Design World June 2016

www.designworldonline.com June 2016

INSIDE:

MOTION CONTROL: Why is preload necessary in some bearing applications?

PAGE 56

MATERIALS: Make the right choice for metal coating for the right application PAGE 70

MECHATRONICS: Five keys to mechatronic success PAGE 80

How to choose APR15-A&C Snipe_Snipe 3/13/15 2:39 PM Page 1

an industrial lubricant 64

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l r o r fo nt d Co e i l & l A n k n tio i Th ma to u A 6/2/16 11:11 AM

We have designed many “field-friendly” features into the Productivity2000 PLC because we understand the pressure that can come with field installations and start-ups. We want you to have everything you need to keep your install on track and your startup on schedule. From OLED displays to QR codes, the features listed here are just a few examples of the many ways Productvity2000 can save you time in the field, which also saves you money!

Field-friendly F

To get the whole story and see even more ways to save, head on over to www.Productivity2000.com

Trouble-free Troubleshooting The standard OLED message display on the P2-550 CPU gives you instant status on your controller and can be used to display system faults.

Also, each analog I/O module includes a high-contrast OLED so you can view fault conditions and analog values such as voltage, current, and temperature without having to disconnect signal wires to get a reading with a meter.

Convenient QR Codes When the pressure is on, don’t waste precious time searching for needed documents. Get wiring diagrams, installation instructions and specifications by simply scanning the QR code tab on each Productivity2000 I/O module.

Configurable Hot Swappable I/O Don’t lose production for simple I/O module changes. The Productivity2000 CPU can remain in the RUN mode without the user-selected I/O modules installed. Choose to allow any module to be removed or configure each module separately.

ZIPLink Pre-wired Solutions The Productivity2000 I/O modules have multiple wiring options available.

Use standard terminal blocks, or our ZIPlink pre-wired cables and connector modules (available for most modules). ZIPlinks not only provide tremendous wiring time savings but can also provide fused isolation from field devices, clean wireways with easy, field-traceable connections, and confidence that your panel wiring is correct.

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ndly Features for LESS!

Don’t forget that our field-experienced and highly-trained technical support specialists are ready to help, FREE of charge. Give us a call at 1-800-633-0405, we’re available 9am - 6pm ET on weekdays.

We also offer FREE 2-day shipping and a 30-day money back guarantee for any of those last-minute modifications.

the #1 value in automation * See our Web site for details and restrictions. © Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.

1-800-633-0405

www.AutomationDirect.com

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Break FREE from the traditional PLC experience and save!

Save time and money NOW...

Built-in Cost Savings The Productivity2000 PLC is designed with many built-in cost savers. The CPU comes standard with on-board data logging and more communication options than anyone else (5 comm ports). It also includes three of the most widely used protocols in the industry (Modbus RTU, Modbus TCP/IP, EtherNet/IP) so no separate communication modules are needed!

FREE Intuitive PLC Software

5

COMM PORTS

PLC CPU and I/O Comparison

AutomationDirect

Ethernet Remote I/O USB RS-232 RS-485

Allen-Bradley

Productivity2000

CompactLogix

Base (if required)

$69.00

N/A

Power Supply

$69.00

$427.00

CPU

$255.00

$3,220.00

16 AC Inputs

$105.00

$264.50

16 24VDC Inputs

$69.00

$222.00

8 Relay Outputs

$51.00

$275.50

8 Analog Input Channels (mA)

$199.00

$797.00

ASCII Comm Module

$0.00

$752.00

Modbus RTU Comm Module

$0.00

$736.00

Total System Price with USB, Ethernet and Serial

$817.00

$6,694.00

P2-04B

P2-01AC

P2-550

P2-16NA

P2-16NE3

P2-08TRS

P2-08AD-1

Built in to CPU

Built in to CPU

N/A

1769-PA4

1769-L33ER

1769-IA16

1769-IQ16

1769-OW8I

1769-IF8

The FREE Productivity Suite PLC software works hand-in-hand with many field devices and third party software. This integration gives this PLC a clear advantage, and gives you a head start with system development. Here are just a few examples: •

•

•

Built-in Function Blocks: Specialized, fill-in-the-blank style function blocks for many operations including communication with EtherNet/IP devices and servo/stepper motor control.

Shared Tagname Database: Export the tagname database from the software and easily import it into C-more HMIs, Point of View SCADA software or other 3rd party database software to jump start your project development.

Auto-discovered Hardware: The Productivity Suite PLC software will automatically configure installed I/O modules - your system is recognized and configured without any manual setup. Up to 16 GS Series AC drives can also be auto-discovered and their parameters stored in the CPU for future reference.

Own It, Don’t Owe On It!

Buying direct with us saves you money. With Productivity2000, you get many standard features that you would pay thousands for elsewhere. Our P2-550 CPU is priced at $255 and I/O modules start at just $40 (P2-08NE3). We aren’t a traditional PLC company - we are here to serve YOU! So check us out!

Visit: www.productivity2000.com

1769-ASCII

1769-SM2

and LATER...

All prices are U.S. published prices. AutomationDirect prices as of 4/27/2016.

Allen-Bradley retail prices taken from www.plccenter.com 4/18/2016.

the #1 value in automation * See our Web site for details and restrictions. © Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.

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1-800-633-0405

www.AutomationDirect.com

5/23/16 12:00 PM 5/4/2016 2:21:05 PM

Wire you paying too much?

Starting at:

$33.00

500 ft electrical wire

Electrical Hook-up / Building Wire At AutomationDirect we want to save you money on every aspect of your system design, even down to the wire! That’s why we have invested in a huge selection of electrical wire and cables, offered at prices that provide substantial savings to you. Not only can you get quality wire at unbeatable prices, but in most cases you can get it shipped for FREE. So, if you haven’t looked at us for your wiring needs, then you’re probably paying too much!

• MTW Machine Tool Wire Primarily used in control cabinets, machine tool applications and appliance wiring applications. Available in 10, 12, 14, 16, 18 AWG sizes, in a variety of colors and in 500 or 2500 ft. reels.

Starting at $35.00 (500 ft.)

• TFFN Fixture Wire Primarily used as fixture wire as specified by the National Electrical Code (NEC). Available in 16, 18 AWG sizes, in a variety of colors and in 500 or 2500 ft. reels.

Starting at $33.00 (500 ft.)

• THHN General Purpose Building Wire Intended for general purpose applications including new construction or 600 volt rewiring needs. Available in 4, 6, 8, 10, 12, 14 AWG sizes, in a variety of colors and in 500 or 2500 ft. reels.

Starting at $33.00 (500 ft.)

• Bulk Multi-Conductor Cable Flexible Portable Power Cord, Bulk Data Cable, Flexible Control Cable and Instrumentation Cable for industrial applications.

Available in a variety of conductors, gauges and lengths.

Starting at $13.75 (20 ft.)

Research, price, buy at: www.automationdirect.com/wire

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved.

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1-800-633-0405

the #1 value in automation

5/23/16 11:55 AM

OFFSET SHAFTS. SOLVED. Offset Couplings from Zero-Max reduce space requirements for parallel offset shafts in large system applications. These specialized couplings provide machine designers with an important option for reducing overall machine size and footprint.

Compact in design, Schmidt Offset Couplings transmit constant angular velocity and torque in a wide range of parallel shaft misalignments. Handling high amounts of parallel offset up to 9 inches, they are available with torque capacities up to 459,000 in-lbs.

Schmidt Offset Couplings can be mounted to shaft hubs or directly to existing machine flanges. They are available for shaft displacements of 0.156 inches to 17.29 inches and torque capacities from 55 to 459,000 inch-pounds. Many design configurations are available including specials.

www.zero-max.com 800.533.1731

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Insights More on the reshoring trend Reshoring continues to make inroads in the American manufacturing sphere. While speaking with a robotics expert recently, he remarked how the cheaper and easier-to-program industrial robots now available are bringing production costs much lower. Low enough, in fact, that in some industries, smaller manufacturers can effectively compete with the low labor cost countries overseas.

The International Economic Development Council recently interviewed senior leaders of American firms about why they were reshoring. Reasons included:

• Labor turnover, training, and costs • Speed to market

• Practical economics

• Flexibility in inventory, and

• Quality assurance

• Customer demand.

Companies found that it was easier to manage a domestic staff as they were able to be more involved in company operations instead of relying on managers in other countries. Conversations can occur more regularly with fewer communication obstacles. There’s also an ability to decrease the mount of time that management spends traveling … and managers are able to work closer with and train new employees more easily.

Another factor was an increase in expenses related to manufacturing overseas. These companies found cost-competitiveness of production offshore had declined based on increased costs to ship products, the decline in the cost of gas, and increasing labor wages demanded by workers.

“As companies experienced a decline in the tax rebates offered by other countries, lowinterest rates, competitive exchange rates, and attractive incentives became attractive to companies considering reshoring,” said Gene DePrez, Managing Partner of Global Innovation Partners and Visiting Senior Fellow of IEDC. Some of the companies interviewed indicated that they experienced issues with quality controls for products manufactured offshore—and there were some inaccuracies in the products.

Not surprisingly, the reshored products were found to be of higher-quality meeting expectations.

The IEDC also noted that the movement of goods faces many potential delays from the time the product leaves the factory to the time it is received by the end user.

“Natural disasters can delay the delivery of products for significant periods of time just as man-made delays can occur including labor disputes and human error. A product is produced to its customer leaves less room for delays and faster turnaround times from order to delivery,” said DePrez.

For companies thinking about returning operations to the U.S., there are some free tools that the government and NPOs have created several. Check out Access Costs Everywhere (acetool. commerce.gov), U.S. Cluster Mapping Tool (www.clustermapping.us), the National Excess Manufacturing Capacity Catalog (www.edastayusa.org) and the Reshoring Initiative’s Total Cost of Ownership Estimator (http://www.reshorenow.org/TCO_Estimator.cfm). IEDC also said that a conversation with the economic development organization located in your community or state can be a good starting place. DW

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

On Twitter @ DW—Editor 4

Insights 6-16_Vs2_PH.indd 4

DESIGN WORLD

June 2016

5/27/16 8:40 AM

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

Compare these Blowoffs

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

The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application.

The goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page summarizes the overall performance.

Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

Drilled Pipe

Blower Air Knife

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

The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and fl at air nozzle, but was comparable to EXAIR’s Super Air Knife. The large blower with its two 3" (8cm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs.

Costly bearing and filter maintenance along with downtime were also negative factors.

Flat Air Nozzles

EXAIR Super Air Knife

As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suff ers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers off er fl at air nozzles where the holes can be blocked - an OSHA violation.

Velocity was inconsistent with spikes of air.

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

Facts about Blowers

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

Here are some important facts: Filters must be replaced every one to three months.

Belts must be replaced every three to six months.

Typical bearing replacement is at least once a year at a cost near $1000.

•

Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate effective airflows.

•

Poorly designed seals that allow dirt and moisture infi ltration and environments above 125°F decrease the one year bearing life.

•

Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer.

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

To discuss an application, contact: EXAIR Corporation 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247 Fax: (513) 671-3363 email: techelp@exair.com www.exair.com/58/423a.htm See the Super Air Knife in action. www.exair.com/58/akvideoa.htm

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

Blowoff Comparison Type of blowoff

PSIG BAR

Comp. Air SCFM SLPM

Horsepower Required

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

Drilled Pipes

60

4.1

174 4,924

35

91

$50

$4,508

$920

$5,478

Flat Air Nozzles

60

4.1

257 7,273

51

102

$208

$6,569

$1,450

$8,227

Blower Air Knife

3

0.2

N/A

N/A

10

90

$5,500

$1,288

$1,500

$8,288

Super Air Knife

60

4.1

55

1,557

11

69

$576

$1,417

$300

$2,293

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

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

The romantic notion of manufacturing jobs It is trendy to speak of bringing back manufacturing jobs to the U.S. Almost every politician on the stump does so.

“Manufacturing is coming back. It’s now our challenge to figure out how .... we can have a renaissance in manufacturing,” says one presidential candidate. “We’re going to bring our jobs back. We’re not going to be losing our jobs to Mexico and all of these other places,” says another. “Look around Indiana and you will find once vibrant and strong manufacturing towns ........ shattered by abandoned factories, shut down steel mills, sky-high poverty rates and foreclosed homes...We need to end the race to the bottom and enact trade policies that demand that American corporations create jobs here, and not abroad,” says a third.

So can we really expect more U.S. manufacturing jobs if one of these blowhards get elected?

Doubtful. Here’s what’s more likely to happen, based on forecasts from the U.S. Bureau of Labor Statistics: Production occupations will have little or no growth for at least five years. Employment for manufacturing is projected to decline 4.6% by 2022. The BLS attributes declines in manufacturing employment in part to foreign competition, but mainly to improvements in efficiency.

And better education, another favorite topic of presidential candidates, is unlikely to change this picture much. The large majority of production jobs typically require a high school degree or less, the BLS points out. The few manufacturing occupations requiring a postsecondary education are all projected to have declining employment.

The romantic notion that the American working class can someday be made up of well-paid factory workers is about as plausible as the Cleveland Browns winning this year’s Super Bowl. The reality is that most occupations in the U.S. categorized as “working class” are not well paid, and that situation won’t change for the foreseeable future.

Individuals who don’t have to campaign for votes are more prone than politicians to admit this reality. One in that camp is Tamara Draut, Vice President of Policy and Research at think tank called Demos. “While America’s public intellectuals wax eloquently, and even idolize, the innovation and ideation done by tech workers, the reality (is) that most Americans actually work in a bargainbasement economy.....Today, the U.S. has one of the highest percentages of working people earning low-wages—one out of four employed Americans—of 26 advanced countries surveyed by the Organization for Economic Co-operation and Development.” she says.

Draut is right. The BLS expects the occupations that will grow the most in the next few years will be mostly in the low-wage category. They include office managers, home health care workers, food prep workers, janitors, and constructionrelated jobs. The only high-growth job category demanding a post-secondary education is healthcare, where the BLS envisions a mushrooming need for nurses.

So when you hear campaign rhetoric in the upcoming months about helping the working class, bear in mind who politicians are really talking about: Not people who work in factories. That is a vestige of a by-gone era. Today’s working class largely consists of individuals for whom a bump in the minimum wage brings a meaningful improvement in life style. And that situation is unlikely to change regardless of who takes the oath of office in January. DW

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

On Twitter @ DW—LeeTeschler

6

DESIGN WORLD

Lee Teschler Column 6-16_Vs1.indd 6

June 2016

5/25/16 10:18 AM

© 2016 Helical Products Company | www.heli-cal.com

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5/23/16 12:05 PM

Te c h n o lo gy Fo r wa rd

The Internet of Things— it’s about security The IoT juggernaut continues: Forecasters like Gartner Research predict that the typical home will have nearly 500 networked devices by 2020 (not me; I’m still wondering why bother?). Big name companies like GE and Siemens pitch their IoT successes at various conferences.

The much-hyped Internet of Things concept promises to tackle common problems: such as the complexities of managing product life cycles and the lack of interoperability between information technology and “operational technology.” (Back in my day, operational technology (OT) was better known as industrial control, as in PLCs, SCADA systems, CNCs, and so on.)

One concern, however, is bubbling up to the top—how will all the gathered data be secured from hackers?

According to a report from Argus Insights, the conversation is shifting from what cool things can we connect to the IoT, to how do we secure all the data? In fact, security is becoming more of a concern than privacy, as well it should. Privacy implies a user has control over when and how data are shared. Security says a user doesn’t.

“Security concerns for consumers are definitely on the rise and this goes double for any enterprise deployments. Security issues are a real roadblock for IoT product acceptance,” said John Feland, CEO, Argus Insights.

Unfortunately, tested, viable security solutions are scarce. Typical solutions like a secure boot or encrypted connection only cover a few vulnerabilities.

Noted the Argus Insights report, the lack of good security software approaches among software vendors “forces engineers to integrate a confusing array of components from many sources only to find they do not play well together or impose an unwieldy demand on scarce system resources.”

This is a problem.

The unpopular reality is that we don’t really understand how to secure devices; this is new territory.

At the recent Disrupt New York 2016 conference, experts weighed in. The best way to lock down data is to not have access to it in the first place suggested Nate

Cardoza, an attorney for the Electronic Frontier Foundation.

If you collect data, interested parties, such as hackers, organized crime, law enforcement (the recent FBI request to Apple, for example) and others will want access to it. Guaranteed.

So some are suggesting a zero knowledge model, where vendors (example: Apple) don’t have access to the data. As engineers and vendors navigate security, this model may become the preferred approach.

The bigger question, though, may be: Why are we networking everything? What, exactly, is the point? In some situations, the data may be useful. But everything?

Just because we can? That’s sloppy thinking.

But vendors will continue to explore anything that can be connected to the internet. Martin Mickos, CEO of security firm HackerOne, has a suggestion for better security. In your design, shift to the open source model where you can invite others to help find vulnerabilities. That’s an interesting approach.

At the heart of the IoT concept is the idea that technology will solve all of our problems. If we just have enough data, we can figure it all out. What if that concept is backwards? What if it’s people, in the form of a “neighborhood watch,” rather than technology, that is the best way to ensure security? DW

Le sli e La n gn a u - M a n ag i n g Edi to r lla n g n a u r@wtwh m edi a .co m

On Twitter @ DW—3Dprinting 8

DESIGN WORLD

Leslie Column (Technology Forward) 6-16 Vs2.LL.indd 8

June 2016

5/27/16 8:42 AM

Proto Labs 6-16.indd 9

5/23/16 12:06 PM

IS THE ANSWER TO MY DESIGN CHALLENGE ALWAYS A PART NUMBER? Ask Smalley. We know that there’s really no such thing as a standard design. So we deliver a level of technical collaboration and customization far beyond what you’d find in a typical parts catalog.

Smalley engineers are always ready to share their expertise with you—tailoring a highperformance Smalley wave spring, Spirolox® retaining ring or constant section ring to meet your unique application requirements.

So don’t settle for ordinary. Talk to a Smalley engineer today.

Stamped Ring Constant Section Ring Spirolox® Ring Smalley retaining rings eliminate the protruding ears that interfere with assemblies, while providing a 360-degree retaining surface.

And their unique design means no special tools are required.

Visit smalley.com for your no-charge test samples.

THE ENGINEER’S CHOICE™

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10/9/15 12:07 1:46 PM 5/23/16 PM

l Contributors Spotlight

ALAN CAIN

70

Group Leader/Research Chemist Chemline Inc.

Make the right choice for metal coating for the right application Alan has been involved with polyurethane and polyurea product development for 25 years. He is also a NACE Level III Certified Coatings Inspector.

JEAN THILMANY Contributing Editor

88 BILL WATSON Director of Application Engineering Klüber Lubrication NA LP

How to choose an industrial lubricant Bill joined Klüber Lubrication in 1989 and has held several positions within sales and marketing. He currently leads the marketing and application engineering department. Bill received his Bachelor of Science degree from the College of William and Mary in Virginia.

64

Sweet Freedom

In the next 20 years, Jean expects to see more virtual reality and holograph applications used in surgery and long-distance diagnosis and treatment. “I hope technological innovations are pushed out to developing countries, in appropriate and humanitarian ways,” she said. “Sadly, I also expect to see the greater effects of global warming and war and combat.” But despite all that, Jean hopes more people will be able to find ways to “slow down the world in their private lives so they’re not connected around the clock.” Her favorite book is Excellent Women by Barbara Pym, a funny, post-war English novel about a spinster. my advice

Enjoy the little things because the big things are complicated to maneuver.

Contributor Page 6-16_vs1.indd 11

June 2016

DESIGN WORLD

11

6/2/16 10:30 AM

Follow the whole team on twitter @DesignWorld

Multi-Axis Communications Just Got Simpler.

1 READY. Use our free SMI™ software to auto detect motors.

2 SET. Set CAN addresses and baud rate.

3 GO. Send commands; start talking.

Same for 2 or 120 motors.

That’s all there is. Simple!

EDITORIAL

GRAPHICS

Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler

Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com

Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora Assistant Editor Michelle DiFrangia mdifrangia@wtwhmedia.com @wtwh_michelle

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Production Associate Tracy Powers tpowers@wtwhmedia.com NEW MEDIA/WEB/ BUSINESS DEVELOPMENT Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Web Development Specialist Patrick Amigo pamigo@wtwhmedia.com @amigo_patrick

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Co nten t s |

June 2016 • vol 11 no 6

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designworldonline.com

F E AT U R E S CONTROL 56 MOTION Why is preload necessary in some bearing applications?

With ball bearings, preload is often a misunderstood concept and overlooked by designers and bearing users alike. Here’s what you need to know.

CONTROL 64 MOTION How to choose an industrial

70 MATERIALS Make the right choice for metal

coating for the right application Metals make it possible to have a variety of products, such as industrial production equipment, automobiles, aircraft, or consumer electronics. The corrosion metals are subject to, however, is a problem. Preventive measures, such as the right coating, can delay or eliminate corrosion.

80 MECHATRONICS

FIve keys to mechatronic success

lubricant

Choosing the right lubricant for an industrial power-transmission design can be a tricky task, because industrial lubricants come in many varieties and formulations, and many industries require lubricants to adhere to specific regulations and standards. Here are some tips to make the selection easier.

Decades of exposure to the realities of keeping farm equipment running have provided FireFly Equipment with insight to the problems, and the solutions, needed to making highly automated agricultural machinery a reality.

CAD 88 3D Sweet Freedom Free, open-source 3D CAD systems are finding their place.

ON THE COVER Lubricants help chain and other power-transmission components last for years, even in harsh environments.

Courtesy Klüber Lubrication NA LP.

2015

2015

2015 O N LIN E

revenue over $3 million

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DESIGN WORLD

CONTENTS JUNE 2016_first page_Vs3.LL.indd 14

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160429_1_3Mill_DW_US.indd 1 Digi-Key 6-16.indd 15

4/28/16 12:08 1:39 PM PM 5/23/16

Depiction of Frequency Waves

6. 2 01 6

Con te n ts

18

INNOVATING SHOCK & VIBRATION SOLUTIONS

D E PA R T M E N T S 04 Insights 06 Teschler on Topic 08 Technology Forward 1 1 Contributors

MADE IN THE U.S.A.

800.838.3906

18 Green Engineering 22 Design For Industry

www.sorbothane.com

28 Design Notes 38 Coupling Notes 42 CAE Solutions 46 Internet of Things 94 Products 96 Ad Index

SIKO MagLine Absolute: ■

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

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SIKO OptoLine: ■ ■ ■ ■

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

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Contents JUNE_second page_Vs2.LL.indd 16

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June 2016

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WITTENSTEIN alpha alpha WITTENSTEIN

Since our origination as Alpha Gear in 1984, WITTENSTEIN alpha Since as Alpha Gear in 1984,systems—right WITTENSTEINfrom alphathe has setour theorigination bar for excellence in motion control has setofthe for excellence in motion control systems—right fromonthe heart thebar Midwest.

Today our North American headquarters sits a six-acre campus in Illinois, we exceed customer expectations heart of the Midwest.

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Wittenstein 6-16.indd 17

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» G re e n E n g i n e e ri n g

n Paul J. Heney • Editorial Director

Getting past wasted energy At this year’s Hannover Fair in Germany, an executive panel touched on the importance of using energy properly. According to the U.S. Energy Information Administration, industry accounts for about one-third of energy used in the U.S. This means that there is an estimated $60 billion in waste. The panel was asked what industry can do to fight this and what may change over the coming decade.

Kevin Yates, President, Siemens Energy Management Division, USA, said that there is a tremendous shift in how energy is created, transmitted and delivered due to availability of renewable energy, low natural gas prices, the need for greater power reliability and regulatory dynamics.

“Though the challenges of this changing landscape often focuses on utilities or independent system operators, the industrial market can also pursue the opportunities offered by a 21st century power mix,” Yates said. “So, even though this shift may seem focused outside of a plant’s walls, today’s energy mix not only can, but is already significantly impacting the way industrial and commercial markets manage and consume energy.”

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Yates explained how Orangeburg, S.C. is home to the world’s largest Ibuprofen factory, which serves as an economic anchor for the region and has over 300 employees. The plant was plagued with power outages due to sub transmission system issues.

“Each time the power went out, the plant was required to shut down production, a costly process that resulted in serious production losses and waste generation,” he said. “The options amounted to either looking for a new site, or working with the local utility to improve power reliability on the grid.”

Siemens partnered with the Orangeburg Department of Public Utilities to develop a Distribution Feeder Automation System for the

city’s power system that transfers power during an outage event so electricity can continue to flow.

The technology was successfully installed and even after a severe ice storm hit the area, Yates said this technology helped transfer power in 90 milliseconds to an alternative source. The Ibuprofen plant was able to avoid costly production shutdowns and keep operations flowing.

Anne Cooney, President, Siemens Process Industries & Drives Division, USA, noted that while studies place energy costs at 5-10% of production costs across all industries, in processbased industries, energy costs may comprise the single largest

component of total costs, as much as 40%.

“Consequently, energy efficiency is always on the initiatives list for most of our customers in the process industries,” she said. “One of the most easily deployed ways that we can help them with that is through energy efficient motors and drives, which can deliver 30% or greater efficiency over older equipment. Depending on the scenario, the gains can be almost astronomical, reaching even 70%.” DW

Siemens usa.siemens.com

June 2016

5/27/16 8:46 AM

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Sponsored Content

Innovative Hydraulic Fan Drives Driving Efficiency and Savings

Abstract ydraulic fan drives are utilized more than ever across multiple markets and applications. To meet the new stringent emission regulations, the engine (charge air) needs more cooling under high load and high ambient temperatures. Sizing a mechanically driven fan for this condition will be very wasteful because in most applications, the engine does

not run at peak load and highest ambient temperature at most times.

By decoupling the engine from the fan drive, hydraulic fan drive speed (power) can be varied to meet the appropriate cooling needs at any working condition. This reduces fuel consumption due to reduced fan power draw and also reduces equipment wear and tear. However, all hydraulic fan drive systems are not

equal. Therefore, it is critical for the engineer to select the right system and the right components, as this will directly affect the resulting fuel savings of the machine.

This white paper addresses in detail the many benefits of hydraulic fan drives on construction equipment, the three different types of systems available, how to size them properly, and the specific types of equipment that benefit most from this technology.

Different Hydraulic Fan Drive System Options Fixed/Fixed Hydraulic Fan Drive System The simplest and most widely used hydraulic fan drive system is a fixed/fixed system. This consists of a fixed displacement pump with a fixed displacement motor and a pressure controlled bleed-off circuit to vary the fan speed.

Parker Hannifin spread ad 6-16.indd 20

5/27/16 8:48 AM

displacement. The control based on the displacement feedback has a very high bandwidth and it is robust and stable. This EDC fan drive system could be driven using an existing vehicle control with the right capabilities. Otherwise Parker has many control modules that can control the EDC system, communicate with J1939, and drive other vehicle functions.

First, the pump control is much simpler and more stable. Second, the number of hydraulic hoses and connectors is reduced. Third, significant efficiency improvements can be achieved by eliminating the control leakage flow with respect to the current state-of-the-art load sense system.

Figure 4 – EDC Fan Drive System

Download the entire white paper on Hydraulic Fan Drives at www.parker.com/fandrives Figure 4 – EDC Fan Drive System Parker Hannifin System Engineers can work with each customer to help in the selection Load Sense Hydraulic Fan of the best system based on their individual application. Whether it is designing the Drive System system and troubleshooting through prototypes or just helping with some controls, Parker Engineers Another common System hydraulic fan can help every step of the way. drive setup displaceSUBH:is a variable SIZING THE SYSTEM ment pump with a fixed motor. The COPY: The first item to address is the amount of cooling power needed at the fan. Typically this first of these variable systemsbyuses a is provided the engine manufacturer. If this is not provided, a general range of 15%20% of the engine power is needed for cooling. It could be slightly more for machines load sensing piston pump. The load such as an excavator, or could be slightly less for machines such as backhoes. Wheel sense piston pumploaders adaptsgenerally the swash fall right in that range. So, this means if the vehicle is an excavator with an engine power plate angle to control the desired fan of 150 hp, it could be estimated that the cooling needed is 30 hp. the power requirement is known, the next step is to size the motor. If the system speed. By adjustingOnce, the swash plate will use 3500 psi working pressure and a required fan speed of 2000 rpm, the torque can angle, the displacement changes to ft-lbs. With the pressure and torque, the size would correspond to a be calculated to 79 not waste any flow across a relief valve, which minimizes the losses seen within the system. This is the current state-of-the-art system for performance and efficiency.

EDC Fan Drive System Figure 4 represents the proposed innovative fan drive system from Parker. This system uses Electric Displacement Control (EDC of the piston pump and position feedback with a displacement sensor (X3). The use of a Parker electric displacement controlled pump allows several advantages.

Parker Hannifin spread ad 6-16.indd 21

The challenge

Constructing a higher quality of life

Parker enables its partners in the construction equipment industry to build new schools the world over while increasing fuel efficiency, minimizing downtime and reducing emissions.

ENGINEERING YOUR SUCCESS.

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parker.com/buildingbetterlives.

5/27/16 8:49 AM

military/aerospace

1

0

» Design for Industry

Easy release for shaft collars

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DFI 6-16_Vs4.LL.indd 22

June 2016

machine tool

Changeovers of shaft-mounted tools, reels/ spools and other objects can be handled more quickly with shaft collars that feature quick-release.

One example is the Easylock shaft collars, which install quickly without special tools for non-slip holding of tools and reels on smooth, case hardened (Rockwell > 55) shafts. A new option – Easylock positive release – assures the collars won’t become jammed on shafts.

A clamping control wheel on Easylock lets users adjust the holding force from 90 to 1,124 lb.

As the clamping control wheel is turned clockwise, the clamping unit is forced against the object being secured, holding it in place. This can generate compression forces that push back against the shaft collar, sometimes interfering with the quickrelease mechanism then making it difficult to slide the collar off the shaft.

To prevent this situation, it was necessary to advance the clamping control wheel a few turns before sliding the collar onto the shaft. The positive release feature eliminates this step. Positive release is activated when the clamping control wheel is turned all the way in a counterclockwise direction.

When the wheel is backed off in this manner, it contacts a stop pin that automatically releases the

locking mechanism so that the quick-release functions properly.

Easylock shaft collars with positive release reduce downtime. The quick-release feature makes them well suited to high volume production where frequent changeovers of shaft-mounted tools, reels/spools and other objects are required. The positive release feature is standard on sizes 25, 30, 35 and 40, and will soon be included on the smaller sizes 10, 12, 15, 16, 20 and 22.

If Easylock is used to hold spools in level winding operations, the pintle points are attached to the face of the unit. As holding force is increased, the points are forced into the spool bore creating a non-slip interface between the shaft and the spool. This permits rapid starts and stops without rotational play of the spool on the shaft. The pintle points also make Easylock useful in processes such as high-speed roll-fed lamination and stretchwrapping. DW Amacoil Inc. Amacoil.com

www.designworldonline.com

5/27/16 8:51 AM

machine tool/aerospace/military

machine tool

» Design for Industry

2

0

Automatically ensure photonics alignment FiberMaxHP is a second-generation 3 to 6 axis photonics alignment platform, built on the ANT nanopositioning product line. The noncontact direct-drive technology can operate in an automated production environment.

It is capable of 2 nm linear and 0.05 µrad rotary minimum incremental motion, with speeds to 400 mm/s, to align photonics packages.

Aerotech controllers work with a variety of smart cameras and machine vision systems to help facilitate first light. Servo scanning algorithms optimize power coupled through the devices. Standard scanning routines include fast align, hill climb, spiral, and raster searches in up to six axes of motion.

Kinematics enable a virtual pivot point where rotation can occur at any user-defined point in space rather than the physical rotation point of the system’s axes. This feature assists the speed and accuracy of active alignment.

The 3 to 6 axes of direct-drive alignment let users specify the exact number of axes needed for an application. Since many applications require manual adjustment of fixtures and parts for a one-time initial alignment, the FiberMaxHP comes with 1 to 3 axes of manual angular alignment with ±2° of motion. These manual adjustment axes mount directly to the direct-drive platform.

The FiberMaxHP is a modular design and can be customized with special arrangement of axes, fixturing, and mounting patterns to meet specific application needs. DW Aerotech Aerotech.com

The Worry-Free Cable Experience

June 2016

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military/aerospace

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0

» Design for Industry

medical

Sensors for medical wearable devices Medical wearable technology continues to be a popular product. Many companies are developing sensors to solve a range of design challenges for these non-invasive body-monitoring devices. One of those challenges is accuracy.

Analog Devices Inc. (ADI) and LifeQ plan to design sensors that enable personalized, continuous and accurate tracking of physiological parameters such as heart rate, sleep phases, sleep quality, blood lactate, 24-hour calorie intake as well as stress markers such as salivary cortisol.

Monitoring this type of data can increase early detection of emergency conditions and diseases in patients.

ADI will offer its semiconductor expertise and LifeQ will provide the bio-mathematical understanding needed to develop sensors that can make body monitoring devices more effective in preventing, predicting and managing diseases.

Analog Devices Inc. LifeQ www.lifeq.com

Smart fluid handling to take you forward, faster.

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Innovation ON THE Leading Edge OF WHAT IS POSSIBLE

Fluid/signal hybrid © 2016 Colder Products Company

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www.designworldonline.com

5/27/16 9:02 AM

a e r o s p a c e » Design for Industry

4

0

Avoid restricted substance risks

When Size and Performance Matters Medical-Industrial Actual Micro-Coax cable bundle diameter compared to a penny.

7.7mm

19mm

Bundle of 128 Micro-Coax Cables

Risks associated with restricted substance regulations include: legal liability, noncompliance costs, re-design, product recalls, and inability to service products due to material obsolescence. Minimizing these risks is difficult. Companies must keep up with shifting global regulations and gather data from suppliers and throughout their organizations. They must often navigate complex combinations of materials, processes, and specifications, or report on legacy products described by Bills of Materials that are in diverse formats, dispersed, and disconnected from data or tools that could facilitate analysis.

The GRANTA MI:Restricted Substances software will helps users navigate the process. It helps eliminate materials and processes risk, helps users design for compliance and analyze products, as well as report on compliance risk for existing products. New developments include extended reference data to fill gaps in in-house information, enhanced tools to manage proprietary knowledge, and fast apps to answer business-critical questions such as “which of my specifications contain at-risk substances?”

(42AWG/85 ohms)

Materials and related processes and specifications are the source of most restricted substance issues. So a strength of MI:Restricted Substances is that it is built on GRANTA MI, an industry-leading system for materials information management. In-house information managed in GRANTA MI is then linked to a regularly updated database of 8,000+ substances and 100+ international regulations that restrict their use. Software tools enable users to apply the resulting knowledge base to analyze risk not only for specifications, materials, and processes, but for designs and products.

Features include: • Updated data on regulations including the IARC Monographs on the Evaluation of Carcinogenic Risks to Humans and the EU RoHS2, China RoHS2, CoRAP, and CLP Regulation lists • Tools supporting the complex process of merging data updates with in-house information • Features to account for multiple surface treatments when reporting on product compliance DW

DFI 6-16_Vs4.LL.indd 25

DESIGN WORLD

19000

4 x 48 AWG Catheter Cable

Industrial Ethernet Cables

Options Available: 600V, High-Flex, Ultra-Limp, Oil/Gas/Solvent Resistant, Outdoor.

Material Science Experts Manchester, New Hampshire , USA Tel: +1.603.669.4347 www.hca.hitachi-cable.com

Granta Design Grantadesign.com June 2016

Actual catheter cable diameter compared to a penny.

25

6/1/16 1:56 PM

Small Size.

Big Performance.

The SPH Flange Gearbox is small in size, but achieves great performance due to a rigid housing, supported planet carrier, high precision gears, and optimized taper roller bearings. It is produced to the elevated standard of quality and reliability customers have come to expect from GAM’s high-performance SPH product line.

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OTHER SPH PRODUCTS:

SPH-W

901 E. Business Center Drive, Mount Prospect, IL 60056

GAM 6-16.indd 26 16_GAM_026_Ad_H.indd 1

SPH-K

SPH-C

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6/1/16 12:37 1:57 PM 5/16/16 PM

pharmaceuticals

5 POWER TRANSMISSION

0

Stainless steel cylinder handles toughest cleanliness requirements One aspect in the manufacture of drugs is cleanliness; equipment may have to withstand harsh cleaning procedures to prevent contamination. Flat-I is a stainless steel, compact cylinder for applications in which frequent, corrosive wash downs are required to prevent the propagation of bacteria.

The cylinder that has mounting holes only where they are needed, with a clean stainless steel exterior. Because of the importance of sterility and the need for cleaning with high-pressure, high temperature sprays applied at close range, this cylinder has the highest possible rating on the Ingress Protection International Scale – IP69K, 6 for being dust-tight and 9 for protection against liquids.

The Stainless Steel Flat-I comes in a wide range of 8 bore sizes and breadth of cylinder options. DW

Bimba www.bimba.com

RETAINING DEVICES & maintenance & assembly tools BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

INCH and METRIC THREADS LEFT HANDED as well as RIGHT -HANDED

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS Materials of: ALLUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

TT

ET

-H

IG

GI

NS US

A

WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.

Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local

or a good distributor.

June 2016

DFI 6-16_Vs4.LL.indd 27

DESIGN WORLD

 

27

33 Higginson Avenue, Central Falls, Rhode Island 02863 Telephone: (401) 728-0700 • FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com

6/1/16 1:56 PM

Âť D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Portable test controller assists composite materials analysis

the most d Test Suite is te ra g te In e Th s used yet. e Inholland ha ar w ft so ile rCAT versat uses an Ethe st controller ti The Moog te ec ws conn ng ace that allo rf te in s bu ld fie vices with tible slave de pa m co AT rC Ethe ion. synchronizat precise time

Last year, the Composite Material Laboratory at the Inholland University of Applied Sciences in the Netherlands installed a Moog Portable Test Controller for single-axis testing of composite materials like fiber-reinforced polymers. The test machine is a 700 x 300 x 1600 mm, 100-kN hydraulic bench. Manufacturers and consumers want lightweight materials in all sorts of products and parts, so the lab had to speed up the number of tests it performs on composite materials. Â Historically hydraulics has been used for its combination of high load and velocity.

The Moog test system consists of a hydraulic actuator, test load frame and test controller. Initially, the lab used the system to perform material tests for aerospace, but then extended its scope to cover things ranging from car parts to hockey sticks.

The composites lab was now able to use the testing machine for a wider range of applications.

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June 2016

6/1/16 2:00 PM

Here, we see a Moog Portable Test Controller for single-axis testing of compo site materials lik e fiber-reinforced polymers. The te st machine is a 70 0 x 300 x 1600 mm, 100 kN hydraulic bench.

For example, while developing a biocomposite scooter, the Inholland University lab was able to conduct full scale testing to simulate certain road profiles. Another example was the testing of cargo straps for aviation to prove compliance with the new EASE regulations. Also, composite materials require significant testing for the determination of material properties. These tests are mainly static destructive tests; the integrated test suite allowed Inholland do all these tests on a single machine. And because the test controller is portable, the lab can also now integrate more I/O devices and obtain real-time and realistic measurements from the lab’s climate chamber.

The software running on the test controller gives engineers more options than other software they’ve used in the past, so researchers can change the force they apply

to a part during a testing sequence. The Integrated Test Suite is the most versatile software Inholland has used yet. The Moog test controller uses an EtherCAT fieldbus interface that allows connecting EtherCAT compatible slave devices with precise time synchronization. The lab is currently using a Q.bloxx measurement system from Gantner Instruments linked to the test controller. The ability of connecting a modular measurement system to the test controller over EtherCAT provides flexibility and has become a key feature to the test lab. DW Moog www.moog.com

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

www.designworldonline.com

Design Notes 6-16_Vs3.LL.indd 29

WHAT DO YOU THINK?

June 2016

DESIGN WORLD

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6/1/16 2:01 PM

Âť D e si g n N o tes

Edited by: Mike Santora • Associate Editor

Modern factor ies need to mon itor a range of proces s parameters re qu iring a higher numbe r of signal cond iti on ers. All factories have the need to be more efficient and save costs by conserving ener gy and saving sp ace wherever possib le.

Energy efficient signal conditioner saves space Modern factories need to monitor a range of parameters requiring a high number of signal conditioners. All factories need to be more efficient and save costs by conserving energy and space wherever possible.

Control cabinets located on a factory floor house many types of equipment typically mounted on a DIN rail inside the cabinet. Equipment can include PLCs, signal conditioners, power supplies as well as DIN rail interconnecting blocks; put simply—space is at a premium. The larger the signal conditioner the more space it takes up inside the control cabinet thereby generating increased costs in cabinet size. Larger cabinets also take up more space on the factory floor.

The need for signal conversion can come in a range of input/output (I/O) possibilities. Signal conditioners with fixed input/output ranges need a different module for each input/output combination.

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June 2016

www.designworldonline.com

6/1/16 2:01 PM

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A warm-up.

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Fifteen years’ service life is not unusual. These low-pressure, high-volume blowers feature rugged, compact construction and quiet operation. Their proven design makes them ideal in applications from chemicals, wastewater and furnaces to vapor recovery and more. Plus, they’re backed by the industry’s most knowledgeable engineering experts. AMETEK can customize your blower for harsh environments, high voltage and specialized applications, too. So make your next air-moving challenge a breeze.

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6/1/15 1:58 5:03 PM PM 6/1/16

» D e s i g n N o tes

and has space efficient The DRSL-U is 6 mm ing that is only a slimline hous n be Up to 50 units ca (0.24-in.) wide. rol N rail in the cont mounted on a DI -in.)

1.8 (1 py only 30 cm panel and occu on the rail.

Non-isolated signal conditioners will not effectively block ground loops or other spurious voltages from passing through the signal conditioner, possibly damaging sensitive downstream equipment such as the PLC or data acquisition system.

Signal conditioners with higher power requirements need larger power supplies mounted on the DIN rail inside the control cabinet, which can take up more space and generate excessive heat.

Older signal conditioners can be up to 25 mm (1-in.) or more in width and require air gaps in between modules for heat transfer for cooling. Consequently 50 units can take up 1.25 m (4.1-ft) or more of DIN rail space, which depending on the size of the control cabinet, can lead to 1 or 2 rows of signal conditioners.

The DRSL-U isolated universal input DIN rail signal conditioner offers galvanic isolation of process signals to SCADA systems or PLC equipment. It accepts thermocouple, RTD, linear resistance, potentiometer, voltage or current input and converts these signals to linear voltage orurrent output. The unit isolates between input, output and supply, provides surge suppression and protects control systems from transients and noise. The DRSL-U 32

DESIGN WORLD

Design Notes 6-16_Vs3.LL.indd 32

June 2016

also offers electrical isolation and eliminates ground loops and can be used for measuring floating signals.

The DRSL-U is space efficient and has a slimline housing that is 6 mm (0.24-in.) wide. Up to 50 units can be mounted on a DIN rail in the control panel and occupy only 30 cm (11.8-in.) on the rail. The DRSL-U’s low power design makes the typical 24 Vdc power requirement for 50 units only 40 W. These signal conditioners can be stacked vertically or horizontally and do not require an air gap in between modules.

The conditioner is configured using the programming interface in conjunction with the configuration adapter. The DRSL-DISPLAY has a 4-line LCD display with scrolling help text in 7 languages (English, French, German, Italian, Spanish, Danish and Swedish), which guides users through all the configuration steps. The DRSL-U is designed with electronic hardware

switches, consequently it is not necessary to open the device to set any internal DIPswitches. DW

OMEGA www.omega.com

WHAT DO YOU THINK?

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

www.designworldonline.com

6/1/16 2:02 PM

VFD CABLES

FOR MOTOR AND DRIVE APPLICATIONS

VFD Lean TR

VFD Dual TR

Servo VFD Combo DS

VFD XLPE TR

VFD XLPE 2KV TR

SAB’s VFD cable series has you covered from fractional to 200 HP drives

about our products and how they can be ready to assist you with your wire and cable needs.

344 Kaplan Drive, Fairfield, NJ 07004 Toll Free: 866-722-2974 Tel: 973-276-0500 Fax:973-276-1515 info@sabcable.com www.sabcable.com

SAB North America 6-16.indd 33

6/1/16 1:59 PM

» D e s i g n N o tes

Edited by: Mike Santora • Associate Editor

WEISS compl eted two chassis systems featurin g an octagon-sh aped, 45.68-in. diamet er dial plate for this application.

The plate footpr int was sized to mat ch the WEISS’ ei gh t station TC220 ro tary index table for a medical parts su bassembly oper ation

by Jerit.

Palletizing dial plate manages multiple robots With over 18 years of experience manufacturing for the robotics and automated machinery industry, Jerit Automation, Inc. is considered a “one-stop” manufacturer. When their team came across a palletizing application chassis system involving two robots− requiring more space for the operators to work—Jerit went to WEISS to collaborate on designing an octagonal dial plate system.

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www.designworldonline.com

6/1/16 2:02 PM

Elesa The Original handwheel VD. Original Design

The design inco rporated two robots−one SC ARA robot for gl ue dispensing, and one 6-axis robo t for part removal, re ject, staging, an d placement into preformed tray s.



1963 The new innovative machine handwheel VD. made in Italy by Elesa, an original design in Duroplast, was introduced for the first time on the market.

1971

The first successful exhibition at the Chicago Design Show.

1977 The Industrial Design Award

from the

IF-Hannover (Germany)

WEISS completed two chassis systems featuring an octagon-shaped, 45.68-in. diameter dial plate for the application. The plate footprint was sized to match the eight station TC220 rotary index table, and was customized for ergonomic, inertia loading, and index speed requirements for a medical parts subassembly operation for Jerit.

The design incorporated two robots−one SCARA (Selective Compliance Assembly Robot Arm) robot for glue dispensing, and one 6-axis robot for part removal, reject, staging, and placement into preformed trays. This meant that more space would be needed to work within than most stations around the dial.

The semi-automated system involved gluing steel into a small diameter plastic part using UV glue, then into a subassembly− requiring a tight tolerance of +/- 0.005-in. The pallet-based production system held four-up nests designed to allow individual parts to be easily loaded by an operator, while keeping parts confined to hold the tight tolerance addressed above.

These nests were approximately 12-in. wide, so the goal was to get the pallets closer to the operators to optimize ergonomics and work space around the dial. Additionally, the

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Design Notes 6-16_Vs3.LL.indd 35

pallets held clamps, pins, cylinders, and so on, that interact with both operators as parts are loaded and indexed to the next station.

The entire system involves a high-level operation sequence: • Operator 1 loads part A, then part A is clamped.

• Dial indexes...Operator 2 loads part B. • Dial indexes...Parts A and B are adjusted to assembly position in pallet.

• Dial Indexes...Glue applied by Scara robot.

• Dial Indexes...Glue drying.

• Dial Indexes...Camera inspection of assemblies for PASS/FAIL. • Dial Indexes...Parts pick and placed with 6 axis robot.

• If “Fail assembly” is present, the robot moves to reject chutes and discards failed parts.

• If “Less than 4 assemblies” are present, Robot moves to staging area and either places or picks parts as needed, to ensure it has four assemblies ready for placement into trays.

June 2016

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The design inco rporated two robots−one SC ARA robot for gl ue dispensing, and one 6-axis robo t for part removal, re ject, staging, an d placement into preformed trays .

» D e s i g n N o te s

• Once the robot has 4 “passed assemblies,” it moves parts to trays and places into the next position available.

• Dial continues indexing back to Operator 1.

Now in its 3rd generation, the WEISS TC220 series heavy duty rotary indexing tables are robust and fast switching.

Using this rotary table as the heart of the system, Jerit could design the frame, oversized table plate, and its associated machining. The frame work and large top plates were designed by the Jerit team to support all their automation devices for their specific application. Weiss manufactured the units and shipped them completed. DW WEISS www.weissna.com

1.800.933.4915 36

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» Co u p li n g N o tes

The role of torque limiters for couplings

Torque limiter’s are devices that allow the limiting of torque for high-shock, catastrophic failure type applications.

Edited by: Mike Santora • Associate Editor

When Coupling Tips.com spoke with KTR Engineering Services Manager, Chris Scholz we asked him about some of the common misconceptions about couplings, torque limiters and the integration of the two. Here are some of the highlights from the interview.

We kicked things off by asking what topics are being brought up most often when fielding application questions and design inquiries.

Here is what he had to say.

“One of the things that I try to understand first, is whether or not the torque limiter will be used only for catastrophic failure, or if the 38

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customer is looking to slip frequently: are they expecting more slips than usual? That, then, tells me whether I want to use an economical friction style torque limiter, or if I want to use the ball detent designs, where they can slip, catch a limit switch, shut off, and then reset themselves, and begin operating again.

They typically can be slipped multiple times through their application, where a friction torque limiter has to be reset every time.

I also try to determine whether a zero backlash component is needed, and address other typical industry questions. The biggest misconception that I want to make sure

people understand is that a torque limiter is not a clutch, and therefore they’re not intended to be continuously slipped.

They generate a lot of heat, obviously, with those frictional connections, and so once a torque limiter slips we want the system to be shut down as soon as possible. We obviously then want to inspect that torque limiter, and check for any wear, or heat damage. Rechecking the setting torque is also important; it will decrease quite a bit if it’s been run too long. We want to make sure that we’re still in the range that we need to be in so we’re not slipping more and more. The way we do that

6/1/16 2:08 PM

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is either with a limit switch, or a proximity switch, and some type of control device. That way when the torque limiter slips, it sends a signal, and shuts the system down so the customer can do whatever it is the torque limiter was designed to catch, or do.”

Why are torque limiter’s important? What are they used for?

“Torque limiter’s are devices that allow the limiting of torque for high-shock, catastrophic failure type applications. They’re used

Here we see an exploded view of KTR’s Ruflex torque limiter.

when people don’t want to damage their equipment. Engineers will integrate a torque limiter to be set at a certain value of torque, so that if it reaches beyond that torque setting the torque limiter will slip to save higher value equipment, or high-cost shafting, or whatever the case may be. In the basic terms, it’s limiting torque, based on a predetermined setting, usually using springs, or ball detents.”

Can you tell us a little bit about idle rotation in torque limiters?

“When a torque limiter of this style disengages, its outer casing shifts back, and will not re-engage until manually reengaged; so it basically becomes a free-running bearing. Then, once the engineer determines the torque overload issue, they can stop the machine, and manually push the unity back in place to be engaged to run again.

We typically see these torque limiter configurations in much larger applications, so there’s time to stop a system, and check things out. We see them in shaft-to-shaft applications, large rollers, steel mills etc.” DW KTR www.ktr.com/us

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» CA E S o lut i o n s

Simpler, faster, smarter: a new approach to system design Advances in design software offer greater efficiencies for designing, deploying and maintaining automation systems Andy Stump • Business Manager • Design Software • Rockwell Automation

Manufacturing and industrial end users are turning to smart manufacturing to be more responsive, efficient and flexible in how they operate.

But this presents a new challenge for automation system designers and integrators.

They’re now expected to deliver the flexible and information-enabled automation systems required for smart manufacturing, while also contending with pressures to increase profitability, improve time-to-market, optimize asset performance and meet regulatory standards.

System designers and integrators need to deliver more complex systems, and fundamentally change how they design, build and commission systems. Fortunately, recent advances in design software can help with that, while also delivering longer term operational and maintenance benefits.

An outdated design approach The traditional approach to designing automation systems is no longer optimal for today’s connected systems.

Using multiple tools to design a system can be especially problematic. It forces designers to jump from one tool to another and learn different programming languages, menus and commands for each. This can be cumbersome and time-consuming, and increase the amount of training required for employees to become familiar with each tool.

The lack of interoperability between these tools restricts data sharing, forcing programmers to re-enter the same code and data in multiple tools. Such redundant programming adds time to the design process and results in coding and data-entry errors.

The use of disparate tools and processes is undesirable for complex systems that require the support of multiple teams. For example, projects for large end users may involve multiple design engineers and system integrators located in different countries and time zones. Schedules and costs can quickly soar out of control for these projects without fluid collaboration and easy data sharing.

Adopting an integrated development environment Design software options are evolving.

Systems that require multi-discipline control and visualization from one integrated development environment can

The Studio 5000 integrated development environment gives users a central point to view the overall automation system, configure devices and manage communications between devices.

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» CAE S olut i ons

simplify the design and commissioning processes.

Engineers can use an integrated environment to create common workflows, more easily share data across geographically dispersed teams and eliminate redundant processes.

An integrated environment gives you a standard way to share tags, alarms and other data across multiple design applications. You can configure information once and leverage it across the entire automation system. You can configure all elements of the automation system in one place, rather than using multiple tools for control and visualization.

Once a system is operational, the integrated development environment provides a central view for all system components. This view gives operators and maintenance technicians a central location where they can re-configure devices, troubleshoot and access information about the system.

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Modeling and simulation capabilities A “virtual” design can increase design productivity and minimize risk. The ability to validate, test and optimize application code independent of physical hardware can reduce project costs, and minimize commissioning and startup time.

Modern integrated development environments incorporate virtual design for designers to emulate a control system within other simulation systems, including operator training systems and 3-D modeling applications. Designers can simply run their 3-D drawings through the virtual design program’s simulation and emulation processes to prove out their designs. System designers already have used virtual design to save anywhere from 40 to 60% in system costs.

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With library management tools, engineers can build, store and control versions of re-usable code that can be deployed across an enterprise.

Library development capabilities help users create parameterized modular code objects. These multi-discipline objects include control code, HMI faceplates, alarms and historical data collection tags.

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Users can enter configuration information once and leverage it across the entire automation system design, reducing the need for multiple tools.

Objects can range in size and complexity, but not every engineer who works with them has to be aware of all of the complexity and relationships. You can simply deploy objects by configuring parameters rather than develop code.

Thus, you can deploy a large number of objects more efficiently. This strategy also reduces or eliminates the need to test and validate each instance of those objects.

For example, an engineer working on an application requiring 500 pumps could create a standard pump object in their library. The engineer would then select that object and configure parameters specific to the instance of that pump. The tool then creates all the necessary files for control code, visualization, alarming and historical data collection for all 500 pumps at one time.

System organization There are organizational aspects of design software that can improve productivity, such as how it presents code that can help end users manage and maintain their systems.

Software that logically organizes code provides a way to create a model of the 44

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system based on the user’s perspective.

This shift in code presentation – from the controller’s perspective to the user’s perspective – lets users maintain and quickly identify the code within the system that may need to be investigated.

Designing to the requirements of the current system and the long-term maintenance and potential expansion of that system helps ensure continued productivity and efficiency for end users.

Enabling smart manufacturing These capabilities – an integrated development environment, modeling and simulation, library management, and system organization – all help engineers design smart machines and automation systems more efficiently, affordably and consistently.

A key responsibility of system designers, integrators and end users is to ensure the right tools are in place before design even begins. The design stage is only a small phase of the development lifecycle, but the benefits of a scalable, modular system design can exponentially enhance a system’s ease of use, expandability and maintenance long after it has been commissioned.

Design software selection should be based on the design time and costs savings it can deliver up front, as well as the maintenance and operations benefits it can offer down the road. DW Rockwell Automation Rockwellautomation.com

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

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6/1/16 2:11 PM

» CAE S olut i ons

Streamline PCB assembly The Valor Production Plan software is certified by SAP, powered by the SAP NetWeaver technology platform. The integration of the Valor Production Plan tool with SAP NetWeaver streamlines PCB assembly planning, including surface mount technology (SMT), manual assembly and test, for better manufacturing efficiency and reduced operational cost. The Valor Production Plan solution can add finite printed circuit board (PCB) production planning to the SAP ERP application.

Valor Production Plan integrates as a content package of SAP Process Integration technology (version 7.4) to exchange critical data with instances of SAP Business Suite software. The Plan can exchange bill of material, work/purchase order and material availability check with SAP ERP 6.0. Choosing an SAP-certified solution can also help reduce overall IT investment costs and risks.

The Valor Production Plan product increases manufacturing capacity and productivity by minimizing line downtime and product changeover. With increased product mix, lot size reductions, and short lifecycles, the Valor Production Plan tool is suitable for electronics assembly manufacturing. This is an optimum, single solution for long-, medium- and short-term planning, which improves on-time delivery with reduced capital expenditure. DW Mentor Graphics Mentor.com WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

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DESIGN WORLD

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... ..

Motors let you know when it’s time for service

T

The monitoring and preventive maintenance of low-voltage motors is often time-consuming and expensive. That could change with the IoT and smart sensors. Attached directly to the motor, smart sensors wirelessly supply information on operating and condition parameters.

The smart sensor gives information on parameters such as vibration, temperature or overload and calculates power consumption. The data are analyzed by a specially developed software program and delivered in the form of graphics for maintenance planning. Downtime can be reduced by 70%. With better maintenance, the lifetime of the motors can extended by up to 30% and energy consumption reduced by as much as 10%.

This innovative solution is not restricted to new motors made by ABB. The sensors can be installed at the factory or retrofitted on already operating low-voltage motors within minutes.

Cyber security is guaranteed at all times with the sensor technology. The sensor is not electrically connected to the motor, so unauthorized parties cannot access the motor through this route. The smart sensors wirelessly transmit the data using encryption protocols to a secure server where they are analyzed using special algorithms. The cloud-based server implementation fulfills strict specifications for cyber security. The data are stored in the cloud in encrypted form. The Internet-based customer portal also uses a role-based access protocol to make the data securely accessible. DW ABB www.abb.com

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Linking serial protocols to EtherNet/IP The serial EtherNet/IP Linking Device lets you include any automation device with a serial RS-232/422/485 application interface in an EtherNet/IP-based network architecture. It supports many serial protocols including Modbus, DF1, produce/consume, ASCII and custom protocols.

It is a cost-effective alternative to in-chassis communication modules.

The distributed EtherNet/IP Linking Device brings several advantages.

Contrary to an in-chassis module, which is physically connected to the PLC, the Linking Device can be mounted close to the connected machine.

The benefit is the possibility to establish a connection through a single Ethernet cable instead of multiple network specific cables. The Linking Devices support ODVA’s Device Level Ring (DLR) for ring topology.

Users access serial protocol configuration through their existing Studio 5000 software. All configuration is made inside Studio 5000 where there is support for Process Variable Data Tags and manual and automatic generation of named and structured Studio 5000 Controller Tags without any required user logic.

Since the Linking Devices are stand-alone (distributed), they do not affect PLC backplane performance (PLC execution time), even when large amounts of data are transferred. The PLC scans the Linking Device as if it were any other I/O device on the network. DW HMS Industrial Networks Anybus.com

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Internet of Things 6-16_Vs5.LL.indd 47

6/2/16 10:03 AM

I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........

Developing new business models for ...... .... .. success in the IoT Billions of Internet-connected devices are coming online, poised to gather information in the field and “call home” with updated data. As intriguing as the rise of the Internet of Things (IoT) has been, equally interesting are the new business models and opportunities for manufacturers and vendors, not to mention the challenges.

As the IoT gains traction, manufacturers find that they need to focus on software development versus the physical hardware design. The value of their intellectual property is increasingly linked to software.

Simultaneously, hardware vendors encounter issues typically faced by software vendors, like reverse engineering, intentional and unintentional misuse of their products, and of course, piracy.

Protecting intellectual property (IP) is a new emphasis for many vendors. Failing to account for it jeopardizes the ability to monetize it. To successfully monetize IP, designers need to leverage four aspects of a software strategy:

• control • management

• packaging • tracking.

Each aspect affects profitability by either reducing costs or increasing revenue. The fact is, despite introducing new risks from unauthorized software use, the IoT has contributed to generating new, lucrative opportunities.

Connectivity helps vendors easily deliver, track and manage enduser entitlements. It has eliminated many manual operational tasks and related expenses associated with licensing, while enabling vendors to introduce new products and features more easily.

The connected, intelligent device delivers a compelling user experience while opening license models including subscriptions and pay-per-use. Improved end-user transparency enables vendors to track usage, see how products are used, and facilitate the development of custom offerings for customers.

Customers have experienced an evolution of their own, and their expectations have changed. They seek Internet-based self-service tools, a change that even applies to traditional hardware-only devices. To capitalize, intelligent device manufacturers differentiate themselves by offering hardware-based software with flexible licensing. The one-size for everybody licensing approach is no longer sufficient. To remain 48

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competitive, vendors develop new ways to deliver a richer user experience and monetize their IP. Devices previously not connected to the internet now are, and they’re delivering new experiences supported by creative monetization of the IoT. For instance, an intelligent guitar can allow the purchase and download of music, along with an ability to use social networks to share recordings.

More expensive equipment – once too costly for smaller organizations – is now offered on a pay-as-you-go basis, even for such products as an MRI machine. The high up-front costs that once kept many away have been overtaken by usage tracking and internet connectivity enabling “pay-as-you-go,” which has allowed manufacturers and vendors to reach new markets. The IoT is changing business models as sellers create rich, interactive customer experiences that also generate new revenue.

Still, while IoT providers are introducing new monetization options, they can also learn some things from the software-only vendors who went before them. IoT connectivity already delivers new experiences from hardware in the field. Feature-based licensing and entitlement management enables manufacturers to provide the same product with different active functions to customers at varying price points. And the products can be easily upgraded remotely. Naturally, they also want the self-service they are accustomed to, and for vendors, that is a win-win because the IoT should lower support and fulfillment costs.

Smart hardware-turned-software companies have already embraced this transition. They understand the benefits this new era holds for them, and they are embracing tools to develop sophisticated packaging and pricing models.

However shifting from an equipment manufacturer business model to something more akin to a software company doesn’t happen overnight.

Intelligent device manufacturers and vendors that embrace the transition, and use proper software monetization tactics, will overcome challenges to aggressively pursue greater market share and reduce costs, all while protecting against IT threats. And those that fail to meet customer demands or try to force rigid solutions on them will soon find the new IoT economy has left them behind. DW Gemalto www.gemalto.com

6/1/16 2:13 PM

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I nter net of Things

“Plug-and-Cloud with the IoT Bus Coupler EK9160 IoT Bus Coupler transmits all control data simply, safely and cost-effectively to all common cloud systems in plugand-play fashion. The new coupler establishes a direct connection to the cloud without special control programming between I/O and the Internet of Things (IoT). Thus, the coupler enables simple and standard integration of I/O data with cloud-based communication and data services.

On an integrated web server, I/O data can be parameterized, such as in data processing and timing, through a simple configuration dialogue. No special engineering tools are needed.

The coupler autonomously transmits the data, including time stamp, to the cloud service. Apart from that, extended mechanisms are available, including local buffering of I/O data on a microSD card (2 GB) to protect against data loss when the Internet connection is interrupted. The cloud services and security functions (encryption, firewall) can be configured with the web server in the same way.

All major cloud systems are supported with the IoT protocols AMQP, MQTT and OPC UA (over AMQP): Microsoft Azure, Amazon Web Services (AWS), SAP HANA, as well as private cloud systems in company networks.

For data communication, the IoT Bus Coupler uses the publisher/subscriber communication principle. As a publisher, it sends data to the cloud, enabling other applications to access the information as a subscriber. It can then publish data if required, which in turn can be accessed by the IoT Bus Coupler.

The devices do not need to “know” each other or individual IP addresses, rather only the central message broker, so the individual applications operate in “decoupled” mode. Moreover, communication for both the publisher and subscriber is always active and directed externally. Both of these factors mean that the firewall configuration and setup in the IT infrastructure of a company are simplified considerably. DW Beckhoff Automation www.beckhoffautomation.com

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Galil Motion Control

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ...........

Diagnostic tool for ........ ...... .... .. Sercos networks

The Sercos Monitor is a diagnostic tool for detailed analysis of the data traffic in Sercos III networks. It is available as a free download.

This version supports the features of Sercos version 1.3.1, as well as the recording and analysis of CIP Safety frames, the S/IP protocol and hot-plug procedures in a Sercos III network. Special highlights are the oscilloscope function and a graphical visualization of the Sercos timing.

The oscilloscope function lets users visualize signals for analysis of value-over-time. The configurability supports many application options. For example, data such as torque and speed values can be visualized individually or collectively. The graphical visualization of the Sercos timing provides a quick and easy overview on the structure of the configured Sercos communication cycle.

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Optimizations and improvements also relate to the execution of long-term measurements especially to record and analyze sporadic errors easily. Additional monitoring functions, such as communication phase change, SVC timeouts and connection monitoring, enhancements of the Telegram Expression Language for a more exact definition of trigger and filter conditions, and enhancements to the Diagnostic Trace are included.

A direct export of the Sercos Monitor configuration from the CoSeMa open source driver is possible. This eliminates the need to create the configuration of the Sercos Monitor based on a conducted phase switching. DW Sercos Sercos.com

www.designworldonline.com

6/1/16 2:14 PM

Internet of Thi ng s

N E WS :

ODVA developing standards for networking to the Cloud ODVA is developing standards for the

gateway and interface technology needed to transport data between the cloud and CIP-enabled industrial control systems (ICS) populated with EtherNet/IP and DeviceNet devices. This work will result in The Common Industrial Cloud Interface Specification.

The scope of work for this interface will encompass two elements in the ecosystem for the industrial cloud: a cloud gateway appliance (Gateway) and an application

program interface (API) for the transport of data from the Gateway to the cloud and from the cloud back to the ICS and its devices.

Based on open and interoperable standards supported by multiple vendors, the Common Industrial Cloud Interface will support device management, process analytics, notifications, remote access, virtualization, visualization and, in the future, control.

The Common Industrial Cloud Interface standard will fit into ODVA’s Optimization

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4.0 initiative, the umbrella under which ODVA aggregates its vision of the industrial Internet of Things. ODVA’s view of its cloud ecosystem is agnostic with respect to the deployment of cloud computing resources in off-premise, on premise, public, private and/or hybrid models. The scope of work for the interface excludes services and applications within the cloud itself. DW

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I nter net of Things

N EWS: .......................................... ................................ ........................ ...................

An approach to securing the IoT .............. ........... ........ ...... .... ..

IT systems leverage firewalls to

monitor security risks on the IT network. But these IT firewalls are not aware of industrial protocols used on the plant floor – limiting the ability to minimize risk throughout the entire network. Cisco and Rockwell Automation are collaborating to develop a deep-packet-inspection (DPI) technology for use in industrial security appliances.

An industrial firewall with DPI technology extends visibility down to the plant floor, enables logging of traffic patterns, and provides the opportunity for informed

decision-making following a set of security policies. Users can log a range of data for any network connection or protocol, such as EtherNet/IP, including where the traffic is coming from, where it is going and with which application it is associated.

When used between industrial and cell/ area zones in a Converged Plantwide Ethernet (CPwE) architecture, a plant-floor application using DPI technology can instruct a firewall to deny firmware downloads to a controller.

This action guards against tampering with firmware and helps protect the integrity of the

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operation. Only an authorized user would be able to conduct the download.

DPI technology will be brought to market in industrial network devices from both Rockwell Automation and Cisco in 2016. DW Cisco Thenetwork.cisco.com Rockwell Automation rockwellautomation.com

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June 2016

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Internet of Thi ng s

N EWS: OPC and CLPA agree to coordinate communications in machine to IT systems

Push the process.

Gain time, find the optimal solution.

Digitalization in industrial automation requires consistent communications across all levels while using Internet technologies. The OPC Foundation and the CLPA hope to enable digitilization by developing an interface specification.

At the Hannover Fair, Thomas J. Burke, President and Executive Director of the OPC Foundation and Naomi Nakamura, Global Director of the CC-Link Partner Association signed a Memorandum of Understanding in which both organizations agree to closely cooperate while developing these interfaces. DW CC-Link Partner Association (CLPA) www.cc-link.org OPC Foundation opcfoundation.org

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June 2016

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preload Why is

necessary in some

bearing applications?

Joyc e La ir d • Con t rib u t in g Ed ito r

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M o t i o n

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With ball bearings, preload is often a misunderstood concept and overlooked by designers and bearing users alike. One of the final steps in the bearing manufacturing process is the assembly of the individual bearing components: the outer ring, inner ring, balls and retainer (or ball separator). When the bearings are assembled, it is necessary to have a controlled amount of internal clearance, or looseness between the rings and balls.

This is referred to as radial play in most bearing catalogs.

“However, in certain applications, this internal clearance must be removed for a pair of bearings to operate properly. The application of an axial load across a pair of bearings – for the purpose of removing free internal clearances – is called preload,” said John Wallace, vice president of operations, AST. Benefits of preloading ball bearings include: • Rotational accuracy and precise shaft positioning • Elimination or reduction of ball skidding • Control and reduction of axial and radial deflection under

applied load • Noise reduction • Load sharing between bearings Applications where preloading is critical “Preload is critical in most high-precision and high-speed applications, particularly where rotational and positional accuracy is required,” Wallace says. “If, under operating conditions, a bearing has radial play, it means that one bearing race can be moved radially and axially relative to the other. With rotation, this looseness translates into wobble or nonrepetitive runout.”

“This motion is unacceptable in applications such as machine tool spindles, electric motors, optical encoders, flow meters, and high-speed hand tools. The application of axial preload forces the balls into contact with raceways, establishing a contact angle which causes the ball set to rotate in a uniform circumferential plane.”

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Here we see the application of an axial load across a pair of bearings – the purpose of removing free internal clearances – is called preload.

Spring preloading provides a relatively constant preload because it is less sensitive to differential thermal expansion and can accommodate misalignment. Spring preloading uses a floating ring that reduces vibration levels transmitted from the bearings.

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Common methods to preload ball bearings • Spring preloading is simple, inexpensive, and should be a designer’s first consideration.

Coil springs or wave spring washers are most commonly used, but a variety of spring types are available. The spring is used to press the races together, or apart.

“Spring preloading provides a relatively constant preload because it is less sensitive to differential thermal expansion and can accommodate misalignment. Spring preloading uses a floating ring that reduces vibration levels transmitted from the bearings, making it a good choice in noise-sensitive applications. However, these types of assemblies will have minimal stiffness. Usually, the spring is positioned to push against the non-rotating ring.”

• Fixed constraint preload is achieved by mechanically fixing the “as-preloaded” position of the inner and outer rings of each bearing. This is commonly performed using the dead weight method. With dead weight preloading, adhesive is used to secure the rings in position while held in place with a weight equal to the specified preload amount. Once the adhesive has cured the weight is removed.

“Still another method for fixed constraint preloading is axial adjustment. This method requires great care, accuracy, proper tooling and cleanliness during the assembly process to avoid excessive preloading and ensure correct conditions. First, two bearings are mounted with the desired axial offset. The shaft and housing are threaded. Finally, the internal clearance in the bearings is removed by installing precision ground washers and then tightening the nut or threaded collar.”

• Duplex bearings are matched pairs of bearings with “built-in” preload. The inner or outer ring faces have been ground to a precise dimension known as the preload offset. This offset corresponds to the rings axial movement when a specific axial preload is applied. When the bearings are clamped together at assembly the offset faces abut, establishing a permanent, rigid preload in the bearing set.

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Preload method and application Wallace notes that in general, provided the design requirements are met, the least amount of preload is desired. Bearing life decreases as preload is increased. With increased or excessive preload, stresses are higher and excess heat is generated.

“Preload selection also varies based on bearing type. Miniature and thin section ball bearings have different internal geometry compared to larger radial and angular contact ball bearings. Be sure to follow the manufacturer’s guidelines, or consult with a bearing engineer.”

What about preloading for machine tool spindles?

He adds that machine tool spindles must be capable of resisting deflection from multiple directions while maintaining both rotational and positional accuracy. “Duplex bearings with their high rigidity and accuracy are ideal for this application.”

Closing recommendations Before deciding which preloading method to employ, designers should be aware of the following considerations: •

• Lightweight aluminum carriage and base with high load capacity.

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“Duplex bearings have increased radial and axial rigidity. There are three common preload configurations. DB (back-to-back) and DF (face-to-face) can handle bi-directional thrust loads. DT (tandem) can handle very heavy unidirectional thrust loads. At higher speeds, these bearings can run hotter due to the rigid preload. These bearings are commonly used in machine tool and other spindle applications, due to their low deflection rate, minimal runout and ease of assembly,” Wallace adds.

• • • • •

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What is the desired or acceptable amount of deflection?

What are the operating temperatures?

Are there concerns with torque?

Is there rapid acceleration or deceleration?

Is the application torque sensitive?

Is there moment loading or misalignment?

DESIGN WORLD

June 2016

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Duplex bearings have increased radial and axial rigidity. There are three common preload configurations. DB (backto-back) and DF (faceto-face) can handle bidirectional thrust loads.

DT (tandem) can handle very heavy unidirectional thrust loads.

“Finally, as a general rule, a preloaded bearing assembly can only handle an axial load equal to approximately three times the preload amount. Beyond this load, one of the bearings in the pair will become unloaded and the deflection rate will equal that of a single bearing.” He adds. “When in doubt,

consult a bearing specialist such as the AST information source.” DW

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M o t i o n

C o n t r o l

Before selecting an industrial application, consult a supplier who can help answer key questions about the design. In the case of a chain drive, ask: Will the installation need to survive an outdoor environment? Will the chain be subject to infrequent service?

Lubricants exist to help chain and other power-transmission components last for years in even the harshest machine setups.

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Choosing the right lubricant for an industrial power-transmission design can be a tricky task, because industrial lubricants come in many varieties and formulations, and many industries require lubricants that adhere to specific regulations and standards. Here are some tips to make the selection easier.

How to choose an

industrial lubricant Bill Watson • Director of Application Engineering • Klüber Lubrication NA LP

For decades, lubricant suppliers have been developing and manufacturing specialty lubricants tailored to the requirements of industrial applications. There are general technical requirements that all lubricants must meet, including the reduction of friction and wear, protection against corrosion, dissipation of heat and sealing. But, depending on the operating conditions and manufacturing processes in the plant, lubricants may also be expected to provide a host of additional properties.

General purpose or synthetic lubricants?

One of the first questions a lubricant supplier should ask is if the equipment’s lubrication will be maintained at regular intervals or if it must be lubricated for life. The answer to this question helps determine whether the use of a general purpose lubricant or a synthetic specialty lubricant is more appropriate.

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M o t i o n

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Some synthetic or specialty lubricants are 50 to 500% more expensive than general-purpose lubricants, but price per pound or kilogram should not be the only determining factor in selection.

Some lubricants such as PAG (polyalkylene glycol) oils are good for sliding friction, but are unsuitable for rolling friction. PAO oils excel in addressing rolling friction and can even handle sliding friction.

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Oils, greases, pastes and waxes, and bonded coatings are the most common categories of industrial lubricants. Typically, an oil lubricant contains 95% base oil (most often mineral oils) and 5% additives. In contrast, greases consist of lubricating base oils that are mixed with a soap to form a solid structure. Pastes contain base oils, additives and solid lubricant particles.

Finally, lubricating waxes consist of synthetic hydrocarbons, water and an emulsifying agent, which becomes fluid when a certain temperature level is exceeded.

The majority of oil lubricants, including many motor oils, are mineral oil distillates of crude oil (petroleum), while synthetic oil lubricants are also used. Synthetic oils such as polyalphaolefins (PAOs) or synthetic esters are produced artificially from other compounds. Because of this, the composition is quite different from petroleum oil. Their higher purity and uniformity provide for several enhanced properties, such as viscosity index, oxidation stability and color.

There are also semi-synthetic oils (also called synthetic blends), which are a blend of mineral and synthetic oil. This class of lubricants provides many of the benefits of synthetic oil at a fraction of the cost.

When synthetic oil is selected, it is generally to provide mechanical and chemical properties superior to those found in traditional mineral oils. When a manufacturer does not stock an appropriate

synthetic lubricant with the performance features needed for a given powertransmission application, that design may necessitate a customized specialty or ‘optimized’ lubricant.

If the equipment will be regularly lubricated, synthetic or specialty lubricant designed to last for an extensive period of time is usually unnecessary. In this case, the lubricant needs only to meet basic performance standards and be replenished regularly.

On the other hand, if equipment is lubricated for life, synthetic base oils are often recommended for their many benefits: • Low and high-temperature viscosity performance • Decreased evaporative loss • Reduced friction and reduced wear • Improved efficiency • Chemical stability and resistance to oil-sludge problems • Extended drain intervals Despite their many benefits, synthetic lubricants are also known for one distinct disadvantage of cost. But the cost may be mitigated by extended change intervals, as synthetic and specialty lubricants can last five times longer or more than nonsynthetic lubricants when a high-quality base oil is used.

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M o t i o n

C o n t r o l

Factors that influence selection The key requirement for selecting the proper lubricant is the base oil viscosity. In order to select the appropriate viscosity, the lubricant supplier will need to gather key information about the application at hand: • Axis operating speed (variable or fixed) • Specific type of friction (such as sliding or rolling) • Load and environmental conditions • Industry standards

For example, some lubricants such as PAG (polyalkylene glycol) oils are good for sliding friction, but are unsuitable for rolling friction.

Likewise, PAO oils are used for rolling friction and can handle some sliding friction, whereas silicon and PFPE lubricants are typically used for extremely high temperatures.

Common mistakes in lubricating power-transmission components During the information-gathering stage, equipment owners often make the mistake of overlooking some basic application details which can have a significant impact on the resulting lubricant’s performance. It is

important to provide as much information as possible and to be specific, as this will help the design-engineering team and supplier identify the lubricant best suited to the task.

Another common mistake equipment owners make is choosing a lubricant based solely on price. Admittedly, there is a vast difference in the price of a synthetic or specialty lubricant and a general purpose lubricant. Some synthetic or specialty lubricants are 50 to 500% more expensive than general-purpose lubricants, but the price per kilogram should not be the only determining factor in selection.

Additional factors to take into consideration are: • Reduced operating costs resulting from less downtime • Improved labor utilization (as there’s less time required for re-lubrication and maintenance) • Measurable energy savings and increased output

Often, when a supplier makes a lubricant recommendation for a particular application, and that application is successful, the customer wants to use the same lubricant in another application.

Unfortunately, this is typically not an option. Remember, every application is different, and while one lubricant may work well for a ball bearing application, it likely will not provide the same performance for a different bearing application.

Ultimately, the first step in choosing the right lubricant is choosing the right lubricant supplier. Look for a supplier to provide quality documentation and detailed test data that demonstrate the consistency and quality of the product being recommended. A reputable supplier will spend time educating design teams so they can make qualified decisions about lubricating equipment. DW

Klüber Lubrication www.klueber.com

Greases (as that on this bearing) consist of lubricating base oils that are mixed with a soap to form a solid structure. Pastes contain base oils, additives and solid lubricant particles. In contrast, lubricating waxes consist of synthetic hydrocarbons, water and an emulsifying agent. Work with the supplier to determine which is most appropriate.

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Haydon Kerk® Linear Actuators...

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Size 17 - 43 mm2 (1.7-in)2 non-captive hybrid linear actuator with programmable IDEA™ stepper motor drive Size 8 21 mm2 (0.8-in)2 captive hybrid linear actuator stepper motor.

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M a t e r i a l s

Metals make it possible to have a variety of products, such as industrial production equipment, automobiles, aircraft, or consumer electronics. The corrosion metals are subject to, however, is a problem.

Preventive measures, such as the right coating, can delay or eliminate corrosion.

Make

the right choice for metal coating for the right application Alan Cain • Group Leader/Research Chemist • Chemline, Inc.

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The annual cost of corrosion worldwide is equivalent to 3 to 4% of the global gross domestic product, or more than $3.0 trillion. Historically, in non-critical industries, corrosion was treated as a repair and maintenance issue. More recently, however, preventive measures significantly reduce corrosion costs. These measures include appropriate material selection, careful component design, and corrosion control.

Active corrosion control involves the use of a sacrificial material (often zinc) that participates in corrosion reactions rather than the metal substrate. Passive protection involves the application of a barrier material that prevents corrosive reagents and water from reaching the surface of the metal substrate. These coatings and films also often provide additional protection against impact, abrasion, and other mechanical damage.

Given the very broad use of metals and the wide range of metal types, the performance expectations differ significantly, as do the acceptable cost/balance ratios. Different coating technologies meet the varied requirements; selecting the best coating technology for an application can be challenging. Here are several guidelines.

Conventional technology: epoxies There are two major classes of coating technologies recognized for protective properties: epoxies and polyurethane-type systems, which include polyurethanes, polyureas and hybrids of these two chemistries.

Epoxies are widely used as corrosion protection coatings for factoryapplied metal applications because they exhibit excellent adhesion to metals and offer high moisture-, chemical-, and impact-resistance.

They continue to be widely used as primers (sometimes zinc-rich) in multi-coat systems, including those with different topcoat chemistries (acrylics for light-duty applications, epoxies, silicones, polyurethanes and polyureas for medium- to heavy-duty applications). Most epoxy coatings used today are high-solids or 100%-solids formulations that meet strict environmental regulations concerning the emission of volatile organic compounds (VOCs).

There are, however, limitations to epoxy coatings that have driven interest in alternative technologies for corrosion control. In particular, epoxy coatings are not very flexible and can crack in applications that

Cast iron pipe coated with polyurethane coating to protect against undersea exposure. Photo: Chemline www.designworldonline.com  

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M a t e r i a l s

PRODUCT PERFORMANCE ON STEEL SURFACES 1

Adhesion

2

4

Polyurea Polyurea Hybrid Polyurethane Epoxy

Impact

Polyurea Polyurea Hybrid Polyurethane Epoxy

Application Temp.

Polyurea Polyurea Hybrid Polyurethane Epoxy

Corrosion Resistance

Polyurea Polyurea Hybrid Polyurethane Epoxy

Chemical Resistance

Polyurea Polyurea Hybrid Polyurethane Epoxy

Weatherability

Polyurea Polyurea Hybrid Polyurethane Epoxy

Abrasion Resistance

Polyurea Polyurea Hybrid Polyurethane Epoxy

Cure Time

Polyurea Polyurea Hybrid Polyurethane Epoxy

Flexibility

Polyurea Polyurea Hybrid Polyurethane Epoxy 1 = Poor Polyurea

2= Fair Polyurea Hybrid

involve substrate movement, high wear, or heavy impacts. They also do not perform well at low temperatures (become brittle) and yellow over time in exterior applications due to degradation upon exposure to UV radiation.

For these reasons, polyurethane and derivative coating technologies are increasingly used as corrosion control coatings for OEM metal applications due to their greater flexibility combined with high adhesion and high resistance to moisture, chemical attack, and impact.

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3= Good Polyurethane

4=Best Epxoy

Chemistry of polyurethanes and polyureas Isocyanates are used to synthesize both polyurethane and polyurea resins.

Polyurethanes are obtained when diisocyanates (or polyisocyanates) react with polyols, while polyureas are generated when they react with amines. In hybrid systems, isocyanates are reacted with a mixture of amines and polyols. For many polyurethanes (except moisture-cured systems, for example), a catalyst is required to ensure

rapid reaction of the isocyanate and polyol components. On the other hand, isocyanates react rapidly with amines, and thus no catalyst is required for the formation of polyureas.

A range of isocyanate, polyol and amine reactants are available for the synthesis of polyurethanes, polyureas and hybrids. Isocyanates can be aliphatic or aromatic. Aromatic compounds (such as, diphenylmethane diisocyanate (MDI) and toluene diisocyanate (TDI)) contain bonds that can absorb UV radiation, which leads to their breakdown and the undesirable yellowing of the coatings. As a result, aliphatic isocyanates (such as, hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI)), which do not have these bonds, are often preferred for the synthesis of polyurethane/polyurea binders intended for the formulation of exterior coatings.

Polyethers, polyesters, and polycarbonates are the polyol types most widely used for polyurethane and hybrid polymer production.

In some cases, the polyol contains more than one type of linkage. Specialized polyols, such as polycaprolactones, are preferred for some applications. The length of the polyol chain has a significant impact on the hardness (short) and flexibility (long) of the coating, while the type of polyol impacts properties such as chemical and moisture resistance.

The diamines used for the preparation of pure polyureas and hybrids are typically polyamines. Often two different types are used: amine-terminated polymer resins, typically polyetheramines, and amineterminated chain extenders, generally pure polyamines. Both primary and secondary amines can be used, with secondary amine reacting more slowly. Hybrids can be formed by reacting isocyanates with a physical blend of polyols and diamines, or by incorporating hydroxyl groups into the polyamine (often the chain extender).

Polyurethanes While traditionally solvent-based, two-component (2K) coating systems, polyurethanes are also available as 1K waterbased PU dispersions, 2K waterborne systems,

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Railroad electrical control box treated with polyurea hybrid for a tough, thick-film protective coating.

Photo: Chemline

and high- and 100%-solids 2K formulations.

Initial water-based systems did not perform as well their solvent-based counterparts and also suffered from application issues.

Advances in PU technology have, however, led to the development of many PU dispersions that have application properties closer to those of solvent-based systems. The 100% solids systems also initially presented application difficulties, but here again advances in application techniques and equipment have overcome these challenges.

The crosslinking that occurs during PU film formation imparts specific properties to these coatings. They exhibit excellent gloss and color retention (for pigmented formulations; clear topcoats are also possible), combined with good chemical and moisture resistance, even for thin film builds, which is crucial for applications where weight is a concern (such as in automotive and aerospace industries). Aliphatic PUs also resist UV light for exterior applications. PU coatings mechanical properties include high impact, abrasion and scratch resistance.

Because polyurethanes comprise two distinct components—the polyisocyanate and polyol portions—their properties are tunable through selection of different isocyanate and polyol building blocks. As a result, it is possible to achieve PU coatings that range from very flexible (elastomeric) to very rigid. In addition, PU coatings can be formulated with a unique combination of flexibility/elongation and harness that is not possible to achieve with epoxy acrylic systems. They also have excellent adhesions to different substrates, including metal.

Thus, one product line can often be used for multiple applications, which can reduce carrying costs in inventory. Furthermore, for light- to medium-duty applications, polyurethanes can be used as single, directto-metal coatings, eliminating the need for 74

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a primer, which also reduces material and labor costs.

Polyurethane coatings cure fairly rapidly, even at lower temperatures, but most require a catalyst. The exception is moisture-cured systems, in which the water in the air acts as the catalyst. These systems are suitable for use in humid conditions.

On the other hand, most 100%-solids PU coatings are more sensitive to moisture (susceptible to blistering) than other technologies, including epoxies, polyureas and PU/polyurea hybrids due to the need for a catalyst. Solvent-based PU coatings are typically applied as thin films (< 5 mil dry film thickness) using conventional airless sprayers, while 100% solids systems can be applied at thicker film builds (> 20 mil dry film thickness), but require the use of plural component spray technology, which automatically mixes the resin and catalyst components prior to spraying. Operation of this complex equipment requires trained/ licensed applicators.

OEM applications for polyurethane coatings cover a broad swath of industries.

Factory-applied, solvent-based systems (including high-solids formulations) are widely used in the furniture, cabinetry, and flooring industries. PU coatings are also used to some extent in the automotive industry in underbody, interior and exterior (primer, base, topcoat) applications, as well as for truck-bed liners (both factory-applied

and aftermarket). All types of PU coatings find use in general industrial metal, heavy equipment and plastic primer, topcoat and clear-coat applications. Direct-to-metal rigid PU systems are used for OEM pipe coating and steel storage tank applications, while elastomeric systems applied as a foam hardcoat are for waterproofing and durability in architectural trim, themed entertainment applications, and occasionally building panels.

Polyurea elastomers Polyurea coatings are 100% solids, zero-VOC formulations that cure rapidly (as little as 30 seconds) without the need for a catalyst or heat, even at low temperatures (down to -°20 C). Due to the nature of the urea linkage, they are not sensitive to moisture; no blistering occurs, even when polyureas are applied on substrates in the presence of liquid water. As with polyurethanes, the formation of crosslinked networks in polyurea films imparts excellent mechanical properties, but the improved hardblock/

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Soft, carved EPS foam panel is protected with polyurea encapsulant to form a durable and paintable surface.

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softblock segmentation in polyureas results in enhanced hardness/stiffness, tear and abrasion resistance and weathering, thermal shock and impact resistance. The urea linkages also contribute to enhanced chemical and water resistance. The combination of isocyanate and amine-terminated polyol segments delivers an attractive combination of flexibility and hardness.

Unlike polyurethanes, polyureas can be applied at very high film builds. As a result, they can serve not only as protective coating layers, but also contribute to the structural integrity of a substrate. They adhere to a range of substrates, including concrete, metals, wood, composites, foam and others.

There are challenges to working with polyureas, however. When first introduced, polyureas often suffered from substrate wetting, intercoat adhesion and surface defect issues.

Developments in both raw materials and application equipment have helped overcome these shortcomings. Even so, proper mixing is crucial for optimum film formation and adhesion. As with 100%-solids PUs, highpressure, plural component sprayers are required for the application of polyureas, and applicator training is necessary to ensure that operators understand how to identify optimum mixing and spray conditions.

Polyurea elastomers are typically unsuitable for applications requiring thin (< 5 mil) coatings.

In general, polyurea coatings are preferred as topcoats for rapid curing applications (fast turnaround times), the coated substrate will be exposed to extreme conditions and

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appearance is not a key concern. In addition, they are used in applications where a thinner topcoat (PU or otherwise) may be damaged, leading to potential problems with corrosion and degradation. Polyureas are also often selected to replace epoxies in applications where elongation and impact resistance are important, because epoxies often crack and delaminate under such conditions. Examples include OEM waterproofing applications and rail and barge coatings. In general, polyureas are frequently used in the field due to their insensitivity to moisture and temperature. On-site applications include roof, pipe and tank coatings, truck-bed liners, liners for large tanks (freight ship lines, bulk transport wagons), car parking decks, bridges and offshore protection.

Polyaspartic ester-based polyurea coatings represent a newer technology based on the reaction of isocyanates with aliphatic polyaspartic esters (aliphatic diamines). These coatings generally cure more slowly than polyureas and can be applied at thinner film builds. Like polyurethanes, they are applied using conventional airless sprayers. Thus, they are often used in the same applications that can use PUs. Hybrids â&#x20AC;&#x201C; the best of both The use of blends of amine- and hydroxylterminated polyols creates even more opportunities for fine-tuning the properties of hybrid coatings. Not only the appearance, hardness/flexibility and mechanical properties, but also the reactivity of these coatings can be adjusted by choosing different isocyanates, polyetheramines and polyols. Controlling the curing time lets you

Polyurethane coating is applied to protect audio box against damage from handling, impact and the elements.

Photo: Chemline

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develop smooth to textured films with the desired surface appearance combined with the higher performance of polyureas.

Hybrids are typically 100%-solids formulations that cure rapidly (catalyst required) and can be applied in high film builds. They have good elongation and flexibility combined with excellent chemical and solvent resistance and resistance to abrasion and impact. Like polyureas, they can be applied at

Unlike polyurethanes, polyureas can be applied at very high film builds. As a result, the can serve not only as protective coating layers, but also contribute to the structural integrity of a substrate. low temperature. However, the application of hybrid coatings is less complex (easier impingement mixing) than that of polyureas, although plural component spray equipment and applicator training are still required.

The customizability of polyurethane/polyurea hybrid coatings has led to their use in a variety of applications where the high performance of polyureas and an attractive finish are both desired. Consequently, they are often preferred over polyureas because hybrids can meet these requirements and still offer rapid turnaround times, and do so at a lower cost than pure polyurea coatings. The most common OEM uses are corrosion control and waterproofing applications where the high performance of polyureas is not required and hybrids provide more attractive solutions on a costperformance basis. In some cases, hybrids are preferred because they offer a unique set of properties that cannot be achieved with a pure PU or polyurea system. Hybrids are also finding use in secondary containment application over concrete and geotextiles.

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Making the right choice There are polyurethane, polyurea, and PU/ polyurea hybrid coating technologies available for practically every OEM coating application imaginable. These chemistries offer a range of properties suitable for different application conditions and performance needs. The factors to consider when selecting a protective coating for a given application include: the type of substrate, the application technology, the conditions under which the coating must perform, the cure time, the desired film thickness and the performance requirements (adhesion, appearance, and mechanical and resistance properties).

Cost is also clearly a key driver in the selection of a coating technology. Polyurethane coatings are the least expensive, polyureas the most costly, and hybrid coatings fall in between. Polyurethanes are often considered to offer the best compromise between cost and performance. Hybrids, on the other, offer 80% of the benefits of polyureas at approximately 50% of the additional cost compared to polyurethanes.

Thin-film polyurethanes suit applications where performance and a high-quality finish are required. In less demanding applications, they can be applied as a single coat (for example, directto-metal), but are often used as the topcoat when the coated substrate must be protected from more extreme conditions.

Polyureas, which can be sprayed in poor conditions including extreme temperatures and high humidity, are commonly used for outdoor or on-site applications. Polyurethanes and hybrids, which require catalysts for curing, are not suitable here. Less-expensive hybrids are preferred for OEM applications where the higher-performance curing properties of polyureas are not required, but similar applied-film properties are desired. DW Chemline Inc. chemline.com

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Five keys to

mechatronic success Decades of exposure to the realities of keeping farm equipment running have provided FireFly Equipment with insight to the problems, and the solutions, needed to making highly automated agricultural machinery a reality.

Steve Meyer â&#x20AC;˘ Contributing Editor

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Forest for the trees? Sometimes we get too close to a problem and the big insights escape us. This is not the case for Steve Aposhian and his family at FireFly Equipment. Aposhian grew up on the family turf farm and landscaping businessâ&#x20AC;&#x201D;and gained a deep understanding of how things work, as well as when some things donâ&#x20AC;&#x2122;t work. After spending a great deal of time repairing harvesters and turf equipment from other vendors, he had the expertise to begin the automation journey that has made his company a success.

Starting with a degree in mechanical engineering from the University of Utah, and later becoming a certified National Instruments Labview developer, as CTO of FireFly, Aposhian has taken turf harvesting into the 21st Century. His vision of a successful, highly automated harvester began from a solid mechanical foundation combined with a unique controls strategy that takes advantage of state-of-the-art actuator and communications technologies. This approach to automation provides the platform for creating the highest throughput, performance and reliability in the harvester. In fact, the entire engineering team at FireFly has decades of design, test, design for reliability and manufacturing process expertise, which has resulted in what is one of the most reliable products in agricultural equipment.

FireFly Equipmentâ&#x20AC;&#x2122;s turf harvester is fully automated, thanks to a combination of state-of-the-art hydraulic actuator technologies and unique controls and communications technologies. www.designworldonline.com

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Hydraulics provides primary motive and auxiliary power, offering high power density and efficiency for the main conveyor, raise and lower functions of the cutter and more.

1

Machines and projects that involve a lot of subsystems can become very complex to manage in development—and the process of meeting the overall performance goals of the system can be a daunting challenge.

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Key in on overall equipment effectiveness How well equipment performs is the sum of several important metrics. Probably the most important is uptime, the percentage of time the machine operates correctly as a ratio of the total number of hours there is demand for production. Another element of effectiveness is mean time to repair—if something fails, how long will it take to repair and get back to work? Efficiency is also an important aspect of performance. Reducing operating cost per hour or per unit of production is a factor that is gaining greater attention in an energy-conscious environment.

All of these elements are important to farmers. Agricultural equipment must perform day in and day out, with a minimum of downtime. If something breaks it has to be easy to fix. Throughput and ease of use are just as important in the field just as they are in a manufacturing facility. And in spite of low fuel costs, reducing fuel consumption is always important. Firefly has focused on all of these elements to create the most productive and reliable sod harvester on the market.

2 Embrace complexity Machines and projects that involve a lot of subsystems can become very complex to manage in development—and the process of meeting the overall performance goals of the system can be a daunting challenge. Sometimes the technology alternatives are not obvious and some investigation is required to explore the options.

The best way to approach complex projects is to divide the big project into its major parts. Evaluate a variety of alternative strategies and look for “best in class” for each subsystem. What works in one area may not be the best choice in another.

The starting point for any major piece of agricultural equipment is the drivetrain that propels the main tractor. FireFly uses a 115-hp John Deere engine and 4-wheel hydrostatic drive for primary motive power.

The same power plant also provides hydraulic pressure to run the auxiliary systems.

Among the key benefits of hydraulic technology are extremely high energy density, generally quiet operation and the efficiency of combining several loads on to a common source. The main conveyor, the raise and lower mechanism on the cutter and numerous other actuators are powered from the same highly efficient source. In addition, FireFly employs a continuous filtration system for the hydraulic fluid to extend operating life and efficiency of the equipment.

While most systems are hydraulic, the stacker requirements were considered to be beyond what could be reasonably accomplished using hydraulic actuators. High speed, smooth acceleration and extreme precision positioning are possible with hydraulics, but it is very expensive and there are serious packaging limitations that made a hydraulic solution for the stacker impractical.

3 Find creative solutions Stacking cut pieces of sod on a pallet is not a problem best solved by hydraulics. The sod is generally soft and pliable as it is cut from the ground. If the stacks aren’t tight, the pallet contents can slip off the pallet and make a huge mess. Part of the stacking requirement is the ability to program different sizes and

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M e c h a t r o n i c s shapes of cut sod. This further requires different pallet stacking patterns to produce precise, tight pallets. Stacking patterns involve locking patterns that are turned 90° from each other in each layer. The stacking solution must run faster than the cutter and conveyor can deliver the pieces to the stacker. This means precision, speed and programmability for the FireFly to reach its maximum productivity.

A 5-axis electric servo system from Kollmorgen was implemented to provide the speed, smooth operation and programmability needed for the stacker.

This hardware solution includes dedicated position sensors that ensure precise repeatability. The electric servo can manage smooth acceleration and deceleration with accuracies comparable to a CNC machine tool. In addition, the electric approach is energy efficient; the motion uses only the power needed during operation, so there’s no energy overhead.

The FireFly 155 carries a magazine of 20 pallets that are automatically loaded to the stacking area as they are needed. The ProSlab lowers the pallet as the stack is loaded and when full, it is gently dropped to the ground for later pickup, maintaining the high pace of productivity that makes the machine unique.

4 Different isn’t a bad thing You’ll find a number of things you don’t typically see on agricultural equipment on FireFly’s ProSlab harvester. It uses a state-of-the art multiprocessor control system from National Instruments as the main control platform for the machine. The controller has 180 inputs and outputs including 40 hydraulic valves.

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Personal CNC Prototyping - Product Design - R&D - Engineering Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line.

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The control software runs 30 parallel control loops to operate all the on-board equipment.

The 5-axis stacker servo system is connected to the controller via EtherCat in a daisy chain configuration that eliminates a significant amount of interface wiring normally associated with electric servo actuators. The EtherCat interface is a dedicated, high-speed network that allows the main controller to manage the motion and stacking pattern. EtherCat reduces the wiring burden, eliminating the position feedback which is the most prone to failure.

And because all the axes are well above ground and conveyor, there are no issues of dirt contamination causing problems with the stacker.

One of the big improvements in the Firefly approach to agricultural equipment is the use of polymer bushings in place of lubricated bearings. The beauty of this approach is the durability, low maintenance and ease of repair.

No lubrication, in practice, means that there is nothing for dirt to stick to and no regular service intervals. Well-fitted solid polymer bearings actually reject contamination from particulates, which is ideal for agriculture. If a bearing wears out, replacement is usually a simple press fit operation.

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Pay attention to control systems Sometimes a little complexity is a good thing.

The harvesterâ&#x20AC;&#x2122;s electronic control system integrates full internet accessibility. The interface is able to communicate using cellular and conventional wireless internet. Monitoring functions for any device status are built into both the local operator screen for the driver, and mirrored on a dedicated cloud server for customer access. This also gives FireFly service personnel complete access to the harvester remotely. Full diagnostic checks can be run on the equipment which also helps operators with local machine functions if there are issues.

In addition to the main controller, the operator has a flat screen interface to the control system that monitors all aspects of machine production and equipment condition. Engine temperature, tractor speed and production are all available parameters on the monitor. Every sub-system condition is accessible from the screen. This information is also served up to a cloud-based database that is reporting back to 86

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M e c h a t r o n i c s

Connect

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All functions, including those of the rotary and linear hydraulic actuators, hydraulic system regulation, vehicle control, engine monitoring and remote access communications are done via one 5-axis electric motion controller—National Instruments’ Compact RIO controller.

Protocols.

Devices.

Locations.

the service staff at FireFly. The service department can not only monitor, but also remotely control any functions of the harvester if there is a need.

Summary As you would expect, the FireFly ProSlab machine incorporates several U.S. patents generated during the process of developing the complete automation solution. Speed and accuracy requirements were pushed significantly as bottlenecks were eliminated. Unique control algorithms were developed to manage the pressure on the cutter so that consistent, even cuts are generated regardless of soil conditions. There are many unique examples of innovation along a path to automate and simplify a unique process.

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Sweet

Freedom Free, open-source 3D CAD systems are finding their place.

Jean Thilmany â&#x20AC;¢ Contributing Editor

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3 D C AD

Until fairly recently, designers looking for open-source CAD software had several good two-dimensional programs to choose from but had a much tougher time finding 3D programs.

There just weren’t that many out there.

That’s changing as 3D printing continues to grow in popularity, says Yorik van Havre, co-owner of the architectural studio Uncreated.net of São Paulo, Brazil. For architectural design he uses the 13-year-old open-source 3D system FreeCAD. In fact, he likes it so much he’s long helped with its development, a perk of using an open-source system, he says.

While frustrating, the dearth of open-source 3D systems is understandable, he says.

Creating open-source CAD systems is difficult because CAD software is complex in a way that few other applications are. To build a commercial quality CAD system, you’re looking at a lot of work, by a lot of experienced (and expensive) software developers. (See the article, Open Source CAD No, Free CAD yes, on 3DCadworld.com blog in July of 2012).

That assessment, of course, is now four years old. While van Havre agreed with it at the time, much has changed, he says.

“The 3D front had been languishing because free, opensource CAD software represents a huge work, with very little interest outside a small sphere of architects, engineers and a few other types of designers,” he says.

“But now, with 3D printing, suddenly everybody needs a 3D CAD tool,” he adds. “This has lead to the birth of many new opensource 3D CAD applications.”

Designers call upon 3D printing systems to create the forms and shapes to be printed, says Terry Wohlers, president of Wohlers Associates, a 3D printing consultancy.

But many of those designers have come to 3D printing through the burgeoning maker environment. They don’t have an engineering or architectural background and haven’t used CAD

FreeCAD is gaining in popularity among the open source CAD programs. Similar to Blender, it has additional features, such as 3D display and rendering speed. Plus, it has a Python platform--like Blender--to build tools on.

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The FreeCAD community of developers and users volunteer their time on development.

The program itself features a forum--as do many open-source software programs—where developers hang out.

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software in the past and they’re not interested in buying an expensive CAD system, learning its many bells and whistles, and continually updating their licenses. They simply want to use the system to create the shapes they envision; the shapes they seek to print, van Havre says.

But he has one more reason for his interest in free, open-source CAD systems.

Open-source software is frequently used by engineers in impoverished areas, or engineers who own small businesses or who work for small clients, he says.

“For small, starting-out offices, especially those in southern countries, the huge price of software licenses is a big factor,” he says. “You have to impose high prices for your services.

You end up working for a very small segment of the population.

“In the field of 3D CAD, where professional software is usually very expensive, I see open-source solutions as a way for new professionals and small businesses to flourish without entering an enslaving relationship based on money,” he adds.

Open-source software doesn’t require an upgrade every year, doesn’t force you to buy new machines all the time, and is by definition accessible to anybody, together with its code, its documentation, its discussion forums, and its learning materials, van Havre says.

For these type of business owners, “open source can be liberating, if not revolutionary,” he adds.

More open-source cad Examples of newer open-source tools include Antimony, created by Matt Keeter, an engineer at FormLabs, which sells 3D printers and materials, and also a researcher at the Massachusetts Institute of Technology’s Center for Bits and Atoms.

Antimony users create designs by performing operations on common geometrical shapes.

To create a cylinder, for example, a user would extrude a cylinder from a circle. The program relies on graphical based text, is fairly straightforward, and is available for Mac and Linux systems, van Havre says. It can also export files in the STL format for 3D printing.

As a researcher at the Center for Bits and Atoms, Keeter is developing AO, an

open-source solid modeling tool. This program also uses text.

Older programs include Blender, initially released in 1995, which van Havre used for architectural design before turning to FreeCAD just under a decade ago. Blender is a 3D computer graphics program that does a good job creating animated films, visual effects, interactive 3D applications, and 3D models.

“But I felt Blender was aimed at another direction than what I needed, which was a more precise, technical application,” van Havre says.

Or, as Mike Szczys, managing editor of the website Hackaday put it on the site: “Using Blender to design a small object to send to a 3D printer is like using a bulldozer to build a sand castle. You can do it, but it’s overkill.”

Blender is best suited for graphics and animations and really shouldn’t be used for objects that aren’t mechanical, both van Havre and Szcyzys say.

With Blender leaving him frustrated, van Havre found his search for a new open-source program frustrating as well. Living in Brazil and working at a small company, he was specifically seeking open-source software.

“I had a little bit of experience in programming gained from working with Blender, but not enough to start something myself that had to have 3D display, rendering speed, and other kinds of high-level things,” he says.

“That’s when I came across FreeCAD, which had all those features already.

And it had a Python platform--like Blender--to build tools on. That was exactly what I needed.”

“At the time I bumped into FreeCAD around 2007, I was, like many other people, pretty frustrated with the lack of open-source tools available,” he adds.

In contrast to Blender, the general-purpose parametric modeler is specifically for use by mechanical engineers, product designers, and

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3 D CA D architects, says Jürgen Riegel, one of the program’s original authors. It imports and exports designs with standard formats that include STEP, IGES, OBJ, DXF, and STL, he adds.

It also includes a 2D component, which allows users to sketch 2D shapes or to extract design details from a 3D model to create a 2D production drawing. It’s compatible with Windows, Mac, and Linux systems, van Havre adds.

Now van Havre and his partner use the program mainly for what he calls the technical side of architectural design, rather than the creative side, which is often still reserved for tools like Blender.

“The first stages of design usually require you to test many undeveloped ideas, for which it is great to have a more free-form tool like Blender or even a simple pencil and a sheet of paper,” van Havre says.

“When ideas consolidate and your client has decided on one direction, you need to settle your design for it to become buildable.

That’s where FreeCAD comes in,” he adds. “We import what we made with other applications or supports, and rework it to become sound and solid precise objects. We then extract plans, sections and views from the models, which will become the actual construction documents.”

Blender is an open-source CAD program initially released in 1995. It is a 3D computer graphics program for creating animated films, visual effects, interactive 3D applications, and 3D models.

Blender is suited for graphics and animations, but less so for objects that aren’t mechanical.

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Free time development After van Havre had used FreeCAD at his architectural firm for a time, he became curious about those who regularly helped with its opensource development. The FreeCAD community of developers and users volunteer their time on development.

The program itself also features a forum--as do many open-source software programs—where developers hang out.

For his part, van Havre—who joined the community in 2008 one year after discovering the program itself--says volunteering on the

development side has been quite worthwhile.

Most of those who aren’t well acquainted with the term open-source view the fact open-source software is free with extreme suspicion, he says.

“But people who work on opensource software do it because they want to have and use that free tool,” van Havre says. “Almost all programmers of open-source applications are actually first users. There’s a creative, dynamic community around you. It’s fun. I’m not the only one who thinks development is worth more than money.”

The lack of marketing drive is also refreshing, he adds.

“Think about that for a second, an application where development direction is decided by the people who use it, rather than by marketing considerations,” he says. “We don’t need to sell you anything, we also don’t need to keep you hooked, or to force you to upgrade. You can use new files with an older version of the application, you can download and install the application anywhere, redistribute it to others.”

Some opens-source licenses--such as the one FreeCAD uses--even allow you to sell it. “Though why anyone would buy it is another question,” van Havre says.

Because most open-source application use open file formats too, what is contained in a file is always extractable, readable, and exportable.

Often, the file user doesn’t even need to have access to the original application, he adds.

But he gets that not every designer will be swayed by open source.

“Just as not everybody wants to switch from Windows to Linux, I don’t believe everybody will want to switch to FreeCAD no matter how good it becomes,” he says.

Then he considers a second.

“But I can still hope,” he says with a grin. DW

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Prod uc t World Miniature stepper drive Applied Motion Products applied-motion.com The STR3 uses a proprietary current control algorithm that optimizes motor performance, providing smooth motion over a wide speed range. Easily configured using dip switches, there is no software required for setup. Powered by 12 to 48 Vdc, it can be easily specified into mobile systems as well as onto the plant floor. Capable of providing up to 3.0 A/phase it can run a wide range of 2-phase step motors, from the smallest NEMA 8 to larger NEMA 23 and NEMA 24 frame motors.

Lightweight couplings Zero-Max zero-max.com The new size in single and double disc models handles bore diameters from 0.375 to 1.125 in. (10 to 30 mm). These new ServoClass couplings are lightweight and are designed with 304 stainless steel disc packs and high strength aluminum hubs and center members. All models and sizes feature clamp style hubs with corrosion resistant socket head cap

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Creaform creaform3d.com/en The MetraSCAN 3D can tackle black, multicolored and shiny surfaces with metrology accuracy for applications directly on the shop floor. It has a volumetric accuracy of 0.064 mm (0.0025 in.) regardless of environment instabilities and is 12x faster than the previous version with 480,000 measurements/sec. The scanner is available in 350 and 750 modelsâ&#x20AC;&#x201D;and both in standard and elite versionâ&#x20AC;&#x201D;so users can choose the speed and accuracy matching their requirements.

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Brushless electric motor Dunkermotoren dunkermotor.com The BG 95 dPro CANopen brushless electric motor is a dc motor with a power range to 3 kW that operates in battery-powered and hydraulicdriven applications. Available as 24, 48, 60 and 325-V versions, the motor features an integrated encoder with resolution to 4,096 ppr. Three different versions of the BG 95 are available for implementation with Hall sensors (for simple rotor-position feedback); setups using integrated controllers for speed control; and an intelligent drive with complete integrated electronics for complex motion profiles.

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SALES

A d In dex Accuride ....................................................... 41 All Motion ....................................................... 4 Allied Electronics, Inc. .................. cover,3,37 Altech Corp.ÂŽ ............................................... 13 AMETEK PMC ............................................... 19 AMETEK/DFS (Windjammer,etc.) ............. 31 Aurora Bearing Co. ...................................... 45 AutomationDirect ....................... IFC,Gatefold AutomationDirect ......................................... 1 Baumer LTD ................................................. 55 Bishop Wisecarver ..................................... 73 Bison Gear & Engineering Corp................ IBC Bodine Electric Co ......................................84 C-Flex Bearing Co, Inc. ............................... 45 CC Link ........................................................49 Clippard Instrument Laboratory, Inc. ..................................... BC Colder Products Company ......................... 24 Del-Tron Precision, Inc................................60 DIEQUA Corporation .............................. 40,54 Digi-Key Electronics ................................... 15 Dunkermotoren, part of Ametek .............. 61 Elesa USA Corporation ............................... 35 Elmo Motion Control ................................... 79 Encoder Products Co. ................................. 47 EXAIR Corporation ........................................ 5 Galil .............................................................. 51 GAM Gear .....................................................26 Haydon Kerk ............................................... 69 Helical Products Company .......................... 7

Helukabel .................................................... 23 Hitachi Cable America ................................ 25 IKO International, Inc.................................. 83 J.W. Winco, Inc. ...........................................53 Master Bond .......................................... 53,93 Moog Animatics .......................................... 12 Nason ...........................................................39 Ondrives.US Corp. ....................................... 67 Parker Hannifin .....................................20,21 PBC Linear .................................................. 59 PHD Inc. ....................................................... 43 Proto Labs, Inc. ............................................. 9 Red Lion Controls, Inc................................. 87 Renco Electronics Inc. ............................... 91 Ringfeder Corp. ........................................... 62 Rollon ........................................................... 63 Rotor Clip ..................................................... 77 SAB North America ..................................... 33 Setco ............................................................ 78 SIKO Products Inc. ...................................... 16 Smalley Steel Ring Company .................... 10 Sorbothane ................................................. 16 Tormach .......................................................86 TRIM-LOK, Inc...............................................36 WAGO, Inc. .................................................... 85 Wittenstein .................................................. 17 Whittet-Higgins Co. ..................................... 27 Yaskawa America, Inc. ............................... 75 Zero-Max, Inc. ................................................ 2

Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Todd Christenson tchristenson@wtwhmedia.com 440.381.9048 @wtwh_todd Jessica East jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia

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