Design World June 2017 by WTWH Media LLC

www.designworldonline.com June 2017

INSIDE:

MOTION CONTROL: Kit encoders using magnetic operation PAGE 56

LINEAR MOTION Higher accuracy drives linear measurement devices PAGE 70

How CAD changing

MECHANICAL: Bearing design considerations for hand tools PAGE 76

the way you

design 82

JUNE DW COVER 2017_fit for gatefold_FINAL1.indd 1

6/1/17 3:13 PM

...and neither FREE SOFTWARE with simulator

“The Do-More software is more user friendly than any I have ever used before. PID, Modbus communications, Filters etc... All very easy to use!” SK in ENDERBY, BC

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INTEGRATED HIGH-SPEED I/O MOTION CONTROL INCLUDED

BRX PLC featured is BX-DM1E-36ED23 priced at $494

20-pt in and 16-pt out discrete, 4-ch in and 2-ch out analog

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ONBOARD AN

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her will you! Modbus®

EtherNet/IP ASCII

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Performance at a Low Cost The new BRX controller redefines what it means to be a PLC. Programmable Logic Controller - sure, but for BRX we prefer Performance at a Low Cost. You won’t find a micro PLC with this many features, at this price, and with the Do-more can-do attitude anywhere else!

INTERNAL RAM AND microSD DATA LOGGING ONBOARD SERIAL/ETHERNET COMM PORTS

This under-budget overachiever was designed and is manufactured in the U.S. and comes with built-in data logging, versatile motion control, onboard serial communication with Ethernet option, an additional hot-swappable communications port, and integrated discrete, high-speed, and analog I/O (select models). Four form factors are available to choose from with various built-in I/O configurations; the BRX PLC units are also expandable with up to 8 additional I/O modules (depending on model). Expandable I/O starting at $36

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Make everything except compromise. HP Jet Fusion 3D Printing is up to 10x1 faster at half the cost2.

1 Based on internal testing and simulation, HP Jet Fusion 3D printing solution average printing time is up to 10x faster than average printing time of comparable FDM & SLS printer solutions from $100,000 USD to $300,000 USD on market as of April 2016. Testing variables: Part Quantity -1 full bucket of parts from HP Jet Fusion 3D at 20% of packing density vs same number of parts on above-mentioned competitive devices; Part size: 30g; Layer thickness: 0.1mm/0.004 inches. Fast Cooling is enabled by HP Jet Fusion 3D Processing Station with Fast Cooling, available in 2017. HP Jet Fusion 3D Processing Station with Fast Cooling accelerates parts cooling time vs recommended manufacturer time of SLS printer solutions from $100,000 USD to $300,000 USD, as tested in April 2016. FDM not applicable. 2 Based on internal testing and public data, HP Jet Fusion 3D printing solution average printing cost-per-part is half the average cost of comparable FDM & SLS printer solutions from $100,000 USD to $300,000 USD on market as of April 2016. Cost analysis based on: standard solution configuration price, supplies price, and maintenance costs recommended by manufacturer. Cost criteria: printing 1build chambers per day/ 5 days per week over 1 year of 30-gram parts at 10% packing density using HP 3D High Reusability PA 12 material, and the powder reusability ratio recommended by manufacturer.

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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.

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I n s i g ht s Do we need to shift the engineering brand? I had the chance to chat with Dr. John Walz, the new president of the Milwaukee School of Engineering—and then hear him speak—at last month’s Fluid Power Technical Conference, held on MSOE’s downtown campus. Walz, who has a Ph.D. in chemical engineering, has a lot to say about STEM education and the challenges being faced by engineering education in this country. But instead of the dire warnings that so many educators have been broadcasting, Walz is more hopeful that we will make the necessary changes. He referred to Richard Smalley’s famous list of the top 10 problems that humanity is facing over the next 50 years, developed a decade or so ago: Energy Water Food Environment

Poverty Terrorism and war Disease

Education Democracy Population

Walz contends that a majority of these issues can, and will be solved by scientists and engineers— particularly energy, water, food, the environment, disease and pollution. “We have not kept up with this increasing need for more engineers,” he said. “I’ve been in academics for more than 25 years. The students at the top are incredible students. We just don’t have enough of them. How do we get more of these students into these fields?” Part of the issue, he feels, is that “we don’t have the greatest image” as engineers. Look at how Michael Douglas’ detective character looked and dressed in the movie Basic Instinct. Go Google it right now. Now check his character as a tycoon in Wall Street. And lastly, see how he was made up to look and dress as an engineer in Falling Down. The differences are striking and not very flattering. As Walz rightly points out, a 16- or 17-year-old student may not have much of an image of what an engineer is beyond those sort of movie stereotypes. So when they’re considering career paths, those images can be damaging. Still, there is hope. Modern engineers, from Tim Cook to Larry Page to Jeff Bezos have founded or are leading companies that every high school student has heard of. And Walz’s take on the problem of attracting female engineers is an interesting one. He postulates that the disconnect may be related to the fact that females are attracted to careers where there is a more obvious connection to helping people and society. So maybe the answer is to change our brand a little. Let’s refocus how we market degrees like mechanical engineering, to better show young men and women how these jobs matter and how they can help save humanity from coming problems. That’s a real opportunity … and I hope colleges, as well as K-12 schools, soon see the wisdom in that. DW

Pa ul J. He n ey - Edi tor i al D i re ctor phe ney@wtwhme di a.com

On Twitter @ DW—Editor 4

Insights 6-17_Vs1.indd 4

DESIGN WORLD

June 2017

5/31/17 4:26 PM

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

Drilled Pipes

4.1

Flat Air Nozzles

Blower Air Knife

Super Air Knife

Comp. Air

Horsepower SCFM SLPM Required

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

174 4,924

$50

$4,508

$920

$5,478

4.1

257 7,273

0.2

N/A

102

$208

$6,569

$1,450

$8,227

$5,500

$1,288

$1,500

$8,288

4.1

1,557

$594

$1,417

$300

$2,311

*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

Big projects, big mistakes Governments today struggle with budgetary overruns and deficits, and the resultant wrangling has put what might be called megaprojects in the spotlight: Big bridges, high-speed rail lines, and new fighter jets are all large-scale, complicated undertakings that typically have price tags in the billions . Of course, when a megaproject runs into trouble, the true price tag can exceed the total gross domestic product of some countries. For example, consider San Francisco’s new Bay Bridge. Originally estimated to cost $1 billion, it came in at $6.4 billion, a little less than the GDP of Kosovo. The total cost of the Joint Strike Fighter program has been estimated at $388 billion, 50% more than the initial projections and a bit more than the GDP of Austria. The culprits usually fingered for massive cost overruns include multiple design changes, politics, and too little consideration of changing market conditions. But one interesting facet of megaprojects is that a high percentage of them are engineering efforts involving hundreds of not thousands of engineers.

And engineers have a reputation for being both conservative and pragmatic – not the sort to underestimate obstacles. So it is worth pondering whether the engineers in these projects are victims of their circumstances or share some of the blame for mushrooming costs. Insights on this subject come from University of Oxford business school professor Bent Flyvbjerg who has analyzed data on huge projects spanning 70 years. If nothing else, Flyvberg’s work shows that underestimates of problems in big projects are nothing new. He says several realities get glossed over or ignored in the execution of these boondoggles, and many of them have roots in engineering. For one thing, the technology and designs underlying megaprojects are often nonstandard or oneof-a-kind. That tends to make participants see their project as unique, so they think the lessons-learned from other projects don’t apply. Similarly, planners sometimes over-commit to specific project concepts at an early stage. The analysis of alternatives tends to be given short shrift or not done at all. And despite engineers’ fondness for citing Murphy’s Law, evidence indicates they don’t account for Murphy in their planning. Flyvbjerg says statistical evidence shows that mangers tend to ignore the

unpredictable nature of big undertakings and often treat projects “as if they exist largely in a deterministic, Newtonian world of cause, effect, and control.” All these difficulties compound, leading to misinformation about price tags, schedules, benefits. and risks. The result is a mixture of cost overruns, delays, and shortfalls in the benefits the project is supposed to deliver. Flyvbjerg estimates that about one in ten megaprojects comes in on budget, one in ten is on schedule, and one in ten delivers the promised benefits. Of course, the joint probability of a megaproject delivering on all three works out to about one in a thousand. “Even if the numbers were wrong by a factor of two, the success rate would still be dismal,” he says. You might conclude from all this that though the engineers involved in big projects that go off the rails aren’t guiltless; there is plenty of blame to go around. The net result is that the megaprojects that get built aren’t really the most promising, but rather the ones that look best on paper. And the projects that look good on paper are those that grossly underestimate costs, overstate benefits, and don’t mention that the whole idea might be flawed. As Flyvbjerg puts it, “They have been designed….as disasters waiting to happen.” 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

DESIGN WORLD

Lee Teschler Column 6-17_Vs2.indd 6

June 2017

6/1/17 4:13 PM

ISO 9001:2008/AS9100C Prototype to full production Wide range of exotic materials ITAR Certified Integrated Attachments Custom design & Manufacturing

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Te c h n o lo gy Fo r wa rd

If additive shifts to manufacturing, what happens to design? Remember when 3dprinting was primarily for the design engineer? Is it still? If you attended this year’s RAPID + TCT Conference, you might wonder. At the RAPID Conference, enough manufacturing innovation was on display to make one ask, “Just what constitutes manufacturing today?”

Vendors are clearly aiming to “give the customer what he wants,” which appears to be the ability to produce hundreds of thousands of parts fast. But what does this move mean for the design engineer? While the prototyping function is not getting as much press as it used to, it is an increasingly useful application for the design engineer. Today, 3D printing/additive manufacturing offers three choices: systems for prototyping, systems for prototyping and low-volume production, and systems for higher volume production. The higher volume units cannot produce hundreds of thousands of parts yet, but you can see the possibilities. But time is money, right? That’s the answer when you ask vendors why should additive go into volume production. For many people, when they think of manufacturing, they imagine a huge building with tens of CNCs, several injection molding machines, and now maybe even a few additive machines. The assumption is that additive will conform to the ways traditional manufacturing systems produce parts. But additive technology has always had a disruptive take on processes.

Traditional manufacturing built thousands of parts in one location, primarily for efficiency and convenience. When you combine additive with cloud connectivity, as many vendors of additive technology and service providers are doing, it breaks the traditional view of manufacturing—manufacturing is no longer confined to a large facility. Manufacturing is no longer confined to the production of hundreds of thousands of parts to be profitable. Manufacturing is no longer confined to “traditional” operators—anyone, including design engineers, can make parts. Today, with additive, a design engineer can build five units of one design at one location, 100 units of that same design at another location, and a thousand units of that same design at a third location. So how do you define volume production now? And any developments and innovations made to volume production additive systems will eventually find their way to desktop units, improving these units’ prototyping as well as production capabilities. Instead of additive technology moving into manufacturing, the next step may be that design and manufacturing cease to be viewed as separate functions. 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 @wtwh m edi a .co m

On Twitter @ DW—3Dprinting

DESIGN WORLD

Leslie Column (Technology Forward) 6-17 Vs3.LL.indd 8

June 2017

6/2/17 12:24 PM

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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 4:22 1:46 PM PM 5/31/17

» G re e n E n g i n e e ri n g

Rubber from grass instead of gas? n Paul J. Heney • Editorial Director

A research team from the University of Delaware, the University of Minnesota and the University of Massachusetts has developed a process to make butadiene—a key component in synthetic rubber and plastic—from renewable sources such as trees, grasses and corn. As a result, products that range from tires to toys may become a lot greener in the near future. The study’s authors are part of the Catalysis Center for Energy Innovation (CCEI) based at the University of Delaware. CCEI is an Energy Frontier Research Center, funded by the U.S. Department of Energy. “Our team combined a catalyst we recently discovered with new and exciting chemistry to find the first high-yield, low-cost method of manufacturing butadiene,” said CCEI Director Dionisios Vlachos, a professor of Chemical and Biomolecular Engineering at Delaware and a co-author of the study. “This research could transform the multi-billion-dollar plastics and rubber industries.” Butadiene, a molecule traditionally made from petroleum or natural gas, is the chief chemical component in a broad range of materials. When this four-carbon molecule undergoes a chemical reaction to form long chains called polymers, styrene-butadiene rubber (SBR) is formed, which

is used to make abrasive-resistant automobile tires. When blended to make nitrile butadiene rubber (NBR), it becomes the key component in hoses, seals and medical rubber gloves. In the world of plastics, butadiene is the chief chemical component in acrylonitrile-butadienestyrene (ABS), a hard plastic that can be molded into rigid shapes. ABS is used to make products such as automotive parts, medical devices and interlocking plastic toy bricks. The past 10 years have seen a shift toward an academic research focus on renewable chemicals and butadiene, in particular, due to its importance in commercial products, Vlachos said. “Our team’s success came from our philosophy that connects research in novel catalytic materials with a new approach to the chemistry,” he said. “This is a great example where the research team was greater than the sum of its parts.” The novel chemistry included a three-step process starting from biomass-derived sugars. Using technology developed within CCEI, the team converted sugars to a ring compound called furfural. In the second step, the team further processed furfural to another ring compound called tetrahydrofuran (THF). www.designworldonline.com

Green Engineering_6-17_Vs2.indd 11

It was in the third step that the team found the breakthrough chemical manufacturing technology. Using a new catalyst called “phosphorous all-silica zeolite,” developed within the center, the team was able to convert THF to butadiene with high yield (greater than 95%). The team called this new, selective reaction “dehydra-decyclization,” to represent its capability for simultaneously removing water and opening ring compounds at once. “We discovered that phosphorus-based catalysts supported by silica and zeolites exhibit high selectivity for manufacturing chemicals like butadiene,” said Prof. Wei Fan of the University of Massachusetts Amherst. “When comparing their capability for controlling certain industrial chemistry uses with that of other catalysts, the phosphorous materials appear truly unique and nicely complement the set of catalysts we have been developing at CCEI.” “This newer technology significantly expands the slate of molecules we can make from lignocellulose,” said Prof. Paul Dauenhauer of the University of Minnesota, who is co-director of CCEI and a co-author of the study. DW Catalysis Center for Energy Innovation www.efrc.udel.edu June 2017

DESIGN WORLD

6/2/17 12:29 PM

Austin 2 0 1 7

NI Week run-down

“Alexa, run LabVIEW.”

National Instruments unveils the next generation of its LabVIEW program with features that include a tool kit for hooking into Amazon web services.

National Instruments Corp. kicked off its NIWeek

NI Week 6-17_Vs2_LT.indd 12

DESIGN WORLD

June 2017

www.designworldonline.com

NI technical program lead Jeff Phillips gave onlookers a quick demo of LabVIEW NXG after announcing the program during his NIWeek keynote presentation.

One notable student project called out at the NI Engineering Impact Awards was this wheel-transformable robot called the TurboQuad developed by students at the National Taiwan University. Using sliding mechanisms in each of its appendages, the TurboQuad makes smooth transitions between a wheeled mode and a legged mode to handle changing terrains. It uses LabVIEW and a Compact RIO for the controls. When the legs form a circle and rotate, the robot moves like an ordinary four-wheeled vehicle, and when the legs are extended, the robot moves like a quadruped.

| background image: shutterstock.com

The winner of the NI Engineering Impact Award for transportation and heavy equipment was Lightning Hybrids for its hydraulic hybrid system that uses an NI System on Module (SOM) to hydraulically store otherwise wasted braking energy as hydraulic pressure that can be reused to accelerate the vehicle. Lightning Hybrids controls engineer Adam Hartzell described the system during a Wednesday keynote presentation.

event in Austin, Tex. with the debut of a significantly upgraded version of its Laboratory Virtual Instrument Engineering Workbench (LabVIEW), a system-design platform and development environment. Among the more interesting aspects of the new release, called LabVIEW NXG 1.0, is a closer relationship to the web. NXG, for example, lets users design virtual instruments that talk to web servers. And a tool kit for Amazon web services lets users interface with the Amazon Echo and its Alexa voice service. NI personnel demonstrated some of the possibilities of the connection during one of the event keynotes. Another interesting aspect of NXG is that it is said to let users do a lot of design work without really knowing much about LabVIEW programming techniques. Said Jeff Kodosky, NI cofounder and business and technology fellow, “For a long time we focused on making additional things possible with LabVIEW, rather than furthering the goal of helping engineers automate measurements quickly and easily. Now we are squarely addressing this with the introduction of LabVIEW NXG, which we designed from the ground up to embrace a streamlined workflow. Common applications can use a simple configuration-based approach, while more complex applications can use the full open-ended graphical programming capability of the LabVIEW language, G.” The nonprogramming workflows build the necessary code behind the scenes. For instance, engineers can drag and drop a section of code equivalent to 50 lines of text-based code. LabVIEW NXG also contains a re-engineered editor that lets LabVIEW more easily integrate with a broader set of languages. The modernized editor improves programming productivity by streamlining the editor micro-interactions, user interface objects based on vector graphics and zooming capabilities. The NXG release as well contains facilities for extending LabVIEW into domains outside those strictly dwelling on test and measurement. For example, programs written in the Python language – a common choice for big data-type applications -- can now use LabVIEW facilities. This happens courtesy of an API in hardwired NXG drivers that can be called from Python programs. DW

6/2/17 12:34 PM

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June 2017 • vol 12 no 6

| Courtesy of AST Bearings

Co ntent s |

designworldonline.com

F E AT U R E S

56 62

MOTION CONTROL Kit encoders using magnetic operation New forms of kit encoders can be built into motors to provide commutation signals and closed-loop speed and position feedback.

MECHANICAL

3C CAD

MOTION CONTROL Current state of programmable automation controllers (PACs) Programmable automation controllers (PACs) excel in commanding complex automation setups that involve PC-based and HMI functions as well as process control (largely because of the way they handle I/O). PACs are also increasingly common for motion applications for machining or handling discrete product thanks to the flexibility and interoperability they offer machine designs.

LINEAR MOTION Higher accuracy drives linear measurement devices The latest linear measurement devices provide top precision and accuracy as more applications than ever call for nano-level measurements.

Bearing design considerations for hand tools Handheld power tools are commonplace in many industries from automotive to aerospace. Ball bearings play a critical role in the performance and reliability of these tools and are responsible for handling combined loading conditions (radial and axial), high speed operation, low friction, low noise and vibration, and high reliability.

Changes in CAD—what you need to know With the March release of Inventor 2018 and AutoCAD 2018, it’s a good time to review several of the recently released major CAD programs. Here’s a look at some of the biggest enhancements and key features of these programs.

ON THE COVER Photo: istockphoto

A | S | B | P|E

American Society of Business Publication Editors

Fostering B2B editorial excellence

ON THE COVER A look at some of the latest updates and enhancements to recently released CAD programs. | istockphoto.com

DESIGN WORLD

CONTENTS JUNE 2017_first page_Vs3.LL.indd 14

June 2017

2017 Regional

Fostering B2B editorial excellence

2017 Regional

PR INT

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Revenue of over $3 million

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The best temperature control valve you’ve never heard of

6. 2 017 D E PA R T M E N T S 4 Insights 6 Teschler on Topic 8 Technology Forward

Every valve in our highly versatile product suite uses an innovative phase change paraffin wax that accurately expands and contracts to control temperature and flow.

1 1 Green Engineering 12 NI Week Report 18 Design For Industry 28 Design Notes

Self-actuating fluid temperature control technology has its benefits

40 Internet of Things

• Uniform fluid temperature in industrial or commercial applications

50 CAE Solutions

• Protects personnel and valuable equipment from exposure to thermal extremes

54 Coupling Notes

• Replaces externally powered valves and actuators • Simplifies and reduces system components

90 Product World

• Reduces maintenance and operating costs It’s simple. As the world leader in self-actuated temperature control solutions, we pride ourselves on the high-quality manufacturing process, problem-solving approach and innovative engineering techniques used to produce self-actuated valves and custom products where no effective solution currently exists. Visit our website for an interactive timeline of ThermOmegaTech’s 30+ years of fluid temperature control innovation at www.ThermOmegaTech.com/solved.

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Contents JUNE 2017_second page_Vs2.LL.indd 16

DESIGN WORLD

June 2017

6/2/17 8:48 AM

Follow the whole team on twitter @DesignWorld 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

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Custom Converting Little to no Minimums Online Catalog Same Day Shipping 3M™ Choice Converter

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6/1/17 9:42 AM

Design for Industry | a e r o s p a c e / m i l i t a r y

High speed data interconnects for higher data-rate needs

Aerospace systems continue to need higher data rates. However, data are more sensitive to signal integrity issues during routing and installation. The Army recognizes that providing electrical margins and installed performance requires new technologies to avoid solutions that add weight. One solution is the Gore-Flight microwave assemblies and Gore Microwave/RF assemblies for military aerospace applications have passed U.S. Army flight qualifications on the MH-47 Rotorcraft. In one example, a complex harness included more than 100 assemblies for the ALQ-211 SIRFC â&#x20AC;&#x201D; a critical aircraft survivability system used by the 160th SOAR (Special Operations Aviation Regiment). A similar 18

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microwave/RF solution was provided for ASE on the MH-60 Rotorcraft that is expected to pass U.S. Army flight qualifications in the next several months. The 6 Series of Gore-Flight Microwave Assemblies recently earned a platinum award for product innovation by the Military & Aerospace Electronics 2016 Innovators Awards Program. DW W. L. Gore & Associates, Inc. | gore.com

www.designworldonline.com

6/1/17 10:26 AM

Design for Industry | a e r o s p a c e / m i l i t a r y

Portable metrology systems helps measure small spaces

Small spaces abound in planes and ships, so finding a portable metrology system to take measurements can be a challenge. One solution is the OT2 Core wireless laser tracker, which uses wireless and controller-free laser tracker technology. It is compact, delivering wireless operation with high accuracy measurement and the convenience of portability. Based on API’s Omnitrac 2 laser tracker unit, the OT2 Core offers many of the same features including an Autolock sensor that can recapture a lost beam. OT2 Core operates using the same highprecision ADM (Absolute Distance Measurement) technology as the Omnitrac 2. The entire system is integrated, so there is no external cabling needed. All the data can be transferred through Wi-Fi. The controller can operate up to six hours on a rechargeable battery with an optional ac/dc direct power adapter. Thus, the tracker can take measurements outdoors and in remote areas where there is no easy-access to a power supply. Even with an integrated controller, the OT2 Core is lighter than many trackers. The total system weight, including controllers, is 10.9 kg. Operating range is 50-meter. It can be taken into tight spaces where other systems cannot measure due to their size. Its rugged design and stable construction fits rough environments at industry plants. In addition, the OT2 Core can operate in versatile mounting positions: sideways, upside down, underneath or directly on a part. DW Advanced Precision, Inc. (API) | apisensor.com

www.designworldonline.com

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DESIGN WORLD

6/1/17 10:32 AM

Design for Industry | m a c h i n e t o o l

Better motion control through matched gearheads and servomotors A problem with bolting aftermarket gearheads onto servomotors to handle torque-speed requirements is that you rarely get a really good fit. The Sigma-7 servomotor line addresses this issue. Gearheads have been designed to pair precisely with every servomotor in the Sigma-7 range, creating complete gear motor solutions rated from a low of 50 watts to as high as 15 kilowatts. This servomotor line fits applications that need high torque at low output speeds. Five different gear ratios are available, ranging from 3/1 to 50/1. The gearheads are perfectly matched with their companion servo motors in mounting conventions, coupling mechanics and output characteristics. Each is custom assembled, balanced and factory tested at Yaskawa’s facility in Buffalo Grove, Illinois, and includes a full Yaskawa factory warranty.

Features include: • Precision helical gearing with a 40% greater tooth surface area for smoother, quieter and more accurate operation. • A system of bearings, including 45% larger planet bearings for guaranteed alignment, high stiffness, greater load capacity and longer life • Balanced, concentric shaft couplings to minimize vibration during high speed operation and reduce the inertia of the gear motor system Yaskawa | yaskawa.com

1.800.933.4915 20

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Power Review

Altra Industrial Motion Vol. 6 | No. 2 | 2017

The Power Brands in Power Transmission

Featured in this Edition... Altra Introduces NEW Stromag Literature and Website

NEW Stromag Literature and Website!

Marland Clutch Certified Rebuild, Service and Assembly Facilities Twiflex LCS Hydraulic Power Unit TB Wood’s Sure-Flex® Plus, Dura-Flex® and AVS Series Couplings Guardian Curved Jaw Flange K45 Series Unique Controllable Features of Huco Air Motors Altra OnDemand Webinars

Find Altra Industrial Motion on:

Altra Industrial Motion Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delroyd Worm Gear Formsprag Clutch

Altra Industrial_#1_6-17.indd 21

The Power Of Experience

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Clutch Stromag Svendborg Brakes

TB Wood’s Twiflex Limited Warner Electric Warner Linear Wichita Clutch

For more information contact us at: info@altramotion.com or visit www.altramotion.com

Scan to download the interactive version of the Power Review

5/31/17 4:12 PM

Altra Introduces NEW Stromag Literature and Website Stromag literature is now available on www.AltraLiterature.com and the Stromag website is now online! Founded in 1932, Stromag has grown to become a globally recognized leader in the development and manufacture of innovative power transmission components for industrial drivetrain applications. Stromag engineers utilize the latest design technologies and materials to provide creative, energy-efficient solutions that meet their customer’s most challenging requirements. Stromag’s extensive product range includes flexible couplings, disc brakes, limit switches, an array of hydraulically, pneumatically, and electrically actuated brakes, and a complete line of electric, hydraulic, and pneumatic clutches. Stromag engineered solutions improve drivetrain performance in a variety of key markets including energy, off-highway, metals, marine, transportation, printing, textiles, and material handling on applications such as wind turbines, conveyor systems, rolling mills, agriculture and construction machinery, municipal vehicles, forklifts, cranes, presses, deck winches, diesel engines, gensets, and stage machinery. For more information, download Stromag literature from www. AltraLiterature.com and visit www.Stromag.com

Marland Clutch Certified Rebuild, Service and Assembly Facilities Your worn Marland Backstops and Clutches can be refurbished to “Like New” condition by the only Authorized Marland Rebuild and Service Center in the U.S. and Canada. S & S Equipment and Supply, LTD is the headquarters and administrative branch of this service. Its subsidiary company, Paducah Gear & Machine, LLC located in Calvert City, Kentucky, performs all repair and rebuild for Marland BCMA, CEBMAG, and CECON Clutch Models. In most instances, your Marland products can be refurbished for substantially less than the cost of a new replacement unit. As the Marland products are received at the repair facilities, they are inspected, tested, quoted for rebuild, and if authorized, repaired to complete and exact standards in which the original Marland product was manufactured. The process in which this is accomplished is: • Inspect and replace bearings, seals, springs, gaskets, stop-lugs, alloy steel rollers, aluminum cages, and fasteners as required. • Inspect and precision grind the outer race and cam if required. • Assemble and test to meet Marland original design and performance specifications. • Paint, crate, and prepare for shipment.

Altra Industrial Motio n

Marland Clutch Certified Rebuild Center in North America Marland remanufactured clutches look like new, perform like new and are warrantied like new. Your worn Marland Backstops and Clutches can be refurbished to “Like New” condition by the only Authorized Marland Rebuild and Service Center in the U.S. and Canada. S & S Equipment and Supply, LTD is the headquarters and administrative branch of this service. Its subsidiary company, Paducah Gear & Machine, LLC located in Calvert City, Kentucky, performs all repair and rebuild for Marland BCMA, CEBMAG, and CECON Clutch Models. In most instances, your Marland products can be refurbished for substantially less than the cost of a new replacement unit. As the Marland products are received at the repair facilities, they are inspected, tested, quoted for rebuild, and if authorized, repaired to complete and exact standards in which the original Marland product was manufactured. The process in which this is accomplished is:

For more information, download P-8117-MC from www.AltraLiterature.com

PGM facilities in Calvert City, KY

• Inspect and replace bearings, seals, springs, gaskets, stop-lugs, alloy steel rollers, aluminum cages, and fasteners as required. • Inspect and precision grind the outer race and cam if required. • Assemble and test to meet Marland original design and performance specifications. • Paint, crate, and prepare for shipment.

Rebuild centers and services are also available in Australia, Chile, Brazil, and South Africa.

Twiflex LCS Hydraulic Power Unit The Twiflex type LCS is a compact electro-hydraulic power unit range designed to operate small caliper brakes in a proven, reliable package. It provides on/off control of spring applied (“passive”) brakes, with a selectable “fast-approach/soft-braking” function integrated into the circuit as standard. This feature rapidly brings the brakes on to a factory-set touch pressure (pads in contact with the disc face) before the remaining pressure decays to zero and the brakes gradually apply. A wide range of motor and auxiliary connection voltages can be accommodated. If required, a terminal box may be specified, in which all electrical connections can be made. This also permits the addition of a motor contactor if preferred. A hand-pump assembly may be provided as an option to manually release the calipers in the event of complete power loss. The LCS is normally mounted via the M10 holes provided in the manifold block. A bracket is also available which permits base-mounting. trial Motion Altra Indus

For more information, download P-8159-TF from www.AltraLiterature.com

Altra Industrial_#2_6-17.indd 22

LCS Hydraulic Power Unit General Industrial Applications

5/31/17 4:13 PM

TB Wood’s Sure-Flex® Plus, Dura-Flex® and AVS Series Couplings Sure-Flex® Plus Elastomeric Coupling Our new Sure-Flex Plus EPDM and Neoprene sleeves are best-in-class for coupling performance and value. Here’s why: • High Torque Rating: 30% Increased Torque Rating • Longer Life: Lasts Over 3X Longer than the Competition • Better Value: Save Money Using a Smaller Coupling • Interchangeable: Retrofits to Existing Flanges

Dura-Flex® Elastomeric Coupling • Outperforms the Competition • Longest Life: Provides better flexibility and longer life in challenging environments • Minimizes Stress: Patented shoe design minimizes bond stress to ensure long life • Easy Installation: “Split-in-half” element design allows for replacement without moving hubs or equipment • No lubrication or maintenance

AVS Series (Adjustable Vertical Spacer) • Coupling used for vertical turbine pumps • No flexible element • Integral “nut” used for infinite adjustment of pump turbine spacing • Major components are AISI 1045 Steel • Grade 8, Zinc Plated Hardware • Meets AGMA 8 balance • Zinc Phosphate coated hubs, spacer, and adjuster nut

For more information, download P-1690-TBW, P-7031-1-TBW, and P-7819-TBW from www.AltraLiterature.com or visit www.TBWoods.com

Guardian Curved Jaw Flange K45 Series

Unique Controllable Features of Huco Air Motors

Torsionally Flexible Coupling • Shaft coupling JF K45 Series Coupling with brake disk for brake calipers • Brake disk and spider can be replaced while being assembled • The brake disk has to be placed onto the shaft end with the biggest mass moment of inertia • The maximum braking torque must not exceed the maximum torque of the coupling

Controllable Speed and Torque Speed control can be adjusted to fine limits by means of a simple flow valve on the exhaust port. Speed change is almost instantaneous due to fast response time. Instant Stop-Start-Reverse Dynatork Piston Air Motors can stop-start and reverse under load with characteristics similar to a stepper motor. Maximum Torque at Start Dynatork Piston Air Motors deliver maximum torque at start up, ensuring no delay or dwell before operation. • ATEX Approved for hazardous areas • Fully Submergible • Corrosion Resistant

For more information, download P-8346-GC from www.AltraLiterature.com

Altra Industrial Motio n

Huco Air Motors are Efficient and we can prove it!

ENERGY SAVING

Compressed air usage can be less than 25% of conventional air motors because leakage is negligible giving maximum torque with minimum air consumption.

CLEAN ENVIRONMENT

For more information, download P-8297-HD from www.AltraLiterature.com

Dynatork Piston Air Motors can use a clean, non-lubricated air supply, eliminating contamination in a clean environment. QUIET OPERATION Dynatork Piston Air Motors deliver maximum torque at start up, ensuring no delay or dwell before operation.

Unique Controllable Features of Huco’s Dynatork Piston Air Motors:

Controllable Speed and Torque

Speed control can be adjusted to fine limits by means of a simple flow valve on the exhaust port. Speed change is almost instantaneous due to fast response time.

Instant Stop-Start-Reverse Dynatork Piston Air Motors can stop-start and reverse under load with characteristics similar to a stepper motor Maximum Torque at Start Dynatork Piston Air Motors deliver maximum torque at start up, ensuring no delay or dwell before operation • ATEX Approved for hazardous areas • Fully Submergible • Corrosion Resistant

Altra OnDemand Webinars The Altra Webinar Series is open to the public and are held on the first Wednesday of each month at 10 AM (CST). They will be accessible after the live presentation for those who are unable to attend the live session and will be posted to our websites for access. For more information, please contact altra-webinar@altramotion.com. OnDemand Webinars: • • • •

Factors To Consider When Selecting A Right Angle Worm Gearbox High Capacity Gearboxes And Overrunning Clutches Warner Linear Product Launch – Introduction To H-Track Factors To Consider When Selecting A Friction Type Clutch, Brake Or Clutch/Brake • Altra Industrial Motion | Proper Torque Arm Use For more information, download the Altra OnDemand flyers P-8121-4-C and P-8121-5-C from www.AltraMarcom.com

• • • • •

Factors To Consider In Coupling Selection Load Holding Brake Solutions: High Capacity Systems Factors To Consider When Selecting A Right Angle Worm Gearbox Helping Us Help You: Product Identification Small Couplings With Big Potential

the launch We are pleased to announce of our OnDemand Webinars!

OnDemand Webinars

- Watch Now! - CLICK HERE TO

VIEW

WEBSITES launch the new brand websites. PORTAL & BRAND and a majority of to announce the NEW LITERATURE App. a new literature portal We are pleased a review of the Altra Webinars! 2nd we launched while also providing of our OnDemand SYNOPSIS: On September features and functionality,

This

key Webinar will highlight VIEW CLICK HERE TO CAPABILITIES to AND FIELD SERVICE opened for Altra | REBUILD, RE-RATE, opportunities have offerings, potential gearbox rebuild, NUTTALL & DELROYD by competitor rebuild processes we have for high capacity to faltering service the capabilities and SYNOPSIS: Due Join us to review capture market share. HERE TO VIEW in place when SIZES - CLICK and field services. re-rate and securely MODERATE needs. : SMALL TO be held safely application that need to meet these BRAKE SOLUTIONS pound to 400 include functions range of solutions to HERE TO VIEW meet LOAD HOLDING from 1 inch - CLICK wide of applications Warner that help customers THE GEARBOXES with capabilities | BEYOND Stieber and A wide variety fails. Altra provides a very STEEL leadership in offerings gearbox offerings and solutions SYNOPSIS: STAINLESS Marland, Matrix, a great deal of product and product off or if power Dynamics, Gear stainless steel Motion provides Boston Inertia applications Industrial on power is shut Altra of offerings from familiar with the Boston Formsprag, SYNOPSIS: we will focus the broader range Most of us are very solutions from stopping at the In this session, Webinar will review VIEW their sanitation challenges. is simple: If you are products. TO This of torque. Product or of the accessory foot pounds - CLICK HERE Electric and Huco. The message food, pharmaceutical, medical maybe with some SYSTEMS be reviewed. who has TB Woods, Warner CAPACITY Electric will Any Altra Seller Bauer, Guardian, session. this S: HIGHGear, opportunities. when attend sales on place in value should missing out BRAKE SOLUTION will provide and securely gearbox, you are products safely in operation. LOAD HOLDING to be heldsteel need stainless systems are thatwhere foot chemical facilities Safely in Place include functions exist where large capacityand exceeding 2 million Keeping Loads up to of applications and Wichita - CLICK HERE TO VIEW A wide variety fails. Many of these applicationshigh capacity ranges SIZES Warner Electric SYNOPSIS: Twiflex, in place when to meet these | SMALL TO MODERATE off or if power Svendborg, safely and securely Marland, BRAKE SOLUTIONS power is shut very wide range of solutionsFormsprag, needs. that need to be held a fromLOAD HOLDING include functions to meet these applicationto 400 Altra provides Product solutions variety of applications wide range of solutions from 1 inch pound SYNOPSIS: A wide Altra provides a very pounds of capacity. TO VIEW industrialwith capabilities Matrix, Stieber and Warner HERE fails. off or if power reviewed. any othersolutions - CLICK and product power is shut Clutch will be on applications than SELECTION their Dynamics, Marland, we will focus coupling solutions solution forInertia from Formsprag, IN COUPLING In this session, range of solutions a wider best coupling Productthe coupling TO CONSIDER of torque. perhaps pounds Altra one family of will likely find FACTORS Motion provides foot take this a designer to reviewed. starts with will bethat Altra Industrial a designer whoElectric We will also would guide SYNOPSIS: application. r, which ensures will focus on key variables cs are for that manufacture characteristi TO VIEW unit selection. need. This sessionthe key performance IT - CLICK HERE and will aid in specific application & HOW WE ADDRESS upon what from our markets w factors that MATTERS as seeing inquiries Bauer, Warner Linear, and we are need-to-kno IP RATINGS | WHERE IT HERE TO VIEW or another based where key are, clutches CLICK USE to highlight on what IP ratings and backstopproviding IP ratings. Currently opportunity TORQUE ARM webinar focuses gearboxes, towards and brakes, are working clutches | PROPER SYNOPSIS: This and brakes, have or L MOTION installation for divisions already can result ourclutches usedofwith which usage and tool problems that ALTRA INDUSTRIA common in process. are a common Boston revieware Printed in USA Torque Arms webinar will Gear We will also review performance P-8121-4-C 5/17 This SYNOPSIS: issues. of other products. products lines. well as a range wrap spring clutch/brake corrective action for those and simple backstops and TYPE CLUTCH, proper mounting A FRICTION from less than There are a WHEN SELECTINGTO VIEW loads on demand. provide an HERE TO CONSIDER will or stopping FACTORS RAKE - CLICK means for starting to consider. This sessionpossible choices for CLUTCH/B an excellent BRAKE OR designers with best brakes are methods for provide a designer Clutches and actuation can and that SYNOPSIS: possible mounting factors to consider wide array of common options and the in USA overview of 5/17 Printed at hand. P-8121-5-C the application

rs - Watch Now!

OnDemand Webina

Altra Industrial_#3_6-17.indd 23

5/31/17 4:13 PM

Boston & Bauer

Washdown Gear Drives & Gear Motors for the Food & Beverage Industry The original Domed Crown™ Design

The Best Choice for Food & Beverage Safety As the leading innovators in gearing and gear motor technology, Boston Gear and Bauer Gear Motor present a full line of Stainless Steel and Aseptic products that provide sanitary protection and optimal performance in the toughest caustic environments.

Distinct Advantages of the Boston Gear and Bauer Gear Motor offering: 1. Wide Breadth of Products • Worm / Helical-Worm / Helical-Bevel or Helical / Parallel Shaft • Gear Drives (Speed Reducers)/Gear Motors/Shaft Accessories • Reductions of 3:1 thru 10,000:1 • Output Torque from 100 lbf-in thru 7,500 lbf-in Scan to watch! Boston & Bauer Washdown Video

2. Critical Product Features for Washdown Suitability & Sustainability • NSF International Certified (Worm Gear Drives) • UL/ULc Certified (Gear Motors) • IP67 / IP69K Compliance • The Original Domed CrownTM Technology • 316SS Cast Housings 3. Performance Competitive Advantages • Proven: Longer Product Life • Proven: Higher Motor Efficiency • Proven: Higher Gearing Operating Efficiency • Proven: Lower Gearing Operating Temperature • Proven: Reduced Installation Time & Maintenance Cost

For more information, visit www.BauerGears.com and www.BostonGear.com

Altra Industrial_#4_6-17.indd 24

5/31/17 4:14 PM

4 POWER TRANSMISSION

Design for Industry | m e d i c a l

RETAINING DEVICES & maintenance & assembly tools

Drive system can be steam sterilized When designing for medical applications, a critical feature of any component is the ability to clean it. Itâ&#x20AC;&#x2122;s not always easy to find motion systems that are easily cleaned for medical use, and particularly for sterilization. The ENX Easy encoder can be sterilized using steam. It is available in an incremental (1024 counts) and absolute version (4096 steps), both designed for 1,000 autoclave cycles. The encoder can be combined with matching BLDC motors and planetary gearheads. It can be integrated into the brushless drives ECX 13 and ECX 16 SPEED (up to 120,000 rpm and 104 W) without any increase in length. When the gearheads GPX 13 and GPX 16 SPEED (0.2 Nm max. continuous torque) are added to the combination, it is still a fully sterilizable positioning system. This system suits a number of applications in medical technology and works well for power tools. DW

BEARLOK

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BEARHUG

CLAMPNUT

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

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Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS

maxon motor | maxonmotorusa.com

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HARDENED TONGUE WASHERS

SPLIT COLLAR

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BEARING ASSEMBLY SOCKET

-H

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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 websiteâ&#x20AC;&#x201C;whittet-higgins.comâ&#x20AC;&#x201C;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. 33 Higginson Avenue, Central Falls, Rhode Island 02863 Telephone: (401) 728-0700 â&#x20AC;¢ FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com June 2017

DFI 6-17_Vs4.LL.indd 25

DESIGN WORLD

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6/1/17 10:29 AM

Design for Industry | m e d i c a l

Easy control of single and multi-axis motion Custom Cords ...

A line of motion control stepmotor products is the result of a partnership

Interpower® manufactures North American and international power cords and cord sets. All Interpower power cords and cord sets carry all the appropriate approvals. • Made in Iowa, U.S.A. • No minimum order or dollar requirements • 1-week U.S. manufacturing lead-time on non-stock Interpower products • Customized cords to your specifications • Interpower manufactured cords are 100% tested • Over 50,000 cords in stock for same day shipments

between IDEC Corp. and Advanced Micro Controls Inc. This product line includes controllers, stepper motors, an integrated controller/drive, an integrated drive/stepper motor, and an integrated controller/drive/ stepper motor. When combined with an FC6A PLC and its embedded motion control macro instructions, these products let users quickly and simply implement single- and multi-axis motion control. Macro instructions embedded in the PLC WindLDR programming software can be configured with drag and drop commands to perform control of up to 12 axes. The integrated controller/drive and drive/ stepper motor units save space and money, and simplify installation by combining multiple components into a single unit. Motion control macro instructions embedded in the FC6A PLC reduce design and programming time, allowing quick implementation in a variety of applications. AMCI by IDEC’s iANF2E (2-axis) controllers can accept encoder feedback to provide stall detection and move verification. Each controller includes six discrete inputs for move conditioning and other functions, and four discrete outputs to indicate status and provide diagnostics. Each controller has a full complement of motion profiles, which can be selected by an IDEC MicroSmart FC6A PLC connected to the controller through an Ethernet-based Modbus TCP communications link. Up to six controllers can be connected to the PLC to control up to 12 axes of motion. • AMCI by IDEC’s iSM2340 NEMA 23 stepper motor comes in standard frame sizes with output torque of 130 or 240 oz-in. • AMCI by IDEC’s iANG1E integrated controller/drive unit can control one to six axes of motion, and it combines all the features of AMCI’s 1-axis controller and a 4.0A stepper drive into a single unit.

Toll-Free Phone: (800) 662-2290

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• AMCI by IDEC’s iSMD23 integrated drive stepper motor unit provides up to 240 oz-in. of torque, and can be paired with the iANF2E to provide a complete solution. The unit can also be controlled by the PLC. • AMCI by IDEC’s iSMD23E integrated controller/drive/stepper motor unit provides all-in-one motion control with all the features of AMCI’s 1-axis controller, drive and stepper motor. No heat sinks are required due to its thermally efficient design. The integrated unit can operate over a wide range of input power, from 24-48 Vdc. DW

IDEC | idec.com

WHAT DO YOU THINK?

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

www.interpower.com 26

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6/2/17 2:29 PM

Design for Industry | m e d i c a l

Miniature board-to-board battery connectors Developed in response to market demand for miniaturization, the 9155-700 Series of right angle board-to-board battery connectors delivers compact, mechanically stable, high-integrity connections for use in medical, industrial, and commercial applications subject to high shock and vibration. These 2 mm-pitch right angle battery connectors are rated for 125 Vac, up to 2 A, and 5,000-cycle durability. They can be used in handheld and portable devices that require dock or cradle charging, patient monitoring devices and other portable medical electronics, industrial programming modules, point of sale (POS) terminals, and a range of IoT devices. Connector height is 4 mm, with a stable contact point 2.1 mm above the PCB. These gold-plated beryllium copper (BeCu) contacts also have two SMT anchor brackets and optional plastic-locating bosses. Made of high-temperature nylon plastic compatible with RoHS soldering, 9155-700 Series connectors are rated for operating temperatures spanning -40°C to +125°C. Two-, three-, and four-way versions are rated for 2 A, and five- and six-way versions are rated for 1.5 A. The series also features

a design that retains the contact nose within the insulator to prevent damage in both the static position and during mating deflection. Also available are right angle board-to-board battery connectors with a 2.5 mm pitch (the 9155-500 Series) and a 3 mm pitch (the 9155-300 Series). DW AVX | Avx.com

#electricRULES Motion control that’s stronger, faster and smarter than pneumatics or hydraulics Make your next machine everything you imagine it can be. Optimize cost, performance and flexibility with our electric linear motion actuators. Motor ﬁles available for all AB Kinetix® drives

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To get the facts, download our e-book: www.tolomatic.com/electricRULES 800-328-2174

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June 2017

DESIGN WORLD

6/2/17 9:03 AM

» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

ngageme

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Modified couplings for Oil & Gas truck-mounted pumps A leading oil and gas OEM needed a torque-dense

disconnect coupling for pumps used at hydraulic fracturing sites. The truck-mounted pumps are driven by energy efficient electric motors instead of traditional diesel engines. The coupling is installed between a 5,000 HP motor, turning at 1,800 RPM, and the pump. The coupling allows the pump to be disconnected from the drive motor to prevent drivetrain damage during vehicle transport. Ameridrives was contacted by the OEM’s consulting engineer to provide a coupling solution. After review of the application, Amerigear FDC flexible gear couplings with a torque rating of 551,000 in.-lb were supplied. The flanged-sleeve, double engagement disconnect couplings with shifting collars are designed to meet quick connection or disconnection application requirements. Units feature a high-speed synthetic rubber lip seal that

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Ergonomic side handles

» De sign Note s allows for disengagement. The 16-in. diameter couplings have a 6-in. diameter keyed bore on the motor hub and a 5-in. diameter keyed bore on the pump hub. Fully-crowned gear teeth provide operational benefits including maximum load-carrying capacity with minimum size and long life. Optimum separation of gear meshes permits high parallel offset capacity. Amerigear models compensate for all three types of misalignment. Units feature accurately machined medium carbon steel hubs and sleeves. Positive-type O-ring seals keep lubricant in and contaminants out. Seals are enshrouded to prevent damage. DW Ameridrives | ameridrives.com

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Pneumatics cut cycle time in half

Diffusion weldi ng systems amidst the prod uction line for starters. Fast pneumatics shortens the cy cle time. Two machines now do the work of three.

The days when you had to hand crank your car to get it started have been long relegated to old black

and white movies. Today, you won’t find a car without a starter, and for decades these have been made by Bosch, the world’s largest automobile supplier. The starters, and since 2011 the start-stop technology, are manufactured around the clock on seven production lines at the company’s plant in Hildesheim, Germany.

The individual production lines consist of approximately 25 machines, which surround the diffusion welding system. This welding unit was designed and built by the GAteK association for automation technology and design. A pre-mounted armature is transported on workpiece pallets, aligned for position detection, and brought into posi-

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tion for welding by grippers. After welding, additional grippers return the armatures to workpiece pallets and transport them to the next production step. Supply, swiveling, and welding are performed at rapid speeds in parallel to maintain the line cycle times.

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The first GAteK machines had three separate control processes for contact movement during welding. This meant waiting during switching times. “Using proportional valves, we can now take the three movements and simulate the smooth sequence of a robot. As a result, we cut the time just about in half in this application,” said Thorsten Hoffmeister, managing director, GAteK. GAteK uses ED series electro-pneumatic pressure regulators. “With their dynamically controlled pressure that can be precisely tailored to the application, they form the basis for optimized, energy-efficient processes in the diffusion welding system,” said Volker Thomas, managing director, GAteK. ED series valves combine control electronics, the pressure sensor, and direct drive via proportional solenoids into a single closed unit.

The SM6 series position measuring sens or provides feedback on wea r.

The regulator detects possible drops or increases in pressure. Here is where the pressure regulator shines, with its high dynamics: Based on a target-actual value comparison, it immediately generates the necessary pressure change to ensure process stability. “Compared with the machines used up to now, we achieve a faster, more stable

process and thus optimized weld quality. This also extends the machine service life and reduces cycle times by 50%,” said Hoffmeister. “As a result, we can reduce the number of machines in a system from three to two.” All seven production lines are planned for gradual conversion. The electro-pneumatic concept also in-

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cludes the AV03 series valve system. In combination with the pressure regulators, GAteK achieves ultrahigh precision. At the same time, valve interaction delivers pressure values that can be consistently reproduced and documented. GAteK benefits from the inner workings of the AV03, which is extremely compact thanks to its diagonally arranged valve spool. In addition, the flexible AES fieldbus control supports all conventional systems and protocols. “We have managed to solve all stroke and travel motions with Aventics,” said Hoffmeister, pointing out the large selection of cylinders. To query the exact position and required travel time, some cylinders are also equipped with the SM6 distance measuring sensor. Thanks to the sensor, it is possible to check the guide wear, enabling preventive maintenance while ensuring the quality of the welding process. The concept of the Internet of Things can thus be implemented in new machines as well as integrated into ongoing production. AS3 series maintenance units ensure not only high compressed air quality and prevent air waste,

ED serie s valves combine control e lectronic s, the pressure sen drive thro sor, and direct ugh prop ortional solenoid s into a s in g closed u le nit.

but also play their part in machine safety: As an inexpensive solution for safe ventilation and exhaust, the integrated 3/2 shut-off valves switch of redundantly in an emergency. DW Aventics | aventics.com

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Robot arms & rockets: plastic bearings in design Plastic bearings often make the most sense when dealing with applications that have weight and external lubrication restrictions, and require smooth, quiet motion. A number of applications require automatically lubricated bearings. Here are just a few unique applications featuring a creative use of plain bearings. Levitate Technologies, for example, is the developer of the Airframe exoskeleton system used to facilitate assembly work. It relieves muscles and supporting movement sequences to prevent worker fatigue and discomfort. The Airframe system uses a wide variety of Igus iglide plastic bearings to minimize weight and maintain smooth rotation while under high axial loads. Lack of external lubrication keeps the users clothing from oil and grease exposure, and allows for use in difficult environmental conditions. A robotic arm in off-shore applications must be rugged enough to handle the harsh sea environment. The French company, Ocean Innovation System, designed its electric manipulator arm to be used in salt or fresh water at depths up to 1640-ft (500 meters). The gripping arm uses more than 30 iglide plastic bearings, including those made from the iglide T500 material, which is able to withstand high loads and has low rates of moisture 34

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The Airframe human exoskeleton su pports movement durin g assembly work, reducing stress on the back, neck, and shoulders.

absorption. The arm, while in the extended state, has a dynamic load-bearing capacity of 35 lbs (16 kg), or 110 lbs (50 kg) while static. Space is definitely an application where you can not simply go up an lubricate the bearing. The German student researchers’ UB-SPACE project analyzes how objects move in space. The system was deployed on the sounding rocket REXUS 21 in March of 2017. The 5 man research team developed a module which transports a socalled “free falling unit,” or FFU into space in order to record how the FFU moves using a system of a cameras and sensors mounted to the wall of the rocket wall using a 3D printed iglide bearing. Additionally, the ejection chute where the FFU is release is lined with iglide V400 low-friction tribo tape. DW Igus | igus.eu/manus

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

How to keep biopharmaceutical obsolescence under control Aging equipment can become a multimillion-dollar issue for biopharmaceutical companies if not addressed. If equipment experiences a failure with no available spare parts, the production of high-value biological products would come to a costly halt and could also result in lost batches. One biopharmaceutical company recently needed to address obsolescence in two of its purification skids, and saw it as an opportunity to make some additional operational improvements in the process. Each production batch begins with a 1 to 4 milliliter ampule of cells that serves as the powerhouse for creating key proteins in their drugs. Through this process, the ampule of cells can grow to a final volume of as much as 12,000 liters. Once the desired volume is reached, the batch is sent on to purification operations. Here, cellular debris, unwanted proteins and other elements are removed through a series of different processes. The last of these processes is tangential flow filtration (TFF). TFF is a pressure-driven process that removes the buffer species from the protein. This helps clarify and purify it into a final concentration that meets the drug’s target specifications, and then it can be sent on to filling. The company has multiple TFF skids for different batch sizes, but it was the two midsize TFF skids that were nearing the end of their service lives. The first skid was put into use in 1998, and the second skid was brought in shortly thereafter. Both skids had programmable logic controller (PLC), variable frequency drive (VFD) and human machine interface (HMI) components that were either going to be discontinued soon or had already been discontinued. “The company knew these systems were getting near the end of their lives and needed to be replaced or upgraded,” said Tom Brown, project engineer, Banks Integration. “Based on the overall health of the skid system, it made sense to upgrade the control systems.”

The legacy skids’ PLC s and VFD were upgra s ded to Alle n -Bradley ControlLog ix 5570 con trollers and the Allen-B radley Pow erFlex 525 VFD (show n here).

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“If equipment experiences a failure with no available spare parts, the production of high-value biological products would come to a costly halt and could also result in lost batches. “

The aging equipment represented a production liability of up to $10 million if they were to go down, given the lack of available spare parts and potential downtime. More than that, however, they were also generating five to six critical alarms per week due to bad communications between components, resulting in unnecessary downtime. A lack of diagnostic information made the alarms difficult to troubleshoot and diagnose, sometimes requiring the support of up to 10 employees from the quality, automation and manufacturing science groups to resolve a single alarm. Additionally, while the two skids were based on the same design, they were still

their own systems. This meant that each skid had its own separate code that had to undergo separate testing for each new production run. The biopharmaceutical producer worked with Banks Integration Group, a Rockwell Automation PartnerNetwork program Solution Partner, to design, engineer and validate the control-system upgrade process based on the PlantPAx modern DCS platform. This involved upgrading the legacy skids’ PLCs and VFDs to Allen-Bradley ControlLogix 5570 controllers and Allen-Bradley PowerFlex 525 VFDs. A single-fault tolerant EtherNet/IP network replaced the company’s existing Data Highway Plus network for better device-level communications and real-time performance monitoring. Additionally, the control systems were integrated into a redundant, client-

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server SCADA architecture to enable a greater level of access, including remote access. The new skid systems use the PlantPAx process objects for life sciences – a library of controller code, display elements and faceplates that are customized for the life sciences industry. These predefined elements can help company operators more quickly configure applications to speed up production deployments and shorten cycle times. The new systems also use FactoryTalk Batch software with equipment editor and recipe editor capabilities that let operators create models and build individual recipes. The FactoryTalk Batch with PhaseManager capability simplifies phase logic programming and configuration by making it possible to create equipment phases without phase logic interface (PLI) code. The new control systems support a “family” code approach in which the same code can be tested once and installed on both skids. “Having two systems that share one set of code essentially cuts the validation costs for the company in half,” Brown said. “It’s no longer twice the amount of testing processes and twice the amount of paperwork.” The new systems have also significantly cut down the critical alarms resulting from communications issues – from five or six alarms per week to zero in the first two months of operations. For any issues that do arise, the new systems give the producer’s team greater visibility into the skids for faster resolutions. For example, the VFDs on the old systems were not being monitored. As a result, operators would re-start a machine rather than sorting through several dozen fault codes to pinpoint the issue. Now, fault codes from the new VFDs are reported back to the PLC and collected in a data historian. “With the new system and the device-level ring, it can tell you exactly where a failure is occurring,” Brown said. “It probably saved the company a day’s worth of troubleshooting in just the first week of implementation.” Additionally, the new network enables information collected at the control-level to flow across the facility. This simplifies gaining visibility into how the system is operating, such as by providing Brown and other employees remote-access capabilities to skids even when they’re not on the plant floor. DW

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I nter net of Things

......................................... ............................... ....................... .................. ............. .......... ....... ..... ... Why your customers . should consider cloud computing

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

When designing products for industrial automation, connectivity and the introduction of cloud computing make monitoring more sophisticated. In this era of the smart factory, Johannes Petrowisch, Global Partner & Business Development Manager of industrial automation software expert, COPA-DATA, discusses the benefits of cloud computing for users in the manufacturing industry.

Head in the clouds The role of cloud computing in the manufacturing industry is not always clear. Manufacturers are not well known for investing heavily in the latest IT systems and technologies on a regular basis, so why are so many now deploying cloud-computing software in their organizations? As industrial automation becomes more intelligent and manufacturers embrace machine-to-machine (M2M) technology, cloud computing is set to become the obvious solution to store and manage the ever-growing expanse of production data. The cloud helps users reduce costs, change business models, provide new services, increase agility, optimize performance and ultimately, drive profitability. Performing a meaningful evaluation of a manufacturing facility’s energy efficiency is only possible when complete energy consumption figures are available. To make sense of the copious amounts of data produced on the shop floor, many manufacturers are deploying energy data management systems (EDMS). Generally, EDMS is set up locally and embedded into the existing IT infrastructure, but there are a number of different scenarios available, including moving the EDMS to the cloud, a possibility which enables company-wide analysis of energy data. Manufacturers want actionable insights from the data they collect. 40

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Predictive analytics, or machine learning, often deliver a complete new service to sell. For some users, there is concern surrounding the storage of production data off-premises. Although these concerns about data loss, security breaches and lack of data ownership are all valid, these fears aren’t as justified as they might seem. Most cloud providers invest heavily to ensure the infrastructure is safe and resilient to any attacks. For example, Microsoft and its cloud platform, Azure, is ISO 27001 certified and therefore provides disaster recovery as a service (DRaaS). By automating the replication of factory data, Azure will provide a secondary data center to act as a recovery site.

Above the clouds Moving to cloud computing isn’t just about moving data storage off-site. Used correctly, the cloud can enhance an organization’s performance in production, efficiency and potentially, its entire business model. DW COPA-DATA | Copadata.com

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..................................... ........................... ................... .............. ......... Ethernet options for ...... ... . pneumatics Line of NITRA pneumatics includes Total Air Prep (TAP) units and NITRA Ethernet/IP protocol compact modular valve (CMV series) modules. Both TAP units contain an automatic drain air filter with clogged filter indicator, relieving regulator, lockable shut-off valve, pressure gauge and air dump. Electric models also have an adjustable electric soft start / shut-off valve and an adjustable pressure switch with indicator LEDs. TAP units have a 0 to 120 psi pressure range and are IP65 rated and CE approved. Two versions of the multi-functional filter-regulator assembly offer a common small footprint regardless of piping requirements. Units ship with ½ in. NPT inlet/outlet ports. Optional NPT or BSPP port inserts in sizes 1/4 in. thru 1 in. are available. Also available are NITRA Ethernet/IP (EIP) protocol modules in the NITRA CMV Series of

compact modular solenoid valves. Two models (single 3/8 in. input and dual 3/8 in. input) are available. The Ethernet/ IP communication end plates permit daisy chaining by using the Ethernet/IP connection versus hardwiring. The EIP units are IP65 rated using M12 connectors for communication and M8 connectors for supply power. NITRA configuration software for use with the CMV series EtherNet/IP modules is available on CD, USB and as a free download. DW AutomationDirect | automationdirect.com/ pneumatics

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........ ..................................... ........................... ................... .............. ......... ...... ... tools . Analytics for the Industrial I nte r net o f T hings

Internet of Things The Control Server and Control System Health App are part of GE’s Industrial Internet Control System (IICS). IICS is an Industrial Internet of Things (IIoT) program that reliably, safely and securely connects thousands of machines to the cloud and brings computing to the edge. As a link to a network that connects all Programmable Automation Controllers (PAC) in a factory or plant, the Control Server collects, stores and analyzes all data that is received using Predix software. It is a scalable platform that enables power plants to extract industrial data, reduce operating costs and is protected from cyber-attacks and other forms of hacking. Using GE’s Field Agent platform, Control Server also lets users optimize apps like Model-based Optimizing Control (MBOC) to inject performance improvements that deliver greater profitability. In addition, the operating and maintenance costs are reduced through consolidation of PC functions provided by virtualization technology on a server-grade platform. With built-in security features, this innovation reduces the cyber-security attack surface and improves compliance with industry regulations. The Control System Health App allows customers to monitor the status of their control hardware from any location with internet access. The app collects real-time data in a time-series database and uses the power of analytics to recommend corrective actions based on faults. Powered by Field Agent and Predix technology, the app offers a view of current and historical faults for both I/O and controllers, CPU firmware revision, temperature indication and controller status. By leveraging real-time data and analytics, the app saves time and allows for situational awareness of controller assets anywhere in the world. OEMs can use this app and turn it into a service that they can provide to their customers to generate a new revenue stream. The app can be accessed on PACSystems RX3i - CPE305, CPE310, CPE330, and CPE400. DW GE Energy Connections’ Automation & Controls business Geautomation.com June 2017

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............................... ............ ........................ ................... .............. ........... ........ ...... .... .. Smart positioning your way to I nter net of Things

Industry 4.0

The demands on the flexibility of modern production facilities

Manual size changeover solutions

continue to increase. The large variety of products and ever smaller batch sizes focus attention on optimum system availability. Short setup times, for example for size changes, are a standard requirement for production and packaging machines. One approach is to consider each machine axis separately regarding size changes and to deploy the size changeover solution most useful technically and economically for the user. Network connectable sensors ease this approach. Whether inexpensively with a hand wheel, process-reliably with bus-capable position display or fully automatically with an actuator, the reliability and handling of the positioning systems used is crucial for flexible production processes. Manual, electronically monitored or fully automatic size changeover – when does each solution make sense?

For setting positions in a machine that rarely needs adjustment, there’s the classic mechanical and digital position indicator. They are inexpensive, and the accurate display of the actual value makes setting the spindles reproducible. However, setup times – i.e. the machine’s downtime during a product change – are the highest with this solution as each position must be set manually. The settings must also be checked manually and possibly verified in a test run of the system before series production can be resumed.

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Monitored size changeover with bus capability Bus-capable position indicators with setpoint/actual value comparison and status display of the manual adjustment offer technical advantages over purely mechanical position indicators, making them “smart.” A machine operator can see from far away the brightly lit LEDs, indicating whether the machine axis is set correctly or not.

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Internet of Thi ng s

Integrated LEDs also display the direction in which an axis should be adjusted. The position indicators obtain their basic parameters and the desired setpoint position from the machine control system through a fieldbus. So when is it advisable to use electronic, bus-capable position indicators? These type of sensors suit applications when several size changeovers are required per day. The integrated setpoint/actual value comparison leads to improved process reliability. Their use is more intuitive than purely mechanical solutions.

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communication interfaces make the drives flexible in integration. Jürgen Schuh, DriveLine Product Manager for SIKO GmbH in Buchenbach, knows from the experience of his customers that standby times for machines and installations can be considerably shortened using automatically driven actuators. Said Herbert Erath (Head of Special Machine Engineering at Fischer): “We were able to reduce the setup times from 45 minutes to less than five minutes. That’s an enormous gain in efficiency.” Intelligent networking The connection of actuators or electronic position indicators to different fieldbus systems allows multiple devices with a single

Through the display and the keyboard, each stored parameter can be checked and adjusted if necessary. Possible operating data can be read out and errors can be diagnosed without an analysis via the fieldbus being necessary.

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communication interface to exchange data with the control system. The range of available interfaces extends from a simple and inexpensive RS485 protocol to the tried and tested bus systems Profibus and CANbus. Standard technologies in the field of industrial Ethernet are also provided with Profinet, Ethernet IP, Powerlink and Ethercat. Intelligent and compact actuators are a first choice for users whenever frequent size changeovers with high quality demands are made. They are essential Industry 4.0 components for current and future machine designs. DW

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I nter net of Things

N EWS: ........................................ .............................. ...................... ................. ............ ......... EtherCAT Technology Group ...... .... .. releases EtherCAT P specification documents

The EtherCAT Technology Group (ETG) published a first draft of the official EtherCAT P technology specification last autumn. Now, the documents have been released to coincide with the last ETG Technical Committee Meeting. The specification provides device manufacturers with an official foundation to implement EtherCAT P technology, which enables data and power transmission on a single, standard cable. In the frame of the recent ETG Technical Committee Meeting, these documents are officially released, with all corresponding documents now stable and available for ETG members. The Application Note, which was published in conjunction with the specification draft, and further developed by Beckhoff, will continue to serve as additional support for EtherCAT P implementations. 48

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In the upcoming weeks and months, the ETG will continue to develop the â&#x20AC;&#x153;EtherCAT P Testingâ&#x20AC;? documentation. Work on the corresponding test specification, as well as test cases for the EtherCAT Conformance Test Tool, are nearly complete. DW EtherCAT Technology Group | ethercat.org

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............................... ............ ........................ ................... N EWS: .............. ........... ........ ...... ...OPC Foundation gains validation of

Internet of Thi ng s

OPC UA security

For some, the importance of security with Industrial Internet of Things components is being taken seriously. Notes the OPC Foundation, â&#x20AC;&#x153;One of the most important things required for the Industrial Internet of Things (IIoT) is to ensure that the data and information exchange between devices and services are secure.â&#x20AC;? The OPC Foundation has worked with many security validation companies and organizations to ensure security. One of those organizations is the BSI, which performed an in-depth security analysis of the OPC UA specifications and a selected reference implementation. The BSI published the results of the OPC UA security analysis. The extensive analysis of the security functions in the specification of OPC UA

confirmed that OPC UA was designed with a focus on security and does not contain systematic security vulnerabilities. Arne SchĂśnbohm, President of the BSI explains, â&#x20AC;&#x153;OPC UA is an important modern standard for secure, cross-industry networking for industrial equipment. Industrie 4.0 offers many opportunities for Germany as an industrial location, but for being successful it is necessary to consider security for digitalization and interconnection of industrial processes right from the beginning.â&#x20AC;? DW OPC Foundation | Opcfoundation.org

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Fieldscale Sense and Charge: Engineering modeling of touchscreens on the cloud

Declaring “the dream that drives all our operations is to extend the boundaries of simulation,” Fieldscale says its mission is to “build software simulation tools that work out-of-the-box and deliver exceptionally powerful technology integrated in a clear, singular user environment, and ultimately to make this technology accessible to every engineer.” The ideas behind Fieldscale took root some years category, and will enable the next generation ago when its co-founders, CEO Yiorgos Bontzios of products created by a broader audience of and CTO George Bouzianas, were experiencing the engineers.” “pains of simulation,” as they put it. They faced often day-long simulation runs to obtain results with the Fieldscale Sense “changes the feel of simulation” required accuracy—and more than once, the solver Sense is a cloud-based engineering modeling and algorithms proved incapable of producing results simulation app that Fieldscale calls “the fastest at all. And all this “while suffering through terribly touch sensor design tool in the world.” complicated user interfaces.” “We live in a touchscreen world,” the company Fed up, the two decided it was time to fix these observes. “Capacitive touchscreens are a vital part problems. “Ever since day one,” the company says, of most portable devices such as smartphones, “our plan is to build simulation software tools that tablets and handheld game consoles, as well as perform substantially better in each and every TV screens and computer monitors. Touchscreens 50

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Fieldscale Sense is a cloud-based engineering modeling and simulation app that Fieldscale calls “the fastest touch sensor design tool in the world.”

have also entered several automotive, industrial, medical, even military applications, where special features are demanded.” The key business driver for touchscreen manufacturers is to create innovative and robust products as rapidly as possible. Core functional requirements for touchscreens are to be compatible with the device’s controller, reliable in recognizing finger touch or proximity, and immune to noise. Further, the touch sensor industry is generally based on proprietary patterns and customized products, so there is continual, ongoing requirement to design and test new designs that come with unique, specialized features. Validating touchscreen design performance Traditionally, engineering performance of a touchscreen design is done either by hand calculations—which, being based on approximations, are thus of no use when product optimization is required—or by expending prodigious cost, time and labor on fabricating and testing physical prototypes. Although touchscreen manufacturers have clear design guidelines laid out by the various IC manufacturers, design validation remains a time- and labor-intensive process, as it requires many iterations between the touchscreen manufacturer and the IC provider for the end product under development. In recent years, Fieldscale observes, touchscreen design has moved into a third phase of evolution: digital prototyping.

“What will help companies benefit from simulation and lead to a real revolution in product development,” Fieldscale believes, is “for digital prototyping to become simple and intuitive to use.” Enabling such intuitive and fast digital prototyping is the objective of Fieldscale Sense, a specialized simulation software tool that helps capacitive touchscreen designers virtually test and optimize their products before manufacture. “Why is Sense the ideal tool for this work?” Fieldscale asks. “The answer is in the simplicity of its workflow: Apart from its incomparable speed and guaranteed results thanks to cutting-edge, fully parallelized algorithms built on top of the Boundary Element Method, Sense offers a simple, clear, intuitive user interface that renders manuals and tutorials pretty much pointless.” Fieldscale Charge: State-of-the-art electric field analysis Charge is a state-of-the-art tool for electric field analysis designed to help engineers detect dielectric breakdowns and partial discharges, identify vulnerable spots, and design safer products and facilities. Fieldscale’s goal with Charge was to “build the most powerful solver engine from the ground up. To do that, we built our solutions on top of the concrete foundation of the Boundary Element Method (BEM). This ensures and enhances simulation reliability. But we didn’t stay there. Our solving engine utilizes a range of best-in-class parallelization June 2017

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Fieldscale Charge is for electric field analysis to help engineers detect dielectric breakdowns and partial discharges, identify vulnerable spots, and design safer products and facilities.

processing techniques. The result is top performance plus engineering time reduced down to 10X.” Charge computes electric fields and voltage with what the company calls “astonishing accuracy. This is true even for the most complex designs. No more compromises or unrealistic design simplifications. Our parallelized algorithms transform a previously overnight process to one of minutes. And without sacrificing accuracy.” Five steps to a great design Fieldscale’s philosophy is that “a great simulation engine must exist within the simplest-to-use environment. Improved user experience leads to increased productivity and efficiency. So we brought the whole design process down to just five simple, intuitive steps. All unnecessary options have been eliminated,” the company says. For more demanding users, Charge’s GUI offers additional advanced functions. Instant access to cloud power Charge provides one-click access to hundreds of computers through the cloud without interrupting the user’s workflow. “You just hit solve, and Charge does all the dirty job in the background. Solve the most complex simulations within minutes.” Having the ability to readily and effortlessly analyze 52

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every detail with high accuracy lets engineers “stop over-designing, and start creating optimal, cost-effective products.” Charge highlights Intuitive 3D CAD reduces engineering time. Powerful meshing engine lets engineers readily analyze the finest details. Highly parallelized solving algorithms deliver accurate results faster than ever. Expanded visualization capabilities help engineers better understand their product designs. People Yiorgos Bontzios, co-founder and CEO, sets vision and long-term targets and direction for the company. He supervises all operations and is “responsible for keeping the engine moving inside and outside the company.” He holds an MSc and a PhD in electrical and computer engineering from the Aristotle University of Greece, is principal inventor of one patent, and has published four books and more than 20 papers. He has developed numerous software tools in various corporate positions and as an independent developer. George Bouzianas, co-founder and CTO, implements novel numerical techniques that form the kernel of Fieldscale’s technology. An expert in computational electromagnetics

and programing of numerical techniques including FDTD (finite-difference timedomain), FEM (finite element modeling) and BEM (boundary element method), he holds an MSc in electrical and computer engineering and a PhD in computational electromagnetics from Aristotle University of Greece. During his studies he won four scholarships for excellence, published more than ten scientific papers, and developed a time-domain numerical model for simulating electromagnetic effects in graphene structures. Backers include Openfund and the PJ Tech Catalyst Fund DW . Fieldscale | fieldscale.com

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N E WS

» CA E Solution s

Siemens PLM software streamlines product development Wintersteiger, a specialist machinery manufacturing company in Austria, selected Siemens as its exclusive product lifecycle management (PLM) software supplier in support of its digitalization efforts. Introduction of the PLM software began this quarter at Wintersteiger headquarters, where Siemens and Wintersteiger work jointly to tailor the solution to meet the needs of Wintersteiger’s diverse business segments. Wintersteiger produces machinery for industries such as service and rental solutions for the ski and snowboard sport, wood technology, seed mechanics, metals and automation. Teamcenter will be rolled out to the Wintersteiger group, covering Wintersteiger AG and VAP Gruber Automations GmbH in Austria as well as Wintersteiger Sägen GmbH and Kohler Maschinenbau GmbH in Germany. Implementing Teamcenter and NX across the group provides a scalable, flexible digital enterprise solution for mechanical design, which will be adapted to changing requirements. Using a single, comprehensive platform will prepare Wintersteiger to quickly and efficiently adapt to future challenges across all industries. “For companies building machinery at the threshold of Industry 4.0, rapidly changing requirements are the norm rather than the exception,” said Hermann Kaineder, Country Manager Austria, Siemens PLM Software. “Solutions that allow users to master new challenges collaboratively, and therefore quickly and simply, will help companies meet these future needs.” DW Siemens PLM Software | siemens.com/plm

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» Co u p li n g N o tes

How do speed, inertia and duty cycles affect beam couplings? Edited by: Mike Santora • Associate Editor

Beam coupling failure most often occurs when maximum speed is exceeded, making a balanced design all the more important at higher RPM. In certain situations, such as a printing application for example, there might be an issue with banding. Vibration in the system can be caused by the coupling, causing the printer to band and create errors. It’s important to note that not all couplings are balanced. There are couplings that do not have a balanced design. Again, printing is one of the applications that can get you into trouble just because you haven’t used the balanced design. Inertia is another concern, specifically, servo coupling inertia determined by mass and distribution about the axis. Too much coupling inertia, especially in systems with intermittent starts and stops, can introduce resistance into the system causing premature failure and poor system performance.

The standard material in the hubs of many flexible couplings is aluminum. Aluminum keeps the weight down and the inertia low. A common scenario where engineers will get in trouble with inertia is with beam coupling applications. In these applications, engineers are often using an aluminum beam coupling and the torque capacity is not what they need. It’s too low. They end up having issues with wind up because the aluminum beam coupling just isn’t strong enough and this ultimately results in positioning error. Many times people say, “we’ll go to the stainless version, we don’t have enough room to put a bigger coupling in, the stainless steel version of a beam coupling has a higher torque capacity and that’s going to solve our problem.” Again, however, stainless steel beam couplings are much heavier than the aluminum versions and it wouldn’t be unusual at all to switch from an aluminum beam coupling, go to a stainless steel coupling, and now you’ve got issues with too much inertia. This leads to the servo or stepper motors tripping out and increasing problems. Again this is an example of inertia causing issues and being a factor in your designs.

Too much inertia can lead to a servo or stepper motor tripping out and increasing problems. Coupling material, and the resulting weight, should always be considered in how inertia might affect a design.

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»» For applications that have a hard stop, hard start, aggressive move profile, a jaw coupling is a good choice typically. It will protect the bearings in your motor and protect the bearings in your actuator from that shock.

Many times, if you’re using an aluminum beam coupling and it does not have enough torque capacity, many many times a better option is to go to a different type of coupling to solve the problem versus going to the much heavier stainless steel version of the coupling, there are better options that just switching to a stainless beam. Lastly, duty cycles. Is the application’s motion continuous, start stop, reversing? How often a system running is always a consideration. Failures often occur when the type of motion is not accounted for or the number of cycles is not understood. With indexing, for example, the coupling is not actually making a full rotation but it could be indexing at a high rate, this is quite stressful on a coupling and it’s not going to last forever just because you are not rotating it at a higher RPM. In another example, this time with a jaw coupling, you’ve might have a hard stop, hard start, aggressive move profile. For that type of an application, a curve jaw coupling is a good choice typically. It will protect the bearings in your motor and protect the bearings in your actuator from that shock. In another example, if you have a gradual start stop application, slowly coming to a stop or reversing, at that point a beam coupling or oldham coupling might work. The aggressiveness of your move profile is definitely a factor in choosing whether you want to use a jaw coupling or something different. DW

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M o t i o n

C o n t r o l

Kit encoders using

magnetic operation New forms of kit encoders can be built into motors to provide commutation signals and closed-loop speed and position feedback.

Christian Fell â&#x20AC;˘ POSITAL FRABA

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Magnetic rotary-encoder technology is a staple for incremental and absolute motion tracking. Now some manufacturers offer new encoder geometries based on the technology to give OEMs and machine builders flexibility in the way they incorporate measurement capabilities into products. The encoders don’t require the extreme cleanliness and assembly precision that built-in optical encoders demand, and that reduces manufacturing costs. What’s more, solid-state electronics in these magnetic encoders are more tolerant of shock and vibration than the transparent code discs and optical sensor arrays of optical devices. More specifically, kit encoders based on the principle of magnetic technology offer price-performance ratios that lie between those of magnetic resolvers and optical kit encoders (built into the motor casing).

Motion and position-sensor manufacturer POSITAL now sells kit encoders for faster integration into servomotor setups. Left to right are the servomotor, an adapter plate for mounting the kit encoder; bolts and a shield to protect the encoder pickup from fields coming off the motor brakes; two magnets on a square plate for mounting to the motor-shaft end; the encoder electronics and screws to sit offset axially from the spinning magnets; and a housing and end clip.

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M o t i o n

C o n t r o l

Electronic components of this kit encoder include four Hall-effect sensor elements and a 32-bit microprocessor mounted on a single 36-mm diameter PCB that’s 20-mm thick. The kit encoder is based on POSITAL’s IXARC magnetic design, but the unbundled version facilitates tighter integration onto rotating axes.

Basics of encoder use for precision motion control Servomotors (common in robots, lifts and cranes, material-handling equipment, and medical-diagnostic systems) are motors with built-in or closely-coupled rotary motion and position encoders. These sensors provide closed-loop feedback signals that ensure precise speed control and accurate positioning of mechanical components that the motors drive. For brushless dc servomotors, rotary position sensors also provide commutation signals to electronics controlling the flow of electric current to motor stator windings. Besides the servomotor applications mentioned, built-in

rotation sensors can help control the motion of wheels in lifts, hoists, and automated guided vehicles (AGVs). Now some motion-sensor manufacturers have begun to offer manufacturers of servomotors and rotating machinery a rugged and cost-effective option for direct encoder integration. These kit encoders leverage core encoder-maker technologies but in morphologies that allow tight integration into the rotating axes of machines. There are no extra moving parts and there’s no physical contact, either. Here’s how installation works: The manufacturer mounts permanent magnets on the motor’s rotating shaft. Electronic pickup components (consisting of four

Hall-effect sensor elements and a 32-bit microprocessor) are mounted on a single pre-engineered printed circuit board (PCB). The Hall-effect sensors respond to the rotating magnetic field created by the permanent magnets on the motor’s shaft ... and output analog signals. Signal-processing software running on the microprocessor filters input data and computes the rotational position of the shaft. Absolute versions have electronic pickups that get energy through Wiegand wires (not backup batteries) that generate powerful voltage pulses in response to the magnet’s revolving field, so the encoder keeps count of complete rotations even without external power. Optical encoders rely on cleanliness and alignment Some kit encoders based on magnetic operation can deliver pulse rates to 16,384 pulses per rotation (PPR) at speeds of up to 12,000 rpm. In addition to incremental rotation monitoring, these devices can provide commutation signals (UVW) for two, four, six or eight-pole brushless dc motors.

Incremental motor feedback

Optical kit encoder

POSITAL kit encoder Optical self-contained encoder

Size

Small

Relatively large

Cost

$-$$

$$$

Multiturn range

Yes

Sensitivity to moisture and dust

High — Needs clean Low environment for assembly

Medium. Sealed housing provides some protection

Ruggedness

High

Code disk and sensors can be damaged by shock and vibration

Equipment for assembly?

Yes — $$$

Yes — $

Skilled worker for assembly?

Yes

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(Absolute versions deliver 17-bit resolution and multiturn position measurements with a range exceeding a million revolutions.) For motor and equipment manufacturers, kit encoders based on magnetic operation are compact and straightforward to build into motors and other rotating equipment. Compared to optical encoder components paired with precision servomotors, the magnetic sensors are more tolerant of sensorto-shaft alignment errors. Some designs also compensate for small positional offsets through a built-in self-calibration capability ... so there’s less need for high-precision assembly techniques. In fact, some servomotor manufacturers and OEMs already use self-contained optical encoders. These typically mount outside the motor casing and require mounting brackets and coupler to connect to the motor’s shaft. Their self-contained, sealed housings protect against dust and moisture, while the use of a flexible coupler can accommodate small alignment errors. While this is an effective solution, kit encoders based on magnetic operation offer OEMs another option for compact built-in position feedback designs — without the need for an externally mounted component or any need to drastically upgrade manufacturing facilities. Plus built-in designs have no need for a separate bearing inside the encoder housing — which further reduces cost and boosts overall design reliability.

Key to magnetic encoding is signal processing As mentioned, magnetic rotary-position measurement technologies in kit encoders can tolerate high levels of shock and vibration. Compared to optical-encoder technologies, magnetic technologies are also much less 60

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vulnerable to the effects of oil vapor. Operating temperatures are from -40 to 105° C. One caveat: Servomotor applications with magnetic brakes can interfere with magnetic-encoder operation. So kit encoders with magnetic operation require a magnetic shield to isolate the measurement system’s magnetic pickups from the brake’s strong magnetic fields. With a magnetic shield in place, the accuracy of encoder pulse count is unaffected by application of the motor brake. Onboard diagnostics help ensure reliable operation over the encoder life. Here, magnetic operation enables real programmable versatility. Software-centric microprocessor-based operation gives the kit encoders field-programmable operation. In other words, an OEM can modify the performance characteristics of any kit encoder through software updates — without changing its mechanical or electronic components. Programmable characteristics in incremental versions include the pulse rate (adjustable from 1 to 16,384 PPR); UVW commutation signals; and rotational direction. Manufacturers can also record in the kit encoder’s memory information such as device serial numbers and date of manufacture for reuse or cloning a machine build. Kit-encoder programmability lets motor and machine manufacturers configure encoders to perform in myriad ways, so they can standardize on a limited number of standard mechanical designs — even while meeting an array of differing operational requirements with software changes to a given standard encoder. Encoder suppliers that sell kit encoders offer programming software that runs on PCs or even mobile devices to support encoder selfcalibration routines and parameter-setting functions. Some kit-encoder suppliers also offer pre-configuration services for large-volume production orders. DW

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M o t i o n

C o n t r o l

Current state

of programmable automation controllers (PACs) for motion

Programmable automation controllers (PACs) excel in commanding complex automation setups that involve PC-based and HMI functions as well as process control (largely because of the way they handle I/O). PACs are also increasingly common in motion applications for machining or handling discrete product thanks to the flexibility and interoperability they offer machine designs. Today’s PACs evolved as an option for complex control when microprocessors with significantly more performance became affordable and commonly available. PACs differ from the still-dominant form of control for motion — the programmable logic controller (PLC) — in that all PACs can perform as PLCs but not vice versa. That’s because PACs serve multiple channels of communication; high-data traffic; and coordination with intelligent subsystems. Most performance PLCs can host intelligent processors in their backplanes — such as Ethernet modules with ports for expanded data and communications, for example. But such setups can be expensive where vendors’ proprietary backplanes and operating systems are costly. Consider how PACs emulate the behavior of electricrelay controls. Relay logic executes sequentially with repeatability and reliability — on hardware rugged enough to survive harsh industrial settings. All logic rungs are defined by inputs and outputs that are logically connected to trigger actions after satisfying precise circuit-logic conditions. This means one logic rung can’t execute without preceding conditions met first. Extra left-hand power rails 62

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for loops and jumps extend relay-system capabilities to build complex logic ... but larger and more complex permutations of these setups can be costly to build and maintain. Some history on this: PLCs themselves replaced relay-based controls and were the first standard as electricity became the dominant power source for manufacturing. As control requirements became increasingly complex, hard-wired relay control became impractical because manufacturing needed more reliable and reconfigurable (programmable) systems. Given their primitive hardware and rigid task execution, early PLCs were difficult to network. In contrast, today’s PLCs are quite easy to

implement. The first PLC in the late 1960s used available electronics that duplicated the behavior of relays — plus were programmable instead of hardwired. This necessitated proof of repeatability and reliability on the plant floor. So custom memory boards, logiccontroller boards, backplane interfaces to I/O modules, and heavy-duty circuitry helped these PLCs run in industrial environments. It was a new concept to let users write application code using the symbols and logic of relays. Today’s PLCs are still more appropriate than PACs in standalone applications such as machine axes that run preset sequences. The rule of thumb is that anywhere PAC functions would otherwise go unused, it still makes sense to use the a more economical PLC. Pressure from plant personnel and the

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enduring value of ladder logic also make PLCs the first choice in many applications. Where PLC setups yield to PACs — and the drive of DCS, RTU, and PC tasks As various industries came to accept PLCs, they came to be used in myriad applications. Increased PLC use has also followed the continuous improvements in their speed, ability to run complex math functions, and communication networks. But once PLC behavior was proven reliable on a computer, the PAC was born. The aerospace and medical industries are two driving forces here. The FAA and FDA mandate that day, date, and time-tagged data about manufacturing processes are stored for extended periods of time — particularly well run on PACs. Even manufacturers of simple consumer products find such information useful for defending designs in product-liability lawsuits. What’s more, it’s not just product-data logging that leverages the datatracking functions of PACs; running predictive maintenance and operations monitoring uses data from controls, too. That necessitates more data and complex network interactions — which means PACs will only become increasingly common. Just as PLCs, the controls known as distributed control systems (DCSs), PCs, and remote terminal units (RTUs) include hardware and programming to satisfy specific applications. PAC hardware can run functions as software to replicate legacy forms of these and other pieces of motion-system hardware. Here’s the catch: Early-generation versions of all these controls were engineered with features to serve specific markets. So for today’s engineers working in siloed industries served by legacy controls, the way in which PACs replicate several control schemes boosts convenience and familiarity during implementation. Note that computer processors’ increasing capabilities and declining cost have blurred distinctions between various control types. Case in point: The PAC itself is the extension of the PLC to incorporate greater data-processing and communications capabilities incomprehensible when the PLC was invented. Originally, DCSs were a collection of RTUs June 2017

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M o t i o n

C o n t r o l

Schneider Electric’s Modicon M580 Ethernet Programmable Automation Controller (ePAC) has native Ethernet in its backplane and controller redundancy (hot standby CPUs). Built for IIoT functionality, it serves as the integrated controller of the supplier’s PlantStruxure automation architecture. Two in-rack motion options include a BMXMSP0200 two-channel pulse train output (PTO) module for servo drives and a BMXEAE0300 SSI module for interfacing with encoders.

programming terminals and storage devices, because their operating systems weren’t robust enough for industrial controls. Now there’s no such limitation, because of vastly improved hardware and widely available realtime operating systems such as Linux for IPCs. Some PACs have multi-processor architecture to support multiple programming environments — and run multiple DCS, RTU, PLC and PC functions. PACs also have high-bandwidth internal architectures that allow multiple processors and multiple tasks to simultaneously execute ... so designers can create myriad control-system structures to satisfy complex and concurrent application requirements.

operating on normal phoneline networks, and their communications were simple alarm states from remote equipment. RTUs were small standalone controllers to execute modest logic tasks — usually off simple information such as elapsed runtime or total units of counted, for example. Early DCSs didn’t transmit data, but one could rent a line from the phone company and create an alarm to indicate that a process value had been exceeded or the RTU needed reading, for example. Industrial PCs have advanced with processor capabilities following Moore’s law. Early industrial PCs were merely

Comparing two controls for motion automation — PLCs and PACs

Typical programmable automation controller (PAC)

Typical programmable logic controller (PLC)

Processor modules

Multiple processors per rack

One per rack

Processor chips per module

Two or more high-performance chips for multitasking

One microprocessor (288)

Communication

Open network • Multiple options • Ethernet/IP

Typically one option (though more are

Programming

Structured text • Function-block diagrams • Ladder logic • Most support IEC-61131 environment

Ladder logic (but with new PLCs supporting IEC 61131

Functionality

Dual scan of logic • Motion control • Data acquisition • Process control

Sequential scan of logic

Memory

Up to 32,000K

Up to 64K

I/O

128,000 (thousands of analog I/Os possible)

3,000

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increasingly common )

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Single-axis and multi-axis motion designs (where PACs make sense) As mentioned, PLCs are still by far the most common choice for simpler setups of standalone or single-axis motion. As a side note, such applications are seeing more inroads from motor drives sporting controller functions. These motor drives excel in machine designs that still need PLC functions with multiple interfaces — including Ethernet communications and digital I/O, for example.

Closed Loop Drives and Motors for EtherCAT® Networks

“PACs have a high-bandwidth backplane that allows integration of various architectures — and allows additional processors to boost the functionality of the primary PAC.” StepSERVOTM Drives and Motors

Because such motor drives can also incorporate motion controls delivering S-curve, camming, and freeform motion profiles, OEMs are more likely to pick them than PACs in otherwise-simple designs eliminating standalone PLCs. Contrast the needs of these motion designs with more complex setups. PLC modules for singleaxis motion are managed by a main processor or primitive sub-processor in the motion module; they interface with a main processor over a PLC backplane. But any PLC modules for single-axis motion control with low encoder-frequency rates can limit performance. Other PLCs limit how fast the position register can update, which in turn limits machine throughput. In contrast, PACs handle higher bandwidth on the backplane, so in complex motion applications can share motion data with multiple motion modules. That boosts performance. High-bandwidth backplanes also makes for more powerful motion modules ... so depending on the processor core, a motion module here may be capable of complex axis-to-axis coordination sufficient for advanced motion in June 2017

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Greater torque, higher acceleration Better throughput in point-to-point motion Higher eﬃciency, quieter operation EtherCAT networking with CANopen CiA 402 operating modes

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Connected. Customized. Closed Loop. StepSERVOTM technology from Applied Motion Products combines the high torque capabilities of step motors with the closed loop dynamic control of servo systems. The result is a motor and drive solution that operates more quietly and eﬃciently, while providing greater torque and higher acceleration rates than traditional step motor systems.

SS-EC StepSERVO Drives and Motors support CANopen over EtherCAT (CoE) control, allowing them to be integrated into new and existing EtherCAT networks. By combining the high-speed networking capabilities of EtherCAT with the motion control performance of StepSERVO, Applied Motion oﬀers yet another feature-packed series of motors and drives designed to help you Make it Move.

800-525-1609 www.Applied-Motion.com Email: sales@applied-motion.com EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany

6/1/17 4:34 PM

M o t i o n

C o n t r o l

This AutomationDirect Productivity 3000 programmable automation controller (PAC) is modular to let engineers customize reliable operations and communications. The controller provides easy communication, programming, data storage, and processing power for industrial automation. Notice how the controller CPU communications ports include those for USB data logging.

machine-tool or robotic applications. No matter the permutation, multi-axis machine controllers include hardware and software in a structure organized around the management of complex motion. Consider the task of tracing a circle with two linear axes. Such coordination necessitates fast axis-position updates and comparisons to predicted position — along with error correction to the speed command of each axis-driving motor. This is a very demanding realtime task. The speed of the processor’s execution must be many times faster than the speed of the motor feedback. Given the

computing capabilities of today’s processors, PACs (and PC-based controllers) are primed to handle such multi-axis motion control. It’s true that each platform does this in its own way — and it’s common to have myriad independent motion axes in a machine with each operating independently off a start-signal input. But full multi-axis motion usually works to coordinate multiple axes through mathematical definitions. The earliest multi-axis motion control was computer numerical control (CNC) of the 1950s. These CNCs had computer hardware running programming languages for automating metal-parts manufacture. The advent of the transistor and integrated circuit drastically reduced the size and cost of CNC hardware, but its command language and architecture persists to today. In fact,

multi-axis motion control since the 1950s has evolved as a unique class of controls to satisfy programming-environment requirements. The development has been complicated by how suppliers choose different processor platforms to go with their proprietary programming languages. User libraries arose to give users higher-level programming tools … but some are still vendor specific, complex, or time-consuming to use. Trends towards standardization continues to address such issues. PAC vendors now produce general-purpose control hardware that integrates into IT networks but is rugged enough for industrial settings — and modular like the PLC form factor. This necessitates relatively advanced controller hardware so the PAC can function in any control application. It also means that

This modular industrial PC is based on the series of Advantech APAX-5000 PACs. There’s also an APAX-5072 high-density Ethernet/IP remote I/O (not shown) that lets controllers, PCs, or HMIs with Ethernet/IP perform read and write actions on system data.

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M o t i o n

C o n t r o l

Choosing between PLCs and PACs is complicated by how they’re similar. But PACs built of SNAP PAC components from Opto22 shown here can (unlike PLCs) multitask with multiple threads — to go beyond a single PLC program path and manage concurrent tasks. This is useful where multiple machines need fast execution of advanced control algorithms and database manipulation. In fact, these PACs run control programs and communicate with HMIs as well as digital and analog I/O.

PACs are equally capable of managing large data-gathering networks, or running machine control logic, or doing both simultaneously. So when it comes to running multi-axis motion control, today’s computing power delivers. Prompting more standardization on the software side is IEC-61131, which dictates the form of much of today’s ladderlogic programming and (in versions 3 and 4) motion extensions for motion programming in the ladder environment. Depending on the motion job, the ladder approach may be fine … but it’s not usually multi-axis. In addition, motion-controller inputs and outputs from homing and limit switches and encoders are high-level inputs that must be dedicated to a specific axis on which they’re setup to work. Sometimes PACs need add-on modules to execute their special functions. Remember that PACs are architected mostly as PLCs, but the major difference (from an electronics standpoint) is how PACs have a high-bandwidth backplane that: • Allows integration of various architectures • Allows additional processors to boost the functionality of the primary PAC. So software in the main PAC can manage intelligent peripherals, but it’s often useful add devices to the system architecture when an application needs control functions that exceed the main processor’s capabilities. A common add-on is remote I/O racks using 68

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standard offerings implemented with highfrequency Ethernet as the communications interface. These setups often use an Ethernet gateway module in a local rack with the main controller … which in turn supports the Ethernet link to the remote I/O rack. Ethernet updates faster than older PLC backplanes ... though in a PAC with high bandwidth, data rates aren’t an issue. Consider the special cases of testing and machine vision. Test setups needing high-speed data acquisition often include timing and triggering functions on their PXI backplanes. Adding a PXI bridge module (or PCI or VME) to a PAC makes the technology available on other bus architectures in the PAC environment. Most machine vision

still uses standalone control because the processing burden and speed of vision demand it. But PAC suppliers continue to expand the repertoire of control capabilities by offering high-speed communications bridges to other subsystems. So machinearea networks with machine vision can be demanding — and yet the high-speed communications supported by PACs are an industry-accepted solution. DW

IDEC and Advanced Micro Controls Inc. (AMCI) offer stepper motors and drives with integrated motion-control functions. The products combine with IDEC FC6A PLCs to let OEMs quickly implement single and multi-axis motion functions. Macro instructions embedded in PLC WindLDR programming software is configurable with drag-and-drop commands to control up to 12 axes. Motion-control macros in the FC6A PLC simplify programming. Case in point: AMCI by IDEC’s iANF2E two-axis controls accept encoder feedback; the controller includes six discrete inputs for move conditioning and other functions, and four discrete outputs to indicate status and provide diagnostics. Myriad motion profiles are selectable via an FC6A PLC connected to the controller via an Ethernet-based Modbus TCP link. Up to six controllers connect to the PLC to drive 12 motion axes.

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L i n e a r

M ot i o n

Higher accuracy

drives linear measurement devices

here nano-level measurement is the name of

The latest linear measurement devices provide top precision and accuracy as more applications than ever call for nano-level measurements.

the game, getting accurate measurements is critical. And depending on the level of precision or accuracy needed, there are many good choices to choose from. Tried and true methods such as optics and magnetics are viable options for higher precision applications, along with linear encoders using laser interferometry.

Nanoprecise linear measurements for high-end industrial applications One recent example of a high-precision application is the IDS3010 from Munichbased attocube systems AG, a wholly owned subsidiary of Wittenstein SE, which brings a new dimension to high-performance engineering precision. The sensing system is accurate to one-billionth of a millimeter and measures target distances up to 30 m away. According to company officials, this interferometric sensor easily

Edited by Miles Budimir Senior Editor

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The IDS3010 system, shown here in a high-precision machining application, combines the precision of interferometry with a compact size.

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M ot i o n A wide range of sensor heads are available for the IDS3010 measurement system including diameters as small as 1.2 mm for a variety of working distances and environments.

“PurePrecision technology is particularly well suited for applications where the encoder is installed in controlled environments that require compact sensor size, small overall footprint and high accuracy.”

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surpasses the performance of conventional glass scales and other available sensor technologies in terms of precision, speed and industrial suitability. The unit is a contactless interferometric sensor that lets designers make highly precise measurements of position and motion. It provides 10-12 m position resolution—in other words, one picometer or one billionth of a millimeter—over working distances of up to 5 m. If fitted with suitable sensor heads, it can perform measurements over a 30-m distance. The IDS3010 measures directly on the target, for example a workpiece, tool or machine component. Inherent or mountingrelated measurement errors due to backlash, wear, deformation, thermal expansion or other influences—which are intrinsic to indirect measuring glass scales as well as inductive displacement sensing systems—are completely eliminated. Stationary or moving targets are sensed at velocities of up to 2 m/sec with a data acquisition bandwidth of 10 MHz. That means a measurement containing all relevant information related to position or movement is generated every microsecond. The IDS3010 is designed as an optical, multi-channel measuring sensor. Up to three miniature sensor heads can be connected via glass fiber cables to the compact basic unit, which measures just 19.5 × 5 × 5 cm, to simultaneously measure positions and motions in up to three axes. The sensor heads can be supplied with optics for different types for measurements on all kinds of materials and surfaces such as glass, plastic, ceramic, aluminum, copper or steel. Customized sensor heads — for example, made from tungsten or sapphire — are available for particularly complex measurement tasks. June 2017

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The device has an integrated web server, so sensor alignment, initialization and configuration can be controlled, adapted and monitored remotely from any location. This makes its suitable for IoT or Industry 4.0 applications. A broad spectrum of real-time interfaces and protocols lets position data be transmitted easily to CNC controllers or RTOS computers. The sensor is also compatible with different fieldbuses and standard industrial networks like CAN open, Profinet, Profinet RT or EtherCAT, letting engineers integrate it into large or complex systems.

Precision optical encoders Older, well-established technologies such as optical encoders continue to make progress as well. For instance, the new MicroE Optira Series encoders from Celera Motion are s aid to be the only encoders in their class to provide a resolution of up to 5 nm with all automatic gain control (AGC), interpolation, and signal processing carried out in the sensor head. The wide alignment tolerances and patented PurePrecision optical technology also make Optira’s miniature sensor head simple and easy to set up. The Optira sensor head comes with two mounting options and a standard FFC connector that offers the flexibility and durability required by designers focused on compact precision motion control solutions. The Optira also consumes low power, and a 3.3 VDC version is available for use in precision instruments powered by batteries. The compact sensor head measures 11.4 x 13 x 3.7 mm. Another plus is that no additional PCBs, adapters, or dongles are necessary for the full functionality and resolution of the sensors. Optira sensors can also be universally applied with MicroE linear glass scales (to +/- 1 μm/m accuracy), linear metal tape scales (to +/- 5 μm/m for Optira), and rotary scales (to +/- 2 arc-seconds). The interface options are A-quad-B or 1-Vpp sin/cos. PurePrecision technology lets designers of precision motion control systems in medical, semiconductor, advanced industrial and scientific applications design smaller,

6/2/17 2:05 PM

Linear encoders — the basics

lighter and more energy efficient machines and instruments. PurePrecision technology is particularly well suited for applications where the encoder is installed in controlled environ-ments that require compact sensor size, small overall footprint and high accuracy. Another optical encoder manufacturer, Renishaw, also has a new encoder called the VIONiC series, a new family of ultra-high accuracy, compact, all-in-one digital incremental encoders. Designed for demanding motion control applications, the VIONiC series brings together Renishaw’s filtering optics with a new custom interpolation and monitoring ASIC (Application-Specific Integrated Circuit) that enhances dynamic signal processing and improves signal stability. Renishaw has created its highest performance incremental encoder system so far, at the same time combining all necessary interpolation and digital signal processing inside the readhead to eliminate the requirement for additional external interfaces. The VIONiC range has been designed to reduce overall system size to the minimum achievable for a high-performance system, while delivering class-leading performance in terms of cyclic error, jitter, speed, resolution and accuracy. Designers can choose between two VIONiC readhead variants. The standard VIONiC readhead features a cyclic error of <± 30 nm, a range of available resolutions from 5 μm to 20 nm, and speeds beyond 12 m/sec. Alternatively for the most demanding performance requirements, the VIONiCplus features best-in-class cyclic error to <± 10 nm, low jitter of <1.6 nm RMS and resolutions from 100 nm down to 2.5 nm. High accuracy encoders are essential to minimise velocity ripple, which is important in constant-velocity applications such as laser scanning. VIONiC series encoders are available with the same linear The MicroE Optira series optical encoders from Celera Motion feature 5-nm resolution with signal processing in the sensor head.

Linear encoders monitor linear movement and provide position feedback in the form of electrical signals. There are two types of output: absolute or incremental. Absolute encoders assign a unique digital value to each position, which allows them to maintain precise position information, even when power is lost. On the other hand, incremental encoders work by generating a specific number of pulses per unit of travel and counting those pulses as the load moves. Because they are simply counting pulses, incremental encoders will lose their position reference if the power supply is interrupted. In order to determine the load’s actual position upon startup or re-start, a homing sequence is required. This means that the sensor (and the load) must move to a reference position, and from there it can begin to determine the load’s position. The two most common kinds of sensing technology are optical and magnetic. While optical encoders have historically been the only option for resolutions below 5 microns, improvements in magnetic scale technology now allow them to achieve resolutions down to 1 micron. Optical encoders use a light source and a photo-detector to determine position, but their use of light makes them sensitive to dirt and debris, which can disrupt the signal. The performance of optical encoders is highly influenced by the gap between the sensor and the scale, which must be properly set and maintained to ensure that signal integrity is not compromised. This means that mounting must be done carefully, and shocks and vibrations should be avoided. Magnetic encoders use a magnetic read head and a magnetic scale to determine position. Unlike optical encoders, magnetic encoders are mostly unaffected by dirt, debris, or liquid contamination. Shocks and vibrations are also less likely to affect magnetic encoders. They are, however, sensitive to magnetic chips, such as steel or iron, as they may interfere with the magnetic field. Another sensing technology is laser interferometry. It’s a well established measuring technique used in applications requiring highly accurate position measurement in the nanometer range. The principle of operation is this; a light beam is split into two and an interference pattern forms from the superposition of the two beams. The changes in the interference patterns correspond to the distance traveled by the light, providing information on position and length. Also, using a laser as a light source provides a single wavelength source of light, making the measurements more accurate.

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6/2/17 2:09 PM

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L i n e a r

Optical linear encoders, like the new VIONiC series from Renishaw, are available with measuring resolutions down to 2.5 nm.

M ot i o n

and rotary (angle) scale ranges as the TONiC series, so that existing users can choose to install VIONiC as a drop-in replacement. Available scale types include metal tape, spar, and rotary rings (including ultra-high accuracy REXM). All VIONiC scales come with customer selectable IN-TRAC reference marks embedded in the incremental channel and dual-limit switches in the case of linear scales. Applications which benefit most from VIONiC are those requiring the highest levels of motion control precision, specifically micro-manufacturing, micro-positioning and precision optics manufacturing. DW Wittenstein | wittenstein-us.com attocube | attocube.com Celera Motion | celeramotion.com Renishaw | renishaw.com

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Bearing design considerations for hand tools John Wallace Vice President of Operations â&#x20AC;¢ AST Bearings

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Handheld power tools are commonplace in many industries from automotive to aerospace. Ball bearings play a critical role in the performance and reliability of these tools and are responsible for handling combined loading conditions (radial and axial), high speed operation, low friction, low noise and vibration, and high reliability. Power tools have a global market of close to $26 billion (approximately $11 billion in the US). Cordless electric power tools are the fastest growing segment, with the industrial and professional market outpacing consumer demand. Products produced for the consumer market generally have lower price points, lower quality and incorporate components that are “off the shelf” or fall into the “commodity” category. In the industrial arena, power tools are highly engineered products that reduce worker fatigue and improve productivity and quality. They are routinely used in all types of operations such as, driving (fasteners), drilling, cutting, shaping, sanding, grinding, routing, polishing and more.

In the industrial arena, power tools like this sander are highly engineered products that reduce worker fatigue and improve productivity and quality. They are also routinely used in other types of operations such as, driving (fasteners), drilling, | Courtesy of AST Bearings cutting, shaping, grinding, routing, polishing and more.

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M e c h a n i c a l

In many industrial environments, power tools (and possibly bearings) are continuously exposed to liquids and various types of particulate debris. Shielded bearings like these should be used in these situations.

In the industrial arena, power tools are highly engineered products that reduce worker fatigue and improve productivity and quality. They are routinely used in all types of operations such as, driving (fasteners), drilling, cutting, shaping, sanding, grinding, routing, polishing and more.

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Typical industrial rotary tools include drills, screwdrivers, nut runners, impact wrenches and drivers, grinders, sanders and polishers. Electric motors and compressed air are the most common types of powers sources used in a factory environment. The following are just a few of the considerations to be made. when thinking of bearings in an application’s design. Bearing Loads: Ball bearings can support both radial and axial loads simultaneously, making them the ideal choice for the demands of power tools. However, due to their internal construction having relatively shallow raceways, the predominant load component should be radial. In the event axial loads are excessive, thrust bearings can be used in combination with radial ball bearings to support these loads. Noise and Vibration: A noisy and vibrating tool will quickly cause discomfort for its operator, particularly in factory or production environments where motion and operations are repetitive. In the case of ball bearings, noise and vibration are directly related to the quality of the materials used for the rings and balls, the internal manufacturing specifications and tight process controls. Bearings used in these applications should be produced to Electric Motor Quality (EMQ) noise levels. EMQ standards are not uniform (except in China where there is a national standard) and vary from manufacturer to manufacturer, but the EMQ rating indicates they are suitable for use in electric motors.

Historically, electric motors must run quietly with little or no vibration, and this terminology came to be as a result. Manufacturers produce bearing components to strict specifications and employ various techniques to produce EMQ bearings. Great care is taken to produce rings with near perfect geometry. Geometrical tolerances control features such as roundness, concentricity, run out and parallelism. Bearings with rings that have poor geometry tend to produce lower frequency noise and vibration. Raceways (the tracks where the balls roll) are super finished to produce mirror like surfaces. High quality balls are also used, meaning they have good geometry, such as being perfectly spherical. Balls or raceways with poor surface finishes tend to produce higher frequency noise and vibration. Certain lubricants can contribute to noise levels as well. The smaller bearings used in these hand tools require “clean” grease. Manufacturers who produce EMQ bearings typically perform 100% noise testing of the bearings using specially designed equipment prior to final lubrication and packaging. Power tool manufacturers must properly specify and apply preload to the bearings used in a power tool to reduce noise and vibration. 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. In power hand tool applications, this internal clearance must be removed for a pair of bearings to operate properly. The application of an axial load across the pair of bearings – for the purpose of removing free internal clearances – is called preload. 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. Preload is critical in high-precision and highspeed power tool applications where speeds can reach as high as 60,000 RPM.

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M e c h a n i c a l

Running Temperature: Power hand tools must be designed and manufactured so that they can be held by an operator for long periods of time. Bearings must be mounted properly, have the proper preload and have the proper lubrication type and amount in order to minimize the running temperature. Bearing Materials: All bearings should be manufactured using components produced from high purity material. Bearing rings and balls are most commonly produced from SAE 52100 chrome steel. This thru hardening alloy has excellent fatigue strength and wear resistance, and is the most cost effective choice in a non-corrosive environment. In hand tools, bearings are typically well protected within a housing or enclosure. However, if there is risk of exposure to moisture or corrosive attack, martensitic stainless Design World P04 half page.pdf 1 1/16/2017 steel, similar to AISI 440C, is recommended.

This 400 series stainless steel offer the best combination of corrosion resistance and fatigue life. It provides good corrosion resistance and has fine, evenly dispersed carbides which result in lower noise and vibration levels than 440C. This material can be specified differently by manufacturers. In some cases, balls produced from ceramic materials, such as silicon nitride, are very beneficial. Ceramic balls are very light weight, highly polished, non-magnetic, exhibit high hardness and are resistant to attack from most liquids and chemicals. Ceramic balls greatly improve the high speed capability of the bearing. Bearings made of steel rings and ceramic balls are commonly called hybrid bearings. While ceramic balls have an impressive list of beneficial features, they are not typically used in hand held power tools. Lubrication: Lubricant selection could be the specification most overlooked by designers and 2:19:57 PM engineers. Bearing life depends on proper lubrica-

tion in terms of both type and amount. In most cases, the smaller bearings used in power hand tools are lubricated once for the life of the device. Thousands of greases and oils are available that are designed to function in a variety of conditions and environments. Operating temperature is the primary consideration when selecting a lubricant. Temperature directly impacts the base oil’s viscosity which in turn impacts the ability to support loads. Due to the wide array of products along with price and availability, both a lubrication specialist and the bearing manufacturer should be consulted before making a final lubricant selection. Harsh Environments: In many industrial environments, power tools (and possibly the bearings) are continuously exposed to liquids and various types of particulate debris. Sealed or shielded bearings should be used in these situa-

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M e c h a n i c a l

tions. Seals are the best option for keeping foreign debris out of the interior of the bearing and keeping lubricant in. The most common bearing seal material is a nitrile rubber. This type of seal is typically Buna-N bonded to a steel insert, which is fixed into a groove in the outer ring. The maximum operating temperature is 240° F. This type of seal makes contact with the inner ring providing better protection in contaminated environments than a metal shield. However, this results in an increase in torque and reduces the maximum speed capability of the bearing, but in almost all cases is a design trade off that is made to improve life. Certain lubricants and chemicals react with rubber. Aside from the Buna-n and nitrile rubber material, other materials are available for higher temperatures and chemical resistance. These include F Teflon fabric and Viton that has good chemical

Seals are the best option for keeping foreign debris out of the interior of the bearing and keeping lubricant in.The most common bearing seal material is a nitrile rubber. This type of seal is typically Buna-N bonded to a steel insert, which is fixed into a groove in the outer ring. The maximum operating temperature is 240° F.

resistance and a maximum operating temperature of 400° F. As evidenced, there are a wide range of bearing options to take into account for optimal hand tool performance. Engineers and designers are encouraged to consult a bearing applications specialist for assistance with calculating load capacity, bearing life,

Planetary Gearheads

fits and component tolerances, as well as evaluating environmental factors in order to properly specify bearing attributes. DW AST | astbearings.com

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Changes

inwhatCAD — you need to know With the March release of Inventor 2018 and AutoCAD 2018, it’s a good

CAD packages are updated with the same regularity as other major

time to review several of

software systems, often annually, with smaller releases to fix bugs or for minor

the recently released major

include major enhancements or completely new features. Other times, they

CAD programs. Here’s a

include new subscription models, as is the case with Inventor, or offer new

look at some of the biggest

ways to access the software, such as through the cloud, which Solid Edge

enhancements and key features of these programs.

Jean Thilmany • Contributing Editor

updates happening throughout the year. Sometimes, the annual updates

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announced with its ST 9 version. Autodesk Inventor Here’s what designers will see in the latest version of Autodesk’s flagship mechanical design package: The big news with the March release of Autodesk Inventor is its subscription-based plan. Users can subscribe for $235 per month. Or, they can choose to pay upfront at $1,890 for one year, $3,590 for two years, and $5,105 for three years. These type of short-term subscription plans are good for companies that may bring on extra designers, and need more software seats, or during certain times of the year, or for companies that have landed a large project and need more help carrying it out, says Luke Mihelcic, an Autodesk product marketing manager. Autodesk also has plans to roll out new functions for Inventor every few months rather than within one big, annual update. That is to say, Inventor will see new versions, or major releases, followed by incremental updates that build upon them, Mihelcic adds. www.designworldonline.com

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3D CAD

Large assembly capabilities have been improved in SolidWorks 2017, which was released in the fall of 2016 and is the latest version of the system from Dassault Systemes.

• Model-based definition

• Collaboration tools and ease of use

Inventor has also upped the tool’s interoperability, Mihelcic says. With the 2018 version, users can output 3D PDF files so design information can be shared with others—whether they’re part of the company or not--including manufacturers, customers, suppliers, and marketing managers.

Large-assembly design has also been made easier in Inventor 2018 from Autodesk. The capability to pan and zoom in on both 3D and 2D designs is improved in this version. The image shows an example of a machine design by equipment-maker Mastenbroek using Inventor. | background image: istockphoto.com

This year’s annual update includes model-based design (MBD) tools that users can use to annotate models with product manufacturing information (PMI) like tolerances, dimensions, and manufacturing notes. The tools help projects move from the modeling to the manufacturing stage faster than without the notes, Mihelcic says. While annotating 3D models already saves time formerly spent creating 2D manufacturing drawings, this new release saves engineers who design in Inventor even more time because they don’t need a special authoring application for 3D annotation. Many engineers who use MBD to annotate models with 3D PMI still have to learn the separate, special application.

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3D CAD

Autodesk released its AutoCAD 2018 design tool in March.

Also in Inventor 2018, the “measure” tool has been simplified and improved to make it easier to use, and bill of materials and parts list sort orders have been made easier to organize because they’re now based on the commands users add themselves, he says.

CAD packages are updated with the same regularity as

AutoCAD 2018 The other big system from Autodesk, AutoCAD turns 35 this year. The CAD software and its cousin, AutoCAD LT—which stands for “light” and doesn’t include the full roster of features seen in the main version--also saw a March update, to version 2018, says Heidi Hewett, AutoCAD technical marketing manager. The newest version is built on a modern code base, which means it runs smoother and faster on current hardware than past versions. In fact, AutoCAD 2018 now supports 4K high-resolution monitors and screens. A 4K display is comprised of 3,840 or higher pixels of horizontal resolution and 2,160 pixels of vertical resolution.

other major software systems, often annually, with smaller releases to fix bugs or for minor updates happening throughout the year.

• DWG 2018 84

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The updated CAD system also includes the 2018 DWG (short for drawing) file format, which is the data-file-format AutoCAD uses to create and save designs. This

format will improve the efficiency of open and save operations, especially for drawings that contain many annotative objects and viewports, according to Hewett. This is the first DWG update since 2013. That’s important to know because, while designs created with AutoCAD 2018 will be saved to the 2018 DWG file format, older versions of AutoCAD cannot read the 2018 format. Designers sharing with users on systems that don’t support the 2018 DWG format will need to save their files using an older version of DWG, likely the 2013 version.

• Navigation and Reference Improvements

Version 2018 also introduces tools to fix broken paths for externally referenced files, which helps reduce problems created by broken reference paths and saves the time spent on relinking paths. The upgrade allows users to replace external paths that have one or more missing references with a new path, according to Hewett. The workflow for creating references is improved with this version. A relative path is automatically assigned to all new, external references.

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3D CAD

Users can still choose to assign references as “full path” as was done automatically in previous versions. They can also specify a relative path before saving their drawing. In the past, they couldn’t specify a relative path until they were saving their drawings. AutoCAD LT won’t see the 3D navigation performance enhancements included in AutoCAD 2018, which Autodesk said offers improvements when using zoom, pan and 3D orbit operations. For example, many larger drawings will no longer degrade as users navigate around the model, the company says. The performance for manipulating 3D models is approaching that of 2D drawings, Hewett adds.

Built in data-manage tools included within Solid Edge ST9 are updated with the ST10 release.

• CAD Viewer update 86

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Autodesk recently re-released the Design Review CAD viewer, which the CAD maker hadn’t updated since the 2013 version. The CAD viewer software lets users view, mark up, print, and track changes to 2D and 3D files for free—even if they don’t own or use AutoCAD. It works with a variety of file formats, including: DWF, DWFx, DWG, and DXF, Adobe PDF, as well as image file types such as.bmp, .jpg, .gif, .png, .tif, .cal and a host of others. The DXF, or drawing exchange format,

from Autodesk allows data to be exchanged and read between AutoCAD and other programs. Solid Edge This CAD system is Siemens PLM’s main design and engineering offering with release ST10. ST stands for synchronous technology, the method Solid Edge uses for modeling rather than the usual constraint-driven or history-tree modeling. It gives designers the ability to edit models directly rather than making the changes within hierarchical and dependent feature trees, according to Siemens.

• Manage information

Also, new built-in data management tools help manage revisions. In a new “revisions” dialogue box, users can see the entire revision history of a part. They can also comment on any revision in the revision tree and ask whether newer versions of a part are available.

• Sheet metal design and more

Users can design sheet metal parts with Solid Edge ST10 and can edit those parts directly, even if they’re bent. They can

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3D CAD also reposition features on the parts, resize them, and change their form without having to go back through the feature tree to correct design errors. Siemens PLM continues to integrate new capabilities into its Solid Edge CAD system through recent acquisitions including Polarion, for development of software embedded within products, and CD-adapco, for design simulation.

• Additional features

A design manager feature has been added to simplify detecting and replacing duplicate files. After launching the tool, users can see if any of the parts in an assembly have geometric matches with different names and replace them with the preferred part. They’re also able to see tell if a part has a drawing, making it easier to determine the value of one component over another.

The automatic routing path feature in ST10 means users can create routing paths automatically between points within an assembly, part, or sheet-metal design. In earlier versions of the tool, they needed to create routing paths manually. This is a boon for users who design pipelines or create designs that include wiring or hoses, for example, notes a spokesman at Siemens. Solid Edge ST10 will be the last Solid Edge release to support Windows 7. SolidWorks SolidWorks 2017, released earlier this year, offers support for virtual and augmented reality devices such as HTC Vive, Oculus, Google Cardboard, and Samsung devices. This version includes a new user interface, though the change isn’t as dramatic as seen in the previous release. The update now makes the order of configurations sortable, rather than existing only in the order they were created. Also, shortcut menus are streamlined and standardized.

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Users can also open proprietary 3D CAD data in SolidWorks 2017. Systems supported include Creo, CATIA V5, Solid Edge, NX, and Inventor.

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3D CAD Associativity is maintained with the original file, meaning updates made within supported systems are automatically reflected in the SolidWorks file.

• Other features

The CAD maker has also expanded capabilities for model-based definition. With this version, users can compare geometry and 3D product and manufacturing information between two revisions, and attached multiple files to a 3D PDF to create technical data packages. The company’s “visualize boost” feature makes for faster rendering speeds. New features include a reliability tab that provides access to information such as how the previous session ended and the version of SolidWorks running. The upgrade also introduces a new feature called “offset on surface,” which allows users to use existing 3D edge and face entities to create new sketches. Other Updates Of course a number of other CAD packages such as TurboCad Deluxe 2017 and NX, also from Siemens PLM, have seen recent updates as well. And we expect to see new features included in future Creo Parametric (formerly Pro/e) versions. In CAD software, as in life, nothing stays the same forever—or even for very long. DW

Autodesk | Autodesk.com

Stainless Steel Machine Components

Siemens PLM | plm.automation.siemens.com SolidWorks | solidworks.com

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It’s not a web page, it’s an industry information site So much happens between issues of Design World that even another issue would not be enough to keep up. That’s why it makes sense to visit designworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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Prod uc t World Brakes for servo motor applications Miki Pulley mikipulley-us.com BX series brakes are a power-off, engaged type brake. When the stator is energized, the brake is disengaged allowing free rotation. When no current is applied, compression springs halt the brake rotor thereby stopping the input shaft rotation. This feature prevents power failure events.

Of the BX series, the BXR-LE has expanded to 3 additional sizes. (6

total size configurations to choose from.) These brakes have advantages including a slim design and high holding torque in a compact package. This brake was designed for smaller machine and robotic applications, where cantilevered loads can negatively impact operation. The brake’s unique compact and lightweight design optimizes machine design efficiency. With accompanying voltage controller, power consumption is stepped down to 7 Vdc after a split second of 24 Vdc for brake actuation.

Right angle gear drives Zero-Max zero-max.com “Crown” gear drives are a smooth operating, quiet right angle gear drive that needs no maintenance. Lubricated for life with Beacon 325 premium grade grease, the Crown drives feature heat treated AGMA Class 10 spiral bevel gears. This combination of bearing design and lubrication formulation ensures long-term, maintenance free operation for demanding industrial applications. The drives feature precision hardened and ground ball bearings with non-magnetic steel shafts for handling speeds up to 2000 rpm in most operating environments.

The internal gears are permanently mounted to the shafts with locking

pins. Sealed-for-life systems using motors, generators and similar equipment in industrial applications require an equally robust gear drive. Crown drives provide that and more. Lubrication with Beacon 325 grease ensures optimum performance in temperature ranges from -50° to +120° C without evaporation.

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

Digital temperature sensors AutomationDirect automationdirect.com The previous line of instrumentation products now includes the ETS series digital temperature sensors. The ETS series combines an RTD sensing element, measuring electronics, and process fitting all in a single stainless steel temperature transmitter probe.

Four standard probe insertion lengths and two integral male NPT

process threads are available and allow direct mounting to the process or thermowells, eliminating the need for separate probe mounting or adapter fittings. A built-in 4-digit display provides indication of the measured temperature. Two yellow LEDs indicate output switch status. The sensor housing can be rotated up to 310° after installation and the digital display can be electronically flipped 180° for inverted installations.

EtherCAT terminals directly connect with field devices Beckhoff beckhoff.com/ELX The ELX series EtherCAT Terminals with intrinsically safe inputs/outputs and compact design, allow direct connection of field devices located in hazardous areas – classified Zones 0, 1 and 2. PC-based control now combines industrial automation and process technology, including all the benefits of integrated and comprehensive diagnostics from the EtherCAT system.

The combination of compact I/O modules and integrated safety barrier functionality

results in EtherCAT Terminals for connecting intrinsically safe field devices. The I/O terminals have either 12 mm housings with up to four intrinsically safe inputs or 24 mm housings with up to eight similar inputs. The slim terminals reduce space requirements in control cabinets by up to 50%.

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Prod uc t World High-power gearboxes

Photoelectric sensors Carlo Gavazzi GavazziOnline.com

Dunkermotoren dunkermotoren.com

In the PD30CN Series Photoelectric Sensors with

These high-performance gearboxes

PointSpot Beam, the visible

cover nominal torque of up to 160 Nm

red light narrow beam makes

and acceleration torque of up to 320 Nm.

detection more accurate and

Company focus is on shock loads, as they

allows detection of smaller

occur in case of emergency stops.

objects, if compared to standard

This line of PLG HP gearboxes can

sensors. When compared to laser

withstand peak loads of up to 480

sensors, the PointSpot beam

Nm with no adverse effects on the

is not only more economical, it’s also safer, as there are no concerns with damaging

gearing. Dunkermotoren’s hallmark

people’s vision.

is the compactness of the modular drive solution: motor, electronics and

Features:

gearbox. The planetary gearboxes

• Elimination of disturbing halo light for best sensing performance

also eliminate the need for a clutch or

• World standard housing style: 10.8 x 20 x 30 mm with two M3 mounting holes

flange to be mounted to the motor. This

further shortens overall drive length.

• N.O. and N.C. outputs, NPN or PNP versions

• 10 – 30 VDC supply with NPN or PNP output

These planetary gearboxes are

(25.4mm spacing)

available in a wide range of outputs,

• IP67 rating

exceeding reduction ratios over to 700:1.

• CE and cULus approved

Lubricating grease for generator bearings Klüber Lubrication klubersolutions.com Klüberplex BEM 34-131 N is a specialty rolling bearing grease for increased reliability of wind turbine generators. Klüberplex BEM 34-131 N offers high load-carrying capacity, corrosion protection and a long lifetime. Klüberplex BEM 34-131 N is also formulated to perform in automatic lubrication systems. Klüberplex BEM 34-131 N can also be used for rolling bearings subject to oscillation, high loads and vibration. In wind turbines, these considerations are found in every rolling bearing, including blade bearings, main bearing, yaw and generator bearings. Due to targeted formulation, Kluberplex BEM 34-131 N can excel in a diverse variety of conditions. 92

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Grid encoder for testing CNC machines Heidenhain heidenhain.us The KGM 281 grid encoder is available with a measuring range of Ø 140 mm and an increased accuracy of ± 1 µm. The 281 model’s grid plate with phase grating has an optical measuring standard. It is embedded in a twopiece aluminum holder. The design of this holder prevents mechanical stress from being induced at the level of the measuring standard even if the mounting surface is not plane. This makes it possible now to guarantee the accuracy grade of ±1 µm for the system.

The KGM 281 can be mated to the same dimensions as the previous

KGM 181, but due to the revised mechanical design it is 21.5 mm higher.

DIN-Rail mount transformers

Addition cured silicone

WAGO wago.us

Master Bond masterbond.com

These transformers have variable input/output voltage with the use of

MasterSil 157 is a two

center tap terminals and a peak output power of 70 VA (787-976) or

component silicone

45 VA (787-974) for 1 minute per hour providing power boost to help

system that features

with heavy loads. With an operating temperature range of -25 to 55 °C

low viscosity and low

and a host of approvals, (CE; UL 5085, cURus Class B, EN 61558-2-6)

exotherm. It provides

787 EPSITRON transformer power supplies are durable and safe for a

electrical insulation

wide range of building automation applications. CAGE CLAMP technology

properties and can cure

provides fast, vibration-proof and maintenance-free connections.

in sections beyond 1-in. thick. MasterSil 157 is serviceable over the wide temperature range of -175° to +500°F [-115° to +260°C].

Similar to traditional silicones, MasterSil 157 is highly

flexible with an elongation of 110-140%, enabling it to withstand rigorous thermal cycling and shock. Featuring a refractive index of 1.43, it has excellent optical clarity and the ability to transmit light from 220-2,500 nanometers. Its optical clarity makes it a good fit for many applications in the optical industry like optical fiber cladding and encapsulating LEDs.

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Prod uc t World Explosion proof encoders

Multi-axis calibrator Renishaw renishaw.com

Posital posital.com

The XM-60 multi-axis calibrator is capable of measuring all six degrees of

IXARC rotary encoders dedicated to Zones 2 & 22 are ATEX compliant and can operate safely

freedom from a single set-up, in any orientation for linear axes. The XM-60 multi-axis calibrator provides a highly accurate laser system that incorporates unique technology with a patented optical roll measurement and fiber

in atmospheres where there are potentially dangerous levels of explosive gases or dust (3G and 3D). These devices can be delivered with

optic launch system. The compact launch unit is remote from the laser unit, reducing heat effects at the point of measurement. It can be mounted directly to the machine on its side, upside down and even on its back, which is

either programmable incremental or absolute

particularly beneficial in areas with difficult machine access.

output.

• For Group II Applications Dedicated to Zone 2 & 22 Provide Absolute Position with No Battery Backup

Reducing uncertainties of measurement is paramount for any user. The

Renishaw XM-60 has been designed to measure machine errors directly, reducing the inaccuracies that can result from complex mathematics used in some alternative measurement techniques.

• Housing Material: Aluminum, Stainless Steel (303 AISI and 316L AISI on request) • Large Variety of Mechanical Combinations Available • Removable Connection Cap or Cable Exit • Resolution up to 16 Bit, Revolution up to 14 Bit • Communication Interfaces: CANopen, DeviceNet, Profibus, SSI, ProfiNet, & Incremental

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Interactive online app Reell reell.com The newly launched “Hinge Selection Guide” introduces a user-friendly resource to pinpoint hinge and torque insert product solutions matching application requirements. This free online tool opens an interactive window to designate an application’s parameters, calculate the torque and rotational angle required for the hinge or torque insert and identify the products best suited for the job.

Custom right angle worm gear motors Power Electric powerelectric.com This new right angle gear motor combines worm gears and compact size. The worm gears provide large gear reduction options and a cost-effective approach with precision and accuracy. This right angle gear motor is fully customizable to customer requirements and specifications. The worm gear motor series comes with the option of dual shaft or single shaft and a wide gear ratio.

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Ad I n dex

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6/5/17 10:51 AM

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