DESIGN WORLD JULY 2021

www.designworldonline.com

July 2021

inside: MOTION CONNECTIVITY:

Connectivity building blocks for motion control

p. 80

ELECTRONICS: Cooling with capacitors

p. 90

FASTENER ENGINEERING:

What causes

fastener seizing and galling?

p. 60

Top 10

considerations

when applying rack and pinion systems

page 84

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I n s ights Do you have an “executive presence?”

As we move through our careers, it’s o en interesting to watch the trajectory of our peers and compare their paths to our own. In many companies, there’s a natural corporate ladder we all climb, sometimes in stops and starts, depending on the overall structure. But we’ve all seen coworkers who rise faster, de ly navigate past roadblocks, and rarely plateau. What’s their secret?

And can you learn it?

At a recent NFPA Future Leaders online presentation, Jennifer Miller of Rockford Gray discussed how to develop an executive presence, which is a key to this type of continued ascendance.

While you may not be familiar with the term “executive presence,” it’s pretty self-explanatory and is comprised of three core aspects that won’t come as a surprise: your appearance, your gravitas, and your ability to communicate.

The first two items are things we all can work on. Make sure you’re dressing appropriately for your industry and your specific organization. Dressing properly tells people that you understand the situation and the audience.

People are making a judgement about your level of judgement, and this lets people determine your intelligence and commitment. With gravitas, think of that as seriousness and importance that cause feelings of respect and trust in others. Your substance, heaviness, gravity, tone, appearance, body language, facial expressions and confidence all add to whether others will perceive you to have gravitas.

But the third component is especially relevant to engineering professionals like us. Communication is o listed as a skill that engineers are poorly adapted to. So what advice does Miller have to communicate better?

“Get to your headline and don’t start with data when you’re communicating,” she said. “You’re not writing a paper, you’re speaking.”

Let’s say you’re going to present at a meeting. Ask yourself, “What is my story?” Remember that the core of any story is a message or handful of messages. Use these messages throughout so they are thematic as you go through the story. You want to make sure that people leave a meeting knowing your story.

For your message, it’s critical to know your audience and what matters to them — and why they care about it. Will your presentation help their career or give them a solution to a problem? Lastly, you can’t have 10 big messages, or you’ll end up watering things down. Go with one, two, or three at the most.

Many people feel that what we’re calling executive presence is something innate, that we’re either born with it or we aren’t. That’s simply untrue. All three of these core aspects are things you can work on starting today — and with consistency and dedication, you can improve your own appearance, gravitas, and communication style to fuel that next promotion. DW

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

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

(408) 460-1345

On Twitter @wtwh_paulheney

4

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July 2021

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DESIGN WORLD

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Teschler on Topic

Sizing up renewable energy aspirations Clean energy is in the news thanks to a Federal budget proposal that would boost spending on clean energy infrastructure by 27% as well as create a federal clean electricity standard and expand clean energy tax credits. To many people, clean energy is a term denoting wind and solar power. And the U.S. Dept. of Energy already has long-term goals for the amount of power generated by wind and solar in the U.S. So it is interesting to see what kind of infrastructure these goals imply.

The DoE figures the U.S. will need 5,500 billion kWh of power in 2050 and hopes that 42% of that, or 2,300 billion kWh, will be generated by solar power.

To get a handle on the implications of that figure, consider that the largest solar power plant in the world today is the Bhadla Solar Park in India. It has an installed capacity of 2.25 GW and spans 14,000 acres, about the size of Newark, N.J. Sufficiently curious individuals can calculate how many Bhadla parks it would take to reach the DoE solar generation goal for 2050. To simplify things, we might assume that all solar panels are illuminated with full sunlight for five hours daily, there are never any cloudy days, panels never go down for service, and panels don’t grow old or dirty so their output never drops.

These conjectures let us estimate that Bhadla park is good for about 4 billion kWh annually. Thus we’d need 575 Bhadla parks to hit DoE’s 2050 solar generation goal, covering a land area larger than the state of Maryland.

A similar exercise for wind leads us to examine the Alta Wind Energy Center, also known as the Mojave Wind Farm, in California. Said to be either the second or third-largest onshore wind energy project in the world, it has a 1,550 MW capacity and occupies 3,200 acres. It’s capacity factor over the past few years was 23.5%.

That means Alta has provided about 3.19 billion kWh annually. The DoE hopes that 35% of our power, or 1,900 billion kWh, will come from wind by 2050. It would take 596 Alta sites to hit this goal, occupying land equivalent to about half the state of Connecticut.

You might quibble with the rationale for these conclusions. After all, off-shore wind power doesn’t use any on-shore land. But these projects are technically challenging and are experiencing the same NIMBY problems in the U.S. that have slowed ordinary wind plant construction. And a lot of solar panels will go on rooftops rather than in solar farms. Additionally, commercialization of more-efficient perovskite solar cells could boost solar farm energy density.

Nevertheless, even optimized versions of wind and solar installations would take up a significant amount of real estate.

With that in mind, it is easy to see the attraction of a next-generation nuclear power plant planned for Wyoming. Called Natrium, it is a joint initiative between Bill Gates’s TerraPower and PacifiCorp, owned by Warren Buffett’s Berkshire Hathaway. It consists of a 345-MW sodium-cooled fast reactor and molten salt-based energy storage. The nuclear industry has an overall capacity factor of 85.9%. If the Natrium plant has the same reliability, it would generate 2.6 billion kWh annually.

Thus 886 of these relatively small reactors would handle the DoE power goal for solar in 2050. If they occupy the average 1.3 square-miles of an ordinary nuclear plant, they would all fit comfortably inside the city limits of Anchorage, Alaska. DW

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

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DESIGN WORLD

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Technology Forward How to keep data safe in the IoT world The news has been filled with cyberattacks on a number of companies’ networking systems, several of which are critical to the U.S. economy. As the IoT, IIoT, Industry 4.0, and similar networks inch forward, recent digital events on networking held sessions on how to secure the transmission of data. One of those sessions was at the recent OPC Day International. The OPC organization promotes the use of the OPC Unified Architecture (UA). While this protocol may not be as well-known as others in the U.S., it has been around since 2008.

The OPC UA protocol transports standardized information from a source, such as an industrial component, to the cloud, and back to IT systems through standard interfaces independent of underlying protocols (like TCP, UDP, MQTT, AMQP, etc.). The organization says OPC UA is an enabler for interoperability of devices on the shop floor and business software. But it provides this interoperability with end-to-end security.

According to OPC, there are at least ten common attack types. These include: • Message flooding through denial of service (DoS) attacks. OPC UA servers combat this by processing incoming packets as minimally as necessary.

If information in the packet doesn’t

immediately align, the server simply drops it. It doesn’t try to recover the data, try to figure it out, or try to have further exchanges with that client – it just drops it. This feature minimizes OPC UA server processing, which preserves the resilience of the server.

• Message spoofing—a way to forge messages. This is sometimes called a man-in-the-middle attack, where messages are manipulated to appear authentic when in reality they are not. OPC UA packets use encryption, certificates, embedded Session ID’s, and Channel ID’s, so fake messages don’t make it through.

• Message alteration, or replay, where hackers try to take a valid message and attempt to replay it a number of times. OPC UA session ID’s, channel ID’s, timestamp sequence numbers, request IDs, and so forth, all take these things into account, preventing the replaying of messages.

• Eavesdropping is eliminated through OPC UA’s data encryption.

All network and interoperability options will need to include some type of security functions. OPC UA views data as being in, what it calls, the data-in-motion state. It looks at data holistically, not just how data may be encrypted as it moves across the wire, but also, who should have access to the information, and what they can do with it.

OPC UA security incorporates know-how from other groups. For example, it follows the National Security Agency concept of defensein-depth, which includes multiple layers of security. Another example is the National Institute of Standards and Technology approach with algorithms. NIST monitors algorithms as they evolve to reduce vulnerability.

And then, there is the use of certificates. Components like small microprocessors to large servers and cloud-based systems make use of certificates for security purposes.

Security policies in OPC UA servers create a combination of different algorithms and exchanges that can be established between a client and a server to mutually prove their identity. The policies include the use of encryption standards on how clients and servers will sign messages; how they are going to encrypt and subsequently decrypt the data, the use of tokens and hashing values, and so on.

Data security will always be a work in progress, as hackers continuously find new ways to access data. But if manufacturers take a holistic view when building their products, and end-user administrators properly configure their systems and supporting networks, the number of security breaches can be contained. DW

Leslie Langnau llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

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DESIGN WORLD

6/23/21 2:06 PM

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Smart. Safe. Productive.

ABB Ability Smart Sensor for mounted bearings

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Green Engineering

How 3D printing can save trees Leslie Langnau

Early in the 3D printing industry, there were efforts to take wood byproducts and use that material to make parts. These early efforts were interesting for the novelty.

Today, however, there’s a more serious effort to turn wood into a usable 3D printable material. Desktop Metal launched Forust, a process to sustainably produce functional end-use wood parts using its single pass binder jetting AM technology. The Forust process upcycles waste byproducts om wood manufacturing (cellulose dust) and the paper industry (lignin) and re-materializes functional wood parts through high-speed 3D printing including digital grain throughout the part.

While primarily aimed at architects and designers of custom wood pieces for home decor, interiors, transportation, and architectural design, this development shows the flexibility of 3D printing/additive manufacturing technology and how it can be used to solve some environmental issues.

William McDonough, architect, globally recognized leader in sustainable development and design, and pioneer of the concepts of Cradle to Cradle, the Circular Economy, and the Circular Carbon Economy, said, “The Forust technology allows us to take something that was previously wood waste and re-materialize it into exquisitely 10

July 2021

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beautiful and useful things. We are honoring the cellulose and lignin of the trees by rearticulating them into assets for present and future generations. By allowing millions of trees to remain in place in their forests, Forust is launching a highly evolved technology for the circular technosphere that supports and celebrates stewardship of the natural, regenerative, and diverse biosphere, making it not only smart, but wise. This is an historic and material opportunity in the history of design and the making of things that reminds me of Arthur C. Clarke’s famous quote, ‘Any technology that is sufficiently advanced is indistinguishable om magic.’ As a lover of wood and forests, I find Forust indistinguishable om magic. The 3D printing of wood using waste natural materials is a gamechanger. We have only begun to explore its beneficial potentials, but it is clear they are immense.”

Transforming wood byproducts Forust is led by industry veteran and ceramics 3D printing pioneer, Andrew Jeffery, who previously served as President of Boston Ceramics. Jeffery is joined by co-inventors

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DESIGN WORLD

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Green Engineering and creative consultants in industrial design, Virginia San Fratello, Chair of the Department of Design at San Jose State University, and Ronald Rael, Professor and Chair of the Department of Architecture at the University of California Berkeley, both of whom are also founding partners of 3D printing company, Emerging Objects.

“The inspiration for Forust was to begin with sawdust and end with forests,” said Jeffery. “Our process is based on extensive research conducted over the past decade in the field of hardwood lumber, leading to complex and elegant finished structures. Through advanced CAD so ware, proprietary materials and Desktop Metal binder jetting mass production platforms, we can now manufacture beautiful, functional and innovative wood products for a variety

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of architectural, interior, and home goods applications om upcycled wood byproducts.”

The Forust process combines two waste streams om traditional wood production, sawdust and lignin, to sustainably produce isotropic, highstrength wood parts. Depending on the size of the parts, Forust can manufacture wood products using either the Shop System or a custom version of the new RAM 336 3D printer, which supports prints up to two cubic meters in volume at speeds in excess of 100 liters of parts per hour.

During the printing process, layers of specially treated sawdust are spread and selectively joined by a non-toxic and biodegradable binder. Digital grain is printed on every layer and parts can then be sanded, stained, polished, dyed, coated and refinished in the same manner as traditionally manufactured wood components.

“Forust offers nearly unlimited design flexibility,” said Jeffery. “From exotic grain structures to grainless wood, we can digitally reproduce wood textures and a myriad of grain types. And, because they are made om a wood and bioresin compound, these parts exhibit the functionality and stiffness in line with conventional wood. Our finished pieces are indistinguishable om traditionally manufactured wood products you would find in a store. The additive manufacturing process literally becomes invisible.”

Because Forust produces parts additively layer by layer without the need for supports, designers have the eedom to create complex features and iconic designs that would be difficult or impossible to produce with traditional woodworking methods.

Unlike particle board or laminate, Forust produces a wooden part with a digital grain that flows throughout the entire part that can be sanded and refinished. So ware has the ability to digitally reproduce nearly any wood grain, including rosewood, ash, zebrano, ebony and mahogany, among others. Parts will also support a variety of wood stains at launch, including natural, oak, ash, and walnut.

www.designworldonline.com

Forust also offers an on-demand manufacturing service where manufacturers and designers can submit their own custom designs for printing, order samples or pursue high-volume partnerships to produce custom, 3D printed wood pieces in volume for use in their products.

“We want to make it easy for designers to explore complex new geometries for a variety of products and applications using an age-old material,” said Jeffery. “At the end of the wood product’s life, we would like to see customers have two choices — dispose of it and it will biodegrade over time as any wood product would, or shred it and repurpose the material into future parts through Forust. Our vision is a true circular manufacturing process.”

“Applications for Forust’s wood parts are really limitless,” said Ric Fulop, Founder and CEO of Desktop Metal.

“There are many applications where polymers and plastics are used today where you can now cost-effectively replace with sustainably manufactured wood parts – luxurious, high-end components in interiors, consumer electronics, instruments, aviation, boats, home goods and eventually in flooring and exterior roofing applications. For the first time, we can produce beautiful parts with the same durability and characteristics you would have in traditionally manufactured wood, but printed using upcycled materials which does not require cutting down or harvesting trees. With Forust, we have the opportunity to have a meaningful impact on sustainability, climate change and waste issues that we as a humanity have brought to the planet. For each tree saved, we are reducing the carbon footprint by a metric ton over its lifetime.”

DW

Forust www.forust.com Desktop Metal www.desktopmetal.com

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Contents 7 • 2021

•

vol 16 no 7

•

designworldonline.com

80 80 _MOTION CONNECTIVITY

90 _ELECTRONICS

Connectivity building blocks for motion control

Cooling with capacitors

Servo and variable frequency drive designs depend on compact and reliable electrical connections.

84 _LINEAR MOTION Top 10 considerations when applying rack and pinion systems

Rack and pinion systems are electromechanical devices uniquely suited for linear or rotary motion solutions unattainable with other technologies. The typical system includes a long straight rack (or linear gear) with teeth on one surface, a matching pinion (or circular gear), and a method for driving one or the other. Curved racks are also possible.

Ordinary vapor-compression cooling is inefficient and un-green. Futuregenerations of air conditioning may instead use electrocaloric techniques with almost no moving parts.

96 _TEST & MEASUREMENT Test instruments evolve to meet next-generation needs

Engineering July 2021

A supplement of Design World

What causes

fastener seizing and galling?

COVER_FE 7-21_FINAL.indd 49

6/23/21 7:48 AM

49-79

The next generation of engineers, digital natives reared on screen time and apps, are finding test instruments designed to suit their experiences.

ON THE COVER Helical-tooth rack and pinion sets offer unique | Dreamstime design benefits to long-stroke axes.

GOLD REGIONAL AWARD

asbpe.org

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www.designworldonline.com

DESIGN WORLD

6/29/21 10:38 AM

Digi-Key 4-21_DW.indd 15 210310_OSOSOW_DW_US.indd 1

6/23/21 8:09 AM 3/8/21 11:29

Interpower® Ingress Protected Outdoor Sockets

7.21

• contents departments 04

Insights

06

Teschler on Topic

08

Technology Forward

10 Green Engineering 18

Interpower Outdoor Outlets conform to IEC 60529 and NEMA 250 standards.

All Ingress Protection (IP) ratings have two digits. The first digit rates contact with moving parts, and the degree of equipment protection against the intrusion of objects. A “0” rating means no special protection while “6” means dust-tight.

Design For Industry

30

Design Notes

38

CAE Solutions

42

Internet of Things

48

Injection Molding Classroom

100 Product World 104 Ad Index

The second digit indicates protection from moisture. A “0” indicates no special protection while “9” indicates the highest protection (water jets).

Interpower’s outdoor outlets are rated IP 65 (protection from dust/jetting water) and NEMA 12/4, indicating protection from dirt, dust, and dripping and splashing water.

®

®

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

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

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

VIDEO SERVICES

WEB DEV / DIGITAL OPERATIONS

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WTWH Media, LLC 1111 Superior Ave. 26th Floor Cleveland, OH 44114 Ph: 888.543.2447

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Medical Design & OUTSOURCING DESIGN WORLD

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

Medium-pressure hydraulic pump for mobile machines

HAWE Hydraulik supplements the series of axial piston pumps in the medium pressure range with the new type C40V as successor model for the type V40M. This particularly lightweight axial piston pump is designed and compactly built for open circuits of mobile machines. Available in various sizes, it supplies system solutions for pressure ranges up to 280 bar with the required flow rate.

The axial piston pump type C40V is lighter than its predecessor and has an even higher maximum self-priming speed of 3,200 rpm. The maximum delivery volume is 85cm³/rev and is available in three sizes (28, 45, and 85 cm³).

A range of applications is opened up by a diverse range of controllers. The load-sensing regulator is available with an integrated or an electro-proportional pressure cut-off. In addition, purely mechanically adjustable pressure regulators or electro-proportional pressure or flow regulators are also available. Flow

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DESIGN WORLD

6/24/21 9:10 AM

regulators and capacity regulators will also be available. Due to the swash plate design, the flow rate can be varied finely and easily via the swivel angle. This makes it an efficient drive for mobile hydraulic systems.

The pump supplies hydraulic consumers, for example, in agricultural and forestry machinery, municipal vehicles, fan control systems and aerial work platforms. It can also be used to drive generators or to steer construction machinery. DW

HAWE Hydraulik | www.hawe.com

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

Pump and motor drive performance with interconnected propel solutions The equipment industry — om construction to agriculture, mining, and beyond — is moving to adopt smarter, more efficient systems and machines.

To maximize efficiency and productivity, users need machines that are easier to maneuver on the worksite, simpler to operate and packed with more power to handle every job.

For OEMs, these evolving expectations mean rethinking how they design and build the critical systems that power their machines. As the footprints of these machines shrink to reduce weight and improve efficiency, OEMs must find new ways to pack more power into tighter spaces. It’s no longer just about components; it’s about how components connect to create intelligent subsystems that are greater than the sum of their parts. Every part must work together seamlessly to unlock new efficiencies and enhance productivity.

Eaton’s new X3 portfolio is designed to help OEMS meet today’s diverse industry demands by combining capabilities for best-in-class performance in a compact package. They provide the ability to pair the X3 two-speed cartridge motor with single or back-to-back pump configurations.

The X3 two-speed cartridge motor is available in 41 and 49 cc displacements, which helps provide more top-end horsepower at the wheel

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while ensuring most small mobile application needs are covered.

The motor also has a built-in speed sensor port, making it easy to add a sensor to measure speed and direction. Using a standard SAE B 2-bolt mount, the motor will fit into virtually any existing machine design and can also be positioned as a drop-in replacement for several motor configurations.

Built for durability in the toughest mobile environments, the X3 motor pairs with back-to-back or single pump options which offer a 36% increase in the side load capacity over previous generations of Eaton pumps. The compact size makes it easier for designers to fit the pump into smaller machines, a key advantage given the increasing need to save space in construction and agricultural equipment. The pump also has improved packaging that better protects the control solenoids against damage.

The X3 pump is available with a variety of controls, including a non-feedback electrohydraulic control, a hydraulic remote control, and a manual servo control. The X3 pumps are Pro-FX Ready and ideally paired with an Eaton HFX Programmable Controller. Eaton’s X3 portfolio can actively sense and dynamically adjust parameters such as position and flow – taking dynamic machine control to a whole new level.

When combined with Eaton’s HFX controller, the X3 pump delivers among the lowest amount of hysteresis (variation) of any pump in its class. By improving accuracy of output flow, engineers are empowered to design systems that deliver greater repeatability — another major ingredient for advancing machine reliability and efficiency.

By combining a cartridge motor, pumps and controls together in one robust solution, the X3 portfolio empowers OEMs to build the powerful equipment that end users demand — offering tight control, smooth operations and fuel savings.

Allowing engineers to reimagine system design and introduce advanced connectivity, X3 provides the foundation for more reliable, stable and productive machines. DW

Eaton Eaton.com/X3

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Design for Industry Food & Beverage

Grippers handle smooth surfaces without leaving an imprint

The bionically inspired gripper technology ADHESO, uses the intermolecularly acting Van der Waals forces for handling components. Made of special polymers, the patented surface architecture of the grippers is optimized by numerical simulation, creating a structure of finely structured legs that adhere to different materials and objects.

The gripper can handle glass fibers; the smallest SMD components or micromechanical parts; sensitive battery components; plastic films; paper and glass. The grippers handle objects that weight up to 33 lb, and more is also possible.

Using Van der Waals forces, the face of the gripper is gently pressed onto the workpiece during the gripping process, increasing the contact surface and locking the grip into place. This effect can be reversed by applying a slight pressure/rotary movement so that the gripper can be loosened om the object without leaving a residue or any marking. The alternative use of a wiper ensures that the object is gently put down.

The respective adhesive forces and removal of ADHESO depend on the type of material, surface roughness or flatness, and miniaturization, and can be customized 22

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to the different requirements of the environment. The adhesive structures can be designed transparent, translucent, or opaque. This degree of individualization ensures that components with dimensions of a few hundred micrometers can be handled as reliably as those measuring several meters.

The adhesive technology is gentle on components, low-noise, and doesn’t require compressed air, vacuum, or current. An external energy supply is not necessary for gripping or for maintaining the gripping force. In case of a power failure in the handling system, the holding forces of the gripper are reliably maintained. The gripper can be used in conventional industrial environments, as well as cleanrooms and vacuum environments. In the field of micro handling, repetitive positioning accuracies of <0.01 mm can be achieved. The ADHESO gripper has a bayonet lock and therefore the grippers can be exchanged in a few simple steps. Installation costs and commissioning efforts are minimal. DW

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Design for Industry Food & Beverage

Filters ensure clean compressed air in food zones The MS series of filtration products include filters that lower the risk of particle contamination when compressed air comes into direct contact with food or packaging in the food zone. The MS series meets or exceeds the highest industry standards for clean air.

MS filters arrive assembled with safety and productive maintenance features typically found as custom add-ons. The units install easily.

The MS series is for food and packagingin-food-zone applications in the dairy, baking, produce, processed foods, pet foods, cra beer, cold food processing, and beverage industries.

The series also suits a range of industries outside of food and beverage where clean compressed air enhances the longevity and efficient operation of pneumatic cylinders and processes.

The three different models in the series – MS4, MS6, and MS9 – not only conform to FDA and Food Safety Modernization Act guidelines for clean air, but they also meet or exceed the top national and international benchmarks, including:

• Safe Quality Food Institute Codes Edition 9 • 3-A standard 604-05 • British Compressed Air Society Guideline 102 • ISO2200:2005 MS series filtration systems are rated for air flow ranging om the MS4 at 360 l/min to MS9 at 7,800 l/min.

In addition to the three stage filters, MS air preparation units come standard with a lockout/tagout feature for operational safety. An exhaust valve, another standard feature, safely evacuates air om the system when filters are changed.

Once the pressure point is set, a lockable filter regulator prevents tampering.

Visual-cue red/green gauges support total productive maintenance initiatives by indicating to personnel that the unit has the correct/incorrect pressure range and whether filters require replacement. Filter drains are manual, ensuring that condensation droplets do not fall onto the facility’s floor and pose a risk of contamination. A corrosion resistant housing supports extended service life. The MS series installs easily and is compatible with a wide range of fittings om NPT 2 all the way down to G 1/8. DW

Festo | www.festo.com/us 24

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Design for Industry Packaging

Sensor detects multipacks

The new dynamic reference diffuse sensor DRT25C.R detects various film-wrapped bottles and cans fault- ee. It uses the conveyor as a reference, and because the detection does not rely on objects, no adjustments are required when changing products.

These sensors are based on the CAT technology (Contrast Adaptive Teach), which enables a new operating principle for binary switching sensors. These sensors don’t reference the object itself, but rather the conveyor belt.

Multipacks are convenient for the transport of beverage bottles or cans. But when it comes to packaging, the diversity of these multipacks can be a challenge for plant operators: The foil-wrapped containers may be metallic, colorful, or transparent. Or there may be holes in the film or cardboard somewhere. But the biggest difference between beverage containers is the shape and height. This makes reliable detection challenging. The DRT25C.R dynamic reference diffuse sensor is made for these types of requirements. It is installed

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above the conveyor belt and uses the conveyor as a reference. The flexible sensor detects all objects that differ om the conveyor belt surface. This detection principle om above is objectindependent and reliable. With its high operating range of 450 mm, the DRT25C.R detects multipacks, regardless of whether they are transparent or have printed film.

Only one sensor is needed per roller conveyor, regardless of the customer’s specific application. And plant operators can set it up in a matter of seconds: A er pressing the teach button once, the conveyor surface is saved as a reference value. Two teach levels offer maximum flexibility. There is no need to change the settings a er a product changeover, as the reference is still the same. That means there is no setup time. Unlike traditional diffuse reflection sensors, the container sensor is more reliable if vibrations and contamination occur on the conveyor belt. These are compensated for by the Contrast Adaptive Teach technology.

Operators who need additional functions, such as warning messages, can easily integrate these via IO-Link. DW

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Design for Industry Packaging

Controller provides multi-axis motion control to packaging systems The so MC compact microcontroller with an EtherNet/ IP interface enables any major OEM programmable logic controller (PLC) to seamlessly control any motion control component, including robots, drives, and motors to add innovation and modularity to packaging systems.

The microcontroller lets packaging machinebuilders interface with Rockwell Automation PLCs and EtherNet/IP networks to add multiaxis motion control to any existing system.

The controller delivers Industry 4.0 machineto-machine communication while simpli ing and reducing the overall cost of motion control system design and configuration. At the same time, so MC increases the flexibility and efficiency of automated packaging lines and expands OEMS’s capabilities to innovate.

A centralized method for designing and integrating additional motion axes and robotics capabilities lets machine builders design and use standard robot models such as delta, SCARA, and cartesian/ gantry robots. The controller provides advanced motion control of the motors, robots, or robotic controllers while handling all communication between the material handling systems and the Allen-Bradley PLC. A decentralized method allows machine builders to customize a system using motors and drives om the STXI Motion product portfolio, which are optimized and ready for use with the so MC. The so MC provides full robotics control and gateway to motion with the ability to communicate with all motor technologies and feedback devices, allowing packaging machine OEMs and end users to add automation capabilities to their existing setups. DW

STXI Motion www.stxim.com

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Semiconductor

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Design Notes

Interceptor metal detectors save pork

producer’s bacon Edited by Mike Santora • Associate Editor

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The North American pork producer installed four Interceptor machines to meet the exacting inspection demands of a new fastfood customer.

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Single pass product learning and automatic calibration stop operatives from constantly resetting and recalibrating the metal detector for different pack sizes.

Four Interceptor metal detectors om Fortress Technology have enabled a North American pork producer to meet its new fast-food customer’s requirements for inspecting high volumes of bacon. The Interceptor’s increased sensitivity and simultaneous multi equency innovation has helped the producer satis its client’s food safety specifications. The Interceptor has also eliminated false rejects by isolating product effect.

When a leading pork producer won a new contract with a major fast-food chain, investment in a higher-quality metal detection system was crucial to meeting its client’s standards. The company’s existing inspection equipment struggled to cope with the notorious product effect common with challenging meat products that are wet and highly conductive.

Salty products such as bacon can be especially challenging to inspect as it increases the conductivity of the wet product. This impacts a metal detector’s ability to distinguish between any metal contaminants, including stainless steel, that may have been introduced during processing and the false signal given by the combination of product attributes. These different factors can lead to false readings and consequently higher product waste.

Regional Sales Manager at Fortress Technology Eric Garr said: “Product effect can make it difficult for standard detectors to tell the difference between the signal generated by the bacon itself and any signal given off by a metal contaminant. As well as resulting in a high volume of false rejects, there’s greater potential for real contamination to be missed.”

With the fast-food chain demanding more stringent sensitivity specifications, the bacon producer sought a solution to conquer product effect once and for all. User- iendly features that support quick setup are always highly valued by this busy production plant, said Eric.

Inspecting retail and bulk packages of bacon ranging om between 10lbs and 15lbs, single pass product learning, and automatic calibration means that operatives are not having to constantly reset and recalibrate the metal detector for the different pack sizes. “These automated technology features make the manufacturing process much simpler for production staff and significantly reduces the time spent introducing and checking operating protocols,” said Eric.

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The Interceptor works by carrying out a real-time analysis of a low- equency and a high- equency output signal simultaneously. Although the size of metallic contaminant that’s detectable depends on the product size and temperature, as well as the aperture size, typically, the Interceptor can improve detection levels for stainless steel by as much as 100% in contrast to standard metal detectors. The result is a more reliable and accurate reading regardless of the size, shape, and orientation of metal particles.

Additionally, a built-in Noise Immunity structure minimizes external electrical disturbances, further lowering the occurrence of false rejects.

The enhanced sensitivity, accuracy, and cost efficiencies have helped the producer’s new clients meet demand. Having invested in four new Interceptors, the pork plant continues to retain its reputation for quality and food safety.

“The combination of 100% increased metal detection sensitivity, elimination of false product rejects, and easy-to-use automated features has reassured our client, their customer, and consequently millions of fast-food consumers,” said Eric. DW

Fortress Technology fortresstechnology.com

www.designworldonline.com

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Design Notes

Precision motors help make history on the Red Planet Edited by Mike Santora • Associate Editor

The helicopter’s camera photographed the ground with the shadow during the flight (left). Next to it is a picture taken by the rover of the hovering Mars helicopter.

NASA’s Ingenuity helicopter has successfully completed its pioneering flight on Mars. This is the first time in the history of powered, uncrewed spaceflight that a device has flown in a controlled manner on another planet.

A short flight for “Ingenuity,” but a big success for uncrewed space flight. NASA’s Mars helicopter flew over the surface of the Red Planet for about 40 seconds on Monday, April 19th, and landed back on four legs. From NASA’s perspective, this is a historic event similar to the Wright brothers’ first controlled flight in 1903.

With the Mars helicopter, the concept of powered, uncrewed, and autonomous flights on foreign planets is being tested. This is comparable to the first Mars rover, “Sojourner,” which paved the way for scientific follow-up missions such as “Curiosity” and currently “Perseverance. “ “Ingenuity” is about to complete several flights over a period of 30 days, each lasting up to 90 seconds and reaching a maximum altitude of five meters. Six micromotors control the helicopter’s flight direction.

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The helicopter is equipped with six maxon brushed DC motors specifically modified for this challenge. The DCX series of drives, with diameters of 10 millimeters, control the pitch of the rotor blades and the direction of flight for the helicopter, which weighs only 1.8 kilograms and is solar-powered. The lightweight design is a prerequisite for a successful flight on the Red Planet, where there is hardly any atmosphere, comparable to conditions at an altitude of 30 kilometers on Earth. “The biggest challenge in developing the motors was the extreme weight requirement,” DESIGN WORLD

6/23/21 11:26 AM

says Aiko Stenzel, design engineer at maxon.

“Every tenth of a gram had to be saved to make the helicopter fly. What’s great is that despite the weight savings, we found a drive solution that has enough power to adjust the rotor blades. And this, in the face of high vibrations and temperature fluctuations.”

The standard variants of the DCX motors are available for everyone and can be configured online according to the individual customer specifications.

Eugen Elmiger, CEO of the maxon Group, watched the NASA transmission of the first flight data live. He said, “It is a fantastic feeling to know that our precision drives worked as planned and that we were able to make our contribution to this historic event. I am proud of our employees and look forward to the next milestones on Mars.” maxon’s drives are also used in the Perseverance rover. There are ten BLDC motors and a special gearbox that will be used, among other things, to handle the soil samples inside the rover. The first of these motors has already completed its task: It placed the Mars helicopter safely on the ground. DW

maxon | mars.maxonworld.com

Close-up view of the maxon DCX motors.

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Design Notes

How injection molding can help power wheelchair applications Edited by Mike Santora • Associate Editor

LUCI is an attachable accessory system that brings smart technology to power wheelchairs for stability, security, and connectivity.

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Brothers Barry and Jered Dean didn’t set out to start a company. But nothing on the market solved their problem: Keeping Barry’s daughter, Katherine, safe in her power wheelchair.

Users can get hurt if the devices, which weigh hundreds of pounds, tip over or run into objects. That happened to Katherine, who was born with cerebral palsy, when her power wheelchair tipped over, resulting in arm and leg injuries.

A er some debate, Barry, a Grammy-nominated Nashville songwriter, and Jered, a Denver-based design engineer, were sketching ideas out at a restaurant on a paper tablecloth — and in business.

“We chose to go ahead and go for it because it didn’t seem anybody was going to do this anytime soon,” Jered. “We couldn’t afford for our family to wait for somebody else to do it.” www.designworldonline.com

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Design Notes founded the LUCI company in 2017.

A er years of development, they began selling the LUCI system in early 2021. The product already has earned widespread recognition, named Time magazine’s Best Inventions of 2020, Popular Science’s Best of What’s New, a CES 2021 Health & Wellness Innovation Award, and Mobility Management’s “Smart Technology” Product Award.

Finalizing the design for the housings holding the millimeterwave radar sensors further involved several calls with Protolabs engineers to tweak the plans. ABS plastic was recommended because it was durable, cost-effective, and compatible with the radar sensors.

What they came up with, along with a little manufacturing help om Protolabs, is LUCI, an attachable accessory system that brings smart technology to power wheelchairs for stability, security, and connectivity.

LUCI’s hardware and so ware combine to give power wheelchairs a 360° view of the world to avoid collisions and drop-offs and warn of tipping dangers. Cloud-based communications can alert loved ones of an accident and securely send user data to family and medical team members. LUCI incorporates stereo-vision cameras and in ared, ultrasonic, and radar sensors in a patented, first-of-its-kind system that gets mounted between the seat and wheels of a power wheelchair.

The Dean brothers, with Barry as CEO and Jered as chief technology officer,

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Design Challenge: Developing fast and creating ‘invisible’ housings In addition to their urgency to create a safer alternative for Katherine and other power wheelchair riders, the Deans’ announcement of their intent to develop such a product generated intense interest om wheelchair manufacturers.

For the speed and flexibility required in the design, the Deans’ turned to Protolabs for the injection-molding of plastic prototypes and production parts.

They also used Protolabs to prototype the sheet metal components and even handle services they hadn’t initially anticipated.

As a power wheelchair steers LUCI with a joystick or other means, onboard sensors map the surroundings to recognize anything in the way, om curbs and vehicles, to pets and people.

The mapping technology includes a pair of millimeter-wave radar sensors that detect the range, velocity, and angle of objects in the environment. The plastic housings that contain the radar sensors posed a design challenge, Jered said, because those housings need to be “invisible” to the business card-sized radar sensors. The housings have to be of a certain shape, material, and thinness to enable the radar devices to do their job of identi ing potential hazards.

Another concern was finding a way of securely attaching all of the plastic housings holding LUCI’s various sensors and electronics to the system’s “smart ame,” Jered said. The ame is a sheet metal platform with several brackets that get mounted between the seat and wheels of a new or existing power www.designworldonline.com

wheelchair to install the LUCI system.

Offering a user experience that merges rider intent and independence with the protection and assistance that LUCI’s technology provides was also a priority. One expression of that, Jered said, needed to be through LUCI’s dashboard, its user interface. The dashboard, located on the wheelchair’s control panel, has four indicator lights to track Wi-Fi and cellular connection and sensor obstruction. He wanted each light to have a corresponding symbol that would identi its function while also being attractive and durable.

Solution: Iterative design, insert molding, pad printing Jered used tech-enabled manufacturing’s online quoting system and automated manufacturing analysis to design plastic housings for LUCI’s sensors and electronics. Getting the design just right for the housings holding the millimeterwave radar sensors further involved several calls with Protolabs engineers to tweak those plans. ABS plastic was recommended because it was durable, cost-effective, and compatible with the radar sensors. Crucially, the material was injection molded in a shape and at a thinness necessary for the radar devices to work properly.

Jered iterated rapidly on the housings, cutting test tools, having prototypes made, and working with Protolabs on revisions before making new tools for another round of prototyping. The process was more cost-effective.

When Jered mentioned his concern about securing the plastic housings to LUCI’S ame, insert molding was suggested. Insert molding, in this case, incorporates threaded metal inserts into LUCI’s molded plastic housings to improve their strength when they’re attached to the ame. Insert molding is working so well that Jered now uses it any time possible for attaching plastic parts securely to metal.

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for the smart ame and brackets that hold LUCI’s sensors.

For LUCI’s dashboard, Jered had considered using stickers, labels, or engraving for the symbols that identi the purpose of each indicator light. He found a better solution in Protolabs’ pad printing process, which transfers a two-dimensional image, like a company logo, to a three-dimensional object. The pad-printed symbols are more attractive and durable.

Outcome Jered and Barry Dean felt a “super sense of urgency” to deliver LUCI to the market, given their personal stake and the high level of interest om potential users and the wheelchair industry.

“That urgency trickled through to everything, how we’re doing our manufacturing, how we’re doing our product development, our sales,” Jered said. “All those things go to how can we get LUCI to the broadest number of users possible. It’s the difference between someone being able to independently drive themselves and somebody being pushed or not having that eedom in all locations. That’s a lot of pressure on getting it out, getting it right, and getting it done.”

That speed and lower tooling costs make digital manufacturing providers like Protolabs a cost-effective choice, Jered said. While piece-part prices are a little higher initially, they become more favorable with on-demand manufacturing. DW

Protolabs protolabs.com

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CAE Solutions

A look at Verisurf 2021

Verisurf 2021 has new and enhanced features that increase measurement and

• GD&T Feature Control Frames added

inspection productivity, om CMM plan creation through execution, particularly for Renishaw PH20 5-axis touch-trigger, and REVO 5-axis scanning probes. Included is additional CMM controller support, enhancements for GD&T feature control ames and ballooning, and an updated So ware Development Kit (SDK) for custom user interfaces, integration of robotics, and automating processes across the manufacturing enterprise.

Verisurf measurement and inspection so ware is dedicated to Model-Based Definition (MBD) and built on a CAD/CAM platform.

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Feature highlights include:

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• 5-Axis CMM programing with support for Renishaw PH10, PH20, and REVO heads • External Productivity Utilities provide time-saving tools and shortcuts • CAD Translator V8.0 with new assembly import and management features • Thickness feature for Dynamic Surface Point improves CMM Plan creation • Digital Product Definition compliance – Boeing, PTB, NIST • Custom Clearance CMM Path added to Generate Path tool • Power Surface option to Orient Starter Plane for surface fit • Power Surface is enhanced to support point clouds or meshes in addition to • •

existing wire ame capabilities Power Surface tools to use starter plane fit options such as least squares, minimum zone, or graphics view, plus an option to use point vectors to help for a better surface fit SolidWorks Inspection First Article & Balloon Dwg Reports using Verisurf -SOLIDWORKS Inspection added to Report Database output

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to CMM Plans and Measured Features staying current with ASME and ISO protocols Verisurf Device Interface (VDI) upgrades for new laser trackers and CMMs So ware Development Kit (SDK) Enhancements for communication with other cooperative devices Feature Align improvements use nominals om the Plan to automatically create a WCS, improving workflow and flexibility Best Fit feature includes multiple enhancements for automated CMMs and user-prompted inspection routines for manual and portable CMMs CAD is at the foundation of Verisurf so ware and 2021 includes new features and improved user experience for model-based inspection productivity. DW

Verisurf | veri.surf/2021

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How to create interactive AR work instructions

Approximately 67% of manufacturers are still using manual paper processes for inspections. These existing methods are o en error-filled, difficult to transcribe, and costly – ultimately becoming barriers to continuous improvement. Vuforia Instruct enables companies to eliminate reliance on paper forms by delivering contextual visual guidance and references to ont-line workers with built-in, real-time inspection feedback to capture critical insights.

Vuforia Instruct out-of-the-box is om the Vuforia Enterprise Augmented Reality (AR) Suite. It lets users leverage 3D CAD data to create, deliver, and scale interactive AR work instructions.

This So ware as a Service (SaaS)-based offering, helps original equipment manufacturers extend the

value of the digital thread to their ont-line workers. Users can leverage 3D CAD data to easily create, deliver, and scale interactive AR work instructions for inspections for Quality and Field Maintenance use cases, for example.

“Vuforia Instruct enables organizations to transform the way they create and scale work instructions to their ont-line employees,” said Michael Campbell, Executive Vice President and General Manager, Augmented Reality Products, PTC. Leveraging existing 3D CAD data, managers can guide employees to exactly where work needs to be done and provide them with detailed instructions for critical inspection procedures in context. DW

PTC | www.ptc.com

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CAE Solutions

Keep electronic and mechanical designs in sync When designing electronic products for IoT, autonomous vehicle, and industrial automation applications, it can be a challenge to ensure collaboration on the same electronic design assemblies.

The design process is a continual dance of importing, exporting, and converting files in an effort to keep mechanical and electronic designs in sync. Of course, this process adds hours of manual labor, data loss, and rework to the design process.

“Export and import of files is what most EDA companies are calling co-design,” says Ted Pawela, Chief Ecosystem Officer at Altium. “That’s like sending someone a letter in the mail and calling it collaboration. The Altium CoDesigner so ware simply keeps MCAD synchronized with ECAD so that electronic and mechanical design teams can truly work concurrently.”

The CoDesigner capability gives PCB designers a faster and easier way to collaborate with mechanical designers working with tools like PTC Creo, Dassault Systèmes SOLIDWORKS, Autodesk Inventor, and Autodesk Fusion 360. Mechanical engineers can use CoDesigner capability at no cost and while staying in their favorite MCAD design environment.

“With CoDesigner capability, we can detect potential problems like we couldn’t before,” reports Jeremie Waller, Sr. Electrical Engineer at Quantel Laser USA, a division of Lumibird, a global leader in laser technology. “We can see silkscreens, hidden vias, make sure polarities are correct, where copper traces are—our models are now 100% complete, including overlay and copper. I don’t have to worry about board shapes, or connector placements, even in very

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tight spaces. We have the confidence that everything will fit exactly as planned when it goes to manufacturing,” Waller adds.

Mechanical engineers can design alongside PCB designers in real-time, and empowers effortless product design reviews.

Accessing CoDesigner is easy for both ECAD and MCAD users. The MCAD CoDesigner extension is included in the standard Altium Designer installation, appearing as a panel that’s always available in the PCB editor. Once MCAD users install the aforementioned plugin, CoDesigner is just as effortlessly accessible. DW

Altium www2.asx.com.au

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Connect and discuss this and other engineering design issues with thousands of professionals online

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NEWS

Keysight expands relationship with Ansys wireless design workflow products Keysight Technologies, Inc., announced an expanded collaboration with Ansys to integrate Keysight’s PathWave Advanced Design System (ADS) RFPro environment with Ansys HFSS electromagnetic simulation.

As a result of this collaboration, radio equency (RF) and microwave engineers can eliminate the time-consuming bottleneck of manually coupling design tools to simpli workflow and improve time-to-market. The initial collaboration between the two companies, originally announced in February 2021, improved the workflow between the companies’

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products to speed time-to-market for 5G, aerospace and defense, as well as automotive applications.

Keysight’s RFPro simulation solution is an electromagnetic (EM) environment for RF and microwave circuit designers and is seamlessly integrated within Keysight PathWave ADS. RFPro makes performing EM analysis easy, simpli ing EM-circuit co-simulation and saving hours to weeks of simulation setup time.

Keysight’s ADS RFPro was introduced in PathWave ADS 2019 and has generated broad adoption within the ADS user community. Keysight is now

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for

addressing customers’ larger workflow challenges with PathWave workflow solutions. HFSS is a trusted, widely used, finite element method (FEM) solver and now in addition to Momentum and Keysight FEM, ADS design engineers have access to HFSS as an additional simulation option within ADS RFPro. The PathWave ADS RFPro HFSS link option will be available in Keysight’s ADS 2022 and is expected to ship in the summer of 2021. DW

Keysight Technologies www.keysight.com

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Internet of Things

A look at why edge computing is needed with CNC controls

The term “edge computing” simply means shi ing computing power to the edge of a network.

With traditional local computing, the necessary devices are installed and set up once. Data transmission is mostly performed through local networks or external storage media. Updating devices always involves intervention in IT in astructure, which is why it is rarely done.

Cloud computing is the exact opposite. Here, data are transferred to a central data center, processed, and the result re-imported. While the cloud’s data center is powerful, the potential volume of data is quickly restricted by the bandwidth of the connection, meaning that it is not possible to use all process data that is generated using the cloud.

Edge computing technology is an interface between local and global data processing. An industrial computer is located at the machine, facilitating resource iendly processing of data streams. It also functions as an interface with the cloud, which will now be supplied with processed data – meaning less data traffic.

Machine-oriented processing makes it possible to process and effectively use even high- equency data that permits only a short check-back indication time (latency).

“Computing at the edge” But what exactly is Industrial Edge? This digitalization platform is much more than just a hardware item. With the help of analytics, it expands existing automation procedures to include machine-oriented data processing — directly within manufacturing companies. Applications are managed and installed via the cloud.

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This means that Industrial Edge has an advantage over local networks in that applications can be updated at any time without having to intervene in the production process. Direct connection to the cloud also allows Industrial Edge to upload processed data directly and continuously.

Machine tools generate up to 2 MB of process data per second. Uploading this data to the cloud om several machines is not possible. Therefore, intelligent algorithms must be used to reduce the volume of data. Big data are turned into smart data, and the Industrial Edge combines local, efficient data processing in automation with the advantages of the cloud.

Why Industrial Edge?

The Siemens concept combines hardware and so ware to bring production and manufacturing data together with globally

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quality assured edge computers tailored to the relevant digitalization task.

You might think that machine tools equipped with Sinumerik CNC already have a powerful processing unit that will cover these tasks. The Siemens CNC controller does feature processing units, but the core competence of a numerical control unit (NCU) is path and speed control, which is ensured by the machine builder. The architecture of the CNC machine is tailored precisely to this core competence. Although computing power for additional data analysis algorithms may exist, sufficient capacity cannot be guaranteed.

With this in mind, Industrial Edge facilitates the integration of applications om various sides. In addition, Industrial Edge will create a relatively open environment in which various technology providers and tool and work-holding manufacturers can develop their applications.

Direct implementation into the CNC would not be possible because these have already been customized by the machine builders and do not offer a uniform platform. This customization is necessary because machine tool builders have to guarantee the productivity

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and quality of the machining process.

Industrial Edge is separate om this system and offers a foundation for other technology providers.

The aim is to create a new business segment around Industrial Edge that various providers can use. With crossindustry influences and global developers of applications, Industrial Edge should become a platform for digital transformation. To this end, Industrial Edge has its own development platform for easy and fault- ee programming of applications. Runtime so ware ensures connectivity with connected automation devices and with the Edge Management system. This connection is an interface to the IIoT cloud. It facilitates further processing of data in higher-level IT systems as well as administration and updating of the applications themselves.

Industrial Edge is not only used for analyzing and processing CNC machine process data, it also offers a platform where data om another sensor technology installed in the machine will be processed. For example, camera images can be constantly evaluated to mechanically monitor component clamping. Results of the data processing

by Edge applications will be imported

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directly back into the machine, therefore optimizing the current process and minimizing wear and improving quality.

Edge computing is going to be a core aspect of machine tool use in the future.

Only by using applications with a specific technological background can further increases in productivity be achieved.

Industrial Edge creates an environment that facilitates real-time data evaluation — thus laying the foundation for use of future-oriented technologies. DW

Siemens Industry, Inc. usa.siemens.com/cnc-edge

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Internet of Things

Drive technology with certified PROFINET PROFIdrive in servo motor

Profibus officially certified the fully integrated Profinet network in this servo motor. The motor, which the manufacturer claims is a milestone in terms of cabling, commissioning and IIoT capability, is the first drive technology manufacturer to fully integrate its certified PROFINET solution with PROFIdrive into a motor.

The certification assures the servo motor meets the high standards of stability, even under extreme bus conditions, are always maintained. Currently the products BG 95 dPro, BG 75 dPro, BG 66 dPro and the BGE 5510 dPro are available with PROFINET interface, covering the output power om 1 to 4000 W. DW

Dunkermotoren USA Inc. www.dunkermotoren.com/en/

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

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DeviceTalks Tuesdays is a weekly virtual event that brings the insights and energy of our in-person events to your desktop.

Each DeviceTalks Tuesday will kick off with a quick briefing from the editors of MassDevice and Medical Design and Outsourcing. These presentations will give attendees insights on what trends will be moving medtech in the days to come

presented by:

Topics include:

TUESDAYS

devicetalks.com

• • • • •

Innovation & Finance Manufacturing & Sourcing Medtech People New Tools & Technology Prototype & Product Development • Regulatory/Reimbursement

@DeviceTalks

Sponsorship opportunities are available for future DeviceTalks programs.

For more information, contact Courtney Nagle. 440.523.1685 | cseel@wtwhmedia.com

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Internet of Things

FPGA-based solution stack accelerates the development of industrial automation systems

Lattice Automate is a low power FPGA-based solution stack. It includes so ware tools, industrial IP cores, modular hardware development boards, and so ware-programmable reference designs and demos that simpli and accelerate implementation of applications like robotics, scalable multi-channel motor control with predictive maintenance, and real-time industrial networking. Intelligent industrial systems made possible by Automate will help in automating future smart factories, warehouses, and commercial buildings.

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F O K C I S ?

S G N I SPR

COIL Technology trends like the IoT and Edge computing are driving development of intelligent automation systems to improve efficiency and worker safety. According to Fortune Business Insights, the global industrial automation market is projected to reach USD $326.14 billion by 2027.

The Automate stack offers reference designs and so ware tools for the rapid development of popular industrial applications, including: • Scalable motor control – accelerates development of flexible motor control systems, including a GUI-based user interface for system monitoring and control.

• Predictive maintenance – minimizes machine downtime by monitoring multiple motors in a system.

• Embedded real-time networking – implements an extensible sense and control system for a large number of devices using a Lattice Nexus FPGA as the central controller.

• Cyber resiliency – enables a hardware Root-of-Trust that can detect, protect, and recover om a firmware-based attack in real time.

• Easy-to-use So ware Design Methodology – the stack supports Lattice Propel for simpli ing development of industrial automation systems with so ware/hardware co-processing using an embedded RISC-V processor. DW

We were too.

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• Large Selection from Stock • Easy to Customize WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

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Request Free Samples at 847-719-5900 or smalley.com 6/24/21 9:53 AM

w w w. m a k e p a r t s f a s t . c o m

Leslie Langnau

Make Parts Fast Classroom now in session: Injection molding Injection molding is one of three main technologies used

Dreamstime.com

to manufacture parts. Injection molding can be used for the predictable and scalable prototyping and production of products.

The process begins when an injection-molding provider creates a mold that will hold the material used to create the part. The mold has a cavity that is shaped to cast the production part. Making this mold can take a number of weeks, but once it is made, it can be used to churn out hundreds of thousands to millions of parts. One caveat here is that the cost of making the mold can be high — especially if the part to be molded is overly complex.

Once the mold is made, it’s mounted on an injection-molding machine. Then material (either plastic resin or metal) is injected into the mold under ram or screw-type plunger pressure. The material fills every nook and cranny of the mold cavity and solidifies into the shape dictated by the mold.

Now in a new Make Parts Fast Classroom, we cover these and other injection-molding processes in more detail — as well as the range of materials that can be used to make injection-molded parts.

References include:

This educational installment sponsored by:

THE BASICS OF INJECTION MOLDING — including information about metal injection molding, additive molding, and various overmolding options INJECTION-MOLDING BEST PRACTICES — including information about injection molding cooling time, how to design robust injection molds, injection molding and machining resins, and how to select metal inserts for molded plastics INJECTION-MOLDING VIDEOS — including those om tradeshows as well as service-provider facilities COMPARISONS OF INJECTION MOLDING TO OTHER OPTIONS — including 3D printing and machining.

Access this Classroom at designworldonline.com

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Engineering July 2021

A supplement of Design World

What causes

fastener seizing and galling?

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Mark your calendars...

She gives two reasons why the industry attracts such loyalty: “There’s always something new to learn and it’s a close-knit community.” At long last, this community is slowly reconnecting in person, after more than a year of social distancing — so get ready to fill your calendars. The next few months offer a lot of new learning opportunities outside of our homes for a change.

The Fastener Training Institute, a nonprofit training organization, has already begun hosting some of its courses live and in classrooms again. Its renowned Fastener Training Week, which successfully took place in May, will be offered again in Chicago from August 16th to 20th. Register, or check out the other programs available, at fastenertraining. org.

The International Fastener Expo (IFE) is returning to Las Vegas from September 21st to 23rd for the annual event, well-known for bringing manufacturers and distributors together to network, share, and learn.

Although it changed ownership a few years ago, IFE initially launched 40 years ago and has only grown since — which is an example of the staying power the industry evokes.

“We’re continually trying to find ways to make subtle improvements to the event and keep developing it,” shares show manager, Morgan Wilson. But this year, more than anything it’s about reconnecting. “The excitement and enthusiasm to see everyone face-to-face seem to be growing every week,” he adds. Turn to page 62 to read more about the history and success of IFE.

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Fastener Fair USA is also returning this year, scheduled for November 8th to 10th in Cleveland. It’s the only exhibition in the U.S. that’s dedicated to the full fastener supply chain, along with an international platform for manufacturers, distributors, and wholesalers.

“This year, show visitors can expect a comprehensive display of industry innovation with technical conference sessions, demonstrations, and opportunities to connect with peers and industry experts,” says the show organizers.

Also, did you know Fastener Fair offers a matchmaking service for attendees? It’s not a dating service (sorry, singles!) but, as an attendee, “You’re eligible to be matched with specific exhibitors who provide the exact products you are looking for,” according to the event’s website. These are customized matches based on the information provided during registration (and not based on sponsors or advertisers).

Learn more and register at fastenerfairusa. com.

As Morris mentions in her profile, “The fastener industry offers enormous opportunities in so many different directions.” It’s about time we get to experience those opportunities together again.

Do you have an upcoming event?

Share it with us at fasteners@wtwhmedia. com. FE

www.fastenerengineering.com

| AdobeStock.com

“Once you’re in it, it’s tough to leave,” shares Jo Morris, who works with the Fastener Training Institute and Desert Distribution. She’s referring to the fastener industry, which is likely somewhat humorous and mostly true for many working in the sector. Morris has spent her career in fastening, which you can read about in her profile on page 74.

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Five best practices for using structural adhesives

Simla AY • Technical Support Manager • Hernon Manufacturing Structural adhesives provide reliable, long-lasting bonds for load-bearing and structural assemblies. There

are several reasons why such adhesives are selected over other forms of joining and fastening. Advantages include assembly cost savings, chemical tolerances, impact and vibration resistance, stress dispersion, curing options, ease of application, and several others depending on the application.

Many types of formulas are also available to meet most project requirements, including epoxies, polyurethanes, cyanoacrylates, vinyl acetates, and phenolics. To ensure the ideal bond for an application, consider a few best practices before choosing and using structural adhesives.

1 Know the environment End-use requirements such as temperature, humidity, and chemical resistance, as well as UV exposure, are determining factors when choosing a structural adhesive’s type and grade. The formula selected should also be tested before use to ensure validation for the intended assembly and the conditions of its end-use environment.

The temperature, humidity, and other potential exposures are important elements to assess during the validation process. For example, along with the temperature, it’s important to factor in whether the material will be exposed to rain, snow, saltwater, sunlight, UV lights, etc. Similarly, if the bonded parts will be subject to fluids (such as oil and gasoline) or must endure high-impact or vibrational forces, the adhesive must be tested accordingly to ensure reliability.

After making the ideal adhesive choice, it’s critical to follow the manufacturer’s recommendations for preparation, application, curing,

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removal, and the correct safety, quality testing, and storage measures.

2 Prep the surface Proper substrate surface preparation is crucial to ensure optimum adhesion with good bond strength. All dirt and fluids such as oil, rust, dust, soil, residual release agents, and other contaminants should be removed from the joint surfaces before application.

Of course, different surfaces will require different methods of prep. And, each adhesive has an ideal surface-

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Structural adhesives typically offer greater freedom in material and design choices.

Compared to conventional fastening, they also often reduce the overall weight of an

preparation method, which should be indicated on its technical documents.

These methods might entail: • Degreasing – removing oil and grease from the surfaces • Abrading – sanding or polishing the area • Cleaning – using a solvent or pretreating chemically

After an abrasion treatment, a solvent should always be used to clean any loose particles left on the surface.

It’s also worth noting that a bond is only as strong as its weakest point.

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Sometimes the weakest point relates to prior use of paint or coatings. A chemical paint stripper should be used to remove any painted surface if a maximum bond is required for an application.

Once the surface is cleaned and ready, apply the adhesive soon afterward to avoid contamination or mechanical damage.

Typically, the ideal surface preparation method will also depend on the substrates used, so be sure to read the technical documents carefully before proceeding.

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assembly. Here, a structural adhesive is used to bond metal to plastic.

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Proper preparation of the bonding surface area is as important as choosing the ideal adhesive.

As adhesives are composed of different structured chemical ingredients, remember to wear protective equipment such as safety glasses and gloves. The application area should also be ventilated in case of fumes or vapors.

3 Read the requirements After the surface preparation is completed, double-check the adhesive’s requirements. Always follow the application instructions and any curing directions.

Although a sufficient amount of adhesive should be dispensed on the joining surfaces, more is not always better when applying adhesives or sealants. A common cause of product recall is excess use during application.

In addition, ensure the substrates are mated within the adhesive’s open time for the maximum bond strength.

If the adhesive is a two-component product, it’s essential to first mix the parts thoroughly. Environmental conditions such as temperature,

UV exposure, and humidity should be considered or controlled beforehand.

For instance, if a bonded joint is exposed to rain or saltwater before curing, the bonding process might fail.

Likewise, if the joint is exposed to the sun, this condition could affect the grade of a UV-sensitive adhesive. The environment temperature is also significant, particularly when dispensing from time and pressure valves. Hot or cold conditions can alter the viscosity of the adhesive and subsequently change the volume applied under the preset valve settings.

Quality testing The structural adhesive market is expected to hit a compound annual growth rate of more than five percent over the next five years. To effectively and reliably compete in the market, adequate testing of the adhesives and bonded joints is important.

This means quality testing should be performed twice: when choosing the final adhesive and after the joint-bonding process. For example, peel and shear tests are fairly common and determine the strength of the adhesive on particular substrates.

These tests should be specified on the manufacturer’s datasheet and performed by the end-user in cooperation with the adhesive supplier.

In general, the standard adhesive tests include: • Shear, peel, and impact strength • Moisture, chemical, and UV-resistance • Creep behavior, especially at higher temperatures and humidity.

Bear in mind that the tested adhesive may fail to give an acceptable performance if the bonding surfaces have not been accurately prepared.

Also, best practices should include quality testing of the procedure used and any related equipment, as well. The test equipment manufacturer should be knowledgeable about customer’s testing and performance requirements.

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After the application is complete, immediately clean the equipment and work area before any excess adhesive cures to such surfaces.

4 Be aware of curing catalysts Curing is a chemical reaction required to convert a liquid or thermoplastic adhesive to a solid. Adhesives typically offer high strength and resistance to temperature, humidity, and chemicals after they cure but are vulnerable during the curing process.

Single-component adhesives — such as anaerobics, cyanoacrylates, and silicones — are premixed and require temperature, humidity, or light to initiate the curing process. The containers carrying these adhesives should be selected carefully as they could cause early curing if not protected during transportation.

Anaerobic adhesives, which include thermoset polymers with high strength and resistance to heat, cure under the absence of oxygen.

To prevent premature curing, the adhesive should remain in contact with oxygen until it’s in use. For that reason, air-permeable plastic bottles, which are flushed with oxygen before filling, are preferred to let the adhesive store well.

Cyanoacrylates are instant bonding adhesives that adhere to most surfaces. Caution is extremely important when handling cyanoacrylates (as they will easily DESIGN WORLD

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Depending on the assembly, clamping the parts together is one method that can provide a secure bond while an adhesive is curing.

bond to a person’s skin). They typically cure instantly in the presence of moisture and degrade when exposed to air.

Adhesives that cure by chemical reactions depend on a set temperature.

These include epoxies, polyurethanes, and silicones. Cure times, pot lives, and open times are shorter at higher temperatures and longer at lower temperatures.

If an adhesive is used outside during the summer, for example, the open time could be as low as half of the reported value at standard room temperatures.

However, on a cool day, the open time could be doubled. So, a 50° F (10° C ) warmer cure environment will cut the open time in half while a 50° F cooler one could double it.

It’s, therefore, extremely important to be aware of the environmental conditions and temperatures, adjusting the cure times accordingly. If the parts are bonded after the open time expires, the result is poor bond strength.

Thermal curing is a more controllable method, providing greater repeatability as an oven’s temperature can easily be set. Among the thermal curing adhesives, polyurethanes do not have high-temperature resistance, so a primer is best used on the substrate before bonding. Silicones bond better to low-surface energy plastics due to their low surface energy.

Depending on the adhesive, its color might change after curing. This can be used as an identifier of the degree of curing that’s occurred. Also, if aesthetics are important to the project, compare cured samples before applying an adhesive on the final assembly.

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5 Think smart storage When adhesives are stored according to the recommendations given in the manufacturer’s guidelines, they will maintain their performance throughout their shelf life.

Each adhesive has a specific storage condition, but several structural adhesives are sensitive to extreme temperatures, light, humidity, and chemicals. To be safe, avoid opening a container until it’s going to be used.

Anaerobics and acrylics should be stored between 41° to 77° F (5° to 25° C). Cyanoacrylates should be stored under refrigeration at a temperature of 35° to 45° F (about 1.5° to 7° C) for an extended shelf life. Before opening, the containers must be warmed to room temperature, or water may condense into the bottle and cause hardening of the adhesive.

Each adhesive has a storage temperature indicated on its datasheet so be sure to refer to it to prolong the life of the compound. As a general rule: use and store adhesives with care and safety in mind. FE

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How plastic welding is

supporting advancements in automotive designs Priyank Kishor • Global Product Manager Branson Welding and Assembly – Emerson (all images courtesy of Emerson)

The sophistication of today’s vehicles is remarkable, with

thousands of low-resistance connections between sensors, cameras, and high-tech lighting. Given the demand for autonomous and electric-vehicle (EV) development, electronic complexity will likely only increase.

New uses for materials — such as reinforced plastics in car manufacturing — require rethinking conventional joining and fastening technologies. Fortunately, new and updated joining methods are meeting these challenges and, in the automotive sector, much credit goes to developments in plastic welding.

Plastic trends Today’s vehicles are far more “connected” than ever before. Ten years ago, the typical car had a relatively small number of sensors, aimed at monitoring the combustion engine and drivetrain components. Now the average number of electronic devices in a car surpasses 200. This includes the sensors, cameras, and radar intended to connect a driver (human or automated) to information about the vehicle and its surroundings.

Typically, these electronic components are a part of tiny, printed circuit boards (PCBs) that are housed in, attached to, and protected by plastic structures. In EVs and hybrids, PCBs and rechargeable batteries require weathertight enclosures.

These housings, which are often made of highly engineered and reinforced polymers, are unique in terms of form, fit, and function.

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High-tech automotive sensors, cameras, and radar are connecting drivers to their vehicle and its surroundings, providing relevant data for better safety. To securely connect these delicate devices (typically to plastic parts or enclosures), joining technologies are advancing, offering greater precision and design freedom.

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J o i n i n g A new “dynamic mode” of ultrasonic welding offers dual-control capabilities based on a material’s density and system reactively.

Available on the Branson GSX E-1 2.0 welder, dynamic welding optimizes part quality by re-calculating and adjusting key parameters during the weld cycle.

The fragility and safety requirements of such devices pose fastening and assembly challenges.

This is where welding comes in.

As auto designers push toward lighter and more fuel-efficient vehicles — and components become smaller and more complex — the welding of the plastic enclosures and assemblies has required greater sophistication.

For example, intelligent exterior and interior automotive lighting now rely on organic light-emitting-diode (LED) lamps, which include electronic control components. These lamps must use precise and gentle welding methods to avoid damage. Similarly, a vehicle’s head and tail-lights also have integrated LEDs and sensors that often span the entire width of a car to illuminate the road and potential hazards. They’re built into assemblies that are primarily made of plastics.

Modern dashboards include driverinformation displays (with interactive maps and satellite radio selections) that must connect to nearly every sensor and camera in the car. The outer plastic housings require joining, as do many of the circuit boards and wired assemblies inside the console. Even a driver’s key fob makes use of plastics in sealed assemblies.

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Plastic assemblies Fortunately, continuous advances in plastic welding mean more than one technology is now available to meet different assembly challenges. Here are a few of the methods used in automotive assemblies.

Ultrasonic welding – creates a high-frequency, heat-generating motion between components that require bonding. It’s not new to the

industry and has been used to join thermoplastics for more than 70 years.

Historically, it was used when parts were too complex or costly to be molded in one piece. Instead, they were molded in multiple parts, which allowed for more efficient and cost-effective welding.

Several automotive components are already ultrasonically welded. However, the precision required for today’s delicate sensors, cameras, and lighting components has led to advancements.

For example, “dynamic mode” welding can automatically adjust to respond to part-to-part variabilities and unique materials.

This technique can safely weld small, thin, or complex plastic parts onto plastic structures directly atop sensors or delicate electronics without damage.

It can also weld parts atop plastic

PulseStaking technology can reliably join several different materials to plastic components or housings — including PCBs, sensors, hinges, buttons, plastic keys, and more.

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assemblies containing compressible internal elements (such as elastomeric seals or cores) and handle materials that vary in hardness or structural consistency (such as composites).

Additional benefits: • Short cycle time (usually < 1 sec) • Strong hermetic seals • No curing time or consumables required • Offers outstanding repeatability Laser welding – useful for fast and accurate assemblies of small to large structures, such as the plastic housings that surround hybrid and EV batteries.

A welded joint has little flash and virtually zero particulates, making it ideal for contamination-sensitive applications, such as battery housings.

Laser welding is also precise enough for use on the smallest of structures with critical or complex geometries.

This means pre-assembled parts can be joined without vibration or high-temperature heat sources, which could otherwise damage internal components. This allows for 3D joint configurations and more flexible part designs.

Additional benefits: • Short cycle times • Strong hermetic seals (provides a tight, waterproof assembly) • No curing time or consumables required • Homogeneous and repeatable welds • Greater material compatibility, including soft materials • Design freedom that allows for contoured visible weld joints • Excellent aesthetics PulseStaking – a new advancement in staking technology. Unlike traditional staking tips, which continuously radiate heat, PulseStaker tips are independently and instantaneously heated, cooled, and localized within the heating effect.

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A vehicle’s marker light, which functions as an auxiliary safety light, has been laser welded for a secure assembly.

Therefore, the pulsing tips can be positioned more closely to heat or vibration-sensitive electronic components (such as PCBs), soldered components, or sensors without the risk of radiant heating.

In fact, this technology allows for such small welds that it can safely and reliably secure four corners of a circuit board inside a plastic housing.

Additional benefits, which include the joining of: • Complex 3D part designs with varied surface contours • Multiple, closely aligned post or flap features • Advanced, blended, glass-reinforced, or chromed/metalized plastics

As developments in manufacturing and electronics for the automotive industry advance, expect welding technologies to follow suit and continue meeting the demands for safe, costeffective, and reliable assemblies. FE

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

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What causes fastener seizing and galling?

Hiroki Goto • Engineering Manager • NBK America LLC

Have you ever had problems with fastener threads getting stuck? If so,

and you attempted to remove the seized fastener by force, you likely ended up with little success to show for it other than a broken screw.

Galling is a form of wear that can lead to seizing, a phenomenon that occurs when a screw is unable to rotate and is locked into place. Unfortunately, these events are common and frustrating, occurring regularly during fastener installation when screws are tightened.

Friction and adhesion are typically blamed for this. However, outside factors can also play a role, such as foreign matter or burrs. Let’s discuss these culprits.

Friction and adhesion Sometimes referred to as “cold welding,” galling occurs when a fastener expands because of the pressure or friction that results during the tightening of a screw upon installation. This causes adhesion in the fastener’s mating threads that can, in more severe cases, lead to seizing. This means the fastener threads are stuck and removal without damage is tough.

Galling and seizing are more likely to occur in high-temperature environments, which makes sense during installation as friction causes heat. Interestingly, the material of the fastener can also make a difference. For example, stainless steel screws are more likely than other types of screws to seize because they have a:

If a fastener has seized up from galling, it’s typically impossible to remove it without cutting the bolt or splitting the nut.

• Higher coefficient of friction – twice that of general steel, which means that heat is easily generated

• Lower rate of thermal conductivity – one-third of that of general steel, which means any heat generated is not easily released

• Larger expansion coefficient – about twice that of general steel, which means the male and female threads will adhere easily to one another

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Friction and adhesion are two common reasons fastener galling and seizing occur. Fortunately, there are prevention measures. For example, the fastener on the left shows clear evidence of seizing, whereas the one on the right is free from galling or seizing. This screw has a fluorine coating, which helped prevent damage during installation.

Whenever fastener threads are prone to adhesion, there’s a greater chance they’ll fuse together. Sometimes with minor galling, it’s still possible to remove the screw without damage. But if the surfaces are completely fused, this is next to impossible.

Also, if enough pressure builds between the contact threads, it can break any oxide coating that’s on the fasteners, further leading to adhesion and seizing.

Outside factors Although galling is typically caused during fastener installation, the environment can also play a factor. For instance, if left outside in the hot sun or in warm conditions for a prolonged period of time, fasteners are likely to heat up. As mentioned, high-temperature conditions can lead to a greater chance of galling, whether that’s caused by friction during installation or the external environment.

Any debris sitting inside of the threading can also pose a risk of increased friction during installation. So, be sure to first check and only use clean parts. If necessary, use compressed air to ensure a clean surface before fastener use.

Similarly, foreign matter such as burrs can cause galling. A burr is a raised edge or small piece of material that’s stuck on the thread of a screw, typically resulting from the thread-rolling process.

Any damaged threading will increase the friction during fastener installation.

Prevention measures It’s important to note that galling and seizing can be prevented by checking the condition of the fastener threads before tightening and using the appropriate torque. Over-torquing a nut can cause damage to the threading, so it can help to use a torque wrench. Pneumatic DESIGN WORLD

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torque wrenches are designed to provide fast, safe, and simple fastening for applications that require controlled bolting solutions.

The load also matters. An increased load will force a fastener’s threading to push against itself while spinning during installation, adding to the friction. So, when possible, decrease the load of the assembly beforehand.

Although changing the thermal conductivity or thermal expansion coefficient is difficult, the friction coefficient can be decreased during fastener installation. This is possible through the use of lubrication and/or surface treatments, such as anti-galling and anti-seize coatings.

Teflon coating is one example of surface treatment for seizing prevention that provides the added advantage of chemical resistance. Fluorine is another type of coating that has proven highly effective. As there are several options, depending on the application, be sure to discuss the ideal surface treatment with your fastener supplier to make the right choice.

As an alternative to coated screws and lubricant, surface-hardened screws reliably prevent galling and seizing. Over time, any coating added to fasteners will peel off, becoming a source of debris and contamination.

This is particularly troublesome in certain industries, including in semiconductor manufacturing and foodprocessing machines. Equipment that’s regularly exposed to high-temperature environments also faces a similar issue. Surface-hardened screws solve this problem, offering a simple fastening solution that helps prevent unnecessary galling challenges. FE

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The making of the

International Fastener Expo Michelle Froese • Editor When the International Fastener Expo (IFE) first launched nearly

40 years ago, the show had a different name and different owners. Las Vegas was also not yet the headquarters for what’s become a key annual fastener event. Back in ’81, veteran fastener expert, Mike McGuire began the expo in his hometown of Columbus, Ohio as the National Industrial Fastener & Mill Supply Expo.

“Mike came from a strong background in the fastener industry,” shared Morgan Wilson, the current show manager with Emerald Exposition, which now owns IFE. “In fact, fastener distribution was a family business that dated back to his father and even his grandfather. So, he got the original idea for the show and then teamed up with a gentleman, named Jim Bannister, who was more familiar with the trade show industry.”

McGuire’s grandfather was a traveling salesman who started a side business as a distributor of nuts and bolts in 1929. His son soon joined the company, which lead to the founding of Capital Sales, Inc. As they say, like father like son — or, in this case, like grandfather like grandsons. McGuire and his brother followed in the family’s footsteps and eventually founded Buckeye Bolt & Nut Co. It’s since been sold but McGuire is still in the industry. Most recently, he founded Worldwide Fastener Sources, a comprehensive fastener sourcing site.

“Mike’s always been an entrepreneur,” said Wilson. “And maybe not surprisingly, he was quite successful with his concept of the fastener expo right

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The International Fastener Expo is back! The renowned event will be live in Las Vegas, September 21-23, 2021, at the Mandalay Bay Convention Center (Bayside B).

off the bat. The first show brought some 100 or so exhibitors and 2,000 attendees.”

The aim was to bring manufacturers and distributors of industrial fasteners, precision-formed parts, and machinery tooling together. Although there was certainly a few regional events at the time, the expo was (and still is) the largest fastener event in North America. Now, it’s held annually in Las Vegas, typically attracting more than 650 exhibiting companies and 5,000 attendees from around the world.

“So, in 1997, Mike and Jim decided to hold the event in Vegas for the first time,” explained Wilson. “The audience

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was mostly from the Midwest and East Coast, and this location was not only more fun but possibly more accessible or inviting to a greater number of people.”

For a few years, the expo was held bi-annually, in Columbus and then in Las Vegas. But it didn’t take long for Vegas to become the go-to, annual spot for the event. Then in 2015, McGuire and Bannister decided to sell. Emerald Expositions, a highly successful owner and operator of business-to-business and consumer trade shows in the U.S. took over.

“Emerald Expositions is actually one of the largest, if not the largest, trade www.fastenerengineering.com

show organizers in North America so acquiring this national fastener event made sense,” said Wilson.

Emerald’s history also dates back to the ‘80s, when United News and Media acquired Miller Freeman Publications, a producer of trade shows and business magazines. After a host of acquisitions, Emerald Expositions was created. At this point, the expo had grown considerably, featuring hundreds of exhibitors from almost a dozen countries.

“It was quite amazing what Mike was able to do with such a small team. When we came aboard, it was basically just him, his partner Jim, and show organizer and manager, Susan Hurley,” he said.

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J o i n i n g IFE is planning a diverse conference schedule this year, with coverage on industry trends, new technologies, testing and inspecting, growing sales, and more.

“And when we jumped in, it was a new industry for Emerald.”

This is where Wilson helped considerably as he had nearly a decade of previous experience working for a distributor in the fastener industry.

“I started as the business development manager for the event and was able to help out with creating more precise branding and enhanced digital efforts, such as web development. We also renamed the event in 2018 to the International Fastener Expo or IFE.”

Emerald also offered a dedicated marketing and sales team, including one that targeted a greater international audience. “We were definitely focused on growing domestically, but also internationally because we have a lot of experience with global suppliers.”

One way the Emerald team did this is by implementing a Source Global Area, which is a specific international area on the exhibitor floor. The result has been an increase in attendees from outside of the U.S., including from about 30 different countries. The average attendee also spends about $1.9 million after attending the show, according to statistics from Emerald.

“We’re continually trying to find ways to make subtle improvements to the event for those who attend,” he shared.

Last year was certainly one of the most challenging, given the pandemic.

“We were preparing for the worst as soon as COVID first hit hard in March 2020, but we had hoped that things would turn around in time for the September event. Unfortunately, that

didn’t pan out,” said Wilson.

Although IFE was forced to skip its annual Las Vegas event last fall, it failed to deter the organizers from offering an alternative. To connect the fastener industry, Emerald presented Match & Meet, a unique, AI-powered platform that offered several live, online conference sessions, with more than 50 exhibitors in virtual booths. The show took place last November, attracting more than 500 participants.

“We’re aware of what IFE has grown to mean to the industry and we wanted to present an alternative,” he said.

“Granted, it was not as ideal as an inperson show and it took a lot of effort to build out the online platform for it, but we think overall it was a success.”

Over the two days of the digital show, more than 2,700 connections were made, with 6,700-plus messages exchanged. “We noticed how much more one-on-one time attendees spent with those exhibiting or speaking at the event than typically happens in person at the show, so this was interesting.”

Another bonus: “Now that the platform is built, we’re able to use it in the future. So, for example, we might incorporate this digital side to the event in Vegas,” said Wilson. Registration is now open for IFE, which is set for September 21-23, 2021.

“The excitement and enthusiasm to see everyone face-to-face is growing every week,” he added. “We’re thrilled to create a safe and comfortable environment for our audience to meet in person again.” FE

The organizers of the International Fastener Expo are dedicated to presenting a safe and effective event in Las Vegas this September. They’ve developed an IFE 2021 Health and Safety Plan, where exhibitors and attendees can learn about the health measures that will be implemented and expected at the event. You can download the plan at fastenershows.com.

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5G TECHNOLOGY WORLD Delivers the Latest 5G Technology Trends

5G Technology World is EEWorldOnline’s newest site covering 5G technology, systems, infrastructure, and wireless design and development.

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5G is hot, keep your components and systems cool 5G’s antennas and the devices that drive them generate more heat than their LTE predecessors. That creates new cooling problems for wireless devices and systems. www.5gtechnologyworld.com/5g-is-hot-keep-yourcomponents-and-systems-cool

5G moves into production, causes test issues 5G Technology World talks with Teradyne’s Jeorge Hurtarte, who explains components and over-the-air production test of 5G components. www.5gtechnologyworld.com/5g-moves-intoproduction-causes-test-issues

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Rolling the dice on success: A company built on vented screws Michelle Froese • Editor It was polio that set Ron Anderson up for a career as a draftsman. Eventually, this path led him to start his own business, UC Components, Inc. — a manufacturer of vented screws and components — from his home garage in Union City, California. He bought a drill press, a spray-mist cooler, and a small compressor on credit and got started. It was 1974.

“My father was originally from Wisconsin and the state sent him for skills training sometime after his polio diagnosis, where he became a draftsman and then moved out west,” explains Ron’s son, Rick Anderson.

“He always wanted to live on the coast.”

Unfortunately, Ron passed away quite a few years ago but not before UC Components became a family business — and a success. Throughout the years, Ron’s wife and three sons (he also has a daughter) worked in different roles at the company. Rick Anderson is the one who most took to the business and he’s now the co-owner, along with one of his best friends from college, Jeff Renggli.

The co-owners of UC Components, Jeff Renggli and Rick Anderson.

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An O-ring being loaded into a vacuum oven. UC Components also offers seals, which are complementary to its vented fasteners for vacuum applications.

“In some ways, I feel like I’ve always been partially involved in the business,” says Anderson. “I remember when my dad moved out of our garage and rented a facility across the Bay in Mountain View. My siblings and I helped him move all of the little boxes of screws and components. I think I was in fourth grade or something like that and even got the day off of school.”

Anderson’s dad began UC Components because he noticed a lack of standardized, specialty vented fasteners for the vacuum industry.

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the Distant Early Warning or DEW Line, which aimed to provide early detection of any potential nuclear missile launches from the Soviet Union at the time,” he shares.

Varian also provided some early technology for space flight, adds Anderson, but most of it was developed

by Lockheed Martin and NASA proper — both of which became early users of vacuum technology and customers of UC Components.

These products evolved to include the ultra-high vacuum, a widely used system in the semiconductor sector that relies on vented components.

“Initially, my dad’s goal was to work

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for himself part-time and earn enough to take his family on vacation. But he was laid-off twice in the early ’70s and decided to roll the dice and take the UC Components on full-time.” There were ups and downs, he says, but it succeeded. And, as Anderson grew up, his interest in the company also grew.

“I suppose, I decided that working at the business was something I might want to do at a fairly early age,” he says. “I mean, I basically grew up using a Sears’ Craftsman drill press. I’d count parts and then drill holes into screws so each one was vented. My brothers and I were paid a nickel per piece and, eventually, I became quite proficient.”

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Fastening + Joining California-based UC Components offers vented and non-vented fasteners in a wide range of sizes and lengths, including custom configurations.

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That’s how Anderson got on UC’s payroll, sometimes making up to $25/hour — which as a teenager was impressive, particularly in the ’80s.

When it came time for college, he decided to attend San Jose State University because it meant he could commute from home and continue to work for his dad.

“College is where I met Jeff Renggli, my current business partner,” he says. “We were advertising majors and, for the most part, we worked summers and then completed our necessary internship working in the marketing department with UC Components.”

Eventually, Anderson and Renggli bought the business from Anderson’s parents, and it’s continued to grow ever since. What started as a niche market for the aerospace and defense sectors has expanded to serve the electronics and semiconductor industries, as well as several other broad-spectrum applications.

“We’ve certainly become more profitable over the years, but the hard work…the core work of the company was done by my father,” says Anderson.

“This included manual labor and long hours spent building it from the ground up. Essentially, my dad commoditized each product from an early stage, assigning part numbers to each component, ensuring every design had a drawing, and so on. And he never once borrowed a cent to do so.”

Anderson and Renggli also deserve a fair share of the credit. UC Components has developed into mostly a national but also a global company, serving OEMs, end-users, government labs and facilities, universities, and other customers around the world. Customers include Silicon Valley start-ups and big names, such as Apple and Google.

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With a team of about 40 employees, they’ve automated as many of the processes as possible and are no longer relying on those Craftsman drill presses. Although the company still does a lot of machining, the original vented-screw product now only makes up about 50% of the business.

“We’ve definitely become a valueadd company,” explains Anderson. “For example, we now offer a great deal of incoming inspection on the other side of the manufacturing process. A lot of this involves the subcontracting for coating and plating, as well as the inspection of those operations. We also provide cleaning and clean packaging.”

A few years ago, UC Components also transitioned to ISO 9001, which is one of the most widely recognized qualitymanagement system certifications. This standard means a business must comply with stringent requirements that ensure reliable products, which typically exceed customer expectations.

“This was another step in refining the business, so to speak, to transition from a somewhat machine-shop model to a more balanced, high-quality enterprise,” he says.

“And, of course, given our background in advertising, we’ve spent a lot more on marketing to ensure our business is wellrecognized.”

There are a few things that Anderson’s learned since taking over the business from his parents.

“Patience is important, but you also have to have trust and enthusiasm — trust that things will work out and enthusiasm for your team. You always want to encourage your employees and be a cheerleader for them and your business.”

He adds: “There’s always something new, or an accomplishment or achieve-ment to be celebrated, which makes going to work every day exciting.” FE

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Like, father like sons: How the Slass brothers took Rotor Clip to the next level Michelle Froese • Editor Launching a new company is no easy feat, even for the most ambitious of entrepreneurs. For Robert Slass, it took getting fired from one fastener company before he ventured on his own in 1957 and founded Rotor Clip — which has since become a global manufacturer of retaining rings, springs, clamps, and more.

“My father was initially hired as a young engineer while he was still in school by a company called, Waldes Truarc,” shares Craig Slass about his dad. Slass is currently the VP of Rotor Clip. He and his brother, Jonathan, have fully run the company since their dad sadly passed away in 2009.

“After the war, the European-based Waldes set up a factory in America and became licensed by the U.S. government to manufacture retaining rings. As it developed building standards for these parts, my father worked as the ‘checker,’ which meant he double-checked the math and calculations of the draftsmen,” he says.

Brothers and the owners of Rotor Clip, Jonathan and Craig Slass.

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Retaining rings, also known as snap rings or

According to Slass, however, his dad had a bit of an attitude and could act self-assured or somewhat aggressive at times. This eventually led to him getting pushed out of the company. “My dad had a strong personality, to say the least, and it got him fired from Waldes.

They actually said to him: ‘You won’t be happy until you own the company.’”

Turns out, they were right.

“This compelled my father to develop a product line of retaining rings and start his own company in Farmingdale, in Long Island, New York,” says Slass.

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components onto a shaft or into a bore.

In the 60s, his dad moved the company to the Bronx and then, in the early 70s, to Somerset, New Jersey, where the company is still headquartered today.

“What’s interesting is that my father started out with next to nothing. For example, he never had any of the equipment or heat-treating machines necessary to actually make these products,” shares Slass. “Yet, he slowly built Rotor Clip up to become a vertically integrated manufacturer, which is what my brother and I continue to own and manage today.”

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circlips, are one of Rotor Clip’s specialties.

Typically, these metal fasteners are installed into a groove on a shaft, or in a housing or bore to retain an assembly.

Robert Slass, the founder of Rotor Clip.

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Fastening + Joining Rotor Clip’s 238,000-square-foot manufacturing facility in Somerset, New Jersey. The company also has operations in England, Germany, the Czech Republic, and China, providing worldwide service to its customers.

This means the company currently does all of its own design, manufacturing, and engineering. “We even have our own miniature steel mill and annealing furnaces, with the capability to provide design, stamping and coiling, laser cutting, heat treating, finishing, and packaging,” he says. “My brother and I have made sure it’s fully integrated and self-sustainable.”

One of several lessons the brothers learned from their father was to never give up on a goal. “I learned the value of staying focused and never doing anything halfway,” says Slass. “It can be intense but if you’re committed to something, ‘no’ is simply not an option.”

One such example: when the company was located in the Bronx, the crime rate became so high at the time that it became a serious problem.

“In fact, it was so bad that my father literally had to weld the typewriters to the desks. So, at one point, he told his accountant that they had to find a way to move out of the area.

His accountant’s reply: ‘Well, you’re an engineer…why not build a place

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of your own?’ And that’s what my dad did, essentially becoming a true entrepreneur.”

That’s when Robert Slass found a piece of property in Somerset to build today’s Rotor Clip location. For him, this also meant driving every morning from his home in the Bronx to the new site in New Jersey to work with the construction crew.

“My father was his own contractor,” Slass says. “He would learn the science of concrete just to be involved with the process of pouring it. He was never afraid to take on projects by himself — from constructing buildings to building roofs, he’d simply learn each step on his own. And so, the foundation of Rotor Clip was truly built on his expertise and love of science and engineering.”

That love of learning was infectious, and both Slass and his brother followed in their dad’s footsteps.

“We were born and bred for attaining anything and believed that anything was possible,” he says. “But as we grew up, Rotor Clip was our playground. I mean, our father even bought us a pony and built his own barn on the company

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property. We were excited as kids to work there one day.”

However, Slass and his brother decided early on to take the company to new levels and do things a little differently. They joined Rotor Clip in the early 90s.

“We were fortunate as kids to learn every aspect of the business, from the hardships of life to watching it grow and prosper. But one thing we decided early on was that we were not going to be paving driveways like our father did,” he laughs. “We made a commitment to focus on the products and make them better than anyone else’s in the world, and that’s what we do.”

Case-in-point: Rotor Clip supports more than a dozen industries (think aerospace, automotive, energy, defense, motion control, medical, and others) and manufactures a full line of inch, DIN, ANSI metric, and JIS retaining rings to global standards.

This includes a complete line of constant section rings, spiral retaining rings, and wave springs. In fact, there are over 50 different styles and over 1,000-part numbers to fit virtually every application.

The company also supports its market with a full line of installation tools such as applicators, pliers, dispensers, and automated assembly equipment.

“We’re constantly asking ourselves how we can best contribute to industry and society, and how to make things better,” says Slass.

Last year, this entailed contributing to the fight against the COVID-19 pandemic by supplying critical wave

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springs that were needed for a ventilator production project.

“We’ve been challenged before, in 2008 with the recession and in 2001 with the 9/11 tragedy. You can’t think about it too much…simply step up and do whatever’s necessary to support society,” he says. “We wanted to be a part of the solution.” For the ventilator project, this involved producing and delivering those springs within two days.

Slass says the company has the same commitment for its employees.

“Healthcare is so important. I feel it’s my job to provide for and cover as much of the healthcare costs as I can for my staff. So, if one of our employees or their kids gets sick, they don’t have to sell their homes to pay for an illness or serious medical problem.”

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Like father, like son. And, in this case, the saying seems profoundly true. Slass says his dad also made little differentiation between his family and employees.

“My father took such pride in his people. Whenever we had family functions, there would be people from the company invited just like they were one of us. I’ll always remember that,” he says. “He may have been extremely determined in business, but he sure cared a lot. My brother and I feel the same way.” FE

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J o i n i n g

A life-long

learning career in the fastener industry

If you’ve been in the fastener industry for any length of time, you’re likely aware of Jo Morris. She’s well-known for her work with the Fastener Training Institute (FTI), a non-profit organization dedicated to education and training in the fastener sector. She’s technically FTI’s director of marketing — although she wears many hats and has throughout her career.

Case-in-point: she also works as an outside sales representative at Desert Distribution, a supplier of engineered components and fasteners.

I’m extremely lucky to work in an industry that I love,” she shares. “And that’s important because both FTI and Desert Distribution are full-time jobs. There’s a lot going on…so you’re always on your toes and have to be high functioning.”

High functioning certainly describes Morris. In addition to a couple of full-time gigs, she’s also a mom to 12-year-old triplets.

“It’s certainly a balancing act on some days,” she admits. “But somehow I manage. Fasteners is a great industry because there’s always something new to learn and it’s a close-knit community. It’s also been my only career as an adult, really.”

Morris graduated from Arizona State University with a business degree and plans to go into international business. But first, she was focused on gaining more work experience. She initially interviewed with a pharmaceutical company and considered hotel management. However, 74

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Jo Morris has several roles in the fastener industry. A couple of these include serving as the director of marketing with the Fastener Training Institute and working as a sales rep for Desert Distribution.

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Fastening + Joining

FTI’s Fastener Training Week is an advanced technical training program, offered in partnership with the Industrial Fasteners Institute, which is ideal for fastener distributors, manufacturers, and end-users. It covers consensus standards, quality control, and more. Learn about and register for the next session, scheduled for August 16-20, 2021 in Chicago, at fastenertraining.org.

“The fastener industry offers enormous opportunities in so many different directions. And the people become like family very quickly. It’s a great career.”

— Jo Morris

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before deciding she figured she could benefit from a few more interviews and, by chance, secured a job with a fastener distributor.

“To be honest, the pharmaceutical company was in Texas but the fastener company was in Arizona…which is where my boyfriend and I lived at the time. So, I went with fasteners,” she laughs. “And though I sometimes wonder where l would be today if I chose differently, I do love how my career has unfolded.”

Morris spent six years at the distributor, Copper State Bolt & Nut, which provided her excellent insight into the industry.

“I was hired to support their marketing efforts but left with experience in that, as well as business development, inside sales, administrative work, and even helped out at the front counter — which was www.fastenerengineering.com

excellent exposure for learning about the products,” she says. “At the time, roles weren’t quite as defined and you wore a lot of different hats, so to speak.”

Copper State is where she met John Wachman — also an industry veteran.

He’s the founder of Desert Distribution and managing director of FTI. Wachman was also recently inducted into the Fastener Hall of Fame, which recognizes professionals who’ve made significant and enduring contributions to the industrial fastener industry on a national or global scale.

“It didn’t take long for John to take me under his wing as an assistant at Copper State, which ended up being the best opportunity of my career,” says Morris. “He was a big proponent for knowing what you’re selling, so I was fortunate to learn from some of the best in the industry. John made sure I had the chance to visit and learn from DESIGN WORLD

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Jo Morris, pictured with

manufacturers when the majority of components were still made in the U.S.” One of their major accounts was selling engineered components to a large airbag equipment manufacturer in the Southwest. So, Morris spent time learning from engineers, even working on the manufacturing line.

“I got to fully understand the purpose and functionality of each part, which has been extremely valuable throughout my career,” she says.

“I’ve also spent plenty of time on the customer side, learning about supply chains and vendor-managed inventory, for example, which was fairly new at the time.”

What made this more significant for Morris was how few women were in the industry at the time.

“It’s changing now…fortunately. I mean now, there are women engineers, CEOs, managers, owners, and mentors.

But when I first started in fastening, there were very, very few women, and my experience was quite unique,” she shares. “I like to say, the cream always rises though and it’s wonderful to see how women have risen to the top of this industry, for sure.”

Eventually, Morris decided to move back to her home state of Colorado, where she married, had triplets, and joined another fastener distributor.

There, she worked her way up to general manager until that company sold and Copper State expanded into Colorado and asked her to return. She said yes, for a while.

“My kids were young at this time though and the full-time workload became a little much. I wanted something part-time and that’s when John offered me a new opportunity,” she says. As Morris was settling down in Colorado, Wachman had decided to venture out on his own and launched Desert Distribution.

“Of course, that was ideal for me and I was happy to work with John again. I was able to begin part-time, representing fastener suppliers in

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John Wachman, at a trade show a couple of years ago.

Colorado, New Mexico, and Utah,” says Morris. Her career in the fastener industry continued. “Then, at some point, John asked me to help him with the launch of an online presence for the Fastener Training Institute, where he served as president at the time. Slowly, this work has compounded and grown exponentially — the rep side and the training side. So, now I have more than one full-time job!”

Morris is not complaining. One of the main reasons she’s stayed in the industry, aside from the life-long friends and colleagues she’s made, is that it continually offers her a chance to learn.

“It’s never boring. Truly,” she says.

“It’s like this never-ending place to evolve. I’ve sat in on countless webinars and training sessions and, somehow, there’s always something new to learn.

Yet, for whatever reason, they still don’t teach fasteners in college.”

She recounts the story of a family friend who recently asked her advice about the correct screw to hold an important safety application at a fire department. “He said something along the lines of: ‘I’m a structural engineer and I’m unsure… they never taught us that,’” she explains. “It’s unfortunate on some level, but that’s where FTI fills a gap.”

Even throughout the pandemic, the Fastener Training Institute was able to reconfigure its courses to offer ongoing, online training. It’s also been providing monthly webinars.

“It’s certainly not ideal for every course because it’s impossible to replace the significance of hands-on www.fastenerengineering.com

training when it comes to fasteners. At the same time, it’s been important for us to continue to be available for the industry,” she says. Fortunately, FTI is gradually returning to the classroom.

It held its renowned Fastener Training Week in person in May and will offer the program again in Chicago this August.

“Once you’re in it, it’s tough to leave,” she shares. “The fastener industry offers enormous opportunities in so many different directions. And the people become like family very quickly.

It’s a great career.” FE

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FASTENER FASTENER 78

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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

Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377 (in the US & Canada)

bokers.com

Structural Adhesives for Specialty Trucks and Trailers Many truck and trailer manufacturers are making the switch to adhesives instead of traditional welding and fastening. Lowering fuel cost, wind drag, and weight has become an important component in manufacturing specialty vehicles. Results have shown that structural adhesives are often stronger and more reliable. Ellsworth Adhesives offers a variety of acrylic, epoxy, and urethane structural adhesives.

Structural adhesives can be used to configure work truck equipment, trailer assembly, and aftermarket upfitting. Applications can range from panel bonding for trailers, installation of tool boxes in construction trucks, shelf hanging for delivery vehicles, plumbing equipment for firetrucks, to electrical components in utility vehicles.

Ellsworth Adhesives Ellsworth.com (877) 454-9224

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Branson GMX-W1 Ultrasonic Wire Splicer from Emerson Blends Performance, Ergonomics The Branson GMX-W1 Ultrasonic Wire Splicer from Emerson delivers precise and repeatable splicing of non-ferrous wires for in-line or pig-tail configurations. The lightweight, compact design of the GMX-W1 splicer makes it ideal for use as a portable unit for wire harness in-line assembly boards.

The user-friendly design of the GMX-W1 splicer features a 22” touchscreen HMI, whose touch-keyboard and drag-and-drop program editor make it simple to create, edit, and recall different production recipes for splices, sequences, and harnesses. The screen also accesses the unit’s multiple welding control modes and offers flexibility for configuring production- and quality- monitoring solutions. The actuator unit of the GMX-W1 splicer is also userfriendly with an illuminated weld area, and a patented vertical stacking feature in the welding head.

Emerson Automation Solutions www.Emerson.com/Branson

NBK Suggests and Supplies Solutions with Specialty Screws NBK’s history and craftsmanship date back to 1560 when the company first began. Our predecessors were proud to offer their advanced knowledge, state-of-the-art technology and using this today, we have developed various products.

One of NBK’s strengths in the high-tech sector is our Specialty Screws such as vacuum application screws, anti-galling screws, specialty metal screws such as Inconel and Hastelloy, and more.

Furthermore, NBK deals with unique functional screws like low-profile screws, small head diameter screws, captive screws, miniature screws (less than M2), ball transfer screws, ball plungers, clamping screws, and more. We are proud to support our customer’s projects with NBK’s Specialty Screws and their unlimited matching applications. We also offer customized screws!

NBK America LLC 307 East Church Road, Suite 7 King of Prussia, PA 19406 Phone: 484-685-7500 https://www.nbk1560.com/en-US/

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Connectivity building blocks for motion control Servo and variable frequency drive designs depend on compact and reliable electrical connections.

Matt Hou • Sales Engineer • Dinkle International

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Figure 2: The Dinkle 0183 series merges screw connections into a reliable and efficient connectorized format, useful for power devices like servo and variable speed drives.

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C o n n e c t i v i t y

Today’s machinery and equipment — whether built for the

consumer, commercial, or industrial markets — are increasingly relying on servo and variable frequency drive (VFD) devices to provide intelligent, efficient, and precise motor control. Developers of these drives are responding to market demands with competitive designs to reduce footprint size and add specialized functions (Figure 1).

To implement these products, designers need to carefully consider all aspects of their devices, including their electrical interfaces for input power, output motor leads, and control and communication signals.

Terminal blocks provide these interconnection points from field wiring to the internal printed circuit board (PCB) of the device, and designers should understand several electrical and mechanical characteristics of these components to choose the ideal parts for drives and other electrical devices.

Physical form factor Traditionally, devices like drives were electrically installed into control panels and within equipment, and then connected to other devices using wires landed on simple screw terminal blocks, sometimes requiring fork or ring lugs to be first crimped onto the wire end. This simple methodology is time-tested, but also time consuming both for the original installation and for any subsequent service. It also introduced multiple failure points where a weak crimp, a stray wire strand, or an improperly torqued screw could lead to trouble — with

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C o n n e c t i v i t y

Figure 1: As servo and variable speed drives are becoming more capable and commonplace in all types of applications, developers of these drives need compact and reliable electrical connectors to simplify installation and maintenance.

extensive troubleshooting often required to find the exact point of failure.

An improved option is to use connectorized plug and socket pairs.

Although these parts might cost slightly more than traditional screw terminals, the ease of installation and serviceability provides many timeand cost-saving benefits over the operating lifetime. The end result is a lower life cycle cost, especially when increased reliability and uptime are taken into account. Connectorized press fasteners are easier for initial wire connections because the installer can positively orient the plug portion to the corresponding socket.

A major benefit of connectorized devices is to make it easier for panel builders to originally install the device, and for maintenance personnel to replace or service the device in the future. Connectorized devices are quicker and easier to work on, and they can be de-energized by unplugging them. By unplugging connections, technicians have better access for testing wiring.

Designers should look for connectorized press fastener pairs with: The necessary voltage and current characteristics

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• Minimal physical footprints • Latching/locking methods suitable for high vibration environments • Multi-point electrical contacts

for secure connections, even when subjected to vibration Additional support pins or structure for extra stability Optional screw-in provisions Good user ergonomics for mating and unplugging UL and IEC ratings Products subjected to rigorous testing from UL and VDE Certified Witness Test laboratories Metal parts with anti-corrosion and anti-aging properties to pass humidity and salt spray tests

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Due to the connector pin spacing (pitch), insulation provisions, and mechanical requirements, some connectors may be unacceptably large. However, styles are available to provide secure connections in a compact form factor, with minimal space required for mounting flange and lock mechanisms as these are incorporated within the basic footprint.

The electrical connection method is the next consideration.

Screw connection, higher power Just as standard screw connections have been common on equipment for

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many years, this configuration can be used in connectorized fittings (Figure 2).

Screw connections can accept stranded and solid wire, up to 10 AWG and 600 V/25 A, making them a good choice for typical servo and VFD device power connections. Proper spacing provides for effective inspection of wiring positions and integrity. Due to the nature of the screw connections, users should ensure the connector product has passed rigorous torque and rotational testing for the best reliability.

Even with the latching mechanism integral to the connector, there is an overall space savings with this connectorized wiring as compared to traditional screw terminals.

Some versions also feature an additional screw used as a secondary reinforcement for maintaining the plug in the socket. On the device side, the socket must be arranged for stable connections to the PCB. For best convenience, there is a second wire connection option.

Push-in connections, secure and efficient Push-in design (PID) wiring connections have gained significant attention throughout industry due to the many benefits associated with their use (Figure 3).

PID connections can accept stranded and solid wire like screw connection, but usually at smaller capacities, typically up to 14 AWG and 600 V/20 A. They are therefore suitable for some power connections, and for all signaling connections. Because a mechanical screw is not needed, these PID connectors can be even more compact than their screw-in counterparts.

Solid wires, or stranded wires using ferrules, are installed by simply pushing them right into the spring cage, which can save up to 50% of wiring time compared with traditional screw connections. Stranded wires can be used directly if the release mechanism

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is operated with a small screwdriver to relief tension during wire insertion. Some terminal vendors offer a small release tool for single-handed installation of stranded wires, and for easy wire release. For best long-term reliability, designers should ensure that PID-type connectors can pass a testing regimen which includes at least 200 wiring connect and disconnect cycles.

From a physical standpoint, the springloaded nature of PID connectors provide excellent vibration resistance for the wire clamping mechanism and electrical contacts, while a latch and support pins securely retain the plug within the socket.

Push-in design (PID) wiring connections have gained significant attention throughout industry due to the many benefits associated with their use.

Connectors are essential for electrical reliability Electrical connection points are just one consideration when designing electrical for hardware like servo and VFD devices.

However, as the electrical interface point between the device and the outside world, they play an important role.

Designers have many modern options to improve the flexibility and electrical/ mechanical performance of their designs by incorporating compact and efficient connectorized components. However, is important for these designers to understand the electrical and mechanical characteristics involved so they specify the right products for the job. DW

Figure 3: Push-in design connectors, as represented by the Dinkle 0150 Series shown here, can provide the most efficient, compact, and vibration-resistant method for connectorized wire connections to devices.

Dinkle International dinkle.com

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Top 10

considerations when applying rack and pinion systems

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This is a rack and pinion assembly with a helical tooth design.

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Rack and pinion systems are electromechanical devices uniquely suited for linear or rotary motion solutions unattainable with other technologies. The typical system includes a long straight rack (or linear gear) with teeth on one surface, a matching pinion (or circular gear), and a method for driving one or the other. Curved racks are also possible.

Chris Popp • Motion Control Consultant You’ve likely heard of rack and pinion steering in automotive

applications. That is a slightly different animal from the focus of this article — rack and pinion sets in industrial applications. In that regard, the four main advantages of rack and pinion systems as industrial or automation solutions are: 1 High linear speeds 2 Virtually unlimited lengths of travel 3 High force transmission in a relatively compact package, and 4 A wide range of accuracy options from very high precision to general purpose use.

A rack and pinion system can be used in three basic ways. The first and most common is fixing the rack to the machine structure and using the reaction force on the driven pinion to move a carriage or other platform over the length of the rack — bringing the pinion and driver along with it in high-speed linear motion.

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Rack and pinion sets are often driven via right-angle servo gearheads. | courtesy Atlanta Drives

The second way to use a rack and pinion system is to fix the power/ torque source, with pinion attached, which then drives the rack back and forth to create high force linear motion, like a linear actuator. The third way is a reversal of that action by driving the rack back and forth with another linear device to create rotary motion on the pinion.

So, with the basic intro aside, let’s get to the top ten things design engineers need to consider (or in other words, what their suppliers needs to know) to correctly select and apply a rack and pinion system. Some of these may be more appropriate for the fixedrack design, but all have relevance.

Parameter one: Machine drive type This relates to whether the motion design is driving the load with a single axis on one side or with two axes on opposite sides of the load. Then, there is also the option of driving with two axes on the same side using a single rack. Identifying the power source configuration and locations will help determine torque required to drive the load, either all on one axis or shared when using multiple axes.

Parameter two: Operation environment It’s important to identify the environment and ambient condition the rack and pinion will operate in to determine if any protective measures or other considerations may be required.

Since the inherent design is an open gear system, any contaminants that can collect in the gear teeth should be accounted for and avoided if possible.

Parameter three: Axis travel length As previously stated, one of the main advantages of rack and pinion is virtually unlimited travel length. Some

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can be longer than 200 ft … but they also work over just a foot or two — especially when using them for the alternative ways initially identified.

Virtually unlimited travel means that rack and pinion sets are only limited by the builder’s ability to mount and align the rack and accompanying guides.

Using longer rack pieces, many offered up to 2 m long, reduces mounting time and provides more accuracy and easier alignment over long stretches.

For shorter runs, standard 1-m, 0.5-m, and custom-cut lengths are also readily available.

Parameter four: Axis weight being moved In fixed-rack systems, it’s common for a carriage or gantry to move along the rack carrying a load along with it. Both the structural weight and the load weight, if combined, need to be identified to calculate the torque required to move the load. When the load varies, the worst-case scenario is the prime consideration. In a fixed pinion system, the linear force required of the moving rack, whether over the full travel or only at the end of the

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stroke, is similarly necessary. In either case, if any additional load or force is applied (whether during the movement or when in position) that’s a need-toknow element as well.

Parameter five: Axis orientation It’s important to communicate if the movement is horizontal, vertical, or somewhere in between. In a nonhorizontal application, the additional forces due to gravity will have to be considered. In horizontal applications, friction forces are a necessary added factor. Whether the tooth connection is on the top, bottom, or side of the mounted rack is also a relevant consideration in some circumstances.

Not always, but it should be mentioned when discussing the proposed design configuration.

Parameter six: Load support It should be no surprise that the load must be supported. How it’s supported can be critical. When using a helical cut rack side forces up to one third of the linear force can be seen. The guide system must be able to accommodate that. Therefore, linear guides should DESIGN WORLD

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be specified to not only carry the weight of the load but also resist the side forces from the gear connection reaction. When using a straight tooth rack there are no side forces. That may allow other guide systems, like rollers, to be acceptable. Helical cut rack has some advantages, like higher force capacity and quieter operation. So, consider the application requirements before choosing the rack type. And after choosing the guide type for the rack selected, communicate the guide friction factor. That will be necessary to calculate the needed drive torque.

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Optimizing the motion profile for acceleration rate and run speed can reduce input drive size and costs Parameter seven: Acceleration and speed Moving the load is what it’s all about.

How fast and for how long are the big questions. Like all motion applications faster inertia acceleration and deceleration requires more torque, which may lead to a larger system.

Slower acceleration rates, although requiring less torque, may then need a faster run speed to get into position in time. Optimizing the motion profile for acceleration rate and run speed can reduce input drive size and costs. One of the highlighted main advantages of rack and pinion is it covers distance quickly. That offers a lot of flexibility in configuring the motion profile.

Parameter eight: Axis duty cycle This is the number of operations or movements of the system, typically in cycles per hour and hours per day.

While certainly a consideration for DESIGN WORLD

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M o t i o n

| Dreamstime

L i n e a r

This rack and pinion set has a straight tooth design.

Special rack designs allow direct mounting of linear rails for precise alignment. | courtesy Atlanta Drives

applying a relevant service factor in rack and pinion size selection, it’s much more important for the lubrication interval and the drive package, especially when a gearhead is involved.

All rack selections assume proper lubrication. In applications where the pinion moves and sits for long periods of time, periodic hand lubrication may be adequate. But as the cycle increases so does the required frequency of applying lubrication.

Refillable automatic “smart” lubrication systems are readily available to meter grease at appropriate quantities and intervals for each application. Gearhead life is more sensitive to starting and stopping torque. Cycles are a key factor in their selection.

Parameter nine: Position accuracy This relates to the necessary positional accuracy or allowable deviation at various points along the length of travel.

Taking the drive system out of the

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picture, this is primarily affected by the pitch error of the rack and pinion teeth.

Higher tooth pitch error will result in less predictable position control. Lower pitch error will increase predictability.

Many rack manufacturers offer different levels of pitch error through different hardening and grinding processes.

Costs can rise dramatically from the lowest to highest quality. Therefore, it makes economic sense to identify the accuracy level really required.

A corollary element is system backlash. Clearance in the rack and pinion tooth mesh or the input gear drive system can affect position control unless the load is always in one direction. However, most rack and pinion system reversals result in some lost motion on the return. Lower rack tooth pitch error may allow closer gear mesh to reduce the effects of backlash.

Parameter ten: The input drive system This involves how the rack and pinion will be driven. In most automation systems a servo motor will be selected because of its controllability. To increase mechanical advantage and reduce reflected load inertia back to the motor a gearhead of some sort is typically added. This could be a planetary inline design or a right angle servo worm.

Each has its advantages. In either case, selecting an appropriate gear ratio can have a significant effect on motor and drive costs and performance. Too high a gearhead ratio will slow down the system. Too low a ratio will require a larger and pricier motor and drive.

Another consideration is pinion size. Smaller pinions must run faster to achieve desired linear speed, but require less torque to provide a given force, while also reducing the effects of backlash. A larger pinion covers more distance per revolution but requires more torque to provide the same force.

Therefore, properly matching motor and drive size, gear ratio, and pinion size can optimize the system performance in the most cost effective manner.

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PROVEN SHOCK, VIBRATION & NOISE REDUCING SOLUTIONS There are certainly applications where other design criteria are important. But for most linear motion systems incorporating rack and pinion sets, identifying the ten considerations described in this article will get you 90% of the way to designing a successful and high-performing system. Because all motion system profiles are unique, it makes sense to collaborate with your system provider by sharing as much application and design information as possible. They’ve pretty much seen it all and can quickly identify the critical elements to help select the best system components to meet your needs.

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Automatic lubrication systems are available to minimize maintenance intervals. | courtesy Atlanta Drives

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Cooling with capacitors Ordinary vapor-compression cooling is inefficient and un-green. Future-generations of air conditioning may instead use electrocaloric techniques with almost no moving parts.

| AdobeStock.com

Leland Teschler • Executive Editor

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H

ere’s some bad news about our warming world, courtesy of the International Energy

Agency: The use of air conditioners and electric fans already accounts for about a fifth of the total electricity in buildings around the world – or 10% of all global electricity consumption. And most homes in hot countries have yet to purchase their first A/C. So over the next three decades, the use of A/C is likely to soar, becoming one of the top drivers of global electricity demand. The IEA figures that by 2050, around two-thirds of the world’s households could have A/C. China, India and Indonesia will together account for half the total.

Another fun fact about the year 2050 is that the evaporative cooling techniques used for A/C and refrigeration today probably can’t be improved enough to be practical thirty years from now. The IEA thinks energy demand for space cooling could consume as much electricity as all of China and India do today.

As a quick review, cooling in traditional A/C takes place via the vapor-compression cycle, which uses the phase change between gas

Operation of the EC system as described by the Xerox PARC/Murata research team.

(A) Relative positions of the EC modules in the two heat transfer stages. (B) The heat flow path. (C) The electric field and actuation timing. (D) Schematic of the Brayton cycle as observed for each MLCC. DESIGN WORLD

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Xerox PARC/Murata EC cooler and key components. (A) Top and bottom EC modules assembled on their plates. The inset shows the copper through-vias behind the MLCCs. (B) Bottom housing structure, including miniature fan and air flow path. (C) Solid model of the cooler assembly. (D) Photograph of the cooler assembly.

Conventional vapor-compression A/C equipment isn’t particularly green. Today it uses refrigerants comprised of hydrofluorocarbons which, though more environmentally friendly than previous generations of fluids, have a warming potential thousands of times higher than that of carbon dioxide.

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and liquid of a refrigerant to transfer heat.

All such systems have four components: a compressor, a condenser, a metering device or thermal expansion valve, and an evaporator. Circulating refrigerant enters the compressor as a saturated vapor and is compressed to a higher pressure, resulting in a hot superheated refrigerant vapor. The superheated vapor passes through the condenser where it cools and condenses completely, and the rejected heat is expelled. The condensed liquid refrigerant then passes through an expansion valve where it undergoes an abrupt reduction in pressure that causes a flash evaporation of a part of the liquid refrigerant, lowering the temperature of the liquid and vapor refrigerant mixture so it is colder than the temperature of the space to be refrigerated.

The cold mixture then passes through the coil or tubes in the evaporator. A fan circulates the warm air to be cooled across the evaporator coil or tubes. That warm air evaporates the liquid part of the cold refrigerant mixture. Meanwhile, the circulating air is cooled and thus lowers the www.designworldonline.com

temperature of the space to be cooled.

Finally, the refrigerant vapor from the evaporator is again routed back into the compressor.

Conventional vapor-compression A/C equipment isn’t particularly green.

Today it uses refrigerants comprised of hydrofluorocarbons which, though more environmentally friendly than previous generations of fluids, have a warming potential thousands of times higher than that of carbon dioxide. In addition, A/C equipment has a limited energy efficiency. In the U.S., the DoE dictates that residential units have an energy efficiency of at least 13 SEER (seasonal energy efficiency ratio). The SEER rating of a unit is the cooling output during a typical cooling-season divided by the total electric energy input during the same period. Thermodynamics efficiencies are usually calculated as a COP (coefficient of performance), the ratio of cooling provided to the energy required. A SEER of 13 is approximately equivalent to a COP of 3.2, which means that 3.2 units of heat are removed from indoors per unit of energy used to run the A/C. The COP of an air conditioner, which follows a Carnot thermodynamic cycle, depends on the outside and inside temperatures. If the outdoor temperature is 95°F (35°C) and the indoor temperature is 80°F (27°C), the maximum theoretical Carnot cycle COP is 36. Unfortunately, it looks as though future COP improvements in vapor-compression A/C are likely to be just incremental at best. More efficient compressors and valves, better heattransfer surfaces, and more exotic refrigerants are all on the drawing board. But all such advances are likely to be more costly and bring limited benefits.

Consequently, there is a great amount of interest in novel cooling methods that are potentially more energy efficient. In particular, solidstate methods are attractive because eliminate the inefficiencies that arise from friction, wear, and other losses.

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Perhaps the most well-known means of solid-state cooling takes the form of Peltier modules which work thanks to the thermoelectric effect. Here a voltage is applied across two special joined semiconductors to create an electric current. When the current flows through the junctions of the two conductors, heat is removed at one junction and deposited at the other, thus cooling the first junction.

A typical Peltier module consists of an array of alternating n- and p- type semiconductors having complementary Peltier coefficients. (Peltier coefficients basically denote the heat energy per electron per unit time carried to the junction.) The array of elements spans between two ceramic plates, electrically in series and thermally in parallel. Materials used are often bismuth telluride, antimony telluride, and bismuth selenide, selected for a combination of low thermal conductivity and high electrical conductivity.

Though Peltier type coolers have niche applications, it looks as though they are unlikely to be practical for ordinary refrigeration or A/C. Thermoelectric junctions devised to date have a COP that is about 25% of that for vapor compression setups.

That puts them at about 10–15% of the ideal Carnot cycle refrigeration efficiency compared with 40–60% for conventional A/C. Indications are that despite decades of intensive research, fundamental material and form-factor limitations may thwart attempts to realize Peltier energy efficiencies approaching that of traditional A/C, let alone produce something better.

Fortunately, there are other emerging technologies that may fare better when it comes to energy efficiency. Among them is electrocaloric (EC) cooling. Certain EC materials change temperature under an applied electric field. The underlying mechanism of the effect is complicated, but an applied voltage basically raises or lowers the entropy of the material.

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In recent years, researchers have devised thin films of lead, titanium, oxygen and zirconium (PZT) that would cool down by 12°C under a 480 kV/cm field change. And there is progress in developing EC materials that exhibit “giant” EC effects. But it has proven to be tough getting the EC effect in components with thermal masses higher than that of thin films. That’s a necessary development for devising practical A/C systems employing EC cooling.

Fortunately, ceramic capacitors show promise as EC components. Recently, a group hailing from Xerox Parc and Murata Manufacturing in Japan described an EC cooler employing lead, scandium, tantalum (PST)

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multilayer ceramic capacitors (MLCCs) as the working elements. A 10.8 MV/m field changes the MLCC temperature by 2.5°C at room temperature. Moreover, the researchers say their cooling scheme, which is now just a lab demo, can use capacitors fabricated in a conventional manufacturing process and can be scaled up to do real work. All in all, they think that scalable materials, together with mechanical simplicity and modular design, can ultimately lead to a system whose size, efficiency, and cost can compete with that of vapor compression A/C. The device invented by the research team isn’t fully solid state. It physically moves the capacitors back and forth between hot and cold regions to effect cooling. Specifically, their system

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includes a pair of stacked modules, each containing EC MLCCs separated by thermal insulating materials. The modules are thermally coupled such that heat can transfer from one capacitor to the next. A mechanism moves the stacked modules laterally relative to one another while an electric field is switched on and off synchronously. The effect is to generate a temperature lift between the two ends of the device that exceeds the MLCC temperature change.

Also key to the design is the use of plates that enhance heat exchange between their layers but are good thermal insulators in the lateral direction. But there is nothing exotic about their construction. They are basically glass-reinforced epoxy (FR4) laminates and copper made via a standard commercial PCB process.

In the regions of the plate where the MLCCs attach, plated-copper throughvias serve as thermal shunts for high through-plane thermal conductivity.

The MLCCs are assembled onto the plates to form the top and bottom EC modules containing five and four MLCCs, respectively. The bottom module has an aluminum platefin heat sink at each end to facilitate temperature stability. The modules sit in a 3D-printed VeroClear housing filled with polyurethane foam insulation.

Besides providing structural support, the housing also minimizes heat leakage. A miniature fan at one end pushes air air across the hot-end heat sink.

The top housing connects to a spring-returned single-acting linear solenoid actuator with about a halfinch of stroke. In operation, energizing the actuator draws the top module toward the actuator. When the voltage returns to zero, the solenoid relaxes and a spring returns it to its original position. The EC module housing provides vertical pressure through a set of wheels to keep good thermal contact between the two modules.

Control software synchronizes the

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movement of the top module layer with the application of electric fields to the EC capacitors.

The MLCCs operate via a Brayton cycle, with two zero-voltage and two equal-entropy stages. The scheme uses a 400-V polarizing voltage (equivalent to ~10.5-MV/m electric field) and a 0.2Hz switching frequency (5-sec period) with about a 50% duty cycle. There are heat sinks at both ends of the device.

Over the course of the experiments, heat sink temperature on the hot end rises, while the temperature at the cold end changes in discrete steps as the heater power varies.

The cooling power seen in this small demonstration device is only on the order of hundreds of milliwatts per square centimeter. A more interesting question concerns its COP. Researchers say the EC system COP is a function of the heat collected from the cold side of the device, the additional electrical work associated with charging and discharging the EC capacitor, and the amount of electrical energy recovered each cycle. There’s also mechanical and electrical work required to move the reciprocating system, but that was so small that researchers figured they could safely ignore it. Factoring in all these parameters, they calculated a COP for the experimental setup that is about equal to that of existing Peltier devices.

That result may sound anticlimactic, but there is a key point: The researchers didn’t optimize any of the components in their cobbled-together setup. For example, the copper traces on the PCB were ordinary and conducted a lot of heat. Making them thinner would allow less heat to escape. Ditto for the PCB material. Replacing the ordinary FR-4 board with a polymer material like acrylic would provide more thermal insulation.

And the MLCCs themselves could be improved. Those used in the demo had a form factor optimized only secondarily for thermal behavior. Researchers note MLCCs of the type used in their device

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have higher thermal conductivity in one orientation than in others. A fix wouldn’t be difficult. There are already other MLCCs commercially available with form factors better suited to use in EC cooling.

Even a change to capacitor electrodes with a higher conductivity would help.

Given all the possible improvements, researchers estimate EC-powered A/C using existing PST capacitor material might eventually hit COPs of about 56.4%, making their system competitive with vapor compression cooling. You might say that would be quite a “cool” development. DW References “A high-performance solid-state electrocaloric cooling system,” https://science.sciencemag.org/ content/370/6512/129

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Test instruments evolve to meet next-generation needs

The next generation of engineers, digital natives reared on screen time and apps, are finding test instruments designed to suit their experiences.

Edited by Miles Budimir • Senior Editor Test and measurement instrumentation is not what it used to be. The

traditional look and feel of test instruments, dictated at least in part by the electronic technology of the time, was the large metal box dedicated to one task only. A typical test bench would hold a number of these boxed instruments (oscilloscopes, frequency generators, voltmeters, ammeters) stacked atop one another with a tangle of test leads and wires scattered about.

But as electronic technology evolved, so too did test instruments. Fast forward to the present; the students of today will be tomorrow’s engineers, and their experience of using electronic devices differs significantly from earlier generations. Tomorrow’s engineers are used to the world of mobile phones and tablets, of apps and video game interfaces, of swiping and pinching to zoom in or out on images.

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Liquid Instruments' Moku:Go offers an intuitive user interface that helps engineering students learn core concepts.

Companies recognize that and are updating designs to reflect this new technological reality. So for instance, there is more of an emphasis on instruments that are reconfigurable, that can evolve and switch functions almost on the fly, as well as housing multiple functions in one package. The shift in design away from the traditional box-style instruments means they are less defined by hardware and rely more on software that can be programmed and changed by users.

Combo instrument platform helps science and engineering students An example of next-generation test instrumentation comes from the aptly named Liquid Instruments. The company’s new Moku:Go is billed as a complete, portable platform designed to bring the engineering lab anywhere and usher in a new era of scientific and engineering education at universities around the world.

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Moku:Go is a software-enabled hardware platform that can fit in a backpack. It was designed for portability, flexibility and durability, to take not just electrical engineering students, but physics, bioengineering, chemical engineering and other majors through all four years of their education and even beyond. It starts with eight instruments including an oscilloscope, PID controller, logic analyzer, arbitrary waveform generator, data logger, spectrum analyzer, and more.

It also features full connectivity with a Wi-Fi hotspot and USB-C, robust hardware features and electrical protection to ensure students can explore new projects without putting themselves or their equipment at risk. The unique integrated power supplies are user programmable with high voltage and high current options for any project.

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The shift in instrument design is away from hardwaredefined instruments to ones where there is more reliance on software that can be programmed and changed by users.

“Our students were thrilled when we first added Moku:Lab to our classroom two years ago, and after seeing the new capabilities of Moku:Go, I’m even more excited,” notes Colonel Brian J. Neff, Electrical & Computer Engineering Dept. Head at the U.S. Air Force Academy. “It’s clear that it will help take students’ educational experience into the modern era, and I look forward to seeing this become a standard part of our curriculum,” added Colonel Neff.

Moku:Go’s software was designed to appeal to a generation accustomed to intuitive user interfaces and broad compatibility. Liquid Instruments is bringing the user experience out of the flip-phone era and has designed intuitive Windows and Mac interfaces that are inviting and powerful for students. It offers remote access capabilities and clearly diagrammed views of the signal processing chain, which makes it easy for students to learn difficult concepts whether they are in person or remote. The student-centric design ensures they’re learning the core concepts, rather than just learning the equipment itself.

The Moku:Go contains eight instrument functions, including oscilloscope and logic analyzer among others, along with a WiFi hotspot and a USB-C connection.

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Not only does Moku:Go help increase student engagement, but incorporation into curriculum also reduces faculty and teaching assistant workloads. The platform supports Python and MATLAB APIs and has published examples of MATLAB live scripts for remote instruction, live student assistance and plagiarism control.

The existing product, Moku:Lab, has been used for years by top institutions worldwide, enabling breakthrough research in the areas of photonics, electronics, and materials science.

“Our first product, Moku:Lab, gave R&D scientists the power and flexibility they needed to do their job, all in a streamlined and cost-effective platform.

Now with Moku:Go we will bring those same advantages to improve the overall quality of education and motivate students to study science and engineering,” said Professor Daniel Shaddock, CEO and co-founder of Liquid Instruments.

Moku:Go starts at $499 and can be customized to match school colors, with volume purchasing for educational institutions.

Instrument suite targets teaching labs Another new instrument offering from Keysight Technologies focuses on the user interface, making it consistent across the company’s offerings. A portfolio of Smart Bench Essentials (SBE) lab bench products deliver the power of four unique instruments, including a triple-output power supply, an arbitrary function generator, a digital multimeter and an oscilloscope, through one powerful graphical interface offering integrated data management and analysis capabilities.

Keysight’s SBE lab bench products are reliable and capable instruments developed for the design and keysight test of products in manufacturing and R&D, offering a compact and stackable design that’s suitable for small manufacturing businesses. They’re DESIGN WORLD

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also well suited for modern university teaching labs that require an enhanced environment conducive to sharing and maximizing learning. Remote learning technology is the new normal accelerated by the recent Covid-19 pandemic. Most universities struggle to Keysight's four unique Smart Bench Essentials series instruments with PathWave adapt to this new environment, seeking BenchVue software lets users configure instruments from the same PC screen. a blended learning experience with the Reproduced with Permission Courtesy of Keysight Technologies, Inc. right technologies.

Keysight’s PathWave BenchVue application software complements the SBE series, letting users configure instruments quickly, while operating on the same PC screen to test devices. It stores data on a PC and exports it in standard readable formats for post-analysis work and report generation.

Keysight’s SBE series also offers the optional PathWave WHAT DO Remote Access Lab software and the PathWave Lab Manager YOU software to enhance the lab experience and productivity.

THINK? Connect and discuss this and other Keysight’s PathWave Remote Access Lab software lets university engineering design issues with thousands of professionals online teaching labs transition to online learning seamlessly. It allows students to remotely access the lab setup and perform lab work through the web browser. Keysight’s PathWave Lab Manager software works seamlessly with the Smart Bench Essential series instruments to manage lab assets effectively and productively.

“All four instruments have a consistent look and feel, the Rod Ends and same graphical user interface and connectivity,” said Christopher Spherical Cain, vice president of Electronic Industrial Products at Keysight Bearings designed Technologies. “The setup of four test instruments connected and manufactured to through the powerful PathWave application software lets Aurora’s exacting engineers focus on their insights and innovation, not managing standards for quality their test instruments.”

Keysight’s SBE series is a combination of hardware and and durability. software that accelerates an educators’ teaching experience and students’ learning experience. It also improves an electronic design and manufacturing engineers’ ability to analyze and troubleshoot products.

Registered and Certified The key benefits include an elegantly integrated system to ISO_9001 and AS9100. letting users focus on insights and core innovations, not managing instruments. Plus, there is the ability to configure, From economy commercial control and monitor multiple instruments from a single screen. to aerospace approved, Users can test, analyze and share lab instruments and data we’ve got it all! remotely from anywhere, providing learning during the pandemic and global access to remote instrumentation. Along with these features is the ability to automate common tasks from test set up, data collection, to report generation, as well as the ability to R centrally manage an entire lab of instruments and configuration to maximize productivity. DW

Your Partner moving forward!

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complete library of CAD drawings and 3D models available at:

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Product World Light guiding terminal blocks Dinkle dinkle.com The 0171 series of push-in-design (PID) terminal blocks provide high-reliability connections and a clear indication of active circuits to assist with operations, maintenance, and troubleshooting.

Reliable electrical wire terminations are necessary for all types of commercial and industrial equipment and machinery. The 0171-series incorporates PID technology, improving upon traditional screw terminals in terms of performance, ease of use, and space efficiency. The consistent clamping tension of PID terminal blocks resists vibration-related connection failures better than screw terminals, and wires are easily pushed-in, saving up to 75% of the wiring time compared with screw terminals.

Integral light pipes route the illumination from underlying device LEDs, ensuring clear visibility for users. This indication is useful to confirm normal operation and support troubleshooting efforts. The 0171-series terminal blocks are rated at 300 V in various ampacities depending on the model. They carry approvals from UL, cUL, and CE, and the material used for manufacturing is compliant with RoHS.

Power supplies maximize system uptime WAGO wago.us Pro2 Power Supplies include six units ranging from 120-960 W and an energy conversion efficiency of up to 96%. The power supplies incorporate an interface allowing them to be tailored to any application requirement. The units also offer monitoring functions that provide continuous power supply data information and signal errors for application monitoring.

They also have easy fieldbus connection with snap-on type communication modules with WAGO’s TopBoost and PowerBoost capabilities, maximizing system uptime and lowering hardware costs. TopBoost has 600% extra output current, enabling protection for up to 15 ms compared to conventional circuit breakers. PowerBoost provides an extra 150% output current for five seconds providing superior reserve power.

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Photoelectric sensors AutomationDirect automationdirect.com Wenglor dark and shiny object detection photoelectric sensors use blue light technology to detect objects other photoelectric sensors cannot see or see objects that get detected multiple times erroneously.

They come in either 50x20x50 mm or 32x12x16 mm body sizes with an M12 or M8 quick-disconnect.

These sensors can detect dark and shiny objects up to 400 mm away and are IO-Link V1.1 compatible.

Also added are four new models to the Wenglor performance line and five laser sensors to the discrete distance detection group.

Options for keyless shaft bushing product line Zero-Max zero-max.com There are now a variety of options within the Posi-Lok keyless shaft bushings (PSL) product line. Options include material choices, plating, and different mounting methods. These options give system designers the ability to select the best shaft locking device for their system. The PSL series allows the user to rigidly and reliably secure shaft-mounted components into position for optimal operating results in their machine.

Posi-Loks are an excellent shaft-hub locking solution, eliminating the need for keyways that can weaken or cause excess wear to shaft components. All Posi-Lok models easily slide onto a shaft for mounting and provide reliable, zero-backlash performance. They provide excellent concentricity with minimal radial and axial runout. Since the Posi-Lok’s fieldproven mechanical design does not require a keyway, it reduces machining costs and simplifies installation.

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Product World Programmable LED strip light Banner BannerEngineering.com The WLS15 Pro is a programmable LED strip light for advanced indication applications. The device allows for more intuitive indication in the visual factory by boosting productivity through improved operator response. Its configurability drives reduced inventory and spare parts lists, helping facilities better manage the supply chain.

The WLS15 Pro lets users visually monitor processes and respond quickly to critical conditions. It provides locational guidance for pick-to-light and assembly applications. It offers long-range visibility of material level, temperature, weight, and more so, operators can monitor machine statuses from a distance and respond to them quickly.

Pro Editor models are discretely controlled and suitable for users who do not have IO-Link but want control and customization capabilities to communicate information visually. The PC-based interface makes it easy to configure a light for various applications, such as displaying machine warm-up time, indicating unique steps in an assembly process, showing distance and position, and communicating multiple machine states.

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Enhanced M12 and M16 connectors Binder binder-usa.com Binder has enhanced several series of M12 and M16 circular connectors with a shielded, two-part right-angle housing design. The new right-angle design meets the growing need for increasingly compact and flexible connector solutions. The improved sealing concept, together with easier installation in constrained spaces, expands the range of usage for these connectors beyond automation engineering to sensor technology, actuators, data transmission, power supply, measuring equipment, and control systems applications.

Features:

• binder Series: 423, 713, 715, and 825 • Connector locking system: M12, M16 • Termination: solder, screw, crimp, and wire clamp • Wire Gauge (AWG): 18 - 26 • Degree of Protection rating: IP67 • Contact plating: Ag (silver) and Au (gold)

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Manual and mechanical pneumatic valves Festo festo.com/us The manually operated VHEF and the mechanically operated VMEF pneumatic valves are small, durable, and versatile core Festo valves and are guaranteed to ship within 24 hours.

Whether the valve is triggered by a workpiece, a component, or a person, manual and mechanical valves are the most direct way to control a process.

VHEF and VMEF do not require energy conversion, additional reaction time, or long cables. The actuated plunger switches the valve and triggers the next step in the process. Given that the conditions in the field are sometimes quite harsh, for example, with sawdust in furniture production or even in agricultural automation, these manual and mechanical valves are designed to withstand environmental stresses.

Each style of valve offers multiple configurations to satisfy a range of applications. The VHEF has seven manual versions, including pushbutton, toggle, finger, hand, and selector. The mechanically operated VMEF offers four actuation versions, including stem, roller lever, roller lever with idle return, and piloted.

Power supply portfolio expansion Emerson Emerson.com SolaHD SVL DIN rail power supplies have been expanded to include economical, three-phase versions engineered for use in both ordinary and hazardous locations within petrochemical refineries, chemical plants, wastewater treatment centers, and auto manufacturing facilities among others. Power factor correction, along with overcurrent, overvoltage, and short circuit protection, adds to their reliability and helps provide industry-leading efficiencies from 86% to 92%.

Suitable for high volume, controlled environments with essential power quality requirements, the new SVL models deliver 24 Vdc output in Class I, Division 2 (C1D2) hazardous locations with 5-, 10-, or 20-amp output, equivalent to 120, 240, or 480 watts, respectively. A 40-amp 960watt version is also available for ordinary locations, assuring maximum design flexibility. C1D2 models provide a safe way to tap three-phase power in hazardous locations where lighting systems, motors, pumps, and other heavy-duty equipment are commonly found.

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Ad Index

SALES

ABB Motors & Mechanical ...9 AllMotion .................................... 4 Altech Corporation ...2,3,19,21 Aurora Bearing Company .......................... 99 Automation Direct ................... 1 Azoth .........................................13 Bay Associates Wire Technology, Inc. .............. 29 Canfield Connector ............. 93 Cornell Dubilier Electronics, Inc. ................. 7 Del-tron ................................... 87 DeviceTalks ............................ 45 Digi-Key .....................................15 Exair Corporation ................... 5

Fabco-Air, Inc. ........................37 FAULHABER MICROMO ....IBC Fluid Line Products ............. 89 Interpower ............................... 16 METCASE .................................17 Misumi USA, Inc. ..................BC Opto 22 ......................................11 OTTO Controls ...................... 39 PBC Linear ..............................25 PM B.V. ......................................41 SIKO .......................................... 33 Sorbothane ........................... 89 Smalley Steel Ring ...............47 THK America, Inc ................. IFC Trim-Lok ...................................23 Whittet-Higgins .....................27

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Boker’s Inc. ...................................50 Ellsworth Adhesives ................. 73 Emerson ...................................... 68

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Fastener Engineering Supplement

Jim Powers

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Engineering July 2021

A supplement of Design World

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