swiss machining, machining ranges between 3mm and 66 mm, and material neutral machining. Within the medical field, the company specializes in manufacturing small diameter components requiring strict tolerances and superior finish. As an industrial distributor, Blackhawk specializes in metalworking equipment categories such as carbide cutting tools, abrasive, fabrication, and machining equipment. DW
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Design Notes
Mechanically cleaned filter handles chemical residue issue
Edited by Mike Santora • Associate Editor
The DCF mechanically cleaned filters operate at a consistently low differential pressure and deliver simple, reliable operation in which a low initial investment is a key driving factor.
One of the largest packaging companies of consumer products in North America produces customized packaging for many popular national brands of household and personal care products in plants located across the U.S. and Canada. Environmental regulations at their plant require process water to be ee of certain specified contaminants before being discharged into the public sewer system. The company was using a large, 24 x 24-in. filter press equipped with a dozen 40-micron filter pads to remove flocculated contaminants om the wastewater before processing it through an ultrafiltration system before discharge. The pads had to be changed twice per day in a messy, labor-intense process that resulted in an average of three hours of downtime daily. The contaminants collected by the filter pads include oils, zinc oxide particles, and silicates that were uncontained once the press was opened, exposing workers to potential irritants and allergens. “Twenty-one hours of downtime per week in a plant operating 24/7 had become increasingly unacceptable to the customer,” said Anita Gupta, product manager of the Eaton distributor, John Brooks Company of Toronto, Ontario, “so they started looking at alternatives like bag filters and manually cleaned cartridge-type filters. They had not considered a self-cleaning automatic filter until we showed them the DCF-800.” The plant processes an average of 400,000 gallons of water per week (approx. 1.5 million liters) through the system. Twelve 40-micron filter pads with a total surface area of 48- ² (4.46 m²) removed about 10 pounds (4.5 kg) of contaminants om the wastewater stream. Two sets were used per day to remove 20 pounds (9 kg) of contaminants. Given those figures, the company’s engineers were understandably skeptical that the physically small DCF-800 could successfully replace the large filter press. Gupta’s team overcame this by introducing them to another customer using a DCF filter in a similar application who was able to answer their questions and demonstrate the success of the unit in operation.
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Eaton’s unique circular cleaning disc design ensures intimate contact with the screen to thoroughly and uniformly clean the media.
Gupta’s team replaced the filter press with a DCF-800 filter with a 38 micron screen. The result was improved protection for the downstream ultrafilter over the old filter press with no adverse impact on flow rates. Operating at consistently low differential pressures, DCF series filters deliver simple, reliable operation with a low initial investment. They are particularly efficient for filtering viscous, abrasive, or sticky fluids, making them a suitable choice for this application. The DCF filter consists of a cylindrical stainless-steel housing that holds filter media. Fluid enters the element and flows through to the outlet, depositing any contaminants on the inside wall of the element. A spring-loaded cleaning disc moves up and down, wiping the filter element clean and depositing the contaminants at the bottom of the housing out of the flow path. Cleaning equency can be based on time, differential pressure, manual selection, or any other application-specific criteria. Because the filter remains in service while being cleaned, DCF filters support high process efficiency. The company has eliminated an average of three hours per day of downtime and the associated labor cost of maintaining the filter press plus the cost of new filter pads and the disposal of used ones. “The ability to reduce significant downtime and create a safer environment is what makes the DCF technology so unique in this application,� said Eaton regional sales manager, Aldo Guarneri. “A low differential pressure and lower cost of production was the ultimate goal. The DCF-800 achieved both and surpassed all expectations.� Building on this successful application, the customer has installed an Eaton filter on another process line to remove any residual contaminants om another product immediately before bottling. Reducing waste disposal costs in Canada, where environmentally iendly business practices are strongly encouraged, provides not only financial savings, but also helps the company employ sustainable business practices. DW
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Design Notes
CNC job shops capitalize on retrofit edge
Edited by Mike Santora • Associate Editor
CNC machining job shops are multi-stage process operations where there is potential for improvement at each stage. Most low to mid-
The custom PLC control panel features Conversational programming, DRO mode, accepts industry standard G-Code programming, and macro instruction programming.
volume run production machine shops struggle in achieving their share of the 5-10% maximum profit margins typically realized on most jobs. If a machine is down for any significant amount of time, you’ve cut into your production output, increased the cycle time, and you’re losing money. Therefore, if a machine is down, you need to move fast to get the machine back up and running. To breathe new life into old CNC mills, or turning a mill into a CNC as a cost-effective alternative, SERVO Products Company (Eastlake, OH), a progressive designer and manufacturer of manual knee-type milling machine tools and accessories, recently introduced its Orion CNC Retrofit package for knee mills and lathes. The CNC Retrofit kits; 1000 M (Milling) and 1000 T (Turning), provide quality upgrades while saving the customer money over purchasing a new machining center. The pre-configured retrofit package is virtually a“plug-and-play” solution that reduces vital machine downtime for almost any make or model of knee mill. It features a PLC control panel, VFD spindle speed control, true servo motors, ball screws, auto lube pump, and runs on single-phase power. End-users can add an optional LED Work Light for safety, wireless MPG pendant, power drawbar lockout solenoid, and dual-channel E-Stop for a complete milling machine package.
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The CNC Retrofit kits; 1000 M (Milling) and 1000 T (Turning), provide quality upgrades while saving the customer money over purchasing a new machining center.
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An ISO 9001: 2015 Certified company, Servo is also family-owned and manufacturers in the USA, with a focus on knee mill power feeds and precision drill presses for the medical, aerospace, jewelry industries. With an eye for innovation, Servo Engineer, Garry Yaworski, came up with the CNC retrofit kit design to address the fact that there were several existing Anilam, Acu-Rite, and other controls in the field featuring obsolete analog systems and failing controls. This also applies to machining centers with failing controls. If an end-user has one of these systems, where support may be nonexistent, the Orion kit is a fast and easy upgrade that can have users upand-running in hours, not days. According to Yaworski, “The ball screws and brackets are already in place on these systems, so you’d just need a new control and motors. The idea was to supply an ‘octopus’ style control box, with all of the cables and attachment pieces, that the user could install on an existing knee mill in the shop. Preconfigured, you’d simply bolt it to the existing machine and connect all the motors. This system can also be used to update a CNC machining center.” Servo’s Orion quickly turns a manual knee mill into a three or 4-axis CNC, and is adaptable to multiple manufacturers. Packaged as a threeaxis kit for milling machines, it is also easily upgradeable for a fourth axis. Importantly, the third axis can drive the knee so you have a full 16-in. of travel up/down. Notably, the retrofit system is as simple as installing power feeds, with the servo motors built in — enabling easy installation — typically within a day. The 400W true servo motors provide up to 300 in/lbs of torque and a maximum rapid travel speed of 105 IPM. Servo also offers the Elrod belt-and-pulley style systems; both systems operate on 208-240V single-phase power, which is suitable for smallto-mid sizes job/home shops that don’t have three-phase power. Ultimately, for today’s machining job shop sector, being better and faster keeps costs lower while raising the bar on potential profits. The ability to avoid downtime by quickly adopting new machine tool technologies like Servo’s Orion Retrofit Kit, becomes paramount to the overall success equation. DW
SERVO | servoproductsco.com
DESIGN WORLD
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AUTOMATION
WIND
MATERIAL HANDLING
STEEL
FOOD AND BEVERAGE
ROBOTICS
TRAYCONTROL® 600 For a shielded option see our TRAYCONTROL® 600-C
TRAYCONTROL® 600 is a flexible control and power cable that is rated for 600 V (UL 1277) and 1000 V (UL 2277) applications. It is torsion resistant, exceptionally flexible and abrasion resistant. Additionally, it is suitable for installation in dry, humid and damp environments, outdoors, conduit and trays (TC-ER & WTTC). The TRAYCONTROL® 600 an ideal fit for a variety of industrial applications, such as robotics, material handling, wind and solar.
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CAE Solutions
Altair announces major updates to its so ware All of Altair’s so ware products have been updated with new features, including intuitive workflows that empower users to streamline product development, allowing customers to get to market faster. The so ware update release expands on the number of solutions available for designers, engineers, and others to drive better decisions and accelerate the pace of innovation. It broadens the scope of the new user experience, enables access to more physics, data analytics, and machine learning, and makes the Altair so ware delivery method more flexible and accessible. Some of the highlights: • Structures • Altair HyperWorks – new interface to Altair’s solution for high-fidelity computer-aided engineering (CAE) modeling and visualization, making learning easy and productivity high • New subsystem entity for modular model configuration • Altair SimLab – fatigue optimization • Altair OptiStruct – includes the addition of new explicit solution and expanded implicit non-linear solutions including 2D axisymmetry • Altair SimSolid – includes advanced 3D seam weld connections to further improve speed • Altair Radioss – employs a dramatic reduction in runtimes for virtual drop testing of electronics devices
• Fluids and Thermal • HyperWorks CFD – provides engineers and experienced computational fluid dynamics (CFD) specialists with the most productive CFD pre- and post-processing capabilities to-date
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• Altair AcuSolve – GPU acceleration
• •
yields 3-4 times increased speed while also supporting nucleate boiling, radiation, condensation/ evaporation and multiphase fluidstructure interaction (FSI) Altair ultraFluidX – includes a new, more accurate wall model and overset grid technique Altair nanoFluidX – is three times faster than the previous version
• Industrial Design and Structures • Altair Inspire integration of Altair SimSolid solver includes support and connector reaction forces, instantaneous reaction time modeling large PolyNURBS models, DESIGN WORLD
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and improved geometry generation om optimization Inspire Studio – advanced morphing of any geometry type
• Manufacturing • 3D printing simulation available
• Systems Modeling • Altair Activate – performs multi physics
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in Inspire with new unit cell lattice generation
• Electromagnetics and Multiphysics • SimLab – electric motor modeling
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and coupling with AcuSolve and Altair Flux; accommodates ECAD file import (ODB++) Altair Feko – provides a component library tightly integrated with CADFEKO Altair FluxMotor now includes thermal and acoustics evaluation Flux includes several enhancements including those for modeling iron losses and skew type motors
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system modeling with hardware-in-theloop and Internet of Things (IoT) for digital twin development Integration of EDEM bulk material modeling with multibody dynamics simulation and hydraulics ideal for heavy equipment and agricultural applications Altair MotionView – has a two-wheeler vehicle dynamics library for motorcycles and scooters Altair Compose – OpenMatrix Language available in Jupyter Notebook Altair Embed – supports three additional target and two additional target families om ST Micro, VRTOS code modifications for MISRA compliance, and OpenCV DNN (Deep Neural Network) module integration
• Data Analytics • Recent release of Altair Panopticon
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monitoring of real-time data – includes major update of cloud based deployment, enabling users to build, modi , and share customdesigned functions and content easily via standard web browsers; hotfix to enable deployment at Nomura Altair Knowledge Hub – improved messages for troubleshooting and robustness; security hardening; more flexible Windows deployment; deployment on Azure; transformations including continuous binning and lookup join (refactoring for performance) and more Altair Monarch – complex Excel input support – “Excel Trapping”; PDF extraction improvements; user experience and UI improvements; enhanced column list and more
– platform for user-driven
Custom Applications Require Custom Solutions Customer Requirement
3D CAD Modeling
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6/30/20 8:26 AM
CAE Solutions
PROTOTYPE ANYWHERE. Basement-friendly. Garage-friendly. Office-friendly. Tormach’s line-up of compact mills, lathes, routers, and bandsaws are designed to set up where traditional CNC machine tools can’t dream of fitting. Plus they run on single-phase power, so they’re likely to operate in your space without any major or minor upgrades.
• Altair Knowledge Studio – new features including Keras model, model stacking, and pivot table; variable transformations node improvements with dataset and variable preview and re-ordering
• Smart Product Development • Altair SmartWorks – major rearchitecture of the edge orchestration and augmentation; ability to validate the edge application in real-time environments and deploy at scale
• HPC and Cloud • Altair Access – updated “work om
Operator-friendly, too. Our machines run on PathPilot control software. It’s easier to learn and use, and it works with your favorite CAD/CAM. And when you buy from Tormach, you get all of PathPilot. Unlike most CNC companies, we don’t charge thousands to unlock function-extending modules.
Buyer-friendlier.
•
•
We recently adjusted prices to help our customers keep making and developing ideas through these unprecedented times. We’re now offering our PCNC 440 at a new list price, with our Entry Package starting at $5,390. Go to tormach.com/440/design to explore and build yours.
home” features; more responsive 3D remote visualization; internationalization; better job resource charts; two-factor authentication and single sign-on; share support on mobile Altair Accelerator – EDA workload support on AWS (with Rapid Scaling), Microso Azure, and GCP; 10x faster for dynamic workloads; container improvements; REST query API; IPv6 Altair PBS Professional – scalability improvements towards exascale; Cray Shasta support; container enhancements for converged AI+HPC workloads; better system maintenance support
All products are available through the Altair licensing model, making access to all Altair’s so ware broader and more flexible. DW
Altair | www.altair.com/2020
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CAE Solutions
So ware includes probing cycles to speed workpiece measurement
ESPRIT CAM so ware now includes a suite of probing cycles for use with sensitive touch probes when assessing the dimensions of a workpiece. The new features include: Offline inspection programming, which offers users the benefits of virtual stimulation for program verification and collision detection Hassle- ee post processing and full control over each probing routine Compatibility with more CNC machines and probe manufacturers
• Using ESPRIT probing and CNC machines outfitted with touch probes will increase throughput on existing equipment while reducing operator intervention. DW
DP Technology www.espritcam.com
These capabilities join the probing cycle’s existing features, such as: • Misload detection, which confirms correct part loading and reduces the risk of damage • On-machine inspection, which generates consistent measurements and eliminates manual measuring errors • Dynamic tool offsets, which automatically adapt the program considering tool wear DESIGN WORLD
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CAE Solutions
Update for IRONCAD 2020 improves productivity and manufacturing workflows
The IRONCAD 2020 Product Update #1 (PU1) features enhancements and capabilities that enable IronCAD users to accelerate productivity and improve product development, om conceptual design to manufactured products. IronCAD’s research and development team delivered IRONCAD 2020 PU1 in response to requests om the IronCAD community around the world. With the new capabilities and enhancements in PU1, users can benefit om an array of options and opportunities to improve system performance in their daily operations, streamline workflows and seek new levels of collaboration and agility to more quickly and cost-effectively deliver products to their customers. Among the many new improvements and capabilities in IRONCAD 2020 Product Update #1 are: • Open/Save/Import Performance: Continued improvements have been performed in this area to reduce the load/save times of extremely large assembly data sets to improve the overall performance when designing with large assembly files. • IronCAD Drawing (ICD) View Creation/Update – Improvements have been made to improve the view creation and view update speed in the drawing environment, especially with large assembly files. • IronCAD Drawing (ICD) View Camera Performance – New options to control functions additional performance settings have been added to aid in the overall camera interaction performance when interacting and detailing drawings.
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Further improvements within Product Update #1 also include enhanced general quality improvements to the 2D Technical Drawing Area. Aligned with IronCAD’s position as a productivity leader for CAD so ware, PU1 also boasts improvements to the Bulk View Creation for automated drawing creation, including new search capabilities and creation om a selected set of parts/assemblies. Additional productivity improvements in PU1 improve the Sheet metal capabilities for Out/In Bend Automatic alignment to the angled stock, Quick Access commands added to right-click menus to improve speed and visibility in accessing commands as well as improvements to now create singled drawing sheets quickly om the selected elements in the scene. DW
IronCAD www.ironcad.com/whatsnew
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HOW FAR
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Internet of Things
Designing smarter industrial applications Cliff Ortmeyer • Global Head of Technical Marketing, Newark
Innovations such as AI, the IoT and the IIoT are pushing more intelligence out into harsh environments, resulting in industrial applications never thought possible before. But it’s also foreign territory for many electronic engineers who don’t have experience designing solutions for extreme conditions. In factory automation and heavy industries such as oil and gas, vibration, temperature extremes, chemicals and fluids take their toll on electrical systems. Ruggedized applications require a different kind of component portfolio than traditional solutions. Standard connectivity approaches aren’t applicable in harsh environments where the stakes can be too high to fail. Design engineers must account for environmental factors before the design stage, choosing products with appropriate qualifications and ratings to ensure the protection of valuable equipment and personnel. While we can’t explore the needs of the entire ecosystem of IIoT components here, focusing on a few key application building blocks will indicate which accommodations to make in a design. Connectors A good starting point is connectors since they are fundamental components to most IIoT applications. Whether they be HDMI, RJ45, RJ11, fiber optic, board-toboard connectors or other types, the key challenges are in preventing dust and liquid ingress, along with the ability to withstand rough handling.
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Ruggedized connectors with IP67/1P68 or dynamic IP69k-rated environmentally-sealed connectors are a good choice for providing secure connections in harsh or hostile environments. They are particularly critical for underwater, agricultural, outdoor metering, medical equipment and other applications where equent washing or exposure to moisture is an operational threat. A robust locking/coupling mechanism is a must for harsh environment connectors as well. Types of connector couplings include ring, twist locking, threaded and quick disconnect couplings, all with different attributes for various types of applications.
continuity. The challenge for designers is that sensors must be small, resilient and low-power enough for ubiquitous deployment, while still being able to collect and deliver data in challenging environments, such as extreme heat, cold, blistering winds, high humidity or even chemicals. As with connectors, seal integrity is essential for reliable operation of sensors in tough conditions. At minimum, they should meet IP standards. Also consider sensors made with corrosion-resistant materials, particularly for outdoor IoT applications. ISO has classified corrosivity categories for materials ranging om C1 (for very low corrosivity) to C5-I and C5-M (for very high industrial and marine applications, respectfully.
Sensors IoT applications use large arrays of sensors to collect data for transmission over the internet to a cloud-based computing resource. Sensing technologies such as accelerometers, encoders, temperature sensors, liquid level sensors, particle counters and humidity sensors must perform reliably in the most extreme situations to ensure both public safety and business
Switches Electrical switches – such as snap action, toggle, tactile, and pushbutton switches – must also offer chemical resistance, ingress protection and other resistant properties for IIoT applications. Sealed switches are typically required to meet the challenges of extreme environments. Since switches are mechanical components that get a lot of human engagement, they tend to get
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banged around and exposed to a variety of fluids and contaminants from both human activity and the environment in which they operate. Think of medical applications, for example, where devices are constantly being moved around and can be exposed to blood and other fluids. Switches need to handle the repeated impact of operators pressing or triggering too hard on the component. Another factor to consider is the materials the switches’ splash-proof boots are comprised of (such as silicon rubber or ethylene propylene rubber). Engineers should also consider requirements such as terminal type, actuator type, their IP rating, and whether the switches will require illumination, all of which would influence material selection. Power Unlike many larger connected systems, IoT products often do not have access to a main power source and must power themselves, typically using either energy harvesting or batteries. Energy harvesting is particularly promising for industrial applications because the energy required is taken from the environment, leveraging movement energy from the equipment, solar panels, heat, or other local sources of energy. But energy harvesting isn’t suitable for all applications. Perhaps the power required for processing data on the device is too high, the needs of the communication technology are too demanding, or there simply isn’t a good source of energy to harvest. In these cases, batteries are often the largest part of an IoT sensor system, giving engineers a limited choice of which one to use. With a wide range of processors, communications technologies and software algorithms, however, the system can be designed to achieve the required lifetime. Often IoT sensors will be designed to operate for their entire life on the original battery, as the labor cost of replacement is so large.
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Connectivity In addition to harsh environmental factors such as temperature, moisture and humidity, IoT applications can be subjected to electrical interference from switching circuits, welding tools, and motors, amongst other things. If hardwired connectivity is the best choice, consider the effects of unwanted disconnection, either as a result of vibration or accidental force applied to the attached cable. Standard connection technologies such as Ethernet and USB were designed for home or office environments, where frustration is the worst outcome of an unexpected disconnection. Industrialized connectors prevent such outcomes using locking mechanisms that increase the retention force of the industry standard connector, or by implementing ingress protection. In addition to ruggedized USB or RJ45 Industrial Ethernet connectors, there are a range of standard industrial multipin connectors that transfer digital and analog signals along with power to the attached sensor. When wireless connectivity makes sense, innovative antenna solutions will be required that are both optimal in their radio function and can withstand harsh environmental conditions. At their simplest, a single element antenna, possibly as a chip-antenna, is designed into a flexible printed circuit (FPC) as one approach. However, radio solutions that use multiple-input, multiple-output (MiMo) antennae are becoming an essential element of wireless connectivity. Regardless of the approach taken, engineers need support and guidance when tackling the RF side of their applications. Custom antennae can often be the best approach, allowing the designer to take into consideration the materials used, the environment, and the object upon which the antenna is mounted. DW
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Internet of Things
All-in-one controller for compact IoT applications Manufacturers are constantly driven to streamline processes om machine setup to operation and maintenance. Even with compact machines and limited budgets, it’s essential to make good use of production data to visualize machine performance and prevent unexpected shutdowns. However, these demands are difficult to meet because they o en require an expensive controller to build an IIoT ready system. The CP2E all-in-one controller cost-effectively enables IIoT connectivity for compact machines. The controller collects machine performance data and shares the necessary information with enterprise networks, while the predefined program data and function blocks allow virtually anyone to set up machines to perform complex control. This reduces the time required for programming, testing, debugging, and maintenance. In addition, the CP2E’s extended operating temperature range makes it a reliable option for machines in non-manufacturing industries, such as in astructure and agriculture, where the demand for controllers is increasing. These industries have typically used non-standard controllers that customers have to manage and maintain using their own expertise, since environmental resistance as well as IIoT is crucial. The CP2E gives these customers a more user iendly option. Key features and benefits of the CP2E include the following:
• Improved connectivity for Ethernet and serial devices. The CP2E has two Ethernet ports with Ethernet switching function: host and HMI connectivity. Up to three serial ports are available for open connectivity to serial devices. • Reduced effort for the setup of complex machines. Function blocks make it easy to achieve 4-axis positioning function with linear interpolation, and the CP2E also provides a PID control with autotuning function block for stable temperature control. • Simplified troubleshooting. The CP2E’s input/output terminal LED indicators ensure quick and easy root cause identification, while the controller’s ability to automatically detect and recover om bit corruption increase machine efficiency and avoids CPU stops.
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• Increased peace of mind. The CP2E is a reliable “install and forget” solution for demanding environmental conditions, as its extended operational temperature increases reliability in special applications and its battery- ee operation reduces maintenance costs. DW
Omron Automation automation.omron.com
DESIGN WORLD
6/30/20 8:53 AM
Monitor machines from mobile devices
The ability to quickly check machine status and performance is becoming more important in the light of digitalization. However, machine builders’ dreams of cloud-based dashboards, alarms and reports om machines in various production sites around the world are o en shattered, since it is o en too technically complex, time consuming and costly to get a fully accepted, secure and working solution up and running. The eCatcher Mobile KPI lets users monitor key performance indicators (KPIs) om any machine equipped with an Ewon Flexy router. By using a mobile device with the eCatcher Mobile app for iOS and Android installed, users get a live look into their machines’ status and performance om anywhere in the world. The eCatcher device is based upon the secure eCatcher so ware which establishes remote connections to Ewon-connected machines via the cloud service Talk2M. HMS has updated the mobile version for iOS and Android - eCatcher Mobile - to enable presentation of live KPI’s om any machine equipped with an Ewon Flexy. Users start by selecting up to six (6) KPIs om the list of defined machine variables inside each machine-connected Ewon Flexy, and all KPI’s can be set to trig alarms. A er a few configuration clicks, the user gets a live view of the chosen KPI’s. The users can see if there are any active alarms and the degree of severity. The alarms are easy to identi thanks to an intuitive color indication of alarm status depending on alarm severity. And,
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if a machine reports a critical alarm, the user can instantly create a remote VPN connection over Talk2M to the machine in question for a quick intervention. The eCatcher Mobile KPIs is also handy for staff working at the corresponding end user facilities where the machines are located. Here, a machine builder can easily put eCatcher Mobile KPI’s at the disposal of the end user or its system integrator, as an easyto-use mobile monitoring tool for all connected machines on site. DW
HMS Networks www.hms-networks.com
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Connectivity and IoT in motion and
general automation Machine designs are evolving with wireless connectivity, Ethernetbased networking protocols, cloud-based operations, open programming, and various forms of edge computing. Connectivity is at the core of modern automation in manufacturing and beyond.
Lisa Eitel • Executive Editor
System links between devices, controls, machines, and the cloud facilitate the use of data so important to IIoT (Industrie 4.0) functionalities. Here, leading trends include the rise of edge computing (including the use of industrial gateways), services that support cloud connectivity, Ethernet-based networks, wireless communications for industrial components, various forms of standardized protocols, open-source programming code, and unifying software environments to facilitate interoperability. Just consider edge devices — the actuators, sensors, and connectivity components including gateways and motor-mounted controllers with computational resources to eliminate data bandwidth and latency issues. Their location at the furthest reaches of
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← Traditional automation and connectivity arrangements associate specific tasks with specific pieces of Enterprise level — ERP hardware. Therefore, the architecture is defined by the hardware ... and there’s a hierarchy to communications.
Device • Factory • Inventory management
Web services
Work cells • Process management MES and SCADA
Configurations shared across facilities
5G
Machines and dedicated functions
Condition monitoring Diagnostics
MQTT
PLC • Motion • IoT solutions
OPC UA
Cloud communications IoT gateways
Control devices — PLCs and HMIs
TSN
Field devices — Sensors • actuators • edge links
EtherCAT
Machines and end designs IO-Link connectivity image courtesy Balluff
Distributed control — Smart field-level devices • Edge computing ← IIoT architectures are based on flexible systems and machines, distributed controls, flat communications with de-emphasis of hierarchy levels, and smart products that network to services. Engineering: PLC — IEC 61131 • I/O • Safety • Drives • HMIs Additional programming: G-code • C/C++ • Blockly • Python
IIoT
Cloud connectivity
Smart products VPN
Intranet Teleservice remote expert
MES
ERP
Cloud
Partner facility
Remote services
Router Secure WLAN Internet
Automation network WLAN • NFC
Supply chain
Switch
RFID
Fieldbus DeviceNet
Logistics and distribution Intralogistics
Local facility
Shipping and delivery Intralogistics CP Factory connectivity image courtesy Festo
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End users
Top left: Traditional machine designs and automated facilities are based on hierarchal system architectures. Top right: Now cloud and fog computing (data processing on the shop floor) is on the rise ... which has blurred the lines of which components execute which functions. Edgelevel solutions with high computing power have accelerated this trend. Bottom: One IIoT example is this CyberPhysical Factory (CP Factory) layout from Festo. It incorporates logistics, IT systems and security, networking, and cloud-connectivity solutions. Separate factories and their components — including semi-finished and finished workpieces and other physical objects as well as various pieces of data — are part of a larger network. Such sweeping networking and data management enable new business opportunities based on big data and universally applicable cloud applications.
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machinery means their processing power is well placed to filter and analyze data before it’s sent onward to central controls or the design’s cloud presence. However, the usefulness of edge devices ultimately relies on interoperability with multiple machine systems. When conjuring such systems, most engineers are likely to picture the traditional automation-communications pyramid. Such architectures include data exchanges between field-level sensors and higher implementation layers … as well as some communications between controls … finally rising to the pinnacle of the enterprise level. But several technologies have facilitated distributed and intelligent systems with flatter machinery communication structures: • Today’s software (along with industrial apps not unlike those for consumergrade mobile devices) • Newer options such as cloud services — as one networking example • Hardware such as programmable automation controllers (PACs) and smart field devices — as two component examples These technologies have changed the structure of the intelligent factory floor — especially over the last decade. What’s the point of all this? Rodney Rusk, Industry 4.0 leader at Bosch Rexroth, explains that smart factories (sometimes billed the Factory of the Future) will increasingly use wireless connectivity including 5G as well as distributed intelligence and edge computing to: • Allow manufacturing to be more responsive to change • Impart more flexibility in production planning • Predict maintenance and failures before critical work stoppages. “These features will let industries reduce warranty, waste, and downtime costs while improving worker safety … and help them attract and retain the best workforce,” he adds. Of course, it’s key when implementing IoT functions that the objectives of machine builders and end users be satisfied.
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Regal Beloit’s Perceptiv wireless vibration and temperature monitoring system can help detect equipment problems before they’re a serious issue.
The role of wireless in IIoT from Dan Phillips The market for wireless technologies, one permutation of IIoT connectivity, has exceeded $1B annually … and will grow as global competition in manufacturing pushes organizations to optimize facilities for minimized cost of ownership. Consider the input of Dan Phillips, director of reliability and maintenance of CMRP for Regal Beloit on this topic and the role of wireless connectivity for industrial applications. Declining sensor costs and improved wireless communication protocols (fueled by the megatrend of IoT) have created an ever-growing mix of suppliers, distributors, and service providers using wireless technologies for machine condition monitoring. Though it’s easy to get caught up in the hype surrounding wireless, it’s becoming increasingly necessary to sort out the financial viability of these new technologies. Start with the business case: As with any sound business decision, suitability depends on financial and time considerations. Addressing the following questions when evaluating the use of wireless technology should be a first step before settling on a particular system. When conditions are detected that indicate a machinery problem, how much time is needed to prepare spare parts, craft labor, and so forth? The ability to detect faults at the earliest stages of failure, especially for low-speed equipment, may require technologies exceeding the sophistication and capabilities of wireless systems.
Regal Perceptiv intelligence provides customizable onsite and offsite diagnostics, monitoring, and smart products that connect to a facility’s current infrastructure.
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What is the cost of lost production in the facility when equipment is run to failure or fails unexpectedly? Determine whether there will be a payback for the instrumentation … minimally in terms of risk mitigation. Deploying technologies on equipment that doesn’t benefit from condition-based monitoring is an inefficient use of time and resources. Running equipment to failure may be a sound business decision if the equipment has redundancy (or spares are readily available) and simply replacing the equipment when it goes down doesn’t adversely affect production and safety. What resources are available to analyze the data generated from the wireless monitoring systems? Interpreting and acting upon condition monitoring data is paramount in sustaining a successful monitoring program. If resources to interpret the data are unavailable at the facility, consider utilizing automation or certified analysts to ensure that data is leveraged to benefit the bottom line. Answering these questions will ensure that a technology which provides a favorable return on investment is utilized. Of course, there are many types of wireless monitoring devices today — and they vary in measurement sophistication, communication methods, protocols, data management, form factor, and durability. From a technical standpoint, it’s key that the specified monitoring system fits the machine’s criticality ranking and operating conditions — defined by the following.
| Courtesy of Regal Beloit
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How often the machine runs: Wireless sensors allow for quick and easy deployment of condition monitoring — where gaps in the data stream won’t degrade system reliability. Gaps in the data are usually inherent to data collection logic, which is often setup to collect data at certain times of the day or when other conditions are met. Because data is collected intermittently, many of today’s wireless monitoring systems are best suited for steady-state machines that are either on or off — such as fans, pumps, and other equipment not required to make frequent starts and stops each day. Speed: Speed feedback on a dynamic machine with varying speeds and loads is critical in diagnosing faults. In some cases, wired systems are preferable. In the hands of a skilled analyst though, speed changes are not a limiting factor, as the analyst can use other methods to determine whether frequency and resolution are high enough.
Failure modes: Each machine has several different possible failure modes — many of which are related to specific fault frequencies in the vibration spectrum. Engineers should consider the fault frequencies that would be present for a given machine to ensure that they don’t exceed the limits of the wireless sensor on both the low and high end of the spectrum. An expert can help identify the specific failure modes that will be captured with a particular technology. Out of sight (and out of mind) location: Some equipment operates in remote locations not frequented by people who may be the first to detect subtle changes in operating noises as well as dripping fluids and other signs that equipment needs servicing. On such remote and nonstationary equipment — in tunnels, on roofs or rafters, or integrated into cranes or mobile devices — wireless
sensors can serve as the “ears” to monitor for trouble. Other forms of (and uses for) wireless connectivity Others agree with Phillips on the benefits of appropriately deployed wireless solutions — even beyond machine monitoring for lower cost of ownership. These functions include enterprise connectivity and operational feedback for on-the-fly changes to machine functions for top throughput … even of variable product types. Wireless products for these functions are often compatible with various standards. Consider wireless networking USB sticks that impart remote connectivity to industrial PCs. According to Matt Prellwitz, motion control product manager of Beckhoff Automation, CU8210 sticks include options for WLAN and 4G/3G/2G mobile communications. The sticks work on mobile robots and
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Lantronix Inc. now sells an xPico 270 embedded IoT gateway and combination (dual-band) WiFi-Bluetooth module. It supports the 802.11ac WiFi standard (also known as WiFi 5) for IIoT applications. Embedded firmware lets OEMs quickly add these and Ethernet connectivity with enterprise-grade security to their designs.
Shown here is a ctrlX CORE 64-bit multicore CPU of the new ctrlX AUTOMATION platform from Bosch Rexroth. The flexible and scalable platform greatly simplifies the integration of machine control systems, IT, and IoT functions.
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automated guided vehicles (AGVs) … and really any applications needing wireless communications with a central controller or supervisory control and data acquisition (SCADA) system. “Users can even monitor drive-based diagnostics — for better preventive maintenance based on real-world application data containing information about the frequency of events,” Prellwitz adds. Others also see mobile applications spurring more wiring connectivity. “With wireless technology and autonomous capabilities on the rise, mobile machinery using industrial controllers is becoming more common,” says Allen Tubbs, product manager for electric drives and controls of Bosch Rexroth. He cites off-highway and entertainment-industry examples: “Agriculture is an industry in which new automation innovations are coming online due to the shortage of available workers to tend and harvest produce. The entertainment industry is another good example — especially as amusement-park rides become more complex.” Today’s off-the-shelf automation controllers in such settings can impart the wireless and safety technologies necessary to protect personnel and communicate with existing computer systems, says Tubbs. As wireless technologies advance, so do the ways in which they’re used. 5G in particular holds promise for manufacturing operations that might benefit from cloud connectivity, because it has the needed bandwidth and stability for production grids — especially where realized as a campus network. “But because there are
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usually network connections available on all machine infrastructures, we consider widespread 5G-based industrial networking a ways off,” notes Markus Weishaar, product manager of IIoT & Software at Dunkermotoren. Others agree though are preparing for the eventuality of 5G in industrial settings. “We expect that as more 5G technologies are adopted, there will be rapid expansion in augmented reality, virtual design, and advanced analytics — also called artificial intelligence or AI,” says Rusk. “With the exponential increase in speed, we expect an estimated processing time up to 10 times faster than what we currently see with 4G systems.” In November 2019 Bosch Rexroth partnered with 3D-printer maker BigRep to demonstrate how wireless 5G technologies are capable of supporting real-time control of complex 3D printing processes from an external server. Ethernet continues expansion in industrial connectivity Industrial Ethernet-based protocols continue to overtake traditional fieldbuses for the messaging of data in automated installations … and in fact, Ethernet-based protocols are now employed in more than 40% of industrial networks. It’s true that some fieldbuses are more reliable than legacy Ethernet offerings that are nondeterministic, but Ethernet speeds lead. “Some old bus systems have data rates of 1 to 20 Mbit and no real-time reaction,” said Horst Messerer, who is the sales manager for data, network, and bus technology at HELUKABEL. “Certain types of manufacturing can tolerate these rates … so bus protocols won’t go away entirely — but they’re seeing reduced market share.” In contrast, Ethernet data rates are at least 100 Mbit to support tracking and processing of data in real time. Plus unlike fieldbus and device networks necessitating various physical layers, Ethernet works off one … and now, Power over Ethernet (PoE) now lets design engineers take use of that single physical layer even further. “Another trend resulting from the intersection of IIoT and motion control is the use of PoE connections on motion controls,” DESIGN WORLD
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Integrated designs from WITTENSTEIN’s cyber dynamic system (CDS) series incorporate drive electronics, ac servo motors, and modern digital feedback. The devices include a safe torque off (STO) functionality as well as multiEthernet (EtherNet/IP, EtherCAT, PROFINET, SERCOS III) and CANopen upstream communications.
says Eric Rice of Applied Motion Products. “In the past it was difficult to get energy sufficient to power a motor from PoE connections … but the rapid adoption of higher-power IEEE standards in industrial Ethernet switches is supporting expansion here.” The 802.3at standard for example provides 25 W of power to connected devices — which is enough to run a NEMA14 step motor at full power. “At Applied Motion Products, we’ve leveraged that capability to develop a fully integrated NEMA-14 step motor with closed-loop current control and a single standard Ethernet connector for power and communications,” says Rice. Each integrated motor receives power and communications via one of two standard Ethernet cables (RJ45 or X-coded M12) and supports common networking protocols such as Modbus TCP and EtherNet/IP. In fact, Ethernet-based connectivity is often in the form of EtherNet/IP. This application-layer protocol allows communication between controls and I/O; certain adaptations allow synchronized and deterministic multi-axis motion control. Also seeing dramatic adoption is Serial Real-time Communications System (SERCOS) III employing industrialEthernet cable to connect drives, motion controllers, sensors, I/O, motors and other actuators. With SERCOS III, deterministic bidirectional real-time motion and control communication is possible. Still other protocols capitalizing on Ethernet advantages include Ethernet for Control Automation Technology (EtherCAT), PROFINET, and CC-Link. IO-Link, HIPERFACE, crossnetwork, and single-cable solutions In many instances, protocols require certification of physical components … including cables, controllers, and feedback devices. Consider CAT5e and CAT6 DESIGN WORLD
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Ethernet cables. 802.3 (1 Gbit/sec or GbE) Ethernet can use Cat5a or increasingly common Cat6 cables supporting the PoE we just discussed. Now two for CC-Link Industrial Ethernet (IE) — flexible chainflex CAT5e and CAT6 cables from igus — are available for use in cable-carrier-bundled bundled energy chains and have UL certification for North American markets as well as the certificate for CC-Link IE protocols so common in Asia and growing around the world. Such cables can make connections between control, device, and sensor-level components via CC-Link variations for these network levels … with all commanded by an industrial computer. Consider one example of such a computer — Mitsubishi Electric Automation’s MELIPC series controllers. These support the CC-Link IE Field industrial network (again, one of several in the CC-Link protocol family) and allow data exchanges to 1 msec for real-time equipment control. The controllers also leverage the network for data computing, remote monitoring, edge computing, and
Shown here are an electric steering motor and steering wheel sensor from Allied Motion; EnduraMax 75i & 95i motors with integrated electronics; and (right) an H-Drive — all of which have optional CANopen functionality. “We create customized motion solutions integrating our gear, motor, feedback, and control technologies. That frees OEMs and end users to focus on their system architecture and not worry about interoperability of individual motion components,” says Jeff Shearer, systems engineer at Allied Motion. The supplier ensures mechanical compatibility of their integrated motion solutions by machining any output required to properly interface end effectors and other subsystems. “In addition, we support control networking by offering systems with various digital and analog I/ Os as well as connectivity to every major networking standard — including CANopen, CANopen Safety, J1939, Modbus RTU, and EtherCAT,” adds Shearer.
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the integration of hardware and software. All models include Windows 10 IoT Enterprise 2016 installed … some include another operating system (VxWorks) and open-platform Edgecross to process and distribute data. Some versions also include a touchscreen to double as an HMI. Elsewhere, HMIs might do doubleduty as gateways … and many motioncomponent manufacturers offer network gateways and cable sets to enable connections of their linear actuators and other devices to CC-Link. For example, the gateways might convert data from a host CC-Link communication protocol to the component suppliers’ own RS-485 communication protocols. Such gateways (and those more sophisticated) make it easy to integrate and control RS-485connected components under the host communication environment. Even beyond the enduring standards of serial interfaces and the burgeoning forms of Ethernet connectivity, other cable and communication standardization is simplifying sophisticated communication between components on a given network level. Consider the migration to singlecable solutions for servodrives and motors: HIPERFACE DSL from SICK is one servo-control feedback interface using single-cable technology. Fully digital twowire communication supports operating communications as well as condition monitoring of servo axes. “New encoder technologies such as HIPERFACE DSL allow the routing of motor power and position feedback through a common cable,” says Jeff Shearer, systems engineer at Allied Motion. “This decreases system complexity and cable costs.” Shearer adds that smart HIPERFACE DSL encoders also include internal memory to store motor information. “Upon initial connection, a servodrive can query this information … thus automating motor setup and commissioning. HeiMotion servomotors — which connect to Allied Motion’s H Drive servodrives — leverage such cabling.” But single-cable solutions may benefit
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A new line of Weintek HMIs include the cMT3092X, cMT3152X, and (shown here) the cMT3162X. Powerful processors provide an experience approximating that from smartphones and tablets. The HMIs allow data display and storage, machine control, PLC communication, protocol translation, alarm notifications, media playback, and IIoT integration. Connectivity includes that via RS-232, RS-485 2W/4W, CAN Bus, Ethernet 10/100/1000 Base-T × 1, and Ethernet 10/100 Base-T × 1.
linear actuators most of all. “Exlar Automation of Curtiss Wright offers linear-motion solutions that are compatible with nearly all amplifier manufacturers on the market,” explains Eric Summerfield, product manager of integrated linear actuators at Exlar Automation. “Adding the single-cable DSL connection as an option allows for a quick and seamless integration from controller to motor while reducing the total cost of ownership.” Another single-cable solution on the rise is IO-Link — that branded standard of IEC 61131-9 defining a simplified system for actuator and sensor connectivity. In fact, the number IO-Link-capable devices could double every year through 2023 as end users and OEMs aim to leverage the expanding suite of IO-Link functions. “We’re actually considering the integration of an IO-Link Master in our intelligent motors — to extend our capacity of connectable sensors for decentralized automation concepts,” says Markus Weishaar, product manager of IIoT & Software at Dunkermotoren. “Of course, because our motors can communicate via industrial Ethernet or CAN bus, we see no need to connect them to IO-Link networks as slaves.” IO-Link can also digitize legacy analog connectors on linear actuators to impart bidirectional communications and quicker commission times. “That’s why we’ve also adopted IO-Link connectivity on the controls side — for multi-protocol support and connection with serial interfaces,” says Rusk. DESIGN WORLD
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Edge computing and gateways proliferate for industrial machinery Reconsider the actuators, sensors, and other edge devices so fundamental to edge computing. Supported by gateways and controllers with dedicated connectivity functions, these components use their logic resources to process data before sending it onward to controls, the cloud, or onsite servers and other IT infrastructures. Also called fog computing, distributed intelligence and data processing out at a design’s most distal device levels (before data heads onward) have been available for some time. But devices with more computing power than in the past now allow more preprocessing and some of the predictive-maintenance functions that Phillips of Regal Beloit outlines for wireless connections. Another benefit to fog computing is a more holistic view of processes for iterative design optimization. “We’ve actually pushed each technology generation to bring more logic, computing, and analytics to the device level,” says Rusk of Bosch Rexroth. He cites IndraDrive electric drives and MLC and MTX controllers as two examples for decentralized control — using what the manufacturer bills drive-integrated logic. These components support modular machine designs for scalability … and accept setup and operation via one software environment. Other connected examples are specific to applications — such as handheld pneumatically and motor-driven tools (complete with integrated control logic) for fastening. Another assembly-specific www.designworldonline.com
example is the PRC7000 adaptiveresistance weld controller that manages weld growth in real time with onboard logic for repeatable spot quality … even on various combinations of sheet thicknesses and materials. But even legacy systems without such IIoT tools and end effectors can benefit from new modes of connectivity. Here and in new installations, the role of gateways for edge computing is central — especially when smarter use of feedback for distributed control is advantageous … and disparate systems need unification. Examples from Weintek USA include cMT-series gateways and HMIs that accept setup via the manufacturer’s EasyBuilder Pro software — which in turn supports multiple programming languages and communication drivers. The gateways also run the supplier’s EasyAccess 2.0 software for remote access to automated equipment (via mobile devices) about machine health and other parameters. Such gateways execute many tasks typically associated with HMIs — such as running macros for control and datatransfer functions; concurrent networking of device arrays; handling and logging alarms; triggering data storage; and interfacing with cloud services. For older brownfield equipment upgrades, IoT gateways and software can provide single-point data collection and preprocessing before data travels to a higher processing system, explains Rusk. His company introduced its first generation of IoT gateways several years ago and has continually advanced their designs. “Our July 2020
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Shown here is a TSM14POE StepSERVO integrated motor from Applied Motion Products. It uses a power over ethernet (PoE) single-cable solution to satisfy motion-control applications requiring minimal wiring and a small footprint. Combining power and Ethernet communications in a single connector simplifies wiring to the integrated motor so it can mount almost anywhere.
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software called Active Cockpit Solution complements the gateways with edge-based visualization and shop-floor management for real-time decision making and collaboration. In addition, our platformneutral WebConnector (based on the Java Runtime Environment) allows additional edge-based flexibility for the rapid exchange of data,” he adds. Yet another example is Lenze’s X4 Remote solution — consisting of cloud gateways and a cloud-based range of easily configurable web services. It integrates smart-factory equipment into superimposed systems such as SCADA, manufacturing execution systems (MES), and enterprise resource planning (ERP) as well as the cloud. Besides the optimization of maintenance schedules previously mentioned, the solution also supports the exchange of information between suppliers and end users. “IoT gateways are adaptable solutions that provide connectivity to nearly all devices and enterprise systems in the marketplace— and in some cases, to multiple PLCs at a time,” says Agnieszka Zupancic, product manager at Mitsubishi Electric Automation. Additional applications include the management of consumable materials, contextualized visualization, and cellular connectivity to remote machines. OEMs in the packaging and printing industries benefit most from the insights gained through this access to production information, according to Zupancic — as they can use resulting data to develop features on their next-
generation machines. Some make a clear distinction between edge device and gateway functions. As mentioned, edge devices let end users receive and evaluate distilled data from the plant or other installation. According to sources at Festo, that’s in contrast with some IoT gateways that may only send data from the machine onward — without processing it. In addition, edge devices tend to support more modes of system monitoring as well as ways to backup data if a cloud link is temporarily unavailable. In fact, Festo is currently developing an edge device that offers typical IoT functions — extracting data and then preprocessing and visualizing it on dashboards. Company representatives indicate that they may combine it with control tasks — to let design engineers closely couple it with their existing field devices. Integrating gateway functions is another trend in increasingly capable controls such as industrial PCs (IPCs) and PACs. Says Prellwitz: “PC-based control is the foundation of our technologies, which means our portfolio provides the advanced connectivity needed for our IPCs to handle complex motion — and serve as gateways to the enterprise or cloud.” Many of the manufacturer’s controllers are certified for Microsoft Azure or Amazon Web Services — more on these shortly. The controllers also employ secure protocols such as MQ telemetry transport (MQTT), advanced message queuing protocol (AMQP), and OPC-UA. Such capabilities make machine data available for analytics, machine
These linear motion axes are monitored by AP10 SIKO position indicators connected via IO-Link. | Courtesy ROVEMA GmbH
Shown here are Bosch Rexroth IO-Link hubs and other components.
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Cable reliability for punishing tasks learning, and display on company or OEM dashboards anywhere in the world. Protocols and cloud connectivity serve advanced operations Consider the various protocols and communications leveraged in IIoT connectivity — for example, the SCADA, MES, and ERP architectures we’ve already covered. These are the most involved in IT/ OT (operational technology) convergence — often involving enterprise-level tasks, gateways, and other connectivity to allow system configuration through standard web browsers … as well as operational adjustments and additional managerial actions. Also employed in many IIoT installations is Structured Query Language (SQL) — programming that allows synchronization of data and event logs to MySQL and MS SQL database servers. The benefit here is IT personnel access that’s more simply implemented than alternatives relying on controls. That’s true whether the systems employ basic controls such as Raspberry Pis or complex PC-based IoT database interfaces (which usually necessitate additional hardware and software). Also seeing massive adoption for how they support multi-pronged IIoT design approaches (involving software, hardware, and connectivity) are infrastructure, platform, and software as a service (IaaS, PaaS, and SaaS respectively) or cloud services. These include Alibaba Cloud, Tencent Cloud, Google Cloud, IBM Cloud, and Oracle Cloud. However, in the U.S., today’s two leading public (offsite not company or machine network) cloud service providers for machine automation are: • Amazon Web Services Inc. with AWS cloud software and services • Microsoft with Azure IoT Edge cloud software and services
These primarily support the use of databases (through products such as Amazon simple storage service or S3 buckets and Amazon DynamoDB managed database services), online DESIGN WORLD
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and local applications, and on-demand computational power. Related to the latter are AWS Lambda services that allow Python, Node.js, Java, and C# programming to run on the service’s servers. The cloud services serve other functions too. Part of what’s driving AWS and Azure adoption for IIoT is how more engineers have become comfortable with building out their own infrastructure on these platforms. After all, cloud-based data services free engineers from extra design work on underlying hardware and software — because the provider executes IT tasks. AWS and Azure also allow use of software that abstracts dataflows and communications — simplifying some design work with GUIs and other tools that shield engineers from dealing with programming minutia. The cloud services also facilitate advanced engineering with virtual machines that run operating systems and applications … over which design engineers maintain control. What’s more, cloud services can accommodate various communication services on protocols employing publishsubscribe principles — to be the master service for them all. That eliminates the need for time-consuming addressing during system setup. All such features can in turn facilitate rather advanced capabilities, including the use of machine-learning algorithms for categorizing and distilling data … to make predictions and prompt machine and production adjustments. No wonder industrial-component suppliers are expanding what they offer for such cloud connectivity. “WAGO’s controllers are based on Linux — and that allows the application of new software technologies … including Docker, secure IIoT protocols for various cloud platforms, and edge-of-network agents such as AWS Greengrass and Azure IoT Edge,” explains Kurt Braun, IIoT market specialist for WAGO Corp. A WAGO cloud service at cloud. wago.com gives engineers a simple way get started with IIoT. The service works with WAGO’s PFC100/200 controllers www.designworldonline.com
For industrial automation, cables must perform mechanically and electrically. Don Nester Product manager of chainflex cables igus Engineers must know the expected service life of cables destined for use in their machinery
— as end users need to know when cables might require replacement. That’s why we offer various mechanical-performance levels for cables of a
given electrical rating — so engineers have more
design flexibility and (where appropriate) the ability to reduce overall design cost.
Such customizability is even possible with
fiber-optic cables. Consider a recent application in an e-spool product used on a design for tracking satellites. There aren’t many continuous-flexing fiber-optic cables on the market … but we sell
them in four different mechanical performance
levels. The most rugged even withstands use on an e-spool, which tends to be very mechanically
demanding — with a lot of twisting and bending. Connectorized cable assemblies complete the
connectivity setup for a guaranteed service life. In another demanding application, our
assemblies prevent the problem of corkscrewing
cables on a paint robot. The connectivity subsystem withstands the aggressive bend radii and fast
speeds so typical of quick and agile paint systems — even where the robots follow paths that are
very hard on cables. What’s more, cables in paint booths must withstand heavy solvents and paint
types used in automotive applications — plus meet UL listings for hazardous environments. Here,
chainflex cables (pre-verified in our German test
laboratory) confirmed the cables were appropriate before final specification and installation.
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and Touch Panel 600 HMIs with a simple onboarding process. Once established, even nontechnical personnel can customize dashboards with trends and configure email notifications using a rule engine managed from the cloud portal. A beta feature also allows remote access to the controllers’ webbased management for software updates — and remote viewing of the controllers’ web visualization, adds Braun.
Exlar Automation of Curtiss Wright offers linear motion solutions that are compatible with nearly all amplifier brands. A single-cable DSL connection allows for a quick and seamless integration of controller and motor while reducing the total cost of ownership.
Cyber dynamic products from WITTENSTEIN include an array of motor, gearmotor, and linear components — including the one shown here. The devices have full ac servo motors and are very compact — with frame sizes down to 17 mm. Modern digital feedback and single-cable connectivity simplify integration. Configuration software on ePLAN.de helps simplify mechanical and electrical design.
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The manufacturer’s PFC200 G2 controller and Touch Panel 600 HMI are both certified for AWS GreenGrass Core. That extends the use of AWS (including AWS Lambda and Things Graph) to let connected edge devices (such as sensors and actuators) act locally on data they generate — and use the cloud for data management, storage, and analytics. With AWS IoT Greengrass, connected devices can also run Docker containers. This containerization service from Docker Inc. comes in both free and professional versions. Recall that in the context of industrial programming, a container is a piece of executable software that holds the codes, system tools, runtimes, libraries, and settings needed for the standalone running of an application. In many machine designs, containers are designed to communicate and synchronize data to other systems or execute various predictions — even when disconnected from the internet. According to Braun, advantages of building applications in containers include: • Easy deployment onto devices • Portability of software to allow its use across different platforms • Improved security by providing a sandbox for engineers’ applications “Docker can install on WAGO’s PFC200 and TP600 products. In fact, WAGO regularly releases numerous prebuilt containers to extend services onto its products. Examples include TosiBox Lock for Container VPN, Inductive Automation’s Ignition Edge, and Dianomic’s Open Source FogLAMP,” adds Braun. Other manufacturers offer Docker containers for their own arrangements.
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“We only offer edge gateways to design engineers wanting a complete solution from us,” explains Weishaar. “But we may soon offer software containers for Docker-based edge gateways that connect our motors. We deem this most effective, as most machine builders and operators don’t want unique gateways from each component supplier. For such builds, we consider message queuing telemetry transport (MQTT) along with REST API and AMQP — another transport protocol for data communication — to be a leading communication standard above the edge.” In fact, MQTT is also indispensable in many IoT connectivity structures. For the uninitiated: MQTT a protocol supporting scalable communications between sensors and mobile devices. Any built-in support for MQTT from a device is also useful because it’s applicable in Amazon AWS IoT services. In addition, MQTT (just like AMQP) is lean and standardized. Consider how MQTT support can be implemented via Festo’s CPX-IoT-GW gateway: This device can handle data from the field level on various cloud or onsite systems. In fact, Festo sources indicate that the supplier will soon offer more MQTT support on its products. They maintain that value-added services at the edge enable provisioning of processed data in third-party systems — which can also run on cloud services. Connectivity to these services is through corresponding modules. One last common option is OPC unified architecture (UA) from the OPC Foundation. OPC-UA includes publish-subscribe communications in its specification definitions, so can serve as an alternative to MQTT for data transport to the cloud. Those in motion control most value the standardized communication protocol of OPC-UA complemented by time-sensitive networking (TSN) as a vendor-independent fieldbus for decentralized automation. “As supplier of intelligent motors, we appreciate how OPC-UA with TSN renders any additional PLC unnecessary,” explains Weishaar. “After all, systems benefit from architectures primarily based on motors capable of
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RS-485 communication connector (CN6) Termination resistor setting switch (SW3) POWER LED (Green)
L-RUN LED (Green)
ALARM LED (Red)
L-ERR LED (Red)
C-DAT LED (Green)
SD LED (Green)
C-ERR LED (Red)
RD LED (Green)
RS-485 communication transmission rate setting switch (SW1) Data edit connector (CN3)
CC-Link station number setting switches (STATION No.×1, ×10) CC-Link baud rate setting switch (B-RATE)
Operation mode setting switch (SW2-No.1)
Oriental Motor NETC01-CC network gateways convert data from the host CC-Link communication protocol to Oriental Motor’s own RS-485 communication protocol. By using this network gateway and its cabling, engineers can integrate and control RS-485 compatible products under the host environment.
CC-Link communication connector (CN2)
Power supply connector (CN1)
DIN lever
processing commands and executing motion tasks while communicating in real time with other devices. The latter can include edge gateways that handle some process logic along with connections to upper systems such as ERP or the cloud.” Increasingly networked operations may be prompting the most dramatic changes in the way motion systems install — and reconfigure. “Today’s plug-and-run technologies automatically identify parallel products, upstream connections, and software residents. Coding with precanned kinematics and function libraries further simplify these designs, especially when they’re as device-neutral or networkneutral as possible,” says Rusk. Sources at Lenze Americas tout the same. They bill such systems as Plug & Produce — and put emphasis on adaptable systems that are capable of efficiently switching between modes for producing small batch sizes. Key here are changeovers with minimal manual effort. Consider one Plug & Produce production line using the system to make packaged consumer detergents: Individual modules can include infeed, pick and place, packaging, palletizer, and outfeed modules that tag into and out of the line for quick changeovers between the packaging of cream cleansers to the packaging of washing detergents.
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In this and other installations, reprogramming is unnecessary; instead an uploading of configuration values prompts and links the right modules. These values primarily control manufacturing processes as well as relay information on tasks and their sequence. Necessary information might include the height of conveyorbelt transfer points; positions to which workpieces must be delivered; and the
speed at which they can be processed. Once all criteria are met and with the appropriate physical interfaces, production starts. Smart factory functions from Lenze also rely on the use of asset administration shells (AASs) as defined by the reference architectural model Industry 4.0 — RAMI 4.0. That’s a standard of the electrical and electronic manufacturers’ association called Zentralverband Elektrotechnik und Elektronikindustrie (ZVEI), a leading manufacturer association in Germany. Each AAS electronically describes a component in a standardized way. That allows exchange of component and system data between assets and higher-level production systems. AASs employed in Plug & Produce systems
OPC UA • MQTT • EasyAccess 2.0
Serial
Serial Legacy (isolated) setup
Serial
Upgraded IIoT setups employing a Weintek cMT-G03 require no additional serial interface, as the gateway integrates this and other networking subcomponents. Weintek gateways have independent network-access cards with one dedicated to the IT network and the other to machine data. This enhances data security and makes it easy to get machine data on the former without the trouble of reconfiguring machine communications. Image courtesy Weintek USA
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Serial bridge between COM1 and COM2
LAN
cMT-G03 gateway
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can exist for individual components as well as modules and entire machines. Contained data includes that relating to the physics of assets (such as dimensions, service life, and operation values) as well as their functions — whether drive, network component, packaging module, or welding installation, for example. The sum of this data forms a digital twin to allow programming and simulation before physical implementation of a given machine. Such open-source communication standards let a machine’s modules and its controls automatically exchange AAS data — or even execute autonomous interactions during production. This requires a unified data and information model as well as standardized semantics so data can also be correctly interpreted. The first is with AASs. For the second, Lenze uses an expansion of OPC-UA based on a PackML companion specification. Mitsubishi Electric Automation sells IoT gateways for networking machine assets to cloud services or onsite servers supporting remote monitoring and visualization. The IoT gateway allows access to production information for operational insights and business intelligence — letting OEMs optimize machine design and end users reduce production costs.
Software and other design support As mentioned at the top of this piece, software that unifies various aspects of automation development is key to IIoT connectivity. Such software typically provides what’s called a universal engineering environment or more commonly an integrated development environment (IDE) to let engineers
connect machinery with IT and other facility architectures. In fact, IDEs can also help minimize downtime — the primary enemy of most manufacturing, packaging, and processing. “Changeovers especially degrade throughput. But as Industrie 4.0 concepts become more widespread due to consumer demands for greater customization and personalization, changeovers are becoming more and not less frequent and necessary,” says Jeff Johnson, mechatronics product manager of Beckhoff Automation. In practice, this is where IDEs really shine — in rendering automated installations both modular and scalable. That’s illustrated by Lenze’s Plug & Produce software structure mentioned earlier — which makes machine modules capable of coupling automatically and self-coordinating when being joined or rejoined with alternative production-line arrangements. But another strength of standardized IDEs is how they can facilitate the integration of more exotic automation equipment. Consider linear-motor conveyors — also called intelligent transport systems or linear transport systems. Programming for Beckhoff’s linear-transfer system called XTS is relatively simple in part because the XTS can be setup with the same TwinCAT software and EtherCAT network
Shown here is a Lenze c550 controller that imparts Industry 4.0 functionality to automated installations necessitating high performance and IT-OT connectivity. It even works in applications for which only industrial PCs worked in the past. “We want to free OEMs from worrying about whether the controller can deliver sufficient computing power for complex tasks. The c500 series has enough,” says Martin Kluge, head of product management automation systems at Lenze. The c500’s Intel CPU is powerful to handle the rapidly increasing requirements of general IIoT control tasks and motion applications. The ability to omit an industrial PC reduces programming and connectivity effort … and the controllers let machine builders use Lenze’s FAST Toolbox standard software modules as well as modules developed in-house. Existing programs and program modules written in standard IEC 61131-3 systems can also be reused.
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This is a Gen 2 PFC200 controller from WAGO. It runs Linux and is certified for AWS IoT Greengrass use — enabling deployment of custom Lambda functions to edge devices for scalable IIoT applications. It has a fast processor, copious onboard memory, and the ability to serve as a gateway between multiple industrial fieldbuses. The controller also allows data transfer to cloud services and SCADA via the MQTT protocol. An onboard web server enables dynamic HTML5 visualizations to let operators and maintenance personnel monitor attached equipment. A built-in firewall and VPN helps in the deployment of defense-in-depth strategies. WAGO’s IIoT portal is at wago.com/us/open-automation; WAGO’s GitHub at github.com/WAGO includes examples, documentation, and source code. Check out the latter for WAGO and other examples of how GitHub is going beyond its role as a resource for IT … and becoming a resource for design engineers as well.
as standard machine controllers. Johnson cites that as a relatively new option for flexible automation that’s heavily reliant on software for advanced functionalities. “Through the implementation of a modular mechatronic transport system in place of inflexible mechanical components, manufacturers can eliminate downtime for changeovers while enabling asynchronous processing. Using our software, program changes can happen on the fly … and in cloud-connected smart factories, machine builder OEMs or offsite engineering staff can remotely execute updates.” The system’s modularity and customizability facilitate rapid changeovers and flexible mass production — down to lot sizes of one, adds Johnson. Engineers don’t have to learn an entirely new programming platform … and in fact, the software’s motion-control library offers myriad preprogrammed functions for XTS — such as point to point, NC, gearing, camming, and flying saw … along with built in collusion avoidance, notes Johnson. Yet another feature of the software — integrated into Microsoft Visual Studio — is that it allows programming via IEC 61131-3 languages and computer-science standards. Other automation vendors see value in the same accommodation of a widening array of programming languages. For example, WAGO’s controllers combine
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established IEC 61131-3 programming methodology (WAGO e!COCKPIT IDE software) with the option of adding newer technologies better suited to IIoT applications. That’s also true of Bosch Rexroth’s new ctrlX AUTOMATION platform, which accommodates IEC-61131 along with programming languages having both established and newer presences in automation applications — such as PLCopen, C/C++, Node-Red, Python, Blockly, Java, and G-Code. All this software standardization imparts benefits that are synergistic with the line-blurring multi-function hardware formats such as the gateways, HMIs, controllers, and motors described above — which don’t rigidly tie set machine functions to specific components. “Similar to the expansion of PLC functions, microcontrollers are becoming less and less micro because the Raspberry Pi and similar offerings along with smartphones and tablets are capable of astounding computing power for a low price — so have revolutionized how we in industrial automation think about computing,” explains Tubbs of Bosch Rexroth. In short, the dominant value for consumer products has moved from the hardware to software. Now (with the typical adoption lag of manufacturing) industrial computing is finally seeing the same trend. After all, industrial-automation processors today can reside almost
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anywhere — in standalone housings, inside a drive, or on a motor. What’s more important is what runs on the processor. “In our new platform, we run on hardware and scale via software to simplify the maintenance of parts and replacements. Applying functions is as simple as downloading the necessary software — just like on a smartphone,” Tubbs adds. DW Motion Control Tips | motioncontroltips.com
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Harnessing waste heat for electrical power
Solid-state devices that convert heat to energy have a reputation for being inefficient. New materials may eventually change the equation.
Estimates are that 61% of the energy consumed in the U.S. is lost to heat. Leland Teschler • Executive Editor
No wonder, then, that there is interest in finding ways to harvest some of these losses and convert waste heat into something useful One of the methods increasingly under investigation is in thermoelectric materials, materials that generate electricity from a heat differential. The classic example of a thermoelectric generator is a Peltier module. When operated as a generator, one side of the device is heated to a temperature greater than the other side. Because of the Seebeck effect, a difference in voltage will build up between the two sides. But several issues limit the scenarios in which Peltier thermogenerators can make sense. One issue is that the typical efficiency of TEGs is only around 5–8%. Modern devices use highly doped semiconductors made from bismuth telluride (Bi2Te3), lead telluride (PbTe), calcium manganese oxide (Ca2Mn3O8), or combinations of them depending on temperature. Several of these materials can be pricey. Finally, it generally takes a high temperature for a Peltier module to generate much electricity. Alloys based on bismuth and antimony, tellurium or selenium are considered low-temperature thermoelectrics but like to see temperatures above 300°F. Thermoelectrics based on lead alloys handle temperatures up to about 1,000°F, and silicon-germanium thermoelectrics are for temperatures up to about 1,800°F. Consequently, Peltier thermogenerators tend to find use only for low-power remote applications.
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Researchers at Beihang University in China rate potential thermoelectric materials in terms of a figure of merit dubbed ZT. Most narrow-bandgap materials work well only over a narrow range of temperatures. Some wide-bandgap materials have a much wider thermoelectric range. To handle a wide temperature range, thermoelectrics may also use several materials with narrow bandgaps. The most promising wide bandgap materials are characterized by layered crystals that have a low symmetry.
However, there is great interest in devising thermoelectric devices that can work at lower temperatures and which convert heat to electricity more efficiently. Research is progressing in two main areas: materials that generate electricity at lower temperatures, and device structures that convert the infrared radiation given off by hot bodies into electrical current. To understand the direction of this work, it pays to know the figure of merit used for thermoelectric materials, often given as ZT=S2σT/κ. Here, S is the Seebeck coefficient, σ is electrical conductivity, T is working temperature, and κ is thermal conductivity. Researchers at Beihang University in China say its tough to improve the ZT because making making improvements in one of the parameters tends to make one or more of the others
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go in the wrong direction. Consequently, many of the strategies for improving ZT so far only work in a narrow range of temperatures. One factor limiting thermoelectric performance is the bandgap, i.e. the discrete energies of the thermoelectric material’s electrons. The bandgap is given by Es=2eSmaxT where e is unit charge, Smax is the maximum Seebeck coefficient, and T is the temperature corresponding Smax. The Seebeck coefficient basically measures the voltage produced with a temperature gradient (S=ΔV/ΔT). To get a thermoelectric material that works over a span of several hundred degrees, the usual approach is to use several materials that all have narrow bandgaps, or one material with a wide bandgap. There are practical problems with material www.designworldonline.com
mismatches in thermoelectrics that employ several narrow-bandgap materials, so the more typical approach currently is to use wide bandgap materials such as tin selenide (SnSe) whose bandgap energy is about 0.86 eV. Beihang researchers report seeing a thermoelectric effect in SnSe that spans the 80 to 980ºF range. However, materials with wide bandgaps also have another problem that can limit their utility as thermoelectrics: They tend to have low carrier densities, i.e. too few charge carriers available to support significant electrical current flow. The approach used to solve the problem is to set up the orientation of the SnSe crystalline material in a layered fashion that makes more carriers available. Researchers at Beihang University say they’ve used this approach to uncover July 2020
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several promising thermoelectric materials, including BiCuSeO, BiSbSe3, K2Bi8Se13, and Sb2Si2Te6. But they warn that it can be challenging to turn material having a high ZT value into a commercial device, particularly one that can work at high temperatures. One issue: The resistivity of the material used for electrical contact can grow over time, particularly in the presence of high temperatures.
Sandia researchers created this device based on tunnel diodes to convert infrared radiation into electricity. The conversion mechanism is light-facilitated electron tunneling and a grating placed over top the semiconductor that funnels light into a thin silica barrier between doped silicon and an aluminum grating. The concentrated light drives charge carriers to tunnel from the P-type to the N-type silicon, generating a rectifying current. The multiple tunnel diodes form a charge pumping mechanism that moves electrons from P-type to N-type wells.
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Harvesting thermal light Objects at a given temperature radiate heat according to their surface temperature. The sun, for example, has a surface temperature of 6,050°C. Photovoltaic cells convert this radiant energy to electricity. Of course, most terrestrial sources are a lot cooler than the sun. From Wien’s law, as the temperature of a black-body source drops, the wavelength at its peak power rises such that source temperatures between 100 and 400°C have a spectrum in the thermal infrared range (7 to 12 μm wavelengths). Estimates are that more than 95% of waste heat generated in the U.S. is below 400°C (752°F). Problem is, ordinary photovoltaic cells don’t efficiently convert this kind of light to electricity. A photovoltaic cell is basically a p-n diode where collected photons create what is basically a reverse current for the diode. But the ability of a photovoltaic cell to generate electricity depends on the band gap of its material; the photovoltaic effect doesn’t occur if the energy of the absorbed light is lower than the bandgap energy of the (typically) silicon photodiode. Silicon at room temperature has a band gap energy of 1.12 eV and a cutoff wavelength of 1.1 μm. To create a photodiode able to better detect mid-range IR light wavelengths, one approach is to rectify IR using a special type of ultra-fast diode structure called a tunnel-junction diode. Rather than create charge carriers from photons, as with ordinary photovoltaic cells, it rectifies light waves via tunneling in a manner analogous to the way highspeed diodes rectify radio waves. A tunnel diode is characterized by heavy doping to a point where the Fermi level of the diode P-type material lies below the valence band, and the Fermi level of its N-type material lies above the conduction band. The quantum mechanics of this setup are complicated, but the point of this structure is that it creates a current flow via quantum tunneling through the P-N junction. (It also has a region in its IV characteristics where it displays negative resistance: When the voltage increases the current through the tunnel-junction diode decreases.) DESIGN WORLD
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Objects at a given temperature radiate heat according to their surface temperature. The sun, for example, has a surface temperature of 6,050°C. Photovoltaic cells convert this radiant energy to electricity. Most of the heat-to-energy devices created thus far work best at temperatures above 1,000°C. Creating devices that work well at temperatures below this level is proving to be tough. One reason is that there are fewer photons to work with than at higher temperature extremes. Nevertheless, there are promising developments taking place in lowertemperature thermovoltaic devices. One device created recently at Sandia National Labs is called a bipolar MOS tunnel-junction diode. The device uses an optical grating to couple light into a small (3-4 nm) area SiO2 barrier which results in a concentrated electromagnetic field that drives photon-assisted tunneling of electrons from a doped-P type silicon to the N-type silicon part. The Sandia device uses what’s called photon-assisted tunneling where a photon gets absorbed in an occupied state near the Fermi level of the metal gate, followed by field-enhanced tunneling into an unoccupied state of the silicon. The result is a small direct photocurrent. A similar time-reversed process happens in the semiconductor that causes a back flow current into the metal gate. The overall direct current is due to the difference between these two currents, which arises from the difference in effective mass for electrons in the metal and in the semiconductor. Sandia researchers devised a special circuit structure to make use of the photonassisted tunneling effect. They use an interdigitated bipolar P-N junction array under the tunneling gate electrode which acts as a charge pump moving electrons 66
from the P-type region to the N-type well. The amount of power this experimental device generates is small. Researchers say they saw a peak power density of 27 μW/ cm2 for heat sources of 250 and 400°C and 61 μW/cm2 for 350°C. The open-circuit voltages produced are in the range of a few millivolts. Researchers also say they can adjust the temperature at which the device is most efficient by changing the thicknesses of the semiconducting and metal layers involved. The energy conversion efficiency of this setup is modest. Researchers say it is 0.4%, but there are ways of improving it using slightly different gate dielectrics, and heat collection designs. Also, the experimental devices were fabricated on a CMOS platform which may make it possible to eventually scale up for mass production. DW References Electrical power generation from moderate-temperature radiative thermal sources, https://science.sciencemag.org/ content/367/6484/1341 Seeking new, highly effective thermoelectrics, https://science. sciencemag.org/content/367/6483/1196 Thermal light tunnels its way into electricity, https://science.sciencemag. org/content/367/6484/1301
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Advanced interferometry techniques help overcome
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Dan Musinski • VP Strategic Business Development • Zygo Corporation Driven by the demand for smaller consumer products and semiconductor devices, manufacturers require thin planar optics for an array of applications. This puts the responsibility on the material and optics manufacturers to ensure the glass is flat and free of material deformities that can cause distortion and effect end-use functionality. This also places a burden on metrology tools that need to measure and confirm the uniformity of thin planar optics. Inherently, the measurement of thin parallel optical surfaces can be extremely taxing. Such optics are characterized by the fact that they are less than a few millimeters thick, meaning that the front and back surfaces are extremely close together. Because of this, standard mechanical phase shifting interferometry (PSI) finds it difficult to discern between the surfaces.
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Figures 2a & 2b. Front (2a) and back (2b) surface form results of a 1.2 mm thick sample shown in figure one.
Figure 2a
Figure 2b
A more advanced solution is Fourier-transform phase-shifting interferometry (FTPSI), which enables easy characterization of the front and back surface, optical thickness variation, and material homogeneity of thin plane parallel glass. FTPSI makes it possible to distinguish between the front and back surfaces and characterize the quality of both in a single measurement, even if they’re less than a millimeter thick. Why FTPSI? To understand why FTPSI is the preferred technique for measuring thin parallel optics, we need to take a closer look at the alternative traditional measurement techniques and see where they fall short. Consider PSI, which works by passing a light beam through an ideal reference optic (called a transmission flat [TF]), to the part
Figure 1. Complex fringe pattern caused by multiple surface reflections.
under test. We see that this technique can’t distinguish between the front and back surfaces of a thin parallel optic. When properly aligned, the TF and the part under test create an interference pattern, recorded as an interferogram. The metrology software analyzes the height variations produced by the phase shifts and reconstructs the surface wavefront, which represents the difference in height between the TF and the test part. When the front surface of a thin, parallel part is aligned, a second reflection is typically returned to the interferometer from the back surface. This results in a complex fringe pattern created by multiple, overlapping interferograms that can’t be accurately analyzed using PSI. (See Figure 1.) | AdobeStock.com
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There are actions that can be taken to improve the situation, but they are time consuming and add unnecessary and potentially damaging steps into the overall process. These include applying black paint to the back surface to extinguish its reflection, coloring with a dark colored marker, or spreading petroleum jelly on the surface. The FTPSI method eliminates the necessity to manually manipulate the back surface of the thin optic to undertake meaningful and accurate measurements. Instead, FTPSI uses the reflection from the back surface to gain more information about the thin optical component in a single measurement. This is possible because FTPSI doesn’t require mechanical motion within the test cavity to create the interferograms. Instead, FTPSI relies on modulation of the wavelength of the laser source to enable the measurement. Each cavity in the optical
path in an FTPSI acquisition produces a unique interference frequency that defines its cavity length, and this enables a clear delineation and accurate characterization of the surface. Algorithms can then analyze both surfaces and characterize their form independently. (See Figure 2) Three- and four-surface FTPSI Let’s start with the basics. A TF — as mentioned above — is used with an interferometer to establish a plano reference for a surface or transmitted wavefront measurement. A reference flat (RF) is a high-quality optical surface that is used to direct a measurement beam with minimal effect on the overall wavefront. The simplest FTPSI measurement is a three-surface configuration that consists of the TF — surface 1 ‚ and the test part — surfaces 2 and 3 (See Figure 3). In this configuration, a back-surface result is provided but it includes material non-
uniformities due to the measurement beam passing through the material of the test part. For higher accuracy measurements of the back surface, a four-surface configuration can be used by placing an RF — surface 4 — behind the test optic. In this configuration, the form of surface 3 is compared to the known RF. This configuration creates a second test cavity between the back surface and the RF and provides a direct measurement of the back surface without the uncertainty of the material in the part. A single FTPSI measurement with both the three- and the four-surface cavity configurations includes a thickness deviation result, which is a full-surface map of the material thickness across the test part. Material homogeneity The four-surface cavity configuration described above enables the characterization
Figure 3. Example of a three-surface and four-surface configuration. Note that for the three-surface measurement, the back surface map is an approximation as it includes effects of the test part homogeneity.
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Figure 4a
Figure 4b
Figure 4a & 4b shows two mounting examples for thin glass optics. The configuration in 4a is prone to be overtightened which can lead to distortion of the part, while the “V-block” image in 4b provides a low stress mounting solution.
of the material homogeneity of the test part, a unique feature of the FTPSI technology. The homogeneity information can be obtained by first measuring the cavity with the test part inside, then removing the part from the cavity and performing an “empty cavity” measurement, allowing a comparison between the TF and the RF. Unlike other homogeneity measurement techniques that only provide the nonlinear component, an FTPSI result maintains a fixed cavity and, therefore, can provide both the nonlinear and linear components of the material homogeneity. The linear portion is critical for applications that are sensitive to beam pointing, as the result can be used to predict how a beam deviates when passing through the test part. Accuracy As with all interferometric test methods the measurement uncertainty is based on a number of factors including the quality of the reference optics, stability of the measurement environment, and mounting techniques.
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For parts less than 6 in. in diameter (150 mm) the reference optic peak-to-valley surface form can be of the order of 2.5% of the wavelength of the light used to make the measurement — λ/40. If the system, for example, has a laser-emitting red light at a wavelength of 633 nm this corresponds to approximately 16 nm. In most cases this enables the resultant measurement to be well within the tolerance bandwidth for thin glass applications. How the part is held in the test cavity is probably the most critical factor when measuring thin optics; more specifically, the mounting technique and the mounting orientation. Simply clamping a thin optic can induce unwanted stress and cause the optic to bend. Differences in orientation can yield different measurement results, especially for thin parts, due to gravity effects. Ideally, the part should be mounted in the same configuration in which it will be used in its end-use application to avoid unexpected differences between the designed intent and actual performance. (See Figure 4.) FTPSI is a compelling choice for optics manufacturers who need to ensure the quality of thin, parallel optics. Unlike conventional mechanical PSI, FTPSI can distinguish the front and back surfaces and characterize their corresponding www.designworldonline.com
surface information in a single, repeatable measurement. Thanks to advances in both equipment and algorithms FTPSI can characterize surface form, thickness deviation, and material homogeneity of optics that are less than 1 mm thick. Faced with the growing demand for thin, parallel optics, and the challenges involved in accurately measuring those optics, FTPSI overcomes the limitations of previous methods. Its strength in characterization along with its ease-of-use makes it a good choice for optical metrology. DW Zygo Corporation | www.zygo.com
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A supplement of Design World
The design, materials, and stories behind the fastener industry.
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A local business down the street from me has a large sign out front that says: “Nothing’s for sure that’s for sure…but we’re reopening June 15.” However, the date has been crossed out and underneath it states, “likely sometime in July.” As businesses begin reopening, there are undoubtedly mixed feelings including skepticism and cautious optimism. Uncertainty is a powerful thing. Although there’s no playbook on dealing with a global pandemic in 2020, there are companies that have learned a thing or two since the government-mandated shutdowns. That’s because these companies never closed their doors. Several fastener manufacturers and distributors, deemed essential, have remained operational despite the risks — and deserve full praise. Many have stepped up to the challenge, mass-producing parts to meet the demands for medical device components, such as for ventilators and hospital beds. Others have continued to supply critical components to the food, power, water, transportation, and other vital sectors. Now, these companies are in an ideal position to share the tips and knowledge gained during the past few months. For example, flexibility has been key for Meridian Adhesives Group, a U.S.-based holding company for adhesive manufacturers. This has meant creating a contingency plan for unexpected or unfortunate events. So, they’re now prepared for a temporary closure of their facilities without disruption — say, for environmental cleaning and disinfection — if this becomes necessary. For Southco, a global designer and manufacturer of access hardware, ensuring at least two suppliers are available for every process has been important so they are never singlesourced or left without options for continued operation. “The planning ahead is what’s important here,” says the company. Advance Components, an industrial fasteners master distributor, suggests investing in a risk-assessment plan. This is a strategic plan that ensures operation and a secure supply chain in the event of an emergency. “We initially foresaw this as planning for an accident… such as a storm, fire, fraud, or theft,” shared the company president. “We didn’t foresee a global viral pandemic wreak havoc on everything. But fortunately, the solutions we put in place helped us be very prepared.” For SPIROL, a global manufacturer of precision engineered components, maintaining positivity has been imperative: “We’ve been circulating success or feel-good stories every couple of days….it’s important employees know that while the world may be turned upside down, there are some great things that are happening every day, too!” Read the full interviews by clicking on the COVID-19 link at fastenerengineering.com. We wish you all great things despite the current uncertainties. Stay safe!
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Why plastics are the
material of choice for most fasteners Barbara Gerard • CEO • Craftech Industries, Inc. Plastic materials are quickly gaining credibility in the fastener industry and for good reasons. Plastic fasteners are strong yet flexible, durable, cost-effective, and they fail to rust, which is a big plus. PEEK, also known as polyetheretherketone, is one type of plastic that offers highperformance engineering and versatility. This material has an extremely stable chemical structure that’s rare to find in other plastics, making it ideal for use in fasteners in several applications and industries. For example, PEEK is often used in components for the automotive, aerospace, marine, nuclear, oil and gas, and in the electronics sectors. It’s also considered an advanced biomaterial and medical implants are made from it. As a result, it’s increasingly used in spinal fusion devices and for reinforcing rods. Additionally, PEEK fasteners are used in the food and beverage industry for food and feed drying. Clearly, this material is versatile and reliable, even in demanding applications. Aside from fasteners, parts such as bearings, pumps, pistons, compressor plate valves, cable insulation, and others use PEEK. Key features PEEK is a semi-crystalline, high-temperature resistant thermoplastic. The processing conditions used to mold it can influence its crystallinity and mechanical properties. Its Young’s modulus (this is the mechanical property that measures the stiffness of a solid material) is 3.6 GPa and its tensile strength is 90 to 100 Mpa. PEEK has resistance to hydrolysis so it’s unable to absorb water. This makes it highly tolerant to thermal degradation and attacks by organic and aqueous environments. A few other features are that it’s susceptible to halogens and strong Bronsted and Lewis acids, as well as some halogenated
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PEEK, or polyetheretherketone, is a high-performance plastic, making the material ideal for fasteners in many critical or demanding applications.
compounds and aliphatic hydrocarbons at high temperatures. (Lewis acid accepts a pair of electrons while a Bronsted acid accepts pairs of electrons at an acidic hydrogen.) PEEK is soluble in concentrated sulfuric acid at room temperature. The material also has superior creep resistance, serving as a high-strength alternative to fluoropolymers. Environmental considerations PEEK has a glass transition temperature of 289° F (143° C) and melts at 662° F (343° C). Some grades have a continuous operating temperature of up to 482° F (250° C). Aside from being resistant to organic and aqueous environments, it’s also highly resistant to thermal degradation. PEEK has a UL flammability rating of V-0 and exhibits low smoke and toxic gas emissions. The plastic resists radiation and a wide range of solvents. It can withstand boiling water
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Several grades of customized PEEK fasteners are available commercially, depending on the application. www.fastenerengineering.com
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Fastening + Joining and the super-heated steam used with autoclave and sterilization equipment at temperatures higher than 482° F (250° C). Grades The unfilled grade offers the highest elongation and toughness of all the grades of PEEK. It is available in light brown or tan and black. Reinforcing fibers are often added to plastic resins to increase the tensile strength and flexural modulus of the composite. • PEEK 30% glass-filled includes glass fibers as an additive. This grade is ideal for structural applications that require improved strength, stiffness, or stability at temperatures of about 300° F (150° C). This grade dramatically lowers the material’s expansion rate and increases its flexural modulus. Glass-filled PEEK is light brown or tan.
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• PEEK 30% carbon-filled uses carbon fibers as an additive. The carbon fibers enhance the compressive strength and stiffness of the material and dramatically lowers its expansion rate. This plastic material grade offers optimum wear resistance and excellent load-carrying capability. PEEK 30% carbon-filled provides threeand-a-half times higher thermal conductivity than the unfilled grade. Therefore, it dissipates heat from the bearing service faster. PEEK 30% carbon filled is black. • PEEK (Bearing Grade, Ketron HPV) is a grade that’s reinforced with graphite, PTFE, and carbon fibers. This grade offers the lowest coefficient of friction and the best machinability of all the PEEK grades. The bearing grade, Ketron HPV sports an excellent combination of low friction and wear, high limiting PV, low mating part wear, and easy machining. This grade is black or dark gray. Thanks to several of PEEK’s properties, the plastic can serve as an alternative to steel, aluminum, and brass fasteners. A summary of its benefits includes resistance to high temperatures, chemicals, hydrolysis (exposure to steam or high-pressure water), and fire. PEEK fasteners can also withstand forces (such as stretching and pulling) and abrasion, making them ideal for nearly every industry.
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2020 Emerson Electric Co.
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How to choose the ideal adhesive for an application Julie Miller • Writer
Engineers are increasingly relying on adhesives as alternatives to mechanical fasteners. They offer several advantages that typically include a lighter-weight assembly, fewer individual components, and faster production. Adhesives also offer the ability to join dissimilar substrates. However, choosing the correct adhesive is critical, particularly given the variety of choices and features available. Load-carrying capacity is often the deciding factor in choosing a product for a particular application. The load-carrying capacity is defined by the maximum load an adhesive-bonded joint can bear without failing.
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When considering loadcarrying capacity, adhesives can be categorized as: • Structural • Semi-structural • Non-structural Structural Structural adhesives demonstrate strengths from 1000-pound-force per-square-inch (psi) up to as high as 4000 psi. Generally, they offer sufficient strength and durability to tolerate environmental exposure and maintain performance integrity when a bonded joint is stressed to its yield point, at least within the given design limitations. Because of their high strength, structural adhesives are used for long-term, permanent attachments. Sectors such as the automotive, aerospace, construction, consumer appliance, electronics, medical device, and other critical industries DESIGN WORLD
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rely on structural adhesives — generally, as an alternative to mechanical fasteners. The advantages of structural adhesives include: • Reduced assembly size and weight • Fewer parts per assembly • An ability to join dissimilar materials • Adaptability to automated processes • Productivity gains with fast-setting formulations • Improved aesthetic design • Lower cost Another advantage of structural adhesives is that they provide strong attachments for a variety of substrates, including metal, composites, and rigid and flexible thermoplastics. Additionally, structural adhesives can
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fill gaps between substrates, sealing out environmental exposure. Chemistries of structural adhesives include acrylics, cyanoacrylates, epoxies, rubber, and urethanes. With liquid or paste application, a consistent bead of adhesive on the substrate ensures the strongest bond. The application of liquid-type adhesives ranges from contact-bond and hot-melt to aerosol and cylinder spray. Tape or film formats are also appropriate in some applications, where the right amount of pressure must be applied to ensure the tape fully adheres and fills the gap between surfaces.
Structural adhesives are generally easy-to-use and cost-effective compared to mechanical fasteners because of the reduced material costs, parts, labor costs, and process time.
Semi-structural Semi-structural adhesives are strong, but many cannot maintain their load-bearing support continuously for long periods without www.fastenerengineering.com
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deformation or failure. These adhesives might be used for short-term or temporary attachments, such as keeping substrates in place in preparation for a subsequent process. However, recent advances in bonding technology have given rise to higher-performance products that can withstand harsher conditions or environmental exposure. They’ve also developed formulations that are easier to apply. The chemistry of semi-structural products overlaps with their structural and non-structural counterparts, such as pressure-sensitive and contact adhesives, hot melts, polyurethanes, and other polymers. Aside from load-carrying capacity, several features should be considered when choosing a semi-structural adhesive, depending on the intended use. • Structural adhesives. Some products have a limited shelf or working life. Adhesives might be repositionable with varying degrees of tackiness. Others may offer short setting times, calling for immediate attachment of the substrates.
Delivery mechanisms include thin-to-medium liquid or paste formulations. Liquid-types can be applied with a brush or roller, via aerosol spray or as a hot-melt formulation that hardens when cool. The advantages of using non-structural adhesives instead of mechanical fasteners include quick assembly, lighter overall assembly weight, and aesthetic design that avoids holes or visible fasteners. In some cases, water-based non-structural adhesives can replace solvent-based products for greater compliance with safety and environmental standards. However, non-structural adhesives are a poor choice for joining materials that will endure exposure to high or low temperatures, moisture, radiation, acidity, alkalinity, and bio-agents. In addition to load capacity, designers should also consider the potential for shear, compression, and cleavage of the joint. For applications that require more strength or more durable bonding, structural adhesives or mechanical fasteners are recommended.
• Adhesion application. Adhesives might require the application of heat to set the bond. Additional time, processes, or equipment may also be needed. • Cost. It’s important to select an adhesive that meets the requirements of the design, but overall costs should also include labor or possible downtime while an adhesive application sets. • Aesthetics. Engineers should consider how the applied adhesive might appear in the final assembly. With some products, creep is possible, causing the adhesive to be visible beyond the substrate.
WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online
Non-structural Similar to structural adhesives, non-structural adhesives can provide attachment between dissimilar substrates, such as paper, cardboard, foam, metal, and plastic. But they are better suited to applications that are not exposed to harsh conditions or extended environmental exposure. The temperature resistance of non- structural adhesives is typically below 200° F (93° C). Many nonstructural adhesives are repositionable with varying degrees of tackiness, while others offer drying times as short as one minute.
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Ultrasonic welding
A versatile technology used in the fight against COVID-19 Tarick Walton • Global Product Manager, Ultrasonics for Assembly Technologies • Emerson
The components of an ultrasonic welding system.
| All images courtesy of Emerson
Ultrasonic welding is a fast, energy-efficient, and permanent fastening method used to join plastic parts and materials. Different variations of this technology are used to bond rigid plastics in automotive components, medical devices, electronic products, and many types of consumer goods. Ultrasonic welding is also necessary for bonding clear film in packaging and tamperresistant containers used in the food, beverage, and packaging industries. The versatility of his type of welding is evident as it also provides efficient, corrosionfree bonds between the thin and exotic metals essential for the high-performance batteries used in electric vehicles, cell phones, and personal electronic products.
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Well-designed joints can be ultrasonically welded in less than a second. Ultrasonic welds create strong bonds that are nearly as strong as the parent material. The COVID-19 pandemic further highlights the value of ultrasonic welding in cutting, seaming, and joining non-woven fabrics and thin plastic films essential to infection control. This includes its role in the production of many types of personal protective equipment (PPE) and infection control products used by medical personnel and first responders. Examples of PPE include surgical masks, gowns, protective curtains, absorbent pads, bandages, bedding, and more. Interestingly, although ultrasonic welding is diverse in its applications, its core technology is quite similar. The basics The components of an ultrasonic welding system are a power supply, an actuator, and a stack. The power supply takes the line voltage (from the wall outlet) at a nominal 120-240V and transforms it into a highfrequency signal. It also provides the pre-programmed weld parameters necessary to operate the actuator and ultrasonic tooling (the stack), which work together to complete the welds. The ultrasonic stack connects to the actuator
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assembly. The stack has three parts: 1. The converter, which translates signals from the power supply into mechanical vibration (amplitude). 2. The booster, which fine-tunes (increases/decreases) the amplitude as needed for the plastics being welded. 3. The horn, which precisely transmits this vibration to the parts or surfaces being joined. The shape of the horn is extremely important. To weld efficiently, the face of this tool must match the profile of the rigid parts being joined or provide a sealing profile when the parts or components are being joined. For each application, the stack (converter, booster, and horn) work together to deliver the optimum level of amplitude to produce a consistent ultrasonic weld. In operation, the actuator lowers the stack onto the parts to be joined, compressing them. Vibration is delivered to the part surfaces by the tool at the bottom of the stack, or the horn. Vibratory energy at the interface of the plastic parts generates frictional heat that melts the plastic, which
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Fastening + Joining Branson ultrasonic welding technology from Emerson is used to cut and bond non-woven fabrics into a variety of sterile surgical drape kits, masks, gowns, and scrubs essential for personal protection and infection control.
Ultrasonic welding is widely used in the high-volume assembly of plastic parts because it: • Integrates easily with automated processes. Ultrasonic welding equipment is available in a wide range of configurations, from compact benchtop to freestanding units that can produce multiple parts in a single cycle. • Offers fast production cycles. Many ultrasonic welds are completed in a fraction of a second, enabling production at a greater rate than processes that rely on other joining methods (such as adhesives or mechanical fasteners). • Requires zero consumables. Ultrasonic welds are completed directly between the surfaces of the adjoining parts. This means no additional material, fasteners, or adhesives are required. • Is extremely energy efficient. Unlike heat-sealing or joining processes that rely on a continuously heated element, ultrasonic welders consume energy only during the weld cycle itself. Since tooling is never heated, there’s no cooling time required to switch ultrasonic equipment over for production changes. Simply swap out the tooling, update the programming, and begin production. • Enables sophisticated and secure data collection. For manufacturers that must validate product quality and ensure product traceability to meet medical, regulatory, or performance requirements, the latest ultrasonic welding systems offer extensive data collection capabilities.
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— under force from the actuator — compresses and bonds, producing a finished ultrasonic weld. Production efficiencies Assembling plastic parts, films, or non-wovens using ultrasonic welding requires some up-front investment, starting with the welder itself. Additionally, product-specific tooling is required to precisely hold the various plastic components in place as a part is welded. All of this is a one-time investment, which means that operators can manage assembly costs, amortizing a single investment over the entire production volume of the part. When the part or product design is finalized, weld tooling can be built and highvolume production can begin. The key to amortizing assembly method costs and realizing long-term assembly savings: first have a firm idea of what the annual production volume is going to be. History shows that those with production volumes ranging from tens of thousands to millions per year generally attain a significant financial benefit with an ultrasonic welding process. Non-wovens and infection control The low cost and utility of non-woven fabrics have made them essential in the global battle to prevent the spread of infection, including COVID-19. Disposable non-wovens provide an effective yet inexpensive barrier against micro-organisms and contamination, making them ideal for surgical protective garb.
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Similar to other plastics, nonwoven fabrics can be joined with ultrasonic welders, using highfrequency mechanical vibration, which is transmitted through tooling to heat and join thermoplastic material. Depending on the selection of weld parameters and tooling, the frictional heat generated by ultrasonics also offers the versatility to: • Cut or slit a large roll of nonwoven fabric into narrower strips (cut edges are simultaneously seamed and sealed by the heat). • Bond two pieces of non-woven fabric into the finished seam of a garment or a piece of protective gear, such as a surgical gown or mask. • “Quilt” multiple layers of nonwoven material into laminated absorbent products. Compared to adhesives, ultrasonic eliminates the cost of consumables, the time required for setup and drying, and the risk of exposure to chemical contaminants. Compared to sewing, ultrasonic offers benefits because it creates high-strength, high-integrity seams without the need for thread and without creating mechanical holes in the fabric, which can hold and conceal microorganisms or contaminants. Ultrasonic seams are ready for use as soon as they are produced.
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Why limiting fasteners can lead to better designs Michelle Froese • Editor
Imagine you’re an engineer with the freedom to create any design you’d like with only one catch: you can only use two types of fasteners. Would this limit or simplify your design? For Marisa Mudge, marketing manager with Mudge Fasteners, Inc. (a supply company owned by her father), the answer is simple: “The idea of designing with limited, standard parts is absolutely brilliant because of the significant time and cost-savings it, ultimately, provides,” she says. Although Mudge is not a design engineer, she’s worked fulltime at Mudge Fasteners for more than a decade (and much longer, if you add in the time she helped her dad at the company in her adolescence). So, she knows a thing or two about fasteners. When she met an engineer from Hewlett Packard on a plane one day — who is limited in his designs by the use of only two screws — Mudge was impressed by the company’s mandate. “One of the biggest problems companies face related to fasteners is lost parts. Typically, fasteners are the smallest part at a job site and minimal efforts are spent tracking this inventory… so the screws or bolts get dropped at construction sites, lost on manufacturing floors, or accidentally left in pockets,” she shares. “So, a project with only two standard fastener choices would have a real advantage.” A few lost fasteners may seem like a small problem, but replacement costs can add up quickly. “Some standard fasteners run in excess of a dollar or two apiece,” Mudge says she often gets calls from companies that suddenly need 200 or 300 additional parts after ordering 20,000 for a job. This means a lost advantage in bulk purchasing 86
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power. “Generally, these costs are significantly higher for custom fasteners.” What makes matters worse are the lead times. “Customized parts can take two or 20 weeks to replace, which can seriously affect project deadlines,” she says. “And most of the calls we get are not directly from the design engineers or project managers. Rather, the calls come from the workers out in the field who are under pressure to have a product manufactured or installed by a certain date. The concern is the workers may develop a workaround.” What Mudge means by “workaround” is the next best solution but, possibly, not the ideal fastener for the job. “This is why it’s extremely important to consider fasteners at the design stage of a project and plan for challenges during construction, such as lost parts,” she says. “It’s also why a DESIGN WORLD
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Simple is often best. Typically, design engineers can save costs and meet project deadlines by only using standard fasteners and limiting the type used for each application.
couple of standard fasteners per application would generally make life a lot easier.” There are additional reasons why pre-planning is important. For example, Mudge worked with one client who insisted on fasteners that would perfectly match the color of a project’s auditorium walls — and at a guaranteed cost. “In this case, we had to provide raw, non-customized fasteners because our vendor was unable to guarantee the paint required to match that exact color.” The reason for this was simple: the environment the fasteners would be exposed could affect the paint and color, so to guarantee it was impossible. “In such cases, the architectural aesthetics can really drive up the cost of fasteners,” she explains. The conditions fasteners are subject to, such as moisture or high heat, can also affect their reliability. “This is where standards come in, which can sometimes be an issue with custom fasteners,” says Mudge. “Standards organizations specify and test the properties of fasteners, but there are several different organizations and standards that should be adhered to depending on the application.”
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Marisa Mudge and her father, Paul, at the Mudge Fasteners headquarters in California.
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Going standard The advantages of designing applications with standard parts and limited fasteners:
• Minimizes problems with inventory management • Eliminates the risk of dead stock related to project design changes • Reduces procurement delays • Facilitates stock replenishment (and re-order points are simple to calculate) • Mitigates “stock out” occurrences because of a limited product range • Saves time and costs
with only two screws
For example, the Society of Automotive Engineers or SAE is primarily focused on safety regulations for the aerospace, automotive, and commercial-vehicle industries. The American Society of Mechanical Engineers or ASME provides manufacturers with guidelines and tolerances that their bolts must conform to. (View a list of the main standards organizations at mudgefasteners.com/ standards-organizations)
because, even as their
Typically, standards are categorized into:
“Hewlett Packard is at an advantage by allowing engineers to design
products change or improve, the company is never going to be stuck with dead inventory or 20,000 fasteners that they bought because procurement and design were not on the same page,” says Mudge.
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• Products – the different types and product gaging (ex. ASME B18.2.1)
• Materials and performance – specifications and strength (ex. ASTM A325)
• Testing – test equipment protocol and methods of testing (ex. NASM1312)
• Quality – fastener reliability (ex. ISO 9000) “Consensus standards offer many benefits that are not covered by nonstandard fasteners,” explains Mudge. This includes guidance and policies backed by significant research and expertise. “ Although an engineer can anticipate performance based on the material when using a custom fastener, the part is not required to meet any of the design
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specifications set forth by the consensus organizations, so there’s risk involved.”. Mudge recommends working with a vendor partner during the design phase of an application to identify standard parts and the ideal choice for an application. “Typically, fasteners are the least expensive component for a job and given little forethought. But this doesn’t mean they’re unimportant,” she says. “In fact, quite the opposite is true. These small components hold an entire application together — which is one reason standard fasteners that are reliable and readily available are often the ideal choice.” One other reason standard fasteners are ideal is to avoid unused inventory, which can happen as a product changes or evolves. “Hewlett Packard is at an advantage by allowing engineers to design with only two screws because, even as their products change or improve, the company is never going to be stuck with dead inventory or 20,000 fasteners that they bought because procurement and design were not on the same page,” says Mudge. “It’s a wise business decision.”
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The paint doctor: How D.L.P. Coatings got its start Michelle Froese • Editor
Treat others how you want to be treated. According to Patrick Murphy, VP of D.L.P. Coatings, Inc., a provider of quality painted fasteners, that is one of the key business lessons his dad taught him. His father, Richard “Dick” Murphy, opened D.L.P. in 1985. “My dad was originally a manufacturer’s rep in the fastener industry and then got a somewhat crazy idea to go out on his own and paint fasteners because he thought he could do it better than what was available at that time,” shares Patrick Murphy. “And, in many ways, he was right.” Murphy says the first shop his dad opened was about 5,000 square feet in Elk Grove Village, Illinois (about a 40-minute drive from downtown Chicago). Today, the company works in a 40,000 square-foot building. “Sadly, my dad passed away last year but this company was his life. He gave so much to it and worked hard to grow it to what it is today. In fact, his very first employee, Mark Duncan, still works for us some 35 years later.” Murphy joined the family business 12 years ago and hasn’t looked back since. “I somehow always knew that I’d work with my dad but first wanted time on my own, independently, to figure things out,” he says. “Then, shortly after I graduated from college with a marketing degree, the 2007-08 recession hit, and the job market was bleak.” Additionally, his father had some health concerns at the time, so it made sense that Murphy began learning the business alongside his dad. “I haven’t regretted a moment of the decision to join D.L.P Coatings. My dad was the best 90
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mentor you could ask for. He was very down-to-earth and supportive of those around him. And he absolutely loved the work.” Murphy’s dad built the business from a general fastener coating company to one that offers several added services, including waxing, assembly, packaging, and others. It also serves several industries such as window and door, residential and composite decking, truck and trailer, lighting, electrical, and automotive — including big companies such as Anderson Windows and General Electric. One unique service D.L.P. offers is a computer color matching system. This process uses a spectrophotometer to measure the exact intensity of color wavelengths. Then, a mathematical analysis of DESIGN WORLD
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t Patrick Murphy, VP of D.L.P. Coatings, with his son Grayson, and his dad, Dick Murphy.
the color sample and a formula for a targeted color match is created. “We do all of the color matching in-house and the process is so precise that it can be modified to fit varying color and lighting specifications,” explains Murphy. “It’s similar to going to Home Depot or Lowe’s to match the paint color for your walls, but for industrial parts and fasteners. So, for example, if a customer has a metal building with sheet metal in Hawaiian Blue, we’re able to match and make that exact color of blue at our facility to paint the fasteners — no matter the shade.” Murphy says D.L.P. offers exterior grade-paints that have been engineered with the company’s manufacturers, with proven UV, chemical, and chip and scratch DESIGN WORLD
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resistance. The paints are also environmentally friendly. “We have a lot of customers who have been with us for a long time and I credit that to my dad. He treated everyone in the same way… he was always fair and respectful. And I try to do the same. We’re not changing anything here. We’ve even kept the same paint and the same kind of paint systems. We’re only working to continually improve the process.” According to Murphy, one of the biggest challenges is that the company is typically considered a second or third-tier supplier, and one of the last considered during a project or for an assembly. “This means we’re typically the last to touch the part and by the time it hits our door, the order is already hot. www.fastenerengineering.com
The customer has been waiting for six or eight weeks, or longer.” The challenge is in, then, getting each part processed and painted as quickly as possible. Murphy encourages people to think of such details earlier in the design stage of a project. “The reality is that most people simply don’t think about the fastener color until late in the game,” he says. “But my dad often called himself the paint doctor and for good reason. He always said there wasn’t a problem we couldn’t solve or customer we couldn’t support at the company and we continue to stand by that.”
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How
ZAGO Manufacturing
has built its success on teamwork Michelle Froese • Editor
Zero regrets are something the owners of ZAGO Manufacturing, a global manufacturer of high-tech, custom sealing solutions and components, can attest to after more than 25 years of business. Husband and wife team, Harvey Rottenstrich and Gail Friedberg began the New Jersey-based company in 1993. “We’ve never once had second thoughts about starting or moving forward with ZAGO,” shares Friedberg. “Over the years, we’ve received inquiries from private equity firms and other companies that wanted to merge with us. But we’ve held firm and said no. We have a really good thing going here and we’re proud of what we’ve built.” The commitment to begin the manufacturing company first began with support from a small-business incubator program, NJIT Enterprise Development Center, which is part of the New Jersey Institute of Technology. “For a few years, the program provided us with office space at a reduced rate for rent, secretarial services, as well as space for assembly and production,” explains Friedberg. “But, perhaps, the most important things it gave us were resources and critical business advice.” At the time, Friedberg was a practicing corporate lawyer and was able to help with the development and legal requirements of opening a business. Rottenstrich is an electrical engineer who had experience working in the fastener industry, which was the initial inspiration for ZAGO Manufacturing. 92
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“My husband had worked for a company that did something similar to what we offer but felt he could do it just as well, if not better. So, essentially, he brought the engineering experience and I brought the legal support, and, between us, we also had a lot of business knowledge,” she says. “Sure, there were challenges, but we were about as prepared as we could be to start the company.” The name, ZAGO, was derived from each of the family member’s initials (the FriedbergRottenstrichs have three kids — one of whom currently works in the company’s factory). “As exciting as it was at first, it was also a lot like jumping off of a cliff,” adds Friedberg. “Starting a business certainly isn’t simple. But you have to just take the leap and push forward because it is frightening. You invest a lot of time, effort, money, and hope for the best. So, there are definitely nerves tied in with that.” DESIGN WORLD
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The wife and husband team behind ZAGO Manufacturing, Gail Friedberg and Harvey Rottenstrich.
The building of ZAGO was gradual and careful. After getting a foothold in the market, the next step was graduating from the incubator program. “After five years, we outgrew the incubator and actually graduated with an official plaque.” Friedberg says they then briefly rented another workspace until finding their current location in Newark, which allowed enough space to grow. “It basically started with just my husband and me, and a telephone, but we now have 22 employees, which is wonderful,” she says. “We’re proud of our team. And we’re very dedicated to growing through automation and robotics for the quality and precision of our products.” To this end, ZAGO does more than just produce customized DESIGN WORLD
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sealing fasteners and components. According to Rottenstrich, ZAGO sealing screws, bolts, and nuts are sustainable, corrosion-resistant, and inherently “green” solutions. Unlike traditional fasteners, ZAGO sealing fasteners are engineered with a rubber O-ring that when tightened, creates an air-tight, 360-degree seal. This hermetic seal effectively shields toxins from leaking in or out into the surroundings while protecting high-asset machinery and complex equipment. “The product was originally a military one and that’s still a major market for us,” explains Rottenstrich. “If you think of marine or aerospace environments, it’s critical these components withstand harsh pressure, temperatures, and environmental conditions — sealing www.fastenerengineering.com
out water or moisture, air, fuel, and dust or debris.” Today, ZAGO produces custom and standard sealing fasteners and switch boots for thousands of equipment manufacturers, including those in the automotive, energy generation and storage, robotics and drones, commercial lighting, electronics, enclosures, and medical device industries. “Some of these products are extremely delicate or tiny and their purpose is unlike a conventional fastener, which is designed to hold components together. Rather, these parts prevent elements from penetrating equipment, which would lead to malfunction,” he says. This is extremely important in medical devices, such as ventilators, for example. ZAGO has been deemed an essential manufacturer during the COVID-19 pandemic and is still operating. “We’ve always sold to the medical July 2020
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Fastening + Joining device industry but their needs have, understandably, grown at this time and we’re grateful to help out. For example, we were selling to Ventech, which is now partnering with GM to make ventilators,” says Friedberg. ZAGO is also determined to support and maintain its staff at this challenging time. “How we treat our team has always been significant to our company ethics,” she shares. “This is especially true right now and we’re doing everything possible to offer our staff full salaries, regardless of how many hours they put in because of split shifts or what have you. People’s needs don’t change because of the situation right now. If anything, they’re greater as they care for family and extended families.” Although the current pandemic is unique, Friedberg says she and her husband have typically used difficult times in the past as opportunities to reflect. “We’ve tried to use slower periods, such as during the recession, to review and improve our operations. Sometimes when you’re busy or constantly on the go, it’s tough to contemplate things or focus on possible changes or improvements,” she says. “So, slower times can also be important for future planning and growth.” That’s one quality Friedberg says has been critical to their success: “We understand that there’s always room for improvement. For instance, we encourage our employees to come to us with suggestions for improvements and we actually reward that, monetarily. If someone comes up with a great idea, we make sure they benefit from it. The worst reason to do something is because we’ve always done it that way.” Rottenstrich agrees. “I think for us, at least from my experience, a willingness to try new things and create…and, most importantly, to ensure there are good, supportive people around us has been the key to our success.” “Teamwork is everything,” adds Rottenstrich. “And we’re so fortunate to have employees that we consider a part of our extended family.”
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July 2020
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F a s t e n i n g
+
J o i n i n g
The how and why
behind the Fastener Training Institute Michelle Froese • Editor The Fastener Training Institute’s John Wachman (managing director) and Jo Morris (director of marketing) at an industry event last year.
What began nearly 50 years ago as a collaboration between fastener distributors to train new employees has since developed into an international organization for novice and advanced individuals working in the industry. Today, the Fastener Training Institute (FTI) provides a host of training programs by recognized industry experts on fastener products, standards, and specifications. The aim, according to FTI’s objective is “to enhance fastener use, reliability, and safety.” “The root of the fastener training Institute began in the early 70s with an industry group called the Los Angeles Fastener Association, or LAFA,” explains John Wachman, the current managing director of FTI. “Those who were a part of LAFA decided that, individually, no one had the bandwidth to train new employees but that collectively they could probably do a decent job. And so, began the first basic industry training classes.” Wachman, a 45-year veteran of the fastener industry — who also founded his own manufacturers’ rep agency in Arizona, Desert Distribution Sales, 96
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which he still runs today — was asked to join the board of LAFA in 2006 “Once on the board, I took part in the product training committee and within a couple of days was asked to serve as the chairperson for the full training committee, which I accepted, and that’s how FTI got its early start and how I became involved with training,” he says. FTI’s future was still developing, however. In 2009, LAFA merged with the Western Association of Fastener Distributors to form the Pacific-West Fastener Association, a western trade association for distributors DESIGN WORLD
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and suppliers. “Pac-West managed FTI for a while, but it was primarily a regional association and the demand for training classes began to grow considerably.” To support the education needs nationally the PacWest Board of Directors decided to formally launch FTI. “FTI became a standalone, registered 501(c)(6) non-profit in 2014 and that’s when it grew from a regional association to a national training platform,” says Wachman. “The classes grew from very basic, which we still offer, to highly advanced.” Today, Desert Distribution manages the Fastener Training Institute under contract with FTI’s board of directors (BOD). The BOD consists of fastener industry producers and distributors from throughout the country, with backgrounds and experience wellsuited to guide FTI’s future. “What’s interesting is that much of our mandate is similar to what it was when FTI started with LA FFA,” says Jo Morris, the FTI director of marketing. “We exist to serve the fastener industry and we continually train new employees.” What has changed to some extent, however, are the needs of the fastener industry. “This is why we’re always asking for feedback so we can best serve the industry with useful and timely training,” she adds. Here are a couple of examples of the changing fastener landscape and how FTI addresses it in their current training curriculum. Maturation. One trend in fasteners that Wachman and Morris have noted is the effects of an aging industry. “There’s a lot of people retiring but without an immediate successor
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who’s been in the industry, climbed the ladder, and gained the experience necessary to take over the role,” says Wachman. “There’s somewhat of a gap in talent here and this means there’s a risk that the tribal or historical knowledge could be lost.” “This is why we offer such a broad product base of training options and only from instructors who’ve worked with fasteners and are considered industry experts,” explains Morris. “Where fastener companies were typically family-run businesses, today that’s changing.” The lack of mid to seniormanagement employees who have “grown-up” in the fastener industry has led to an influx of new employees, who require significant training. Although these new employees typically offer management experience from other industries, the in-depth insight that’s specific to fasteners is often lacking. For FTI, this has led to two challenges: teaching decades of “historical knowledge” in a short time period and securing industry retention rates. “We’re supporting a lot of new hires. By providing them with proper training and a sense of community, our goal is to ensure these individuals gain the confidence and skills required to stay in the industry and succeed,” says Morris. Troubleshooting. Much like any industry, fasteners do experience failures. According to Wachman, however, it’s rarely the result of faulty components. To this end, one of the most significant advanced engineering classes FTI currently offers is on fastener failures. The aim is to increase the reliability and safety of the industry
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and the professionals working in it. “I’m certainly not implying companies never make faulty fasteners. It happens,” says Wachman. “But the primary reason for joint failures is rarely a defective fastener. It’s usually because a person either specified the wrong fasteners or improperly installed them.” “Typically, when there’s an application failure the fastener gets blamed,” agrees Morris. “But as John mentioned, most fastenerrelated problems relate to misuse either from improper selection, specification, or installation. So, it’s extremely important that FTI offers advanced engineering classes focused on fastener selection and proper installation to prevent unnecessary faults and failures.” One of the ways FTI ensures successful training is by only offering classes with instructors that are recognized industry experts. “Our instructors are full-time, industry engineers with decades of experience in the industry — they’re not academics,” says Wachman. “They’ve worked 20, 30, or 40 years on the job. So, when teaching a class, the instructors are offering the class content as well as years of reallife career experience.” Wachman adds: “It’s so great when we hear we’ve impacted the work and knowledge-base of newcomers and industry veterans. That’s what we’re here for.” Check out fastenertraining.org to learn about FTI’s current virtual classes and webinars.
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Fastener Engineering Products
Surface-friendly wave springs Rotor Clip rotorclip.com Engineers choosing springs for bearings typically prefer ones with a high axial load to reduce vibration and noise — and prolong bearing life. However, standard single-turn wave springs with a gap have sharp corners at the cut-off area of the spring ends. These corners can scratch the surface of the bearing and mating parts when the waveform shows a steep incline, depending on the load specification. This debris can lead to failure of the bearing and an entire application. Rotor Clip’s patented design solves this problem by flattening the ends of the spring so they avoid causing excessive wear that can damage an application. As with all of Rotor Clip’s wave spring designs, there are no tooling costs for custom designs with this end feature.
A U-handle with power-switching function JW Winco jwwinco.com JW Winco has added electrical features to mechanical components to create the GN 422 U-handle with power-switching functions. The electrical push-button is made of high-quality stainless steel and equipped with a special twocolor LED, which switches between red and green depending on the polarity. This indicates the current production machine status. For mounting, including professional electrical installation, the U-handles come supplied with either a plug connector or cable. The cable pass-through is covered, with the cable running out the back of the housing to be out of the user’s sight. Depending on the application, the U-handle can be ordered in black or silver with one or two LED buttons.
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Fastener Engineering Products
A thermally conductive epoxy sealant Master Bond masterbond.com Master Bond EP62-1AO is a two-part epoxy adhesive and sealant with an extremely long working life — ranging from 12 to 14 hours an at ambient temperature for a 100-gram mass. This is ideal for bonding and sealing large or intricate parts that may require ample time for mixing and applying. EP62-1AO is electrically insulating and thermally conductive with a thermal conductivity value of nine or 10 BTU•in/(ft2•hr•°F), or 1.30-1.44 W/(m•K). The adhesive can withstand a wide range of acids, bases, and solvents. The viscosity of the mixed compound offers a thixotropic paste consistency. The material has a high-strength profile with a tensile modulus of 600,000 to 650,000 psi and a tensile strength of 5,000 to 6,000 psi. The service temperature range is -60° to +450° F.
ASSEMBLY SIMPLIFIED
330.220.5100 contact.us@araymond-industrial.com www.araymond-industrial.com ARaymond Tinnerman’s Lean Product Development begins by understanding the application, evaluating the process and then providing recommendations for efficient assembly solutions. We help manufacturers look for opportunities to streamline the process efficiency, reduce costs, and create higher quality finished products.
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Fastener Engineering Products
Advanced parts counter Advanced Poly-Packaging, Inc. https://ecom.advancedpoly.com Whether bagging fasteners, hardware, or components, Advanced PolyPackaging’s Ultra-Count Series counters provide the flexibility and speed to get the job done quickly and accurately. The counters offer thick-coated, stainless-steel bowls, which provide a long life (even when running abrasive or sharp parts) and easier filling capabilities. A programmable, self-training photo-eye count is available for only those parts that are within the set range of acceptance. Additionally, the reliable and heavy framework offers a “two-cushion” suspension for smooth and accurate parts flow. An integrated conveyor system automatically adjusts the speed for maximum production.
Titanium cap screws Keystone Electronics keyelco.com
Standard Parts. Winco.
Hygienic Design Standard parts for applications in hygienically sensitive areas. 800-877-8351 sales@jwwinco.com
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Keystone Electronics’ new series of metric threaded, titanium socket-head cap screws are manufactured from C-276, Grade 2 Titanium, fully meeting DIN912 specifications. These screws are ideal for use in corrosive environments involving seawater, acids, chemicals, petroleum, biomedical, or power-generation operations. The socket-head cap titanium screws have a high strength-to-weight ratio and are about 40% lighter than steel screws. Designed with a knurled head featuring a hexagonal drive socket, the screws are available in M3, M4, M5, and M6 threads and lengths of 10, 16, 20, 30, and 40mm.
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FASTENER FASTENER 104
Selecting the Optimal Washer Flat: Generally used for load disbursement Tab/Lock: Designed to effectively lock an assembly into place Finishing: Often found on consumer products Wave: For obtaining loads when the load is static or the working range is small Belleville: Delivers the highest load capacity of all the spring washers Fender: Distributes a load evenly across a large surface area Shim Stacks: Ideal for simple AND complex applications
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Trusted Ultrasonic Technologies for Nonwovens – Worldwide Every day, manufacturers trust Branson™ ultrasonic welding technology from Emerson to transform nonwoven fabrics and thin plastic films into vitally needed personal protective equipment, face masks and clothing, sterile packaging, and a range of absorbent and personal-care products. Our ultrasonic technology includes standalone assembly solutions like the Branson 2000X, a family of welding systems with the versatility to handle both rigid and nonwoven plastics. And, there’s the family of Branson DCX power supplies, trusted to drive and control ultrasonic cutting, seaming, and bonding operations in custom nonwovens production machinery. Best of all, every Branson solution is backed by the people and resources of Emerson’s global service network.
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Adjustable Levers with Special-Tipped Threaded Studs from JW Winco
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Adjustable levers have proven to be ideal wherever parts have to be clamped in a confined space or with a particular lever position. The series WN 306 with plastic lever body and GN 306 with zinc die-cast lever body are available with various special-tipped threaded studs. The brass and plastic tips help to avoid damage to the workpiece being clamped whereupon the hardened tip provides an oval point-shaped pressure point. The swivel thrust pad can easily be clipped on and taken off.
Find out more at www.jwwinco.com.
JW Winco, Inc. Phone: 800-877-8351 sales@jwwinco.com www.jwwinco.com
www.fastenerengineering.com
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FASTENER
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High torque synchronous drive/ timing belts
Product World All-in-one controller for compact IoT applications
AutomationDirect automationdirect.com Synchronous drive belts and pulleys use teeth to prevent slippage
Omron automation.omron.com
and unwanted speed variations. AutomationDirect SureMotion 5M and 8M (5 mm and 8 mm pitch) high torque synchronous drive/timing belts have a
The CP2E Series all-in-one controller provides advanced
curvilinear HTD (High Torque Drive) tooth profile which allows the belts to have a
control that enables IIoT connectivity for compact
much larger pulley contact area for improved performance.
machines. The controller improves manufacturing
The chloroprene belt body is heat and ozone resistant with a high tooth shear
productivity and quality by making it easy to visualize the
resistance. Fiberglass tensile cord provides high dimensional stability and maximum
performance and data of connected machines through
flexibility. The nylon tooth cover offers durability, wear resistance, and increased
simple programming.
power capacity. Belt operating temperature range is -13/+185°F (-25/+85°C).
The CP2E cost-effectively enables IIoT connectivity for compact machines. The controller collects machine performance data and shares the necessary information with enterprise networks, while the predefined program data and function blocks allow virtually anyone to set up machines to perform complex control. This reduces the time required for programming, testing, debugging, and maintenance. Features
SureMotion timing belts are a suitable choice for many industrial applications. Belt widths from 9 to 30 mm and circumferences from 180 to 4400 mm are available. Pitch sizes and widths match SureMotion pulleys to cover a wide range of power transmission requirements.
Commission and control SCARA robots directly from a laptop ABB abb.com/robotics
• Improved connectivity for Ethernet and serial devices. The CP2E has two Ethernet ports with Ethernet switching function: host and HMI connectivity. Up to three serial ports are available for open connectivity to serial devices.
RobotStudio is ABB’s simulation and offline programming software. Robot Control Mate is an add-on to RobotStudio,
• Reduced effort for the setup of complex machines.
enabling users to jog, teach, and calibrate
Function blocks make it easy to
robots from their computers, making it
achieve 4-axis
easier than ever to control a SCARA robot’s
positioning
movements. For the first time, the offline programming software can be used to
function with linear
control the physical movements of a robot in real-time. Robot Control Mate also
interpolation, and the
makes robot programming possible when a FlexPendant is not in place.
CP2E also provides
Robot Control Mate will first be available on the IRB 910INV ceiling-mounted
a PID control with an autotuning function
robot and will be expanded to other robots in the portfolio later this year. RobotStudio is a PC-based solution for programming, configuration, and
block for stable
virtual commissioning before installation. ABB offers a complete digital twin of
temperature control.
physical assets or systems on a production line. The offline programming tool enables users to create, simulate, and test a complete robot installation in a virtual 3D environment without disturbing their actual production line.
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For further information about products on these pages visit the Design World website @ www.designworldonline.com
Condition monitoring sensor Balluff balluff.com This condition monitoring sensor can measure vibration, temperature, relative humidity, and ambient pressure. The sensor collects and
Linear guides
processes these readings and outputs digital statistical data to a host system via IO-Link.
NB Corporation nbcorporation.com
The sensor can detect and communicate its condition, continuously reporting its temperature, number of operating hours, and start cycles. By automating costintensive manual inspections, it minimizes unscheduled stops and faults in
EXRAIL linear guides have more rollers in less space
the production process. This condition data is an essential component for implementing
than other linear bearings, which increases load
smart and flexible manufacturing.
capacity and disperses the load more evenly. It has
The sensor is available in two versions, both in a small stainless-steel form factor. The first measures contact temperature and vibration in all three axes of motion and has IP67 and IP69K ratings making it useful for harsh environments. The other adds the additional environmental variables of relative humidity and ambient pressure and delivers an IP67 rating.
longer rollers for greater contact surface and less contact pressure. In comparison to presently available linear guides, the EXRAIL slide guide pro-vides smoother movement. It uses multiple small diameter needle rollers that reduce dynamic frictional resistance and
Integrated high-fidelity 3D profile sensors
range of fluctuation of dynamic frictional resistance.
Matrox Imaging matrox.com/imaging
when a slide guide receives load in pitch, yaw, or roll
Another EXRAIL feature is that its Static Load Capacity is higher. Localized deformation occurs directions. High Static Load Capacity means that there is a relatively large amount of load that the block can sustain before it deforms. In fact, for the
The Matrox AltiZ is a series of integrated
new design, independent testing data indicated
high-fidelity 3D profile sensors with a
that it exhibited higher performance than presently
dual-camera, single-laser design.
available products.
These fully integrated 3D profile sensors
The EXRAIL has 1.5 - 2 times higher static load
have an optimized design that lessens scanning
rating as well as allowable static moment in the
gaps. Simultaneous viewing of the laser line by the Matrox AltiZ’s
rolling, pitching, and yawing directions in comparison
two opposed optical sensors reduces optical occlusions — frequently
to other products on the market.
encountered at critical surface junctures — caused by the laser line being obstructed from the view of a single image sensor because of a surface’s orientation. Matrox AltiZ 3D profile sensors achieve something common 3D profile sensors —equipped with a single laser and single optical sensor — cannot. Matrox AltiZ’s dual optical-sensor design and data-fusion capabilities offer higher 3D reproduction fidelity through its ability to combat occlusion and outlier data. The Matrox AltiZ delivers high levels of control over spurious data, providing robust reproductions.
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Product World Clutch/brakes for indexing conveyors and palletizers Force Control Industries forcecontrol.com Posidyne clutch brakes feature oil shear technology for rapid and
Faster production rates and significantly longer service life than
precise stopping, starting, speed change, and positioning, all without
traditional (dry) clutch/brakes (often 5 to 10 times longer) yields
adjustment or maintenance. Suitable for applications with frequent
increased uptime, productivity, and ROI. Posidyne clutch/brakes are
start/stop cycles — such as indexing conveyors that feed palletizers,
field-proven in diverse applications such as packaging lines, food and
rotary tables, batch feeders, rotary coal samplers, cutoff machines, and
chemical processing facilities, lumber mills, shingle plants, fiberglass
more — these unique motion control devices allow higher cycle rates
insulation production, metalworking, and many more.
(up to 300 cycles per minute), to increase production rates with lower downtime.
Outdoor HMI family expanded to include 15-in. wide screen Pro-Face profaceamerica.com A 15.6-in. display option has been added to the SP5000X Outdoor HMI series. This wide-screen display is an extension of the eXtreme HMI line. A larger display offers users an easier-to-read screen from further distances offering yet another solution to the automation industry’s long time need for HMIs that can be used in extreme and hazardous conditions, including outdoor applications. Combine this 15.6-in. SP5000X wide sunlight-readable display made with an aluminum die-cast, stainless steel bezel, with the SP5B90X box unit, to create an overall eXtreme solution for applications that require a large screen with sunlight visibility. This combination offers operating temperatures ranging from -30º to 60º C, a high brightness liquid crystal panel displaying screens at 1000 nits, and a UL 50E Type 4X outdoor use rating. The SP5000X series is suitable for multiple applications under harsh environmental conditions (3C3), including use in vehicles such as fire trucks, trains, and construction equipment, parking lots and gas stations, and the oil and gas industry. Connect a J1939 communication module to Engine Control Units (ECU) to monitor and control electric generators, highway trucks, agriculture machines, and construction machines.
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Back Page ADVERTORIAL
Edge Processing Enables Improved Operations
By Derek Thomas • Vice President of Marketing & Strategy • Machine Automation Solutions at Emerson
Many companies are tempted to tackle the big data issue in one fell swoop with mega-scale projects. A better path for most manufacturers is to start small with a little data approach to greatly simpli and speed implementation, with positive results generated in days instead of the years. Of course, one must keep in mind the ultimate goal, which is larger scale implementation, o en through integration with enterprise IT systems. A key enabling technology for creating value om little data is edge computing, whereby data produced by sensors is analyzed by a field-located device to generate insights. This information allows personnel close to the source to quickly assess issues and take appropriate action. In the past, this type of edge processing would have required the addition of a separate industrial computing device, or an edge gateway connected to a server, to process the data. In either case, the solution would have required integration with the existing controller and manufacturing network. This would have been a problematic step due to the complexity of setting up and programming in two different environments—and due to synchronization requirements, lag/ latency issues, cybersecurity concerns, and other factors. But today, advances in processor technology enable edge controllers to perform two functions within a low energy use and compact form factor. The first function is real-time deterministic control using IEC 61131-3 languages, much like a traditional programmable automation controller (PAC). The second function is edge processing using advanced programming and scripting techniques. Integration effort, cost, and complexity are reduced because both functions are performed in one device. Each part of the controller is virtually connected via OPC UA, allowing the two functions to be operate seamlessly,
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yet also separately such that real-time control tasks and performance are not affected by the edge applications. PAC-based control is familiar to anyone working in the industrial automation arena, but edge processing contained in the same device is a new concept for many. In traditional implementations, a PAC would simply collect data and then forward it to a host system for processing. This host system would typically be PC-based, and it would o en be located some distance om the edge, perhaps even in a data center or the cloud, raising a number of potential issues. Processing data at the edge, instead of at a remote host, addresses these issues by providing local: • Data storage, processing, and analytics • Data logging • Operational diagnostics • Closed-loop optimization opportunities • Visualization, dashboards, and other HMI functionality when connected to a display Edge processing creates an open, flexible ecosystem with broad compatibility across all layers of automation systems. Users can create dashboards, improved analytics, and trends—all acting upon full fidelity and complete data sets—to empower local operators. Data communication and storage
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requirements are substantially reduced because only results are transmitted, instead of entire data sets. With today’s PACs, customers can only write rudimentary analytics utilizing IEC 61131 languages. In contrast, edge controllers support execution of modern programing languages such as C/C++, Python, and Java. These and other advanced languages can be used to apply complex optimization algorithms or analytics to improve operations. This “outer loop” or “advise” layer runs in parallel with the underlying closed-loop control. In the event of a disruption to this “outer loop”, realtime deterministic control remains unaffected. This functionality delivers on the potential of machine learning by allowing adjusts in real time based on actual performance data collected and analyzed at the edge. It also provides the ability to update machines/ programs by staging upgrades, or sequencing them in real-time, to minimize impact. An edge controller can thus be viewed as an end user’s on-ramp to the continuous journey of digital transformation. End users can start to solve big data challenges, one manageable little data chunk at a time, and edge controllers provide the scalability required to eventually transform entire discrete part manufacturing enterprises.
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Ad Index
SALES
ABB Motors & Mechanical ......... 9 AllMotion ...........................................4 Altech Corporation ................ 19,21 Aurora Bearing Company ....... 33 AutomationDirect ...........................1 Bay Associates Wire Technologies, Inc. ................. 27 Bison Gear and Engineering .. 37 Canfield Connector ....................30 CGI Inc. ............................................ 31 Del-tron ..........................................48 DeviceTalks ................................... 67 Digi-Key ........................................... 15 Elesa USA Corp ............................ 17 Exair Corporation ..........................5 FAULHABER MICROMO .......... IBC Fixtureworks .................................. 16
HELUKABEL USA ......................35 HYDAC International ................49 IKO International, Inc. ................41 Nason .............................................. 7 PBC Linear ..................................20 R+W America ...............................53 Sager Electronics ......................65 SEW Eurodrive ........................... BC SIKO Products ............................... 11 Sorbothane .................................30 Smalley Steel Ring .....................51 THK America, Inc .......................IFC Tormach ........................................38 Trim-Lok ........................................25 TTI, Inc. ............................................ 2 Whittet-Higgins ..........................29 Yaskawa Electric America ....... 3
Fastener Engineering Supplement
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Engineering July 2020
A supplement of Design World
The design, materials, and stories behind the fastener industry.
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A.Raymond Tinnerman Industrial Inc .......................................... 100 Boker's Inc. ......................................................81 Ellsworth Adhesives .................................. 94 Emerson .........................................................76 Fall River Manufacturing .......................... 89 Fastener Training Institute .................... 103 Gluespec.com ............................................... 77 Hernon Manufacturing ............................. 101 Infasco ............................................................ 99 J.W. Winco, Inc. ........................................... 102 Master Bond .................................................85 NBK America LLC .........................................95 Women in the Fastener Industry ........ 107
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Fully Integrated Speed Controller, within 6.2 mm
The FAULHABER BXT Flat brushless DC servo motor family has grown; now available in all sizes with a diameter-compliant, integrated speed controller. With an additional attachment length of just 6.2 mm, the combination of the BXT H motors with the integrated speed controller is the ideal solution for space-confined applications, particularly if speeds need to be controlled precisely, and high torques are also required. Typical applications are medical devices, pumps, hand-held instruments, optics systems, and robotics & end-effectors.
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Overworked? Tired of working overtime on motion control projects? It’s time to contact an SEW automation specialist. Our exclusive software modules empower you to perform complex automation very simply and without experience. Or, we can provide a complete package, including project planning, software, components, commissioning, and global support. Sleep in... We got this!
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