DESIGN WORLD JUNE 2019

www.designworldonline.com

June 2019

inside: MOTION CONTROL: VFDs with integrated motion

and machine controls

p. 96

LINEAR MOTION: Up your conveyor game

p. 102

ADDITIVE TECHNOLOGY:

Pneumatics ensures safe

post processing of metal 3D printed models

p. 72

Step into

CAD

Immersive design technologies make CAD models uniquely interactive page 108

JUNE 2019 DW COVER-GATEFOLD_FINAL.indd 1

6/3/19 10:03 AM

PLCs starting at only $69.00

HMIs

Whether the job is very simple or extremely complex, we have the affordable PLC solution you need. Our three PLC families provide a variety of control options and can handle a wide range of applications from simple counter/timer logic to coordinated motion. So don’t break the bank with those other guys, keep your project on time and under-budget with AutomationDirect!

CLICK starting at

R

$69.00

The CLICK PLC family offers extreme value for everyday applications. The compact size and easy programming make CLICK great for small applications and beginner projects.

AC V star

Dynam a varie few of rating one G and th

starting at

$197.00

The Do-more PLC family features one of the most advanced instruction sets in the market as well as many other features that allow it to stand strong against any challenge.

Sen star

You ne access sensor voltag starting at

$171.00 (P1-540 CPU)

With d autom

The Productivity Series PLCs are scalable, high-performance tag name based controllers with expansive built-in communication options and other features you’ll love at an awesome price.

With our PLCs you’ll never get hit with extra fees since our software, manuals, tech support, and access to online resources are all completely FREE! You can learn all about our PLCs by visiting:Today, Ships Order

Today!

* See our Web site for details and restrictions. © Copyright 2019 AutomationDirect, Cumming, GA USA. All rights reserved. www.automationdirect.com/ADCPLC

AutomationDirect gatefold_digital edition_6-19.indd 2

6/4/19 2:10 PM

HMIs starting at $98.00 Our C-more HMIs are designed to provide complete system visibility and utmost cost savings for your interface needs. From basic systems to advanced, C-more HMIs have the animations, logic, math, alarming, remote accessibility (web server/mobile app) and communication needed for modern systems.

www.automationdirect.com/ operator-interface

AC VFDs starting at $108.00

e or

Dynamic braking, PID, V/Hz control, sensorless vector control and a variety of communication options including BACnet are just a few of the features available with our AC drives. With horsepower ratings up to 300 hp and the ability to control eight motors with one GS4 drive, you’re guaranteed to find the AC motor control and the savings you’re searching for.

www.automationdirect.com/VFD

Sensors/Switches starting at $8.50 You need sensors? Well, we’ve got tons, actually over 3,000 sensors and accessories! We currently offer rotary encoders for detecting position and speed, sensors for detecting proximity, pressure, temperature, level, flow, current and voltage, and limit switches for detecting presence or end-of-travel limits.

With discrete or analog outputs, these sensors can provide critical data when automating any machine or process.

www.automationdirect.com/sensors

e tag ation .

Over 25,000 low-cost quality industrial control products are available on our webstore (www.automationdirect.com) 24/7/365 and each one comes with the customer service and support you deserve. So for your next project, check us out and remember when it comes to automation, no one gives you more than AutomationDirect!

Today!

umming, GA USA. All rights reserved.

AutomationDirect gatefold_digital edition_6-19.indd 2

1-800-633-0405

the #1 value in automation 6/4/19 2:09 PM

Nobody does FREE better than AutomationDirect...

NO PURCHASE NECESSARY!

linePLCTr n O

ing ain

FREE

FREE ONLINE PLC TRAINING Over the years, we have seen the demand for PLC training grow exponentially not just with our customers but with those new to PLCs in general. To support this demand, we have expanded our online PLC training offerings, allowing easy and free access to anyone interested in learning about industrial controllers.

This completely free online PLC training course is available 24/7 so you can learn at your pace and at your convenience. To access the training or learn more about what is provided, follow the link below.

www.automationdirect.com/plc-training

FREE PLC SOFTWARE

FREE TECH SUPPORT

FREE FAST SHIPPING

Our CLICK, Productivity and Do-more series PLC software packages are available to download as many times as you’d like, free of charge. Our Do-more Designer software even includes a project simulator, so no hardware is required to test your logic.

To try out ladder logic or test drive our PLCs, visit: www.automationdirect.com/ADCPLC

Free technical support is available via phone ((800) 633-0405), email or chat, M-F 9am to 6pm EST. Our technical support specialists are continually trained on our vast selection of products and can provide assistance with selecting the right products, troubleshooting technical issues, and/or finding the proper solution for any application.

With the pace of business today, waiting around for components to be delivered is unacceptable. We understand this, and with our automated warehouses and huge inventory we are able to ship products the same day (if ordered before 6pm) and get them to you fast with 2-day delivery free on orders over $49 (visit our store for further details/ restrictions).

...and our prices are unbeatable too!

Order Today, Ships Today! * See our Web site for details and restrictions. Š Copyright 2019 AutomationDirect, Cumming, GA USA. All rights reserved.

Outside Front Gate_AutomationDirect 6-19.indd 1

1-800-633-0405

the #1 value in automation

6/3/19 7:56 AM

Altech 6-19.indd 1

5/28/19 12:33 PM

Design with motion plastics for less grease and maintenance drylin® lead screw

energy chains and chainflex®

iglide® PRT slewing ring drylin® drive technology iglide® bar stock

www.igus.com igus 6-19.indd 2

800-521-2747 5/31/19 8:23 AM

Go Ahead.

Submerge It. Watertight, dust-proof, and flame-retardant, Hammond IP68-rated enclosures keep your internal electronics safe in brutal environments.

1.800.433.5700

© Allied Electronics & Automation, 2019

Allied Electronics - Hammond_5-19_DW.indd 3 MAY19 Allied-Hammond Ad (DW).indd 1

Get your A&C fill at

alliedelec.com

5/31/19 8:24 AM 4/22/19 1:37 PM

NEW!

I n s ights

4 AXIS SERVO from

2.25”

The legality of dealing with problem employees

One of the more interesting speakers I’ve heard in some time was Pamela Krivda, who recently spoke at NAHAD Annual Meeting & Convention in Las Vegas. She’s an HR legal expert and she presented the audience — many of whom were smaller, family-type hose distributors (along with some larger manufacturers) — with tips to better deal with problem employees. Here are five of her suggestions.

- brushed or bldc motors - 5 amps per axis - 16 analog inputs - 16 on/off drivers - home and limit in - live tech support - made in the USA See the

EZQUAD SERVO in action!

WWW.ALLMOTION.COM

(510) 471-4000 30097 Ahern Avenue Union City, CA 94587

1 Don’t be afraid to suspend people with pay. Krivda said that she doesn’t use it as her first option; this would be after a verbal warning and then a written warning.

“Then you’re going tell the employee, ‘Here’s what we’re going to do. I want to know what you really think about your job here. Do you want this job or not? Now, if you want the job, you have to have it under the same terms and conditions as everybody else. You don’t get anything special. You have to take it under these same terms and conditions,’” she said. Krivda said that the employee should then sign a form acknowledging that they want their job. That the employee acknowledges and accepts his/her responsibility. Their job description should also be attached to it — if you don’t have one, now is the time to write one up. Tell them you want them to go home for a couple of days and think over if they want the job or not. If they want the job it’s here, but they have to change their attitude. If they don’t want the job, tell them you will either figure out something or give them a little bit of time to find another job or just release them with no hard feelings.

2 Demotion or reassignment is not a good idea. Do not repurpose a problem; all you’ve done is take your headache and moved it to another supervisor. Then, that supervisor will need two years’ time to get rid of this person. And the person you demoted or reassigned is pissed off. Demotion never works. Reassignments usually don’t work because the employee’s embarrassed. And if they don’t want to work, they don’t want to work. They’re not going to want to work for somebody else.

3 There’s no rule of thumb for severance in this or any industry. The number that you offer somebody is something that your company president can decide. Make it an amount of money that will make your employee snatch it out of the air, sign, and leave you alone forever.

4 Set a precedent with last chances. You don’t want to set a precedent that everybody gets 15 last chances. So truly, make it one. It’s like a toothbrush: everybody gets one.

That’s all they get. This person must follow the same rules and requirements as everybody else. You’re not asking for anything different. You’re not asking them for any more than all the employees are required to give. You have an opportunity for the employee to read and consider it. Let them go home. Let them go off in a corner and read it for a while and think about it.

5 Instead of a non-competition agreement, she recommends non-solicitation agreements. Most or all states will enforce a non-solicitation agreement because you are only enforcing what you really created. The employee, while working for you, created or maintained these contacts, these personal relationships and you’re only protecting what you really created. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com

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

(408) 460-1345

On Twitter @ DW—Editor

4

June 2019 www.designworldonline.com DESIGN WORLD

DW Insights 6-19_Vs2.indd 4

5/31/19 9:46 AM

# Zero-Max_full_pgs_r10_Design World 2/12/10 4:02 PM Page 1

Your ball screw Your servomotor Our coupling

Together a winning combination for today’s servomotor applications.

Our ServoClass® couplings have been recently redesigned to enable your actuator to go even faster and achieve the positional accuracy that will take your designs to the next level. Our couplings will do all this with low bearing loads.

3 New sizes now available.

Now, size, select and see the right ServoClass® coupling solution for your application with Zero-Max 3D CAD files.

Check our FAST deliveries.

www.zero-max.com 800.533.1731 © 2010 ZERO-MAX

Zero Max ad 2-18.indd 5

5/31/19 8:26 AM

Teschler on Topic Management by moron—Why companies choose bad executives I once worked at a company that eventually entered bankruptcy, thanks largely to the actions of a chief executive brought in from outside by the firm’s board of directors. Before the company got into financial trouble, he came across publicly as extremely confident. And most who worked with him day to day would probably include arrogance among his more prominent personality traits.

That all changed during the dot-com crash of the early twenty-first century.

The company stock went from trading in the $30 range to under ten-cents a share before it was delisted. Prior to the CEO’s firing, he was interviewed by the local newspaper. When asked about how the company came to be in financial shambles, the CEO gave an answer which included the phrase, “I’m not a numbers guy” – exasperating to those of us who had endured his management style: You’d have to conclude that CEO was a bad hire. Tomas ChamorroPremuzic might say the hiring process was an example of an inability to detect incompetence in male leaders. Charmorro-Premuzic is a professor of business psychology at University College London and Columbia University, and an associate at Harvard’s Entrepreneurial Finance

Lab. He says when men are considered for leadership positions, the same traits that predict their downfall are commonly mistaken as signs of leadership potential or talent.

Although traits like self-absorption and overconfidence should be seen as red flags, they are often equated with charismatic leadership.

Part of the problem in picking leaders comes from human nature: We tend to think confident individuals know what they’re doing until proven otherwise. Another difficulty arises from the fact that supremely confident CEOs tend to be narcissistic to the point where their actions are more for their own benefit than for that of the companies they lead. CharmorroPremuzic points out that organizations may see nothing wrong with hiring narcissistic leaders because their confidence can energize followers. But the benefits of narcissism disappear during difficult times, something my old company found out the hard way.

You might think the better alternative to hiring narcissist jerks as CEOs is to do the opposite.

Unfortunately, studies show people – and particularly men – who display non-narcissist traits such as agreeableness and empathy tend not to earn as much as egomaniacs.

Researchers Timothy Judge of the University of Notre Dame, Beth Livingston of Cornell, and Charlice Hurst of the University of Western Ontario

found this to be the case regardless of the occupation they examined. Thus altruistic employees are less likely to rise high enough in organizations to be considered for top jobs.

Can companies stuck with narcissistic CEOs fix the problem with training? Probably not, says Charmorro-Premuzic. Narcissistic leaders have a reputation for not reacting well to negative feedback, retaliating rather than taking criticism to heart.

So the best approach is to hire the right kind of top managers in the first place.

There’s plenty of readily available advice on what to look for in candidates. A good place to start is with management consultant Jim Collins, author of Good to Great and other business best sellers. Collins examined CEOs of firms that had outperformed their industry for years and found that the most effective of them were humble and persistent. Rather than being egocentric, they focused on getting people to work together.

The evidence is that good things happen under humble leaders. Researchers from BYU and the University of Colorado found that employees tend to emulate humble managers and are more open to feedback and alternative ideas.

Charmorro-Premuzic figures that women frequently exhibit these kinds of management traits, and it’s probably a mistake to choose a big talker over a more modest female candidate for leadership roles. All I can say is that my old company likely would have fared better with someone at the helm who had a bit more humility. DW

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

6

June 2019 www.designworldonline.com

Lee Teschler Column 6-19_V2_LT.LL.indd 6

DESIGN WORLD

5/31/19 9:49 AM

YOU DESERVE

reliable timer relays with targeted signal control

Timer relays from Selec

 Alternative solution to controllers in simple applications  Multiple time functions and ranges  Reliable digital output functionality  Timer functions can be easilly adjusted via push buttons or rotary knob

Multifunction timer relay 800XU-CU Item no. 400296

$35.82

-10 %

Cyclic timer relay 55XC-P8-CU Item no. 400295

$35.46

MSRP: $39.80

-10 %

MSRP: $39.40

Digital multifunction timer relay 600DT-CU Item no. 102080

$42.66

-10 %

MSRP: $47.40

automation24.com/timer-relays

YOU DESERVE

fast delivery – all products in stock in our US warehouse Automation24 – your online supplier for automation technology

Continuously growing brand selection

Best service with tech support

Exceptional pricing

Need technical support? We are happy to advise you personally!

800-250-6772 (toll-free)

Automation24_6-19.indd 7

or

610-981-2900

mail@automation24.com

Same-day shipping

LIVECHAT www.automation24.com LIVECHAT

LIVECHAT

5/31/19 8:27 AM

Technology Forward Additive manufacturing is

looking to hire As of late 2018, the additive

manufacturing industry was a $7 billion industry. According to The Wohlers Report, it grew 21% in 2018. For 2019, this industry is estimated to grow to more than $9 billion. There are people who are unimpressed by that number given that the manufacturing industry as a whole is viewed as being worth $12 trillion. Still, $9 billion is nothing to ignore. The prospects for job opportunities in additive are strong.

• For those with skills in servicing these systems, roughly 8.5% of show vendors were looking for you.

• And for those who wish to design new additive systems, 2.8% of vendors were looking for future employees.

One company recently explored potential job opportunities with many of the vendors at the 2019 RAPID + TCT conference. The company, i-AMdigital, is an online platform for AM jobs and training. One of its goals is to help organizations recruit AM professionals and help others upskill current employees.

According to information i-AMdigital released, most of the companies at RAPID are looking to hire people. It found at least 2,088 job opportunities at the show alone.

(That’s reason enough to attend such conferences.) According to the report, the growth of the market brings demands for skills, which are not being met.

The opportunities break down like this, says i-AMdigital: • The largest need is for employees in production and operation at 28.6%.

• Opportunities in R&D and Engineering came next at 21.2%.

• If you have an interest in sales or marketing, that category was next highest at 20.4%.

• Software is playing an increasing role in AM, as part of overall process control and as part of managing the build cycle. Current oppor tunities reported at RAPID were at 11.7%.

Of course, the next question is who is hiring?

The vendors individually were looking for specific skills. According to i-AMdigital, for example, HP was listed as doing the most hiring overall, especially for sales and marketing positions. Materialise was shown as hiring more for application and consulting positions. Stratasys came out as a top hire for production and operation positions. And GE Additive is looking for people with design and R&D experience.

So if you have any of the skills listed, now is a good time to explore your options. Additive manufacturing is a growing industry with a lot of opportunities DW.

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

8

June 2019 www.designworldonline.com

Tech Forward 6-19_Vs2.LL.indd 8

DESIGN WORLD

5/31/19 9:50 AM

ÖLFLEX CONNECT ®

CUSTOM CABLE SOLUTIONS

Engineered To Meet Your Needs With ÖLFLEX® CONNECT, we deliver cable assemblies that meet your specific requirements—from initial concept to final assembly. Available in nylon, steel or a combination of the two, our cable chains maximize performance in the most demanding environments.

Our extensive product range includes: • • • • •

Highly flexible cables Servo cables Protective conduits Industrial connectors Durable cable marking

lappusa.com LAPP LAPP USA USA 6-19.indd 6-19.indd 99

6/4/19 5/30/19 11:30 3:36 AM PM

STAINLESS IS STANDARD

Electrical Coupler

Gear Assembly

Our rings provide the same fit and function as stamped rings, but are easier to assemble and remove with no special tools. Standard parts available in stainless (302 & 316) and carbon steel. Standard or custom, we’ll provide you with the right ring, in the right material, for your application.

FREE SAMPLES: Call (866) 478-9757, or visit expert.smalley.com/DW/rings

Smalley — (p.u. from 4-19)Rings_V2_6-19.indd 10

5/31/19 8:28 AM

Green Engineering • VP, Editorial Director

| istockphoto.com

Paul J. Heney

Sustainable material doesn’t sacrifice

performance

Star Plastics Inc., a compounder of engineering grade thermoplastics, introduced ReStart, a ULrecognized, high-performance material product line that contains 35% to 50% recycled content for customers with sustainability initiatives.

With heightened environmental awareness and a push towards corporate responsibility in the world today, brand owners, OEMs and plastic processors are turning to their suppliers for support.

“As a custom compounder and material supplier, we felt it was our job to find a solution that not only gives recycled materials a new chance at life but also provides brand owners with sustainable options that don’t sacrifice performance,” said Chuck Hoop, Director of Sales.

The ReStart product line is an opportunity for companies to reduce waste, meet sustainability objectives and deliver quality parts. ReStart is the fourth material line to join Star Plastics’ product offering, which includes StarPrime, ValuPak and EcoPlas. ReStart can be used in electronics, lawn and garden, household appliances and any other application that typically requires PC, PC FR, ABS or PCABS materials.

The recycled content of the UL-recognized material ranges from 35% to 50%, but still follows the stringent controlled ranges and behaviors expected of prime materials. True to the company’s core business of custom color compounding, the new ReStart materials are customizable to all colors.

DESIGN WORLD

Green Engineering 6-19_Vs2.LL.indd 11

With an origin of processing recycled materials, Star Plastics has first-hand knowledge of formulating with recycled-content feedstock.

“We are skilled in qualifying various recycled material feed-streams,” said Technical Lead James Holland, who was instrumental in developing the product. “The star team understands the physical and performance characteristics and have the ability to find their value as feedstock.”

Material quality is the cornerstone of the company.

With a full-service laboratory in house, all material goes through a thorough testing, developmental and certification process that allows Star to proudly stand behind its products.

“Some say Star Plastics does too much testing,” said Doug Ritchie, president and CEO. “We believe it is the foundation for our past success and indicative of our future growth.” DW Star Plastics Inc. | starplastics.com

www.designworldonline.com

June 2019

11

5/31/19 9:07 AM

Contents 6 • 2019

•

vol 14 no 6

•

designworldonline.com

A supplement of Design World June 2019

ensures safe post processing of metal 3d printed models 72

102

68

76

A spotlight on AM

How small can additive

partnerships

technology build?

COVER_MPF 6-19_Vs1.indd 67

67-81

Medical www.designworldonline.com

96 _MOTION CONTROL

102 _LINEAR MOTION

VFDs with integrated motion and machine controls

Up your conveyor game

Today’s ac drives can be controlled by either an external or internal PLC. Those with built-in controls move machine intelligence to the edge.

5/28/19 8:17 AM

New alternatives to traditional conveyor systems offer better efficiency and more flexibility, helping to boost manufacturing throughput.

A Supplement to Design World - June 2019

How to design

for home healthcare

Medical Tips cover 6-19_FINAL2.indd 82

5/28/19 10:36 AM

82-94

108 _3D CAD Step into CAD

Immersive design technologies make CAD models uniquely interactive

ON THE COVER

Virtual reality helps designers immerse themselves with their designs to address potential flaws and issues early in the design cycle. | istockphoto.com

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

2019

BRONZE REGIONAL AWARD asbpe.org

12

June 2019 www.designworldonline.com

CONTENTS 6-19_Vs3.LL.indd 12

DESIGN WORLD

5/31/19 12:48 PM

190430_ISOT_DW_US.indd 1 Digi-Key 6-19.indd 13

4/30/19 5/31/19 12:50 8:29 PM AM

Machine Tool Components

6.19

• contents departments 04 Insights 06 Teschler on Topic

Spring Plungers

08 Technology Forward 11 Green Engineering 18 MC2 School

Clamps

22 Design For Industry 36 Design Notes 46 CAE Solutions

Workholding Grippers

56 Internet of Things 116 Product World

®

Fixturing Accessories

120 Ad Index

Rollers & Bumpers

Request a

550+ page

catalog online! www.fixtureworks.net 888.794.8687 CONTENTS 6-19_second page_Vs1.indd 14

14

June 2019

DESIGN WORLD

5/31/19 12:50 PM

Visualization Products

AVG Automation, GmBH

Free Enterprise. Fiscal Discipline. Family Values. Firm F

OEM DISPLAYS

LCD, Motherboards & Software • SmartLCDdisplaysTM & CE Operator Panels • PowerWareTM to create GUI in minutes • Short Time to Market • LCD Display & Touch screen Integration • Windows CE & Computer Motherboards • LCD Monitors & Computers

• Operator Interfaces • HMIs with Built-in PLCs • Marquees • Industrial PCs • Text Panel Interfaces • Programmable Controllers

The Inventor

• Programmable Limit Switches • Resolvers and Decoders • PLC Input Cards • Press Monitoring Products • Electronic Motor Brakes • Counters, Rate Meters, and Speed Switches

•

USA

“Innovation by Design”

E

<50 PPM

RH C

E R STAR SOFT

E

<50 PPM

R

SOFT

E

Innovation is in our blood, we never do just a “me too product” We design and manufacture 99% of our products in U.S.A. Ship Factory Direct, passing on to you the 50+% mark up by an importer like ADC/Maple

• MADE

7 7

STAR

Here is what makes us different ...

PROUDLY

IN THE

“Home Automation products with latest technology to make life easier for modern and busy families” “Home Automation products with latest technology to make life easier for modern and busy families” “Home Automation products with latest technology to make life easier for modern and busy families” “Innovation

by Design” “Home Automation products with latest technology to make life easier for modern and busy families”

T W AT

• Operator Interfaces • HMIs with Built-in PLCs • Marquees • Text Panel Interfaces • Programmable Logic Controllers • Windows CE Platform Panels • Industrial Monitors

• Programmable Limit Switches • Resolvers and Decoders • PLC Input Cards • Press Monitoring Products • Electronic Motor Brakes • Counters, Rate Meters, and Speed Switches

AVG Automation India, Pvt. Ltd.

OEM DISPLAYS

WA

• Operator Interfaces • Marquees • Industrial PCs • Text Panel Interfaces • Programmable Controllers

“Innovation by Design”

Made in America, Price Buster Innovative Automation Products

Resolvers and PLS Controls

Embedded Applications

ER

363 St. Paul Blvd.

Carol Stream IL. 60188

OEM Divisions Catalog, Internet Slaes Division

N

www.avg.net

OEM Divisions Industrial Automation Controls

“Most Innovative Automation Products, built like a tank, that will put a smile on your face.”

ER

Founding Chairman

N

Shalabh “Shalli” Kumar

Mr. Kumar immigrated to the U.S 50 years ago and has invented over 100 different very innovative technologies and products, such as PLS, Digisolver, Digibrake, Tonnage at angle, HMI, Touch PLC, Programmable Power Supplies, Encoders and TDRs with digital displays, iMarquees and many more. He holds dozens of Patents.

Over the years he has been celebrated as the most outstanding OEM Divisions New Citizen of Chicago, an American Jobs Creator, Entreprenuer ofRepublican Hindu Coa Republican Hindu Coa the Year, and has servedAmerican on President Reagan’s AdvisoryCollective Voice of Conservative Hindu A Water Softener Specially designed forBusiness India Guaranteed 7 StarWater Water <50PPM AnySpecially Time, All the Time or your Money EZAutomation EZAutomation American Softener designed for India back Council and President Trump’s Transition Team.

Besides inventing, Guaranteed 7 Star Water <50PPM Any Time, All the Time or your Money back EZAutomation EZAutomation Shalabh “Shalli” Kum he devotes substantial time to philanthrophy and community service.

Founder & Chairman RH C

•

Introducing the Latest Engineering Marvel

3.5” TFT, 12 DI, 8 DO, 8 RLY, 2 AI, 1 AO + Quadrature Input for EZTouch mini.PLC

®

4, 1 form C Relay outputs, 5 Amp, 250 VAC

LED indicators for all I/O

3.5” TFT LED display, 400 nits, 75k hrs.

5” x 4” x 2” deep

12 Digital inputs sink or source including quadrature up to 50KHz

Order Now to avoid long lines!

Plug-in removable terminal blocks 8 Digital sourcing outputs, 50 V, 500 mA, short circuit proof

T

T

FREE

R PO

Technical/Application Support 7 AM - 7 PM

Check out our website www.ezautomation.net with new EZ navigation & configuration tool, Promocode: DW05FAD19 for special discount

AVG-EZ Automation 5-19.indd 15

EZiest integrated programming software

2 Analog In, 1 Analog Out Voltage, 0-10V, 12 bit

Widest selection of TouchPLCs from the Inventor of HMI + Modular PLC integrated in one package ...

• 4”, 6”, 7”, 8”, 10”, 12”, 15” Displays HNICAL SU P EC • Fixed or Modular plug-in I/O modules • Expandable to 1024 I/O points • 8 different series of EZTouchPLC

1-877-774-EASY (3279)

$299

EZAutomation Factory

PROUDLY

MADE

IN THE

USA

FACTORY DIRECT

customer plant

Scan to learn more about this product QR App needed

5/31/19 8:32 AM

363 St Paul Blvd Carol St www.rhc-usa.org

Current Sense Resistors • Non-Inductive Designs • High Stability • Surface Mount

MP821 Precision Low Resistance TO-220 Style Metal Tab Power Film Resistors

SR10 and SR20 High Stability Precision Current Sense Resistors

• Resistance as low as 0.020Ω at ±1% • 20 watts at +25°C case temperature • Non-Inductive design

MP900 Series Low Resistance, Lower Cost TO-220 and TO-126 Style Power Resistors

• 1 watt and 2 watt versions at +70°C • Resistance as low as 0.005Ω at ±1% • Compact footprint • Four terminal (Kelvin) connections • Non-Inductive design

CD and CC Surface Mount Low Resistance Chip Resistors • Resistance as low as 0.010Ω at ±1% • Flip Chip versions for SMT • Aluminum wire bondable versions • Non-Inductive design • High power chips for IMS or ceramic substrate designs

• Resistance as low as 0.010Ω at ±5% and 0.050Ω at ±1% • 30 watts in TO-220 style 15 watts in TO-126 style at +25°C case temperature • Non-Inductive design

MP2060 Low Resistance, Clip Mount TO-220 Style Power Film Resistor

MP725 Surface Mount D-Pak Style Power Film Resistors

• Resistance as low as 0.005Ω ±5%, 0.010Ω ±2%, 0.020Ω and above ±1% • Up to 60 Amps at +25°C case temperature for 0.005Ω up to 0.015Ω • Up to 60 watts at +25°C case temperature for 0.020Ω and above • Non-Inductive design

High Performance Film Resistors from

CADDOCK

ELECTRONICS, INCORPORATED © 2019 Caddock Electronics, Inc. L-444.0319

Caddock 6-19.indd 16

• Resistance as low as 0.020Ω at ±5% and 0.050Ω at ±1% • 25 watts at +25°C case temperature • Non-Inductive design

For Samples and more Information contact Applications Engineering: Sales Office - USA and Canada Applications Engineering 17271 N. Umpqua Hwy. Roseburg, Oregon 97470-9422

phone: 541-496-0700 email: sales@caddock.com For Distributors listed by country see caddock.com/contact/dist.html The Caddock General Catalog includes specifications on over 250 models of high performance resistor products. Call for your copy or see us online at caddock.com

RoHS

product information at www.caddock.com

5/31/19 8:33 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

DIGITAL MEDIA/WEB/ DEVELOPMENT

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

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

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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

CREATIVE SERVICES

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

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

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

Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

EVENTS

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

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Julie Ritchie jritchie@wtwhmedia.com

Digital Production Manager Reggie Hall rhall@wtwhmedia.com

FINANCE

Controller Brian Korsberg bkorsberg@wtwhmedia.com Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

2011 - 2018 2014 Winner

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

Medical Design & OUTSOURCING DESIGN WORLD

Staff page 6-19_Vs1.indd 17

www.designworldonline.com

June 2019

17

5/31/19 9:12 AM

w w w. d e s i g nw o r l d o n l i n e . c o m / M C 2

Couplings Miles Budimir

O

One of this month’s MC2 installments shines the spotlight on couplings.

A coupling is used to connect together two rotating shafts or fix a motion component to an axis in order to transmit or control motion or power.

Couplings are characterized in different ways, but one common classification divides them into rigid and flexible. Rigid couplings are preferred in cases that call for precise shaft alignment while flexible couplings are used mainly for transmission of torque and where some misalignment is acceptable. The type of application will usually dictate the right kind of coupling to use.

In our Motion Control Classroom on couplings, you’ll find resources on the basics of couplings and how to select the right one to satisfy application requirements. From technical overviews to selection tips, information is included on the many different kinds of couplings — including bellows couplings, gear couplings, beam couplings, and servo couplings, among others.

Find this Motion Control Classroom and read more about couplings at www.designworldonline.com/couplings-motion-control-classroom.

Educational installment brought to you by:

18

June 2019 www.designworldonline.com

Motion Control Classroom_6-19_Vs5 LE.indd 18

DESIGN WORLD

5/31/19 9:55 AM

DC motors Lisa Eitel

TRADITIONAL BRUSHLESS DC MOTOR

SLOTLESS MOTOR

A

According to the most common industry naming conventions of today, there are three dc motor subtypes: dc brush motors, dc permanent-magnet (PM) motors, and dc universal motors. But as you’ll see in this month’s Motion Control Classroom on dc motors, there are an array of caveats, crossovers, and sub-classifications. Many larger dc motors still employ brushes and wound fields … though PM motors dominate fractional and integralhorsepower applications below 18 hp ... and PM motors are increasingly common for most motion designs.

Motors without permanent-magnet types use two currents: 1) Current through armature (rotor) windings to interact with a stator magnetic field for output of mechanical rotation and 2) Current through stator windings to make that magnetic field.

In contrast, permanent-magnet brush dc motors use current through armature (rotor) windings to interact with a stator magnetic field (for output of mechanical rotation) ... permanent magnets on the stator make that magnetic field.

Brush dc motors without permanent magnets are wound-field motors and include shunt-wound motors, in which the armature and field coils connect in parallel ... so field current is proportional to the load on the motor. Armature and field coils in series-wound motors connect in series. Coils in compound-wound motors include both series and shunt windings.

Brushless dc (BLDC) motors replace mechanical commutation with electronic commutation. That avoids the wear of brush dc motors. In BLDC motors, permanent magnets are on the rotor and coils in the stator. Coil windings are separated from each other electrically for top controllability.

Going a step further in this taxonomy, brushless dc motors can have a slotted or slotless configuration.

Motors with slotted stators have stator coils that wind through lamination slots.

Magnetic induction is high because the airgap between the laminations and magnets is small. So, the motors allow a small magnet diameters. With coil in the stator slots, there is reduced coil-stator thermal resistance. The catch is that these motors can exhibit cogging or detent torque ... so some motors include skewed laminations to minimize this issue.

In contrast, motors with slotless stators have coils wound and formed without laminations, so exhibit no cogging. There is higher thermal resistance than in comparable slotted motors, but slotless motors also have high power density … and iron losses are low at high speeds.

Read more by accessing the dc motors MC2 at www.designworldonline.com/MC2.

Educational installment brought to you by:

DESIGN WORLD

Motion Control Classroom_6-19_Vs5 LE.indd 19

www.designworldonline.com

June 2019

19

5/31/19 9:56 AM

w w w. d e s i g nw o r l d o n l i n e . c o m / M C 2

Encoders Danielle Collins

A

An important part of almost any motion control system, encoder technologies are evolving at a rapid pace. That means there’s a suitable design for virtually any rotary or linear application — from rugged magnetic encoders that can withstand shocks and vibration without compromising performance, to glass-scale linear encoders featuring sub-micron resolution for coordinate measuring machines.

To help you navigate the choices and select the best encoder for your application, the Motion Control Classroom on encoders breaks down the various technologies, looks at the difference between accuracy and resolution, and explains quadrature encoding and how it can be used to boost encoder resolution.

This installment of Motion Control Classroom also includes primers on how to decide whether you need a rotary or a linear encoder and how to determine what resolution your application requires. And although encoders are most often used for angular or linear position measurement, we explain how two techniques — pulse counting and pulse timing — can be used to measure speed.

You’ll also find a library of examples demonstrating how and where each encoder technology is applied and learn how trends in IoT and robotics — especially collaborative robots and AGVs — are driving new encoder designs and increased functionality.

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

Signal diagram for a TTL output encoder 360° 90°

90°

90°

90°

A A Educational installment brought to you by:

B B

Z Z

20

June 2019 www.designworldonline.com

Motion Control Classroom_6-19_Vs5 LE.indd 20

DESIGN WORLD

5/31/19 9:57 AM

ELIMINATE BACKLASH BY USING HELI-CAL® MACHINED FLEXURE COMPONENTS Flexible Couplings

·

Machined Springs

·

U-Joints

Features: •

Eliminate elastomeric elements like rubber bushings, spiders, rubber discs and pads

•

No maintenance, no backlash, no lubrication, constant velocity, and smooth bearing loads.

•

End attachments can include tangs, clamps, flanges or threaded ends.

Applications: • • • •

Machine Tools Encoders CNC Machines Motors

• • •

Power Generation Instrumentation Robotics

Industries: • • • •

Aerospace & Defense Agricultural Automotive Industrial & Manufacturing

• • • •

Commercial Medical Petrochemical Recreational

w w w. he li- ca l .co m

HPC-DW-Jan2019Rev.indd 1 MW Industries 1-19 (Helical).indd 21

11/15/20185/31/19 10:15:13 8:34 AM AM

Design for Industry M a c h i n e To o l

Design lessons for HMIs

F

Olga Zinoveva • Senior Software Engineer • Bright Machines

From the physical push buttons, lights and switches of the 1980s, to the multi-touch screens of today, Human-

Machine Interfaces (HMIs) have evolved over the last few decades. However, as someone with a background in software engineering for games and consumer applications, I’ve noticed many opportunities to replicate best practices from the User Design (UX) discipline in the consumer technology sector on the factory floor.

Whether a professional designer or not, we can all 1 Maintain visual consistency identify impactful UX. Think about the change from One of the most important design principles in button-based phones and keyboard-only interfaces consumer UX is consistency. Consistent design to powerful, easy-to-use, touch-based smartphones elements (whether visual or strictly functional) are and tablets. This evolution of interfaces created new intuitive – they eliminate confusion and help users interaction models and UX paradigms, which brought understand how to use your product faster. significant usability and productivity improvements Consistency in industrial UX can be even more to consumers; why should factory workers not critical because of the various nuances not present experience the same? As factory hardware becomes in consumer UX. In these settings, where an array increasingly sophisticated, it’s imperative that HMIs of hardware devices are connected to each other in be as intuitive to use as the most popular consumer complex ways, and users range from operators on the applications. factory floor to project managers in remote offices, I spent years working on various consumer industrial UX goes far beyond a single screen. Instead, applications in the past, especially games and it encompasses the full experience of using the system, websites. Since moving to manufacturing, I’ve including any interface or device that connects to it. observed four important ways that UX best practices It’s a mix of software (dedicated touchscreen panels from consumer applications can be leveraged to or apps) and hardware (buttons, feeders) interfaces greatly improve HMIs for the factories of tomorrow: controlling the machines on the floor, monitors

June 2019 www.designworldonline.com 22

DFI 6-19 Vs3.LL.indd 22

DESIGN WORLD

5/31/19 11:02 AM

giving real-time status updates about the production line, and services generating reports based on data collected in the cloud over many weeks. Almost every component we build becomes a part of the user experience.

Of course, most design engineers in manufacturing don’t have control over the end-to-end experience given the number of third-party suppliers and integrators used in factory settings. But consistency can still be applied to those interfaces you do control. For example, if you’re designing HMIs for different machines on the line, functionality that is consistent across those machines should look identical. If you’re also designing an interface that shows information about the line as a whole, that should also use consistent visual language – i.e. the same colors and symbols – to represent similar data and concepts.

2 Introduce user testing Another core principle of UX design is that people form mental models of how a system operates (whether we want them to or not), and if their model sufficiently differs from reality, it will lead to frustration and mistakes.

To avoid this and ensure systems are in line with users’ mental models, UX designers conduct user testing – often employing one-on-one interviews. User testing is an essential part of the UX design process that ensures that feedback becomes a core part of the product, making it as intuitive as possible from the very start.

Mental models, of course, aren’t limited to consumers. Factory workers also have preconceived notions of how a system should operate. But in the factory context, user testing for HMI – or, extensive usability testing – is minimal compared to what is done for software or mobile apps. More thorough user testing would be very impactful given the complexity of modern HMIs. As the role of software in manufacturing grows, and more tasks move from hardware to software – whether running on the device itself, in a local server, or in the cloud – the number of ways that factory workers can interact with the system and the complexity of these interactions increases. The next-generation HMIs must be intuitive and straightforward, without being oversimplified. The goal is to design a UX that helps users build the right

DESIGN WORLD

DFI 6-19 Vs3.LL.indd 23

June 2019

“

I need more than products; I need a real partner. We need relationships and services today that will improve performance for the future.

Decisions Made Easier— with the Expertise of Emerson.

Emerson’s fluid control and pneumatics offering applies industry expertise and clever solutions to your unique business challenges today and tomorrow. Our strengthened portfolio of brands—ASCO™, AVENTICS™, TESCOM™, and TopWorx™—deliver an extensive suite of leading fluid control and pneumatics products. In an increasingly competitive landscape, smarter technologies and expert partners become more critical for your success.

Find the products, solutions, and services that can help your business grow.

Turn to the fluid control and pneumatics experts who know your industry and applications.

Visit Emerson.com/automation or reach out to ContactUs@Emerson.com to engage with one of our engineering experts.

The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2019 Emerson Electric Co.

23

5/31/19 11:03 AM

THE ORIGINAL THEPUSH-PULL ORIGINAL PUSH-PULL CONNECTOR CONNECTOR

Design for Industry M a c h i n e To o l conceptual models from the start to maximize productivity and minimize training time and mistakes.

Implementing user testing and ensuring that the system operates in accordance with a factory worker’s mental model can help you achieve this goal. Practically speaking, each industry, factory and region may have operators with different mental models, so the challenge is to find a consensus that is usable for most. Even if you’re not set up for formal user research, taking the time to see if an operator on the factory floor can figure out how to do a task with your new HMI without explanation is a great place to start – if they can’t, work to understand why not.

LEMO, a global leader in the designaand manufacturing LEMO, global leader in theof precision interconnect design and manufacturing of solutions,interconnect provides high-quality precision product and services. solutions, provides high-quality product and services.

Key Features: Key Features: • Metal & Plastic Connectors ••Metal & Plastic Connectors Push-pull & Ratchet Screw Type • Push-pull & Ratchet Screw Type • Hybrid Configurations ••Hybrid Configurations Fiber Optics

••Fiber Optics Cable Assembly Services • Cable Assembly Services

3 Prioritize response time A few years ago, Google conducted research that found that more than half of mobile website visitors abandon sites that take longer than 3 seconds to load. This 3-second rule has become the de facto standard in the consumer UX world. Page load speeds have become so important to good user experience that UX designers often prioritize response time above all else. While in the consumer world, long loads or slow response times can lead to losing a user or customer, in the factory context, the risk can be more serious. If an HMI is not responsive on the factory floor, it can present a huge safety issue for humans working the line, or cause production issues.

For example, the threshold at which response from the system appears to be instantaneous to the end user is 0.1 seconds – if it takes longer than that for the system to process the user’s input, the system should show that it received the user’s command (a button might change color slightly when pressed, or a transition animation might play). If the system doesn’t respond at all, the operator may think that they didn’t quite press the button, or that something glitched, and might try the button again or even mash it multiple times. If the button is moving a heavy robot arm, redundant commands will make it move in a way the user doesn’t expect and could damage equipment or, in the worst case, even be dangerous to the operator.

24

At anything greater than a second, a loading spinner or progress bar visual is advised. Folks in factories are more likely to wait it out than a smartphone user, but it’s important to communicate to the operator that the system has received their input and is working on responding if the response is not immediate.

4 Implement common UX guidelines The ubiquity of thoughtfully designed consumer devices has raised the bar for the quality of user interactions, responsiveness, and clarity in the factory context. Almost every worker in a modern factory has used a smartphone or tablet – this year, global smartphone usage is expected to hit 2.5 billion (and it’s growing). As a result, today’s factory workers have a high level of technical literacy and have come to expect industrial interfaces to work as well as their personal smartphones By simply borrowing general design principles from the consumer application world (which were developed through extensive user research), HMI designers can ensure ease of use, and significantly reduce training time for any UX that follows these standards. One example is the idea that users should always know where they are in the UI and how to get back to where they started. A common way to do this when an app or website has a lot of pages in the hierarchy is by using breadcrumbs, but even something as simple as making the navigation bar clean and visible at all times, and highlighting the location or page that the user is currently on, can greatly improve usability.

With advanced technologies like robotics, software and computer vision transforming the manufacturing industry at record speed, the factories of tomorrow demand a more rapid pace of design innovation. By taking a page from the consumer UX playbook, HMI designers can bring more intuitive user experiences to these complex factory environments and help inform the next wave of industrial innovation. DW

Bright Machines www.brightmachines.com/

June 2019 www.designworldonline.com

DFI 6-19 Vs3.LL.indd 24

DESIGN WORLD

5/31/19 11:04 AM

Power Review

Altra Motion Vol. 8 | No. 2 | 2019

The Power Brands in Power Transmission

Featured in this Edition...

NEW Marland BCMA Backstop Automatic Grease Lubrication System Warner Electric Electrically Released Brakes for Stage & Theater Applications Altra Certified Rebuild Services â&#x20AC;&#x201C; Marland, Formsprag, & Ameridrives NEW Stromag Product Solutions Bauer Gear Motor Sub-Fractional Gearmotors for General Industry Boston & Bauer Washdown Gear Drives & Gear Motors for the Food & Beverage Industry

NEW Marland BCMA Backstop Automatic Grease Lubrication System Provides protection from external contamination Follow Altra Motion on:

Creating A Premier Industrial Company Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delevan Delroyd Worm Gear Deltran

Altra Industrial_#1_6-19.indd 25

Formsprag Clutch Guardian Couplings Huco Jacobs Vehicle Systems Kilian Kollmorgen Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Portescap Stieber Stromag Svendborg Brakes

TB Woodâ&#x20AC;&#x2122;s Thomson Twiflex 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

5/31/19 8:35 AM

NEW Marland BCMA Backstop Automatic Grease Lubrication System Marland Clutch recently introduced an automatic grease lubrication system designed to eliminate the need to manually grease the labyrinth seals of popular Marland BCMA backstops.

In many instances, Marland BCMA backstops are located in difficult to reach areas making regular grease maintenance very difficult. By installing the new automatic lubrication system, regular grease maintenance is performed, but no longer requires maintenance personnel to be directly involved in this critical daily process. In fact, the large grease capacity of the system allows for 6 or more months between refills.

The automatic system is designed to provide regularly scheduled injections of the proper volume of grease into the labyrinth seal to maintain a fresh grease barrier that protects the oil seals from outside contaminants and extends seal life. This automated process provides the highest level of protection against external contaminants assuring years of service life.

The automatic grease lubrication system can be linked to Marland’s new Smart Marland condition monitoring system for an additional layer of protection.

For more information, download P-8747-MC from www.AltraLiterature.com

Warner Electric Electrically Released Brakes for Stage & Theater Applications For decades, Warner Electric’s low noise emission safety brakes have been a preferred choice by many global stage and theater equipment manufacturers.

A variety of single and redundant braking solutions is offered, including FENIX S Series Brakes; FENIX Series Brakes; ERS VAR 15 Series Brakes for use on all types of upper and lower stage equipment.

Within a range from 5 Nm up to 5000 Nm all Warner Electric brakes noise emissions are below 50dB(A) and comply to the most recent regulations and directives such as BGV C1, DIN 56950-1; DGUV V17; EN81-20/50. All units feature convenient “plug & play” installation.

For more information, download: • P-8350-WE-A4 • P-8351-WE-A4 • P-8352-WE-A4 • P-8353-WE-A4

• P-8354-WE-A4 • P-8355-WE-A4 • P-8749-WE-A4

or visit www.AltraStageandTheater.com

Altra Certified Rebuild Services – Marland, Formsprag, & Ameridrives Marland: Your old, worn Marland clutches can be refurbished for substantially less than the cost of a new replacement clutch. Our economical rebuild service applies to all Marland Clutch BCMA, CECON and CEBMAG models. The local Marland Rebuild Service team will perform the following to restore your clutch to likenew condition: Inspect and replace seals, energizing springs, alloy steel rollers, aluminum cages, bearings 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 and prepare for shipment.

For more details on our cost saving certified Marland Rebuild Program, call 1-888-216-3515.

Formsprag: Send Formsprag your old clutches to make them like new again. The difference is not just cosmetic. Consider these advantages: Price – A guaranteed savings of at least 30% or more versus new product, Speed – Clutches are received, inspected and rebuilt in the shortest possible time frame, Warranty – 1 year on labor and materials, same as new clutches, and Emergency Breakdown Program – All products that are air freighted into the Warren plant are processed immediately and, in most cases, are able to be rebuilt within a 24-hour period.

For more information download Application Guide P-1465-FC from www.AltraLiterature.com.

Ameridrives: Ameridrives Rebuild Service can refurbish your old, worn couplings for substantially less than the cost of a new replacement coupling. The economical rebuild service applies to all Ameridrives couplings including Ameridisc®, Ameriflex® and Amerigear® high performance, high speed couplings used primarily on turbomachinery, compressor and pump applications in the power generation, oil & gas and marine industries. Other coupling brands are accepted on a case-by-case basis. For details on the rebuild program, call 1-814-480-5095, download P-7948-AC from www.AltraLiterature.com or visit www.Ameridrives.com.

Altra Industrial_#2_6-19.indd 26

5/31/19 8:35 AM

NEW Stromag Product Solutions P-8739-SG-A4 | SIDEOS Sc - SIDEOS Sc is a speed monitoring system that secures lifting operations controlled by a joystick. SIDEOS Sc is designed to secure all moving equipments: tower cranes, overhead cranes, etc.. This configurable speed monitoring system enables the speed monitoring according to a variable threshold following the speed requested by the crane driver (joystick control) in Ascent or in Descent.

P-8740-SG-A4 | SIMAN (Safety Intelligent MANager) - This safety management system monitors all the operation parameters of the Hydraulic Power Pack that provides the hydraulic pressure to open the emergency brakes. It pilots the brakes opening and closing, indicates and records, if they occur, all operation faults or inconsistencies.

P-8716-SG-A4 | Braking Solutions for Nuclear Applications - Stromag provides braking solutions for reactor building cranes, fuel storage cranes, heavy lifting cranes and lowering devices. Products include: Service Brakes for intensive use at “high speed”, Emergency Brakes for safety use at “low speed”, Electrical Power units allowing controlled and manual load lowering, Hydraulic Power Packs with a large range of options, Configurable Monitoring Systems of the kinematic chain (SSCC), and Elastic Disc Couplings for the transmission of the torque with damping of the operation vibrations and shocks.

P-8715-SG-A4 | Braking Systems for Flat-Top and Luffing Cranes - Stromag develops and provides a large range of technically advanced brakes, hydraulic power packs, controls and sensors to ensure safety of modern concept cranes as flat-top cranes and luffing-jib tower cranes. Products include: SIME Brake Calipers, CSH Hydraulic Power Packs, NFF Brakes, and Light Cam® series geared cam limit switches.

For more information, download Stromag literature from www.AltraLiterature.com

Bauer Gear Motor Sub-Fractional Gearmotors for General Industry Inline and Right Angle Gearmotors Features and Benefits: • • • • • •

IP54 standard / IP65-IP66 optional Synthetic oil standard for long gearing life Hardened gearing with ball bearing support High-tensile strength pressure-cast aluminum housing Multiple foot, flange, and shaft combinations Special output shaft dimensions on request

• • • • • •

Foot and flange mounting available Inverter-duty motor Brake and encoder options available Non-ventilated motor available Class I Div II / Class II Div II explosion-proof rating Washdown ready; Aseptic coating available Bauer Gear Motor

Facilities

Europe

Germany Eberhard-Bauer-Strasse 37 73734 Esslingen - Germany +49 711 3518 0 Slovakia Tovarenskå 49 953 01 Zlate Moravce - Slovakia +421 37 6926100

United Kingdom Nat Lane Business Park Winsford, Cheshire CW7 3BS - United Kingdom +44 1606 868600

North America

Middlesex, NJ T476 Union Ave. Middlesex, NJ 08846-1968 - USA +732-469-8770

Charlotte, NC 701 Carrier Drive Charlotte, NC 28216 - USA +704-588-5610

Altra Motio n Asia Pacific China 18 Huan Zhen Road Dabo Industrial Zone - BoGoang Village ShaJing Town - BaoAn District Guangdong Province 518104 Shenzhen City - China +86 755 27246308

Customer Service Benelux Brussel (Anderlecht) +32 2 5295941 Finland 01510 Vantaa +358 207 189700 France Brussel (Anderlecht) +32 2 5295941 Italy

Grisignano di Zocco (VI) +39 0444 414392 Russia Volokolamskoye sh., 142, Business Center „Irbis“ bldg 6 125464 Moscow - Russia +7 495 6420468

The Brands of Altra

Motion

Couplings Ameridrives www.ameridrives.com Bibby Turboflex www.bibbyturboflex.com Guardian Couplings www.guardiancouplings.com

For more information, download P-8707-BGM from www.AltraLiterature.com

Huco www.huco.com Lamiflex Couplings www.lamiflexcouplings.com Stromag www.stromag.com TB Wood’s www.tbwoods.com Linear Systems Thomson www.thomsonlinear.com

Geared Cam Limit Switches Stromag www.stromag.com Engineered Bearing Assemblies Kilian www.kilianbearings.com Electric Clutches & Brakes Matrix www.matrix-international.com Stromag www.stromag.com Warner Electric www.warnerelectric.com Deltran www.thomsonlinear.com

Heavy Duty Clutches & Brakes Twiflex www.twiflex.com Stromag www.stromag.com Svendborg Brakes www.svendborg-brakes.com Wichita Clutch www.wichitaclutch.com Gearing & Specialty Components Bauer Gear Motor www.bauergears.com Boston Gear www.bostongear.com Delevan www.delevan.com

Engine Braking Systems Jacobs Vehicle Systems www.jacobsvehiclesystems.com

Bauer Sub-Fractional Gearmotors for General Industry AC 3-Phase and AC Single-Phase

Precision Motors & Automation Kollmorgen www.kollmorgen.com Miniature Motors Portescap www.portescap.com Overrunning Clutches Formsprag Clutch www.formsprag.com

Marland Clutch Warner Linear Delroyd Worm Gear Belted Drives www.marland.com www.warnerlinear.com www.delroyd.com TB Wood’s Stieber www.tbwoods.com Nuttall Gear www.stieberclutch.com www.nuttallgear.com Neither the accuracy nor completeness of and performance characteristics the information of these products may contained in this publication is guaranteed conditions of sale can vary depending on the be viewed at http://www.altramotion.com/ter application, installation,by the company and may be subject to acquire or use a product change in its sole discretion. operating conditions referred to herein, including ms-and-conditions/sales-terms any person who buys -and-conditions. These and environmental factors. The company’s The operating from a licensed distributor terms and conditions of these branded products. apply to any person whoterms and Motor LLC. All rights reserved. All trademarks may buy, in this publication are the sole and exclusive property of Bauer Gear Motor LLC or one of its affiliated companies.

©2019 by Bauer Gear

Boston & Bauer Washdown Gear Drives & Gear Motors for the Food & Beverage Industry 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 2. Critical Product Features for Washdown Suitability and 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

Scan to watch Boston & Bauer Washdown video

For more information download P-8026-BBG from www.AltraLiterature.com

Altra Industrial_#3_6-19.indd 27

5/31/19 8:36 AM

C E L E B R A T E S

15

Years

2004-2019

AS A LEADING GLOBAL DESIGNER AND PRODUCER OF A WIDE RANGE OF ELECTROMECHANICAL POWER TRANSMISSION AND MOTION CONTROL COMPONENTS AND SYSTEMS From engine braking systems for heavy duty trucks to precision motors embedded in medical robots to brakes used on offshore wind turbines, Altra brands have been serving customers around the world for decades.

Creating A Premier Industrial Company Ameridrives

Deltran

Kilian

Portescap

Twiflex

Bauer Gear Motor

Formsprag Clutch

Kollmorgen

Stieber

Warner Electric

Bibby Turboflex

Guardian Couplings

Lamiflex Couplings

Stromag

Warner Linear

Boston Gear

Huco

Marland Clutch

Svendborg Brakes

Wichita Clutch

Delevan

Jacobs Vehicle Systems

Matrix

TB Woodâ&#x20AC;&#x2122;s

Nuttall Gear

Thomson

Delroyd Worm Gear

www.AltraMotion.com Altra Industrial_#4_6-19.indd 28

5/31/19 8:36 AM

M a c h i n e To o l

Inductive sensors monitor mold deformations in aluminum die-casting

I

Safe grip ergonomic knobs

Safer, more comfortable tightening

In the production of aluminum die-cast parts, liquid aluminum is pressed

n

Safer tightening Unique award-winning grip design allows more direct application of torque by operator

n

Easy identification Center cap available in seven standard colors

n

Tough construction Glass-fiber reinforced polyamidebased polymer material

into a mold under high pressure. The two mold halves must be held together with significant force. Despite this high contact force, the tool halves are pressed apart minimally. This process is also called mold breathing. Although minimal openings are normal and intended during this process, a gap causes fraying on the component if it is too large. These splinters must be reworked to meet the high quality requirements of the final product. If aluminum residues remain on the tool, they also lead to increased wear, which reduces tool life.

Monitoring tool deformation using inductive displacement sensors based on eddy current enables high product quality combined with improved tool life and reduced rework. Usually, three to four eddyNCDT 3005 eddy current systems are used to ensure consistent gap monitoring at several measuring points.

A system consists of a compact and robust controller, which together with the cable and sensor, form a unit. The integrated system design increases robustness and resistance to external factors, making the system insensitive to high temperatures, dust, dirt or pressure, and delivers accurate results regardless of the environment.

Due to its compact design, the eddyNCDT 3005 can be integrated into an existing machine at any time. DW

elesa.com Toll-Free 800-374-7686

Request Catalog 077AM

Micro-Epsilon | www.micro-epsilon.com

DESIGN WORLD

DFI 6-19 Vs3.LL.indd 29

www.designworldonline.comâ&#x20AC;&#x192;

June 2019

29

5/31/19 11:06 AM

Design for Industry Aerospace

Meeting the need for a transparent single source of product record

T

The US Congress enacted reforms to close the defense technological gap and accelerate adoption of commercial technologies for military use. As a result of these changes, commercial firms are leading in defense technologies in the United States, capitalizing on dual-use opportunities for products across sectors. According to a 2018 study by PWC, commercial electronics and technology companies are pushing into defense with innovation, risk-taking willingness, and larger R&D budget spends than past traditional defense contractors. Once a part of the defense supply chain, these companies must adhere to the United States International Traffic in Arms Regulations (ITAR) and Export Administration Regulations (EAR) regulations, which control the export of defense articles including technical data, defense services, and dual-use articles and technology.

Arena PLM for AWS GovCloud will help designers developing products subject to these regulations. This program lets designers use one platform for all product and quality assurance processes from design to sustainingâ&#x20AC;&#x201D;while complying with Federal security mandates. Arena PLM for AWS GovCloud addresses system access, data storage, and technical data access compliance requirements critical to these regulated product companies.

June 2019 www.designworldonline.com 30

DFI 6-19 Vs3.LL.indd 30

DESIGN WORLD

5/31/19 11:07 AM

Higher Reliability smaller footprint New Ready-To-Use Cable Assemblies Now Available with Reverse Fixing Screw-Lok for Design Flexibility - Save time and money on tooling, training and testing cables - Metal back-shells for maximum strain relief and RF shielding - Up to 45% smaller and up to 75% lighter than Micro-D

Companies operating in controlled regulatory spaces, including ITAR and EAR, need a secure, transparent single source of product record. “Our customers wanted a solution that provided the product control, collaboration, and quality benefits of Arena, but within an environment that assists with their federally mandated compliance needs, ” said Craig Livingston, Chief Executive Officer of Arena Solutions. “Arena PLM for AWS GovCloud makes modern, cloudbased product realization enablement easy to implement while maintaining the integrity and security of digital export-controlled product data throughout the supply chain.”

Electronics defense suppliers previously limited to on-premise systems, spreadsheets, or cumbersome toolkit systems can use Arena PLM for AWS GovCloud to speed new product development and ensure product quality while meeting critical financial and market goals. DW

- Resists extremes of shock, vibration and temperature - Excellent out-gassing properties

Arena Solutions | www.arenasolutions.com

DESIGN WORLD

DFI 6-19 Vs3.LL.indd 31

www.designworldonline.com

www.harwin.com/gecko-sl June 2019

31

5/31/19 11:08 AM

Design for Industry Medical

Motordrive offers high torque, speed, and positioning control

A

As equipment and designs incorporate more modern features, basic elements like

motors, need to keep up. The EnduraMax 75i Series is a 75 mm diameter brushless dc motor with an all-digital integrated drive. The compact, high power density motor controls torque, speed, and position in a range of commercial/industrial applications including: AGV vehicle traction or steering, medical patient-handling equipment, rotary/linear actuators, pumps, mobile HVAC blowers, and material handling systems. Compared to brush dc motors, the EnduraMax 75i features quieter operation and longer life without the need for brush maintenance, making it a choice in equipment modernizations and new designs.

The EnduraMax 75i offers three standard stack lengths with continuous rated power up to 370 W, continuous rated torque up to 1.3 Nm (190 oz-in.), and rated speed of up to 5150 rpm. The 12, 24, or 48 Vdc winding voltage choices make the EM75i suitable for battery-powered applications. Command inputs may be: Âą10 Vdc, 4 - 20 mA, or via an optional CANopen or Modbus port. Custom winding designs and voltages, shaft, and mounting options are available to meet custom application requirements. DW

Allied Motion Technologies | www.alliedmotion.com/

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

32 June 2019 www.designworldonline.com

DFI 6-19 Vs3.LL.indd 32

DESIGN WORLD

5/31/19 11:09 AM

Medical

Precise photo etching for medical devices

Photo chemical etching can be applied to a range of metals including various medical grade alloys that have high strength-to-weight ratios, are biocompatible, and are corrosion resistant. The etching process is a precise tightly controlled metal machining technology used to manufacture complex metal components with exacting details, and is characterized by low-cost digital tooling, retention of material properties, the manufacture of burr- and stress-free parts with clean profiles, and no heat-affected zones.

Precision Micro recently attained ISO 13485 medical devices standard, making it one of a small number of chemical etching specialist companies in the world accredited to supply exacting medical components to its customers.

Sales Manager for the German market, Markus Rettig says, “The inherent characteristics of the chemical etching process, its precision, and the

elimination of burrs and irregularities makes it an ideal technology for medical applications. As such, medical OEMs use the process for many products including cranial implants, pacemaker parts, micro components (connectors, contacts, springs and meshes for hearing aids), and medical instruments such as bone saws used for knee and hip implants.” DW

Precision Micro | www.precisionmicro.com/

Same Day Shipping on Thousands of Parts

CALL US TODAY!

FREE SAMPLES

Test Our Trims and Seals for Fit and Function

FREE CATALOG

Quickly View Our Most Popular Lines of Trims and Seals

DESIGN ASSISTANCE

Let Us Help you Find the Right Trim and Seal

IF YOU HAVE AN EDGE… WE HAVE A TRIM! HEADQUARTERS 6855 HERMOSA CIRCLE BUENA PARK, CALIFORNIA 90622

DESIGN WORLD

DFI 6-19 Vs3.LL.indd 33

MIDWEST MANUFACTURING 1642 GATEWAY COURT ELKHART, INDIANA 46514

www.designworldonline.com

800-933-4915 WWW.TRIMLOK.COM INFO@TRIMLOK.COM June 2019

33

6/3/19 2:32 PM

Design for Industry Medical

Liquid silicone rubber keeps nutrients flowing in medical device for cell growth Wilson Wolf created a paradigm shift with its cell culture design disrupting age-old beliefs regarding cell production. Minnesota Rubber and Plastics (MR&P) facilitated the unique design with an efficient, high quality molded, assembled and packaged product ready for the medical marketplace.

Wilson Wolfâ&#x20AC;&#x2122;s G-Rex design was accomplished through DFM (Design For Manufacturing) collaboration with engineering teams from both companies. The group effort eliminated several components, and improved the overall design and final product cost.

Key to the G-Rex design is the Liquid Silicone Rubber (LSR), a 0.010 thick membrane molded by Minnesota Rubber and Plastics. In the device, the LSR membrane uses convection, not diffusion, to transport nutrients generating the most cell cultures in the least amount of space. Convection achieves maximum cell growth with uninterrupted access to nutrients. When

compared to diffusion processes, Wilson Wolfâ&#x20AC;&#x2122;s design provides an easier and faster way to generate the most cells in the least amount of space. It can turn 300 million cells into 100 billion cells in 11 days. G-Rex is a patented FDA registered Class 1 medical device.

The G-Rex LSR membrane is contained in a 4 component thermoplastic assembly consisting of an incubator shelf, a high nutrient capacity bottle, supported by a ring at the base and a cap at the top. All molding, assembly and packaging operations are done in Minnesota Rubber and Plastics ISO 13485 Class 7 and 8 clean rooms.

Explaining its operation, Wilson Wolf officials said the G-Rex process begins by adding cells and a large volume of media into the device. The incubator is set in

The G-Rex LSR membrane is contained in a 4 component thermoplastic assembly consisting of an incubator shelf, a high nutrient capacity bottle, supported by a ring at the base and a cap at the top.

34

June 2019 www.designworldonline.com

DFI 6-19 Vs3.LL.indd 34

DESIGN WORLD

5/31/19 11:11 AM

Precision Control for Your Operations

Clutches, Brakes and Motion Control Products

The G-Rex design uses a Liquid Silicone Rubber (LSR), a 0.010 thick membrane, that enables convection rather than diffusion to transport nutrients to generate the most cell cultures in the least amount of space.

Clutches and brakes for complete motion control, designed to meet exact specifications. From ultra-precise medical procedures to heavy equipment across a variety of industries – CJM is everywhere.

Oxygen from ambient air and CO2 from the media is exchanged through the Gas Permeable Membrane. Cells obtain oxygen and nutrients on demand (no need for media exchange, shaking or rolling). The cultured cells are collected by withdrawing 90% of the media volume and removing the cells.

The product is now available to the medical community in multiple sizes and packaged quantities.

Minnesota Rubber and Plastics’ experience in advanced material formulation enables it to be compliant with FDA, EC 1935/2004, NSF 61, and NSF 51, plus ISO 10993 and ISO 13485. DW

• electrical, mechanical, pneumatic and hydraulic models • system design and integration • expert engineers working on every order

Minnesota Rubber and Plastics www.mnrubber.com

Engineering Solutions for Clutches & Brakes

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

www.cjmco.com Phone: 860-643-1531 291 Boston Tpke, Bolton, CT 06043

DESIGN WORLD

DFI 6-19 Vs3.LL.indd 35

www.designworldonline.com

June 2019

35

5/31/19 11:12 AM

Design Notes Planetary drives (or gearboxes) use one sun gear in the middle and planet gears around it, all embedded into a ring. All of the gears, including the ring, have involute profiles. These types of drives are ubiquitous – they are used in a broad diversity of applications, including cars and other road vehicles, and are produced by virtually every gear manufacturer in the world.

CNC grinding machine helps

robotics application get in gear

Edited by Mike Santora • Associate Editor

When the Taiwanese machine tool company Chien Wei Precise Technology needed CNC grinding machines for manufacturing specialist gears used in robotics applications, they called on CNC highend application company, NUM to assist.

Based entirely on NUM’s latest-generation Flexium+ 68 CNC platform, Chien Wei’s new machines are designed to speed the production of both involute and cycloidal profile precision gears. These machines are believed to be the first gear grinding machines on the market that are capable of handling both types of gear profile. There are two versions of the grinding machine, one for internal gears, the other for external gears.

Chien Wei Precise Technology initially specialized in precision machine tools such as vertical grinders, jig grinders, and machining centers, together with coordinate measuring machines (CMMs).

Over time, it also diversified into robotic automation systems.

36

June 2019 www.designworldonline.com

Design Notes 6-19_Vs3.LL.indd 36

DESIGN WORLD

5/31/19 12:16 PM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

Robotic systems typically use either planetary gearboxes equipped with involute gears or cycloid drives based on a combination of a reduced epitrochoid rotor and a cycloid stator. While planetary gearboxes have been around for a long time and are quite common, cycloid drives have far fewer moving parts and offer a more efficient means of achieving high reduction ratios. A speed reducer with a ratio of 200:1 would typically need a chain of three planetary gearboxes with twelve moving involute gears. The same reduction ratio could be achieved with a cycloid drive using one stator and one rotor.

However, cycloid gears are notoriously difficult and expensive to manufacture.

In 2015, Chien Wei decided to bring gear manufacturing in-house, by developing its own gear grinding machine. By producing its own gearboxes, the company could control quality, shorten lead times, and reduce costs. It would also enable it to sell gearboxes to machine builders â&#x20AC;&#x201D; and possibly the machines themselves to gear manufacturers.

Chien Wei initially based its gear grinding machine on a Fanuc series 0i-MF CNC system, which it uses for other machine tools, together with Mastercam CAD/CAM software and its own CMM. But it soon became apparent that the profile complexity of cycloidal gears meant that CMM data was inadequate for controlling the manufacturing process. Another major disadvantage was that customers wishing to purchase the machines would also need to invest in an expensive CAD/CAM system and additional personnel.

The company decided it Gearboxes that use cycloid needed a CNC system that gears have few moving parts fully supported gear grinding and are some of the most from the outset so that its customers could input the efficient and reliable speed parameters of the gear they reducers available today. Single wanted with the CNC then stator/rotor combinations can accommodate ratios as high as 300:1 and can provide efficiencies higher than 93%.

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

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

ADAPTER SLEEVE ASSEMBLIES

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

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

TT

ET

-H

IG

GI

NS US

A

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

Visit our 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 DESIGN WORLD

Design Notes 6-19_Vs3.LL.indd 37

June 2019

37

5/31/19 12:17 PM

Hybrid Control Systems Product Line

Stepper Motors

Compact Linear Actuators

Linear Slides

Linear Cylinders

What is

Rotary Actuators

Hybrid Control System?

Oriental Motor's hybrid control system performs accurate positioning, speed and torque control operations with ease. The position of the motor is always monitored, and then the driver automatically switches between 2 types of control, depending on the situation.

Featured Benefits of Combines Benefits of "Open Loop Performance" and "Closed Loop Control" Continuously Monitors Motor Position With High Response, No Hunting, No Gain Tuning Mechanical Multi-turn Absolute Sensor Means No Battery Required

Simplify Setup & Control

Built-in Controller Types Available

Providing Innovative Motion Control Solutions Since 1885 570 Alaska Avenue

Torrance, CA 90503

Tel: 800-GO-VEXTA (468-3982)

sales@orientalmotor.com

www.orientalmotor.com Oriental 2-19.indd 38

5/31/19 2:22 PM

Design Notes controlling all aspects of the machine’s dressing and grinding processes in realtime.

The new generation of Chien Wei’s gear grinders together with NUM’s new profile grinding technology now provides the ability and flexibility to manufacture both cycloid and involute gears on the same machine.

Chien Wei’s internal gear grinder is a 9-axis machine. The work piece table is mounted on a linear axis that moves axially towards the grinding wheel, which is belt-driven (due to space constraints inside the gear) and mounted on a vertical axis driven by a linear motor. As the grinding wheel spins, it is driven up and down by the linear axis, while the work piece table moves in continuously. Both flanks of the gear are ground simultaneously. The machine also handles gear dressing. During the

dressing cycle, the entire tool head is moved horizontally to the right, and a symmetrical dressing disk moves along the outer shape of the grinding wheel in three sections, right/left flank and tip. Cycloids and involute shapes can be dressed.

The external gear grinder is an 8-axis machine. Broadly similar to the internal gear grinder in operational terms, it features a direct drive grinding wheel.

Again, like the internal gear grinder, it also handles dressing. However, in this case, the shape of the tooth gap can be reduced epitrochoids or involutes.

Manual correction of the gear tooth shapes is possible on either machine.

Both machines are controlled by Flexium+ 68 CNC systems, equipped with FS153i touch-sensitive operating panels.

The application-specific HMI that has been jointly developed by NUM Taiwan

and Chien Wei controls both the grinding and dressing cycles and allows users to fully specify the required gear profile by entering the appropriate parameters.

Graphical DXF (Drawing Interchange Format) files can be imported from — and exported to — CAD systems, and the system features a comprehensive database for grinding wheels and work pieces. The NC programs are generated entirely automatically, without any need for operator involvement. DW

NUM | www.num.com

LASER EYE PROTECTION REQUIRED laser laser laser laser

welding cutting drilling marking

laser laser laser laser

tube cutting machining ablation anything

Cadence proudly announces the acquistion of cadenceinc.com /arcor | 800.252.3371

DESIGN WORLD

Design Notes 6-19_Vs3.LL.indd 39

www.designworldonline.com

June 2019

39

5/31/19 12:18 PM

Design Notes

High torque retention knobs help

reign in tooling budget Edited by Mike Santora • Associate Editor

Tooling is a vital process in the production of automobiles, as every single part of a new car requires a unique tool. What if an invisible problem inherent to CNC manufacturing existed? One of the major initiatives at the forefront of today’s automotive manufacturing community is to answer these challenging tooling cost containment questions and find progressive solutions therein.

Boeing profile Automotive industry manufacturers have basic requirements from their suppliers — on-time delivery, accuracy, and sufficient available stock. They want perfect parts, but they want them to be immediately available at a price they can control. Automotive industry suppliers need to have the ability to maintain production volume and quality, while maintaining a competitive edge through cost containment.

The big automotive companies hold their suppliers to stringent requirements relative to quality while expecting them to be very flexible in response to fluctuating demand, and still produce parts as economically as possible. Nearly every component manufactured for use in the automotive industry has CNC manufacturing involved in its production.

Perhaps it’s time for automotive manufacturers to take a giant step backward and get down to the basics of manufacturing issues that exist on the production floor, which cost the industry billions of dollars per year and go largely unrecognized.

Tooling is a vital and often overlooked process in the production of automobiles, as every single part of a new car requires a unique tool. What if an invisible problem inherent to CNC manufacturing existed? What if an actual flaw in the tooling was robbing manufacturers of the ability to produce parts accurately, and interfering with the production rates and cost containment? One of the major initiatives at the forefront of today’s automotive manufacturing community is to answer these challenging tooling cost containment questions and find progressive solutions therein.

40

June 2019 www.designworldonline.com

Design Notes 6-19_Vs3.LL.indd 40

DESIGN WORLD

5/31/19 12:20 PM

THE ORIGINAL

VARIABLE VOLUME PUMP,

REINVENTED FOR SAVINGS.

We set the standard with the industry’s first precision variable volume pumps. Now, the same space-saving design and reliable performance are available at a fraction of the cost.

Our new LPD Series Precision Dispense Pumps offer unmatched reliability AND affordability, giving you exceptional total value.

Compact Design Maintenance-free Multiple Dispense Volumes Available Worldwide Engineering Support Give your device the benefit of our experience.

Contact The Lee Company or visit www.LeePumps.com

See us at SLAS, Booth #448 and MD&M West, Booth #2459

2 Pettipaug Rd, Westbrook CT 06498-0424 860-399-6281 | 1-800-LEE PLUG | www.TheLeeCo.com

The Lee Company

LEE_OrigPump_DW_12-2018.indd 1 The Lee Co. 6-19_Med Tips Co 5-19.indd 56 Supp.indd 41

WESTBROOK•LONDON•PARIS•FRANKFURT•MILAN•STOCKHOLM

11/5/18 4:34 PM 5/31/19 5/7/19 2:23 3:50 PM

Design Notes A few years ago, Boeing (Seattle, WA) contacted one of their tooling manufacturers, Briney Tooling Systems (Bad Axe, MI), a supplier of CNC tool holders and shrink fit tooling systems in North America, reporting that they had performed testing that revealed a flaw in the V-flange tooling they were using. Requesting a solution, Briney reached out to JM Performance Products, Inc. (JMPP: Fairport Harbor, OH / formerly J&M Machine) to help them handle the problem. In turn, within the following week, JMPP began an intrinsic investigation and designed a gage that mirrors the interior grind of a CNC spindle. This gage measures movement or growth of the toolholder taper down to 7.5 millionths inch in diameter.

The JMPP team identified that the flaw as toolholder expansion. Using their gage to perform extensive testing, the team proved that toolholder expansion is

caused by the installation of a standard retention knob into a V-Flange holder.

Briney had reported expansion of their holders with as little as 13 ft./lbs. of torque during retention knob installation.

This expansion creates a bulge in the holder at the small end, causing the holder to make contact with the small end instead of the large end. This reverses the way the toolholder is designed to fit the spindle, allowing the holder to move randomly within the spindle. This movement results in a loss of contact between the spindle and the toolholder and causes a laundry list of issues: vibration and chatter, excessive run-out, poor finishes, shortened tool life, high power consumption, excessive spindle wear, need to slow down, and the need to reduce the depth of cuts.

Using the taper shank test fixture, the JMPP team redesigned the knobs, finally reaching a design that

Schuster Mechanical Profile

eliminated toolholder expansion. Their high torque retention knobs are designed to thread deeper into the bore of the holder where there is a thicker crosssection of material to resist deformation.

Boeing’s primary complaint was associated with the vibration and chatter — it was causing tolerance and finish issues on costly parts. The introduction of the high torque knobs eliminated the chatter issues. Once the knobs were made available to the general milling population, the JMPP team began to get feedback from customers that served to emphasize how rampant and detrimental a problem toolholder expansion represented to the manufacturing community.

Nearly every component manufactured for use in the automotive industry has CNC manufacturing involved in its production. Perhaps it’s time for automotive manufacturers to take a giant step backward and get down to the basics of manufacturing issues that exist on the production floor, which cost the industry billions of dollars per year and go largely unrecognized.

Schuster Mechanical, LLC (Detroit, MI), a CNC job shop focused on auto test equipment, was investigating new CNC machine investments which included TRAK 2op and TRAK LMP. The TRAK 2op is the first portable (2.5 x 4-ft footprint) VMC to focus on Second Operations Work, featuring an 8-station tool changer, and 10,000 RPM spindle. The TRAK LMP VMC is a low volume/high mix production system that incorporates technologies to markedly reduce the changeover times that plague high-mix, low-volume shops.

42

June 2019 www.designworldonline.com

Design Notes 6-19_Vs3.LL.indd 42

DESIGN WORLD

5/31/19 12:21 PM

Itâ&#x20AC;&#x2122;s not you, Mark.

I just need more space.

Thin, Powerful and Frees Up Space.

Shrink your device with ultra low profile capacitance.

Visit cde.com/flatpack for full details or contact us at (864) 843-2277.

Cornell Dublilier 2-19.indd 43

5/31/19 2:25 PM

Design Notes Owner Robert Schuster wanted to proactively ensure that his spindle cartridge would last as long as possible to maximize the dependability and productivity of the new machining centers. Schuster engaged with JMPP’s sales engineering personnel at an industry trade show, who showed him how their knob’s threads ran deeper into the holder–causing less distortion at the small end of the taper. Schuster was immediately impressed that his holders were not damaged by the expansion caused by the standard knobs and could still be used in production with the High Torque knobs–with no spindle damage occurring.

Initially, Schuster was considering implementing an HSK toolholder system, but found that it was an expensive

Sandvik Profile THIN ENOUGH?

system that had too many limitations to justify conversion from V-Flange.

The HSK design features a cup-shaped holder that doesn’t provide a long reach, the socket is shallow, and the walls are thin. The High Torque knobs maintain spindle/taper contact, with the benefit of the more affordable V-Flange CAT/BT holder system. Subsequently, Schuster determined BT30 knobs (JM31109HT) would be a more cost-effective solution to extend the life of the new VMC machines.

Using the taper shank test fixture, the JMPP team redesigned the knobs, finally reaching a design that eliminated toolholder expansion. Their high torque retention knobs are designed to thread deeper into the bore of the holder where there is a thicker cross-section of material to resist deformation.

BXR Brakes · Up to 480 in-lbs static · Up to a 1.125'' bore · 19 watts or less · Produced for over 10 years Our Innovative design features a very thin profile, reducing weight and space.

For more information: Call: 800.533.1731 www.mikipulley-us.com

Increasingly, the automotive industry is using more carbide tools primarily because they can cut both aluminum and hard materials such as titanium, carbon, and exotic alloys at high speeds. Carbide tooling is expensive and also fragile, so it’s imperative to watch for microfractures which yield poor surface finishes. If a microfracture occurs, the whole tip may disappear and the inserts can be rendered useless.

44

June 2019

Design Notes 6-19_Vs3.LL.indd 44

www.designworldonline.com

DESIGN WORLD

5/31/19 12:24 PM

Recently, Sandvik, a high-tech and global engineering Group with about 42,000 employees, lent out one of their engineering representatives to test the best retention knobs for Caterpillar with a $1,200 solid carbide tool.

The specification included: a toolholder, retention knob, tightening spec, proper placement, and then lock it down.

The test’s goal was to get the custom carbide tool to run without shattering.

A variety of standard retention knobs did not work. When tested with JMPP’s High Torque knobs tightened to their provided torque specifications, it worked every time with no tool shatter. The fact is, a carbide tip cannot vibrate when it makes contact, or it shatters. Essentially, carbide must smoothly enter into the pocket and maintain its position in the pocket or it breaks. Carbide can last a long time with the right chip load and RPM. It could last weeks, but let it vibrate and it could be minutes.

Ultimately, by making a simple change — moving to the high torque retention knobs, CNC manufacturers across the board can eliminate the vast majority of issues, improve their milling operations, and get the best results while saving money. Moreover, this solution creates a real opportunity for U.S. tool shops to grow along with their automotive OEM and Tier One customers in creating progressive tooling cost containment solutions. . DW

JM Performance Products www.jmperformanceproducts.com

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

DESIGN WORLD

Design Notes 6-19_Vs3.LL.indd 45

June 2019

45

5/31/19 12:22 PM

CAE Solutions Simulation of Drug Injection and Bolus Growth David Milner and Yev Kaufman | Thornton Tomasetti Applied Science

W

When a drug is injected into tissue, it forms a concentrated volume in the tissue called a “bolus” (figure 1). For certain drugs, it is desirable to keep that volume as localized as possible. For example, when injecting a chemotherapy drug, the drug may need to be kept in the vicinity of the tumor for it to be effective. Similarly, an injection of cortisone or other steroid may need to remain localized in the inflamed tissue it’s intended to treat.

The size of a bolus is influenced by the injection rate and the properties of both the fluid and the surrounding tissue. With that in mind, we sought to develop a computational framework to estimate the bolus size for a given fluid, tissue, and injection rate. Additionally, we wanted to compute the strain in the tissue, which could potentially be used as a measure of relative pain the patient might feel.

Bolus formation At the outset of this work, we recognized that there are multiple computational approaches to simulating this problem, including full CFD analysis with coupled fluidstructure or fluid-tissue interaction. As a starting point, however, we decided to treat the problem as one of fluid flow through a porous medium where flow is determined

by Darcy’s law. This is an approach commonly recognized and accepted by a number of researchers in the field.

Epidermis Dermis

Furthermore, the finite element analysis software Abaqus/Standard already includes an analysis option that calculates pore pressures coupled to mechanical stresses and strains of the porous medium; this analysis option was originally developed for the petrochemical industry to model oil extraction and fracking. Given the general acceptance of the Darcy’s law conceptualization and the availability of the coupled analysis option, this seemed an appropriate starting point for investigation.

We sought to verify our analyses against experimental results determined by Kim, et al (figure 2). In their paper, the researchers injected a mixture of insulin and visualization agent into samples of porcine adipose, or pig fat. Two injection rates were studied; one injection was performed over 20 minutes, and the other over 5 minutes; injection rates like these are what might be delivered by pumps.

X-ray images were taken periodically throughout the injections to visualize the bolus. From these images, the bolus size was measured and its growth plotted vs. time. The bolus was reported to be slightly ellipsoidal, resulting in different radii in the vertical and horizontal dimensions. The differences were small, however, so for our analyses we considered isotropic material properties and fluid loading, which essentially means that boluses were spherical.

Figure 1. A bolus of liquid drug forms beneath the skin during an injection. Image reprinted from “Effective method for drug injection into subcutaneous tissue,” Scientific Reports, Hyejeong Kim, Hanwook Park & Sang Joon Lee, under license by Creative Commons https:// creativecommons.org/licenses/by/4.0/

Subcutaneous tissues Muscle 46

June 2019 www.designworldonline.com

CAE Solutions 6-19_Vs3.LL.indd 46

DESIGN WORLD

5/31/19 12:27 PM

5.55 [.22]

"A"

4.70 [.19]

0.50 02] 3.18 [.12]

15.75 [.62]

8.13 [.32] SNAP-IN BRACKET (V20 / V25)

3.18 [.13]

1.22 [.05]

25.20 99] [.99]

22.00 [.87]

Ø21.80 [.86]

13.200 M MAX 522] [.52]

Figure 2. Bolus growth during injections. Note the X-ray images at the bottom of the graphs showing the tip of the needle and the expanding bolus of injected fluid. Image reprinted from “Effective method for drug injection into subcutaneous tissue,” Scientific Reports, Hyejeong Kim, Hanwook Park & Sang Joon Lee, under license by Creative Commons https://creativecommons.org/licenses/by/4.0/

We faced a number of challenges in successfully modeling this problem. These included material characterization, numerical issues such as model stability and convergence, and even interpretation of results.

The permeability of adipose material Regarding the permeability of porcine adipose, values previously reported by multiple researchers differed by up to two orders of magnitude, and few of them accounted for changes in permeability that arise from deformation of the tissue. In reality, as the fluid pressures within tissue pores increase, the surrounding tissue deforms, allowing the pores to dilate.

Because larger pores should correspond to increased permeability, the tissue permeability should actually be a function that varies with porosity or void ratio. This behavior is commonly acknowledged and included in analyses in the petrochemical field. To account for this, we leveraged permeability data in the literature that focused on the flow of saline through canine adipose (not porcine adipose) to incorporate deformation-dependent permeability in our simulations.

DESIGN WORLD

CAE Solutions 6-19_Vs3.LL.indd 47

M19x1.0 19xx1..00 7.75 7.

7. [.[[.3 .331 31] 1] [.31]

4.65 [.18]

June 2019

AY REL

5.80 [.23]

2.75 X 0.50 TYP 2.

2.7 [.11 [.[ 1 X .02] [.1 .0 7.00 .0 [.2 ] [.28 [.28]

(2X) (2X ((2 2X) 22X X)) Q0.40 X Q00...440 [.02] [.0 [[.02 ..02 .0 0022]

Our current coupled pore pressurestress analyses appear to be an effective approach for evaluating slow injections.

This approach, with the assumptions mentioned above, produces spherical boluses that are comparable to the ones Kim has observed for suitably slow injections. For rapid injections, which may result in a dish-shaped or asymmetric bolus, assumptions such as isotropic permeability will need to be relaxed and additional physics such as localized damage modeling may be required.

However, the overall approach of using a coupled pore pressure-stress analysis is still likely to remain valid.

For slower injection rates, our analyses compare quite favorably with experimental results (figure 3), and could be further improved with additional information.

(Note that our analyses capture the injection only, not diffusion after the termination of the injection.) The physical test results were performed by injecting a mixture of insulin and visualization agent into porcine adipose, while our permeability function was derived from tests of saline flowing through canine adipose. With further information, we could scale our permeability function to account for the differences between canine and

CIT

25.75 [1.01]

Comparison of simulation with experimental results

www.designworldonline.com

2.00 [.08]

(2X) ( 0. [.0 [.02] 2.54 [.10]

2.60 .600 [.10] 0]]

5.088 5.08 [[.20] .22200]

5.08 55.0 .08 .0 [.[.20] [.2 [[.20 .20 .2 .2200]

[

116.00 16 6.00 0000 [.663] [.63] 20.20 220.

20 00.20 20 [.80] [.8 [[.80 .80 80 80]

2X 4.75 [.19]

2.80 TYP. [.11]]

YP

88.00 .00 00 [.31] [.3 31]

00.80 TYP. [.0 [.03]

4.0 [.16] [[..16 16]

15 [.60

0.80 TYP [.03]

12.1 12 2.1 2. [[.[.48] .48 48]

Ø1.5 [[.06]

15.1 [.60]

16.0 [.63]

47

5/31/19 12:29 PM

CAE Solutions

Figure 3. Simulation results compared against experimental data. Image reprinted from “Effective method for drug injection into subcutaneous tissue,” Scientific Reports, Hyejeong Kim, Hanwook Park & Sang Joon Lee, under license by Creative Commons https://creativecommons.org/licenses/by/4.0/

Figure 4.

Top: Tissue strain during a 20-minute injection.

Bottom: Tissue strain during a 5-minute injection. | courtesy Thornton Tomasetti Applied Sciences

porcine adipose, as well as for saline and the insulin mixture. In general, we know that saline is less viscous than the insulin mixture and should result in a larger bolus, as reflected in our results.

However, we don’t have specific enough information at this time to quantify these differences.

Because the Abaqus/Standard solver couples tissue response with fluid flow, it is also possible to compute the localized tissue deformations caused by the injection (figure 4.) Note that strains during the 5 min injection are about 4 times as large as those during the 20 min injection. The faster injection also shows a much larger region of influence. Capturing comfort using such simulation-based measures could play a significant role in designing better injectors or even specifying different, more comfortable, injection rates when possible.

flow comes straight from classical geotechnical engineering. The finite element implementation of that law and its coupling with mechanical stresses were developed for the petrochemical industry. Support for the concept of a variable rather than constant permeability also came from the petrochemical industry. In addition to the primary goal of developing a computational framework for injections, this work also serves as an effective demonstration of how product design engineers in drug and medical device companies can benefit from collaborating with teams that have interdisciplinary experience. DW

Thornton Tomasetti Applied Science www.thorntontomasetti.com/ services/applied_science/.

Successful cross-industry collaboration A noteworthy feature of this work is that some of its major contributions arose directly from or were confirmed by experience in other industries. For example, Darcy’s Law describing fluid

48 June 2019 www.designworldonline.com

CAE Solutions 6-19_Vs3.LL.indd 48

DESIGN WORLD

6/3/19 3:02 PM

YOUR CUSTOM SOLUTIONS ARE CGI STANDARD PRODUCTS

Advanced Products for Robotic Applications CGI Motion standard products are designed with customization in mind. Our team of experts will work with you on selecting the optimal base product and craft a unique solution to help differentiate your product or application. So when you think customization, think standard CGI assemblies. Connect with us today to explore what CGI Motion can do for you.

800.568.GEAR (4327) • www.cgimotion.com

copyright©2019 cgi inc. all rights reserved. 025rbt

CGI 2-19_Robot Report.indd 49

5/31/19 2:24 PM

CAE Solutions A unified platform for design automation and design change management

P

PUES Corporation, a Japanese electric vehicle (EV) systems provider, needed a way to speed and simplify the development of next-generation automotive electrical/ electronic (E/E) systems.

50

PUES turned to Capital electrical design software from Mentor, a Siemens business, after years of using discrete point solutions across multiple engineering domains. These legacy tools were ultimately overwhelmed by increasingly complex E/E challenges resulting from automated driving requirements, stringent global emissions regulations and unyielding market pressure to reduce costs and speed time-to-market. With the limited compatibility of the legacy tools and the challenges of coherent data exchange through the E/E flow, design changes in one domain required time-consuming and error prone rework in other domains, executed using diverse design environments.

The Capital suite gives PUES a unified platform for design automation and design change management across multiple E/E domains. PUES uses Capital for an array of tasks including E/E system architecture definition, electrical system and wire harness design, configuration and change management, as well as functional verification and manufacturing process generation.

Because the software automates the production of documentation linking assets such as wiring schematics, component locations, harness views and diagnostic procedures, PUES can add value and boost customer satisfaction, even

June 2019 www.designworldonline.com

CAE Solutions 6-19_Vs3.LL.indd 50

as autonomous drive functionality and other requirements increase the complexity of EV systems.

Developed for transportation applications, Capital software spans an extended flow from concept and electrical architecture definition to wire harness design, manufacture and vehicle maintenance. Combining design automation and modern enterprise integration capabilities, the software creates digital continuity within the electrical domain to help compress development cycle time and reduce costs.

Capital tools can be implemented individually or deployed together in a unified flow that matures data within a consistent environment. Robust integration with adjacent domains (such as requirements management, mechanical CAD and PLM) is fully supported, as is cross-organizational collaboration. DW

Siemens Digital Industries Software www.siemens.com/plm.

DESIGN WORLD

5/31/19 12:32 PM

CAE Solutions

Rod Ends and Spherical Bearings designed and manufactured to Aurora’s exacting standards for quality and durability.

Maple 2019’s data analysis capabilities identify biomarkers of several cancers

Your Partner moving forward!

Registered and Certified to ISO_9001 and AS9100.

From economy commercial to aerospace approved, we’ve got it all!

The ability to leverage complex data as a strategic asset is increasingly critical, but the current labor market has a shortage of resources in big data analytics. Companies are faced with several challenges related to the inadequate resources necessary to process data. A long-time Maple user and quantum

R

mechanics researcher, Marvin Weinstein, refers to the problem of extracting meaning from large data sets as, “How do we find

Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538

a needle in a multi-dimensional haystack, when we don’t know what a needle is, and we don’t know if there is a needle in the

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

haystack?”

w w w. a u r o r a b e a r i n g . c o m

Wire Your Machine With Pre-Terminated

Cables!

www.icotek-usa.com

U P TO

ULTYPE

4X

Split Cable Entry Frame KEL-ER: Cable entry frames for routing preterminated cables with protection class up to IP66 / UL type 12/4X.     

DESIGN WORLD

CAE Solutions 6-19_Vs3.LL.indd 51

June 2019

Certified protection class Very high strain relief according to EN 62444 Warranty of pre-terminated cables remains Quick assembly High cable density

E! RE 4 F a.com E N us

5 T O ekGE @icot 3-231 info 12-64 3

51

5/31/19 12:32 PM

CAE Solutions The core of DQC is an algorithm that maps a problem of unsupervised clustering to a problem in quantum mechanics.

Dynamic Quantum Clustering (DQC) accomplishes this feat by creating a density map of data using DQC’s proprietary Maple library, and Maple 2019 visualization tools. The result of a DQC analysis is an animation that gives a visual record of the complex computations going on behind the scene. According to Marvin, “these animations leverage the human ability to spot patterns developing in time and space.”

With Maple’s prototyping abilities and customizable features, Marvin was able to get DQC up and running within a week. Noted Marvin, by using the DQC compiled library within Maple, it was possible to have a powerful GUI without having to build the interface from scratch. Marvin believes that time

Reliability

is often wasted with unnecessary coding and analysis tasks, and exploits many of the built-in features of Maple to save time drive his research forward.

The core of DQC is an algorithm that maps a problem of unsupervised clustering to a problem in quantum mechanics. It uses quantum evolution to identify correlated information and reveals the details of the process through a Maple animation. This animation typically reveals hidden and unexpected insights into complex data. Marvin asserts that the aim of DQC is to “let the data speak for itself.”

The advantage of working without making assumptions or hypotheses, without cleaning the data, and without the need for expert knowledge means that DQC is a data exploration method that is fast, inexpensive, and efficient.

for miles For 75 years, Vlier has steadfastly delivered a level of quality, value, selection and precision that, to this day, remain unmatched. That’s real reliability. That’s confidence earned.

Insist on Vlier. Vast Product Selection. Versatile Applications. Superior Value and Performance.

Ball Lock Pins

Vlier Products,

a unit of Hutchinson Defense & Mobility Systems 1.800.821.1090 | vlier@vlier.com | vlier.com

1811085_VLIER-AerospacePrintAd.indd 1 CAE Solutions 6-19_Vs3.LL.indd 52

Leveling Devices

Quick Release Plungers

ISO:9001 Certified AS9100 Certified Cage Code: 01226

5/23/19 10:11 AM 5/31/19 12:33 PM

9.25x5.5

Spring Loaded Devices

One of DQC’s major accomplishments thus far has been the identification of several biomarkers strongly correlated with multiple cancers. According to Marvin, TCGA analysis was selected as the initial step towards cancer research because cancer is a problem that everyone understands to be a big deal, and “we’ve all lost people we love to cancer.”

The hope was that better clustering methods would allow mRNA from various tumor samples to better classify tumors into biologically relevant groups. The study identified 48 of 73,000 mRNA expressions that defined all five different cancer types.

This analysis, published in Nature Scientific Reports, demonstrated the ability to provide an accurate diagnosis of cancer type, based on molecular information alone, and has further revealed significant sub-typing of cancer cells, beyond what pathologists can currently achieve. The sensitivity to variation in mRNA expression patterns is the “holy grail” of precision medicine, because it promises to tell us which tumors are likely to respond to a drug and which tumors will not. Moreover, the analysis showed that DQC outperformed tSNE-HDBScan, the current gold standard clustering method used in cancer data analytics.

Now, Marvin is working in pharmacogenomics to offer better diagnosis and treatment methods for cancer and other diseases. His company, Quantum Insights, is working towards developing effective, data-driven strategies. While Quantum Insight’s initial focus was cancer, the goal is to expand this research into other healthcare applications. Marvin believes that the DQC technique will help save lives wherever better analytics are required. Other successful applications of his research include Alzheimer’s data, detection of contraband nuclear material, analysis of the Sloan Digital Sky Survey Data, and other areas that use large amounts of data. DW

10:11 AM

Simplify the power entry element with a module. Reduce assembly costs by combining several components into one module. Interpower® has modules with 2 to 5 functions and a wide range of component

Maplesoft www.maplesoft.com

choices, plus the products that work with these modules, such as cord sets and fuses.

An assortment of modules are in stock with

WHAT DO YOU THINK?

n

same day shipping available. There are no minimum order or dollar requirements. To lock in a quantity price break and help reduce the cost over one year utilize a blanket or

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

scheduled order.

®

®

Toll-Free Phone: (800) 662-2290 E-mail: sales@interpower.com Business Hours: 7 a.m.–6 p.m. Central Time 9.25x5.5

ed ed 26

Simplify the Power Entry Element

Order Online!

DESIGN WORLD

CAE Solutions 6-19_Vs3.LL.indd 53

www.designworldonline.com

June 2019

53

www.interpower.com

5/31/19 12:34 PM

CAE Solutions

T

FactoryTalk Analytics module makes predictive analytics accessible

T

The new FactoryTalk Analytics LogixAI module, formerly known as Project Sherlock, uses artificial intelligence (AI) to detect production anomalies and alert workers so they can investigate or intervene, as necessary.

Many existing analytics technologies require deep expertise in both data science and industrial processes. But this add-on module for ControlLogix controllers reduces that burden by doing the job of a data scientist. It fits directly into a control chassis and streams controller data over the backplane to build predictive models. It can continuously monitor a production operation, detecting anomalies against its derived understanding.

“The FactoryTalk Analytics LogixAI module makes predictive analytics more accessible to help more workers make better production decisions,” said Jonathan Wise, product manager, Rockwell Automation. “The module learns your ControlLogix application and tells operators and technicians when things are changing in unexpected ways. This can help them get ahead of product quality issues and protect process integrity.”

For example, the module can help operators spot performance deviations in equipment like mixers that could affect product quality or lead to downtime. It can also be used as a virtual sensor.

Instead of workers taking a reading, like the humidity of a packaged food product, the module can analyze variables from line assets like sprayers, dryers and burners to predict a measurement, virtually.

54

Workers can then be notified of problems by configuring alarms on a human machine interface (HMI) or dashboard. Future features of the module will go further, helping workers focus their problem solving or automate the optimization of a process.

The FactoryTalk Analytics LogixAI module is the newest addition to the FactoryTalk Analytics portfolio from Rockwell Automation. The portfolio includes FactoryTalk Analytics for Devices, which learns about an automation system’s structure to tell workers about problems with individual devices. The LogixAI module expands on this by learning about an automation system’s application and helping identify anomalies with its overall function.

Both products work individually, but each will benefit the other in future iterations. The FactoryTalk Analytics platform aggregates multiple sources of data, so workers can discover new insights. FactoryTalk Analytics for Devices and the LogixAI module will both be data sources for the platform going forward. DW

Rockwell Automation | www.rockwellautomation.com

June 2019 www.designworldonline.com

CAE Solutions 6-19_Vs3.LL.indd 54

DESIGN WORLD

5/31/19 12:35 PM

Cham pions M12 Power S & T Code

M12 Ethernet D & X Code

M12 Stainless Steel

B & D Code Crimp

www.binder-connector.us

ServoKinetics 2-19_FPW_NEW.indd 9 Binder 6-19.indd 55

5/3/19 2:25 4:00 PM 5/31/19

Internet of Things

Trends in UX Design: the IoT perspective Dorothy Shamonsky, Ph.D. • Boston UX

M

Many Internet of Things (IoT) companies are looking to improve an

existing product or create a notable new product by investing in user experience (UX) design. This is one reason UX design is a booming profession and evolving quickly.

We designers need to keep updating our design practices to apply ever-advancing technologies to old and new problems.

Industrial market sectors such as transportation, manufacturing and the medical device sector, under pressure or excitement (hopefully the latter) from the emergence of the IoT, have been progressively embracing UX for the past few years. Even though company commitments vary between diving in headfirst or just dipping toes in the water, with the success of products like the Nest Thermostat and the Amazon Alexa,

56

June 2019 www.designworldonline.com

Internet of Things_6-19_Vs3.LL.indd 56

a growing number of companies are swept up in the expectation of good user experience.

And there’s no reason to think that this embrace of UX will stop anytime soon. On the contrary, it’s expected to continue at a rapid pace throughout 2019. From the perspective of an embedded and IoT UX designer, here are some emerging trends UX professionals should be aware of:

DESIGN WORLD

5/31/19 12:41 PM

1

Educating stakeholders is critical Raising awareness of usability issues and practices has always been a part of our dynamic profession. You would think by now that everyone has at least a passing understanding of what UX design offers, but education may be a larger piece of any design project than you might expect. Since many IoT stakeholders are just getting their feet wet with UX, they need to learn as they go along. Many of the concepts and practices are new to them. And they need to justify to business partners the processes and costs involved. As designers, we need to spend the time to make our practices more transparent, and to explain why we do what we do.

Standard Parts.

Winco.

2

Voice is the new touch Or is it? Last year saw so much hype about voice interaction that some people consider voice to be the new touch. But touch isn’t losing ground. Voice is just the newest interactive modality to mature enough to make an impact in the consumer marketplace. It’s a more convenient modality in some contexts where touch is not the best solution, like in-vehicle interfaces, where taking eyes off the road to look at a screen is not the safest option. But in many devices, touch will remain as it is, or as a partner to voice just like on a smartphone, and users will choose what works best for them to use at any given moment. The growing presence of voice does mean that many more UX designers will be required to get up to speed with the principles of designing for voice.

3

Context of use is growing in importance With the rise of IoT and a proliferation of specialty devices, context of use -- the conditions under which a given artifact or software product is used or will be used in a normal day-to-day situation -- becomes a more important component of design. When devices are specialized, each device can have a unique context of use -- unlike the case with desktops, laptops, tablets and phones, which each having their own relatively consistent context of use. For instance, with a phone app, designers barely have to think of context of use. That’s because a user will likely hold the phone the same way and have the same mobility when using any app. Also, built into the OS components is usability for a phone context (although this may not apply for unusual apps like augmented reality games).

With IoT devices that’s not the case, so context is everything. Say you’re creating an airline check-in kiosk. You’re dealing with a fairly unique context. The user is standing at a fixed device at a particular location, with a limited number of devices. And they are probably in a hurry. Here’s another example. Say you’re designing a medical device for use in an operating room. It could be positioned on a stand that is mobile or fixed, or it could be secured to a wall. It could require interaction using sterile gloves or some other replaceable sterile shield. Each element requires different design decisions.

Considering context of use is vital when designing with most IoT devices.

DESIGN WORLD

Internet of Things_6-19_Vs3.LL.indd 57

June 2019

JW Winco offers stainless steel standard parts with high corrosion resistance, and the ultimate in material quality.

JW Winco | 800-877-8351 | sales@jwwinco.com | www.jwwinco.com

Key Bellevilles, Inc. LARGEST MANUFACTURER OF DISC SPRINGS IN THE WORLD Live Load with Belleville Disc Springs LARGEST STOCK OF STAINLESS STEEL AND INCONEL SPRINGS IN THE WORLD HIGH TEMPERATURE FLANGE BOLT

FREE ENGINEERING ASSISTANCE FLANGE BOLTING SERIES ON STOCK H-13, STAINLESS, INCONEL, AND TITANIUM

MANUFACTURED TO DIN AND NACE SPECS Metric and English sizes available

OUR PRICES ARE THE BEST ~ BUY DIRECT ~ Made in the U.S.A.

Immediate Delivery!

24-Hour Service 7 Days a Week!

Tel: 724-295-5111 Fax: 724-295-2570 Toll Free: Tel: 800-245-3600 Fax: 800-847-1672

Visit our Website: www.keybellevilles.com for a FREE Design CD-ROM

LIVE LOADING VALVE PACKING GLANDS

100 Key Lan e Leechbur g, PA 15656, U.S.A. Visit our Website a t: www,key bellevilles.com Email: sales@keybellevilles.com

57

5/31/19 12:41 PM

Internet of Things

4

Multi-device experiences are the new normal The proliferation of specialpurpose devices leads to experiences that can take place on multiple devices -- or what is referred to as multi-device experiences. A user will complete a task in the most convenient way for them, across devices. For instance, you might turn your security alarm “on” using your home-security system screen before leaving your residence, but you might reset your homesecurity code using your phone while sitting on the train on your way to work. Multi-device experiences are dynamic and adaptable for users. They let you complete your user journey in the most convenient way possible. Creating these experiences requires device-agnostic design, which asks designers to think holistically in terms of a user journey. The focus is on the user and what is most convenient for them, not on the devices and what they can do.

5

Design systems are gaining new fans With the proliferation of IoT devices comes a proliferation of platforms.

It’s the Wild West in terms of design consistency. As a result, design systems -- shared design language -- are more popular as a way to fix the consistency problem for users, as well as address the extra work of dealing with multiple platforms. According to the 2017-2018 UXPin Design Industry Report, 67% of companies are now using a design system or are actively building one.

That’s good news for designers and users. Design systems are “the single source of truth which groups all the elements that will allow the teams to design, realize and develop a product.”

In other words, they are patterns, components and guidelines for designers and developers. Embedded in these

58

tangible tools are the principles a team wants to embody, such as brand values, shared processes, and shared beliefs.

Well-known design systems include Material Design System, IBM Design System and ADG by Atlassian.

At first glance, design systems seem to benefit designers more than users because, once a system is established, it economizes work, reduces chaos and improves quality. But users are definitely beneficiaries of enhanced UX quality and consistency because they end up with a better product in the end.

6

UX designers are actively thinking about AI Analysts have predicted that machine learning and artificial intelligence (AI) will become the key technology trends of 2019. That means designers need to think deeply about AI and how it impacts the user experience. Industrial IoT is considered the top use case for AI, which can assist in root cause analysis, outlier detection, and predictive maintenance of the equipment. Companies like Amazon, Google, Apple and IBM are investing heavily in R&D to bring AI closer to consumers. It’s up to designers to find ways for AI to make sense for users.

June 2019 www.designworldonline.com

Internet of Things_6-19_Vs3.LL.indd 58

7

Ethics is essential By now, almost everyone has been the victim of some kind of data breach, which inflicts a huge amount of inconvenience and often fear. At the same time, we’re witnessing first-hand how social media can affect a democracy, inciting divisiveness. Speaking of social media and time behind a screen, several major studies have found that more time spent staring at a screen leads to decreased happiness and at times depression for young people. While UX designers study the behavior of users in order to serve them better, they have also figured out how to manipulate them better with what have been called “dark web patterns.”

As these issues continue to play out, there is growing interest in ethics as they pertain to UX design. In 2019, the conversation around ethics will grow louder. So who is talking about ethics in design? For one, the Center for Human Technology. They are directly concerned with UX design and have focused on user attention and dark web patterns. Others include the Palo Alto-based think tank Institute of the Future and a program in the investment firm Omidyar Network called the Tech and Society Solutions DESIGN WORLD

5/31/19 12:42 PM

Lab. Both groups are interested in the junction of technology and society and together have put together the Ethical OS guide. Their goal is to encourage communication between researchers who study technology’s increasing impact on society and the large tech companies that produce this technology and the resulting products.

What it all means In the last couple of years, digital technology has revealed it’s dark potential. Although the IoT doesn’t deal literally with dark web patterns, safety and security are huge issues with many IoT devices. That’s why the onus is on designers to smarten up. Practicing user-centered design means creating designs that are good for users -- for

people -- in all ways. Look for 2019 to bring new urgency in designers’ understanding of user manipulation.

And look for designers to gain better facility designing IoT devices in a way that limits potential for safety and security breaches.

As the proliferation of IoT devices continues, the demand for UX designers will continue to climb. This is all good news for UX designers. They are in higher demand than ever, with no end in sight. DW

Resources: • [medium.com/thrive-global/howtechnology-hijacks-peoples-mindsfrom-a-magician-and-google-s-designethicist-56d62ef5edf3] • humanetech.com/], • www.iftf.org/] • www.omidyar.com/our-work/tech-andsociety-solutions-lab • ethicalos.org/]

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

May Design World Ad.pdf 1 4/29/2019 4:21:17 PM

DESIGN WORLD

Internet of Things_6-19_Vs3.LL.indd 59

www.designworldonline.com

June 2019

59

5/31/19 12:42 PM

Internet of Things

Majority of middle market manufacturers recognize Industry 4.0 opportunity

N

Ninety-nine percent of middle-market manufacturing executives are at least moderately familiar with Industry 4.0, according to BDO’s Middle Market Industry 4.0 Benchmarking Survey. But while more than half (54%) of middle market manufacturing executives have either developed or are in the process of developing an Industry 4.0 strategy, only 5% are currently implementing one. Another 25% plan to develop an Industry 4.0 strategy, but have yet to get started on it.

BDO’s Middle Market Industry 4.0 Benchmarking Survey polls senior executives at U.S. manufacturing companies with annual revenues between $200 million and $3 billion on their Industry 4.0 readiness and strategic goals. The survey finds that middle market manufacturers have ambitious goals to transform their business models and are tentatively taking steps to digitize their operations. However, significant challenges lie ahead as they struggle to get major strategic initiatives off the ground.

“Over time, Industry 4.0 will radically transform how manufacturers derive and deliver value,” said Eskander Yavar, Industry 4.0 co-leader and national leader of BDO’s Management & Technology Advisory Services. “But the window of opportunity is closing fast. Manufacturers who don’t invest in 2019 risk falling behind the curve. The middle market is no exception.”

WHAT ADVANCED TECHNOLOGIES ARE MANUFACTURERS USING NOW? 63%

Cloud computing

60%

Advanced analytics

59%

Internet of Things Robotics Process Automation

52% 49%

Blockchain Artificial intelligence

46%

3D printing or additive manufacturing

46%

Augmented or virtual reality

60

45%

June 2019 www.designworldonline.com

Internet of Things_6-19_Vs3.LL.indd 60

Top findings from the survey: • Business model diversification tops Industry 4.0 goals Middle market manufacturers know that Industry 4.0 has the potential to transform their business. As they look beyond their immediate needs and toward tomorrow’s digital future, most (71%) are prioritizing business model diversification above all else; which suggests a fundamental shift in customer demand that can’t be met by the traditional manufacturing toolset.

Improving operational efficiencies and increasing market penetration tie as the second most-cited goals, at 67% each.

• The biggest barrier to implementation is poor communication Successful Industry 4.0 adoption requires collaboration between functional areas of the business that have historically operated in silos, like information technology and operations technology.

Two in three executives view poor communication as the biggest barrier to successful Industry 4.0 implementation.

Rounding out respondents’ top five implementation barriers is interoperability with legacy technology (64%), lack of skills or insufficient training (63%), lack of leadership and vision (60), and underinvestment (54%).

• Industry outsiders pose the greatest threat Even without manufacturing roots, a technology upstart has the potential to disrupt manufacturing, whether through hyper-customization or transforming the economics of production. As a result, middle market manufacturers are most (69%) concerned that failure to adequately invest in Industry 4.0 will lead to encroachment from non-traditional competitors.

DESIGN WORLD

5/31/19 12:43 PM

Beckhoff 6-19.indd 61

5/31/19 2:26 PM

Internet of Things

• The digital thread is more theory than reality In an idealized Industry 4.0 world, supply chains become the digital thread— integrated value chains with end-to-end traceability and transparency, enabled by the constant, bi-directional flow of information. Most middle market manufacturers, however, aren’t there yet. While just 7% of respondents say their data is totally siloed, pointing to increased information sharing internally, only 6% claim they have transparency across the entire value chain.

Industry 4.0 is creating jobs.

While 63% of middle market manufacturers plan to leverage thirdparty outsourcing solutions to support Industry 4.0 enablement, more than half

(57%) plan to hire new talent. To close knowledge gaps within their existing talent pools, 60% are implementing training to upskill current employees.

The Middle Market Industry 4.0 Benchmarking Survey offers manufacturing executives a useful barometer to measure their Industry 4.0 maturity against their peers across six key dimensions, including: organizational strategy, governance, technology, process, data and security. To see the full survey results, click here.

The 2019 Middle Market Industry 4.0 Benchmarking Survey was conducted

by Market Measurement, Inc., an independent market research consulting firm. The survey included 230 executives at U.S. manufacturing companies with annual revenues between $200 million

and $3 billion and was conducted in November and December of 2018. DW

BDO USA | www.bdo.com

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

For Absolute Feedback, we’ve got your solution EPC’s Absolute Encoders offer: • 16 bits resolution for single turn, and 43 bits resolution for multi-turn • SSI, CANopen, or EtherCAT communication protocols • Electronic cam switches on CANopen and EtherCAT models • Maintenance-free and environmentally-friendly magnetic design • Energy harvesting magnetic multi-turn technology • No gears or batteries

Call us today.

We’ll help you find the motion feedback solution you need.

1-800-366-5412 • encoder.com Internet of Things_6-19_Vs3.LL.indd 62

5/31/19 12:44 PM

Internet of Things

Make IoT sensing accessible with IoT plug and play module

S

SensorTile.box helps designers discover the power of IoT and quickly understand how they can easily collect and send sensor information to the cloud.

The flexible IoT Plug and Play module connects easily with Bluetooth Low Energy to a smartphone, allowing users to watch the sensors function as a pedometer, asset tracker, environmental monitor, or as other instruments. For more experienced designers, SensorTile. box has developer and expert modes that help build sophisticated applications using a graphical wizard or by writing custom embedded code.

SensorTile.box contains ST MEMS devices for motion, context, and environmental sensing housed in a 57 mm x 38 mm x 20 mm IP54 plastic container.

SensorTile.box serves a range of sensing, tracking, and monitoring use cases and is delivered ready to use with a 500 mAh lithium battery and 8GB microSD card already fitted. The onboard sensors leverage ST’s broad portfolio of proven high-performance MEMS MEMS: Micro Electro-Mechanical Systems devices and are managed using an ultra-low-power STM32L4R9 microcontroller. They include: • STTS751 high-accuracy temperature sensor • LSM6DSOX low-power 6-axis inertial measurement unit (IMU) with Machine Learning Core (MLC) • LIS3DHH and LIS2DW12 3-axis accelerometers • LIS2MDL magnetometer • LPS22HH pressure sensor/altimeter • MP23ABS1 analog microphone • HTS221 humidity sensor In addition to pedometer, asset-tracking, and environmental-monitoring applications, beginners can also explore vibration monitoring, data recording, inclinometer/level-sensing, digital compass, and baby-monitoring applications.

Extra flexibility in developer mode lets users activate or shut down individual sensors to optimize power consumption, leverage sensor fusion by combining data from multiple sensors to improve overall accuracy, and individually calibrate sensors after final assembly using dedicated internal routines. In addition, the LSM6DSOX machine-learning core and AI extensions to the STM32Cube development ecosystem allow advanced users to run neural networks for sophisticated pattern recognition such as activity tracking and audio-scene classification.

Professional users can also develop applications quickly and efficiently within the STM32 Open Development Environment (STM32 ODE), leveraging the STM32CubeMX configurator and code generator, and the STLink-V3 programmer and debugger. DW

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

STMicroelectronics | www.st.com DESIGN WORLD

Internet of Things_6-19_Vs3.LL.indd 63

www.designworldonline.com

June 2019

63

5/31/19 12:44 PM

When technology and expertise come together Phoenix Contact’s expertise spans a wide range of applications so that you can make power, control, and network connections with absolute confidence. Whether your connection is on a printed circuit board, through an enclosure, or to a field device, you can trust Phoenix Contact for consistent quality, reliability, and high performance—every time. www.phoenixcontact.com/ConnectConfidence

© PHOENIX CONTACT 2019

LMC-001716-ADV_Ad_DESIGNWORLD.indd 1 Phoenix Contact 6-19.indd 64

4/5/2019 8:29:34 AMPM 5/31/19 2:27

ASi-5 I/O modules transmit larger quantities of data

T

The AS-Interface is one of the leading approaches for the efficient networking of sensors and actuators at the automation base. The ASi-5 generation opens the way to the next dimension of digitalization. ASi-5 is backwards compatible with the previous ASi versions and devices. With ASi-5 larger data quantities can be transmitted faster and even intelligent sensors such as IO-Link can be integrated more easily.

The ASi-5 digital modules are available in three versions: with 16 inputs (BWU3164), with eight in- and outputs each (BWU3163) and with eight inputs (BWU3802). So one ASi-5 slave delivers a high I/O density in the field. It is possible to collect signals from up to 16 sensors exactly where they occur.

In addition to the IP67 versions, there is an IP20 version available for each ASi-5 digital module. DW Bihl+Wiedemann, Inc. www.bihl-wiedemann.com

DESIGN WORLD

Internet of Things_6-19_Vs3.LL.indd 65

www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

June 2019

65

5/31/19 12:45 PM

Change the way you look at pressure gauges

digital pressure gauges

kelleramerica.com

Keller 6-19.indd 66

5/31/19 2:28 PM

A supplement of Design World June 2019

ensures safe post processing of metal 3d printed models 72 68

76

A spotlight on AM

How small can additive

partnerships

technology build?

COVER_MPF 6-19_Vs1.indd 67

5/28/19 8:17 AM

A d d i t i v e

T e c h n o l o g y

A spotlight on

AM partnerships Until recently, announcements of new developments

in additive manufacturing machine capabilities came almost daily. As advancements take a pause, additive companies are turning to partnerships to move the technology forward.

A

Leslie Langnau • Managing Editor

Additive manufacturing (AM) is a key element of a Digital Manufacturing strategy, where digital technologies deliver the right information to the right place in the value chain. In fact, you could say, AM enables digital manufacturing. AM itself is a digital technology, taking data from CAD programs and turning that data into three-dimensional objects at any location, particularly locally.

Many believe AM will not only disrupt distribution and warehousing, it will alter the nature of manufacturing.

While we’re not at that point yet, the news from this year’s RAPID + TCT conference highlights a new area of focus on the part of additive vendors -- partnerships. A number of companies are working together in various areas to advance additive manufacturing.

For example: 3D Platform has formed collaborations with ORNL, Dynamic Tools, and Novatec. 3D Platform and ORNL have a Cooperative Research and Development Agreement (CRADA) to focus on industrial materials, medium sized molds and objects, and specialty filled filaments with long fibers.

With Dynamic Tools, 3D Platform is the exclusive ‘Master Distributor’ of Dynamic Tools’ machines in North America. And with Novatec, 3D Platform will offer a complete process solution; from drying standard filament spools to 3D printing from raw material pellets.

DSM is making partnerships too. It will work with Origin, a San Francisco-based pioneer in Open Additive Manufacturing, to develop new materials for additive manufacturing. The companies have been working together for months to optimize DSM’s photopolymer material for Origin’s ‘programmable photopolymerization’ (P3) technology.

Royal DSM announced a partnership with Adaptive3D, an additive manufacturing polymer resin supplier. DSM will help produce, distribute and

68 June 2019 www.makepartsfast.com

LEAD FEATURE MPF 6-19_Vs3.LL.indd 68

DESIGN WORLD

5/31/19 12:56 PM

Materialise announced a number of partnerships with HP, Nikon, Essentium, and others. In addition, it announced it will release a new version of its 3D printing operations management software, Streamics.

sell Adaptive3D’s Soft ToughRubber, a 3D printable photopolymer. The new material allows manufacturers to explore applications in medical models and consumer products such as audio earbuds and footwear. The material will also serve anatomical medical models and wearable electronics. The material combines the feel and mechanical properties of silicone with the resolution and surface finish that Digital Light Processing (DLP) printing provides.

Fast Radius, Inc., a leading manufacturing technology company, announced a partnership with Desktop Metal to help companies accelerate applications on the Desktop Metal Production System. Desktop Metal is addressing the unmet challenges of speed, cost, and quality to make metal

DESIGN WORLD

LEAD FEATURE MPF 6-19_Vs3.LL.indd 69

HP’s new Jet Fusion 5200 Series 3D printing system addresses issues of manufacturing predictability, efficiency, repeatability, and quality for customers scaling to full production.

www.makepartsfast.com

June 2019

69

5/31/19 12:56 PM

Additive Technology The WorkCenter 500, from 3D Platform has a print area of 1,400 mm wide by 2,800 mm long by 700 mm high. This next-generation printer includes an enclosure to enable printing of high temperature-engineered polymers within a large format.

Additive manufacturing (AM) is a key element of a Digital Manufacturing strategy, where digital technologies deliver the right information to the right place in the value chain.

70

3D printing an essential tool for engineers and manufacturers around the world.

As part of the partnership, Fast Radius will be one of the first companies to receive the Production System. The partnership also includes the development and execution of a Fast Radius Application Launch Program (“ALP”) targeting production applications with Desktop Metal’s binder jetting technology. This is an invite-only, ninemonth program where non-competitive companies leverage the Fast Radius software platform and team of additive application engineers to identify, evaluate, design, and ultimately launch a productiongrade application leveraging the latest additive technologies.

Henkel announced it is partnering with EnvisionTEC to align Henkel´s materials with EnvisionTEC´s printer technology. Through its open access program, EnvisionTEC certified Henkel´s Loctite materials portfolio for use on its 3D printers. Henkel will include EnvisonTEC’s continuous Digital Light Manufacturing (cDLM) technology platform into its 3D printing ecosystem.

EnvisionTEC has successfully used the silicone elastomeric resins for 3D printed orthodontic indirect bonding trays and molds for injection molding.

HP and Siemens announced an expansion of their strategic alliance to help customers move into industrial AM.

June 2019 www.makepartsfast.com

LEAD FEATURE MPF 6-19_Vs3.LL.indd 70

HP will expand its integrated additive manufacturing system, incorporating new systems and software including overall product lifecycle management (PLM), AM factory optimization, industrial 3D printing and data intelligence, manufacturing execution, and performance analytics. This agreement includes the new HP Jet Fusion 5200 Series 3D printer.

HP is also expanding its strategic alliances with BASF and Materialise, launching the HP Digital Manufacturing Network, a global community of largescale 3D printed parts providers.

And Materialise announced partnerships with Nikon and Essentium.

Stratasys announced an authorized materials partner program designed to expand the range of high-performance polymers available for Stratasys’ fused deposition modeling (FDM) processes. As an initial step, advanced materials leader Solvay has been selected to help launch the program and deliver new polymers for the Stratasys F900 3D Printer.

Under the authorized materials partner program, Solvay will access exclusive tools and Stratasys expertise to develop materials aligned with the company’s quality and performance benchmarks. The partners will share an authorized partner materials roadmap to DESIGN WORLD

5/31/19 12:57 PM

guide Solvay’s selection and development of materials for Stratasys FDM printers.

These are just a few of the recent partnership announcements. You can find more news on partnerships on www. makepartsfast.com.

New products A few companies introduced new 3D additive systems.

3D Platform introduced the WorkCenter 500, which offers a larger print area of 1,400 mm wide by 2,800 mm long by 700 mm high. The WorkCell is a next-generation printer that includes high-end mechatronics and an enclosure to enable printing of high temperatureengineered polymers within a large format.

Cincinnati Inc. CI offers several 3D printing systems, notably the SAAM and SAAM-HT 3D printers. The SAAM machines were designed as a complement to CI’s larger BAAM and MAAM industrial sized additive manufacturing machines. They allow for prototypes to be created before entering full-scale production on the larger machines.

Blacksmith is an Artificial Intelligence (AI)-powered program from Markforged that ensures every part is produced as designed. Blacksmith will create a continuous feedback loop to make 3D printed parts more accurate.

DESIGN WORLD

LEAD FEATURE MPF 6-19_Vs3.LL.indd 71

Henkel and EnvisionTEC are partnering on materials development. EnvisionTEC has successfully used Henkel’s silicone elastomeric resins for 3D printed orthodontic indirect bonding trays and molds for injection molding.

Both the SAAM and SAAM-HT suit create functional parts. The machines are small enough to fit on desktops. Both machines use CI’s patented Automated Ejection System for continuous, unattended 3D printing.

SAAM handles carbon-fiber composite and PLA 3D printing. The SAAM HT offers more power and a wider range of options. It prints in ULTEM 9085 PEI, PEEK, CarbonX, Carbon FiberNylon, Makeshaper PLA Spool or any thermoplastic up to 500°C (260°F).

As mentioned earlier, HP Inc. introduced the Jet Fusion 5200 Series 3D printing system, an industrial 3D printing version that addresses issues of manufacturing predictability, efficiency, repeatability, and quality to customers scaling to full production.

The Jet Fusion 5200 Series 3D printer brings together new systems, data intelligence, software, services, and materials innovations. The system expands manufacturing predictability with high quality and optimal-yield of parts at industrial levels of efficiency, accuracy, and repeatability. It increases flexibility, improves uptime, streamlines workflows, and simplifies fleet management for factory production settings. New data intelligence, software, and services capabilities, including the HP 3D Process Control and HP 3D Center software offerings and the HP 3D Parts Assessment service deliver operational efficiency and repeatability, and identify and optimize production of 3D applications.

In the software arena, Markforged announced Blacksmith — an Artificial Intelligence (AI)-powered software that makes manufacturing machines ‘aware’ so they can automatically adjust programming to ensure every part is produced as designed. Blacksmith will create a continuous feedback loop

www.makepartsfast.com

to make 3D printed parts more accurate.

The intelligent software cuts waste and accelerates time to market. It analyzes a design, compares it to the scanned part, and automatically adapts the end-to-end process to produce perfectly in-spec parts. n MPF 3D Platform | 3dplatform.com DSM | www.dsm.com Desktop Metal | Desktopmetal.com EnvisionTEC | Envisiontec.com Fast Radius, Inc. | Fastradius.com Henkel | www.henkel-northamerica.com HP | Hp.com Materialise | Materialise.com Stratasys | Stratasys.com

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

June 2019

71

5/31/19 12:57 PM

A d d i t i v e

T e c h n o l o g y

Pneumatics

ensures safe post processing of metal 3D printed models Thanks to pneumatic valves, cylinders and air preparation, a machine builder developed an automated cleaning booth for post processing of

O

metal additive manufactured parts.

One of the more time intensive processes of 3D printing is the post processing of a part—the removal of supports and the finishing steps to give the part its final look. 3D printed parts for the Sagrada Família in Barcelona, one of the most significant examples of architecture of Antoní Gaudí, were particularly challenging for post processing. However, the engineers at Solukon Maschinenbau, an Augsburg Germany based machine builder, developed an automated cleaning booth to safely and effectively clean 3D printed metal components; and pneumatic components played a key role in the booth’s design.

One example of the 3D printed parts needed by the Sagrada Família is round, a little twisted in some places, and looks like it grew organically instead of being planned and built. Additive manufacturing has simplified the realization of such challenging architecture significantly, making the production of complicated components easier, or even possible at all. To transform Gaudí’s visions into a reality, architects are examining and analyzing the

72

drafted design using 3D models to help complete the building.

Additive manufacturing technology has long established itself in industrial applications. Besides unique design freedom for complex components, more efficient use of materials also plays a crucial role. Despite these advantages, though, metal printing also entails risks, as fine metal powders can be harmful and when stirred up, they can sometimes

June 2019 www.makepartsfast.com

EMERSON MPF 6-19_Vs3.LL.indd 72

DESIGN WORLD

5/31/19 1:07 PM

g

Architects can use 3D printing for examining and analyzing complex designs, like the Segrada Familia church in Barcelona, a project underway since 1882.

DESIGN WORLD

EMERSON MPF 6-19_Vs3.LL.indd 73

www.makepartsfast.com

June 2019

73

5/31/19 1:07 PM

Additive Technology Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone

Engineering

The protected cleaning booth from Solukon is equipped with pneumatics from Emerson’s AVENTICS.

Plastic Films

Teflon™ PTFE Ultem® PEI Kapton®- HN, FN, XC Cirlex® PEEK™ DuPont® Mylar PET TPX® & Many More Slitting Die-Cutting Die-less Knife Cutting Adhesive Lamination Automated Sheeting Belting

even form an explosive atmosphere.

Following the construction process, large amounts of powder often remain in the support structures and interior contours in the 3D printed components and are difficult to remove. These residual powders can cause significant difficulties and waste time in follow-up processes.

“Until recently, post-processing of metal prints had been given little consideration,” explains Andreas Hartmann, CEO of Solukon Maschinenbau GmbH. “Our solution was to develop a reliable cleaning booth with an automatic cleaning process.

One of the challenges was developing an efficient cleaning device free of ignition sources within a process chamber filled with inert gas. Mainly pneumatic components are used to manage this demanding task.

While selecting components, we relied

on the expert consultation of our Emerson AVENTICS partner, Michael Lehner Fluidtechnik, from the start,” Hartmann continues. “Quick availability of information and samples, combined with the comprehensive AVENTICS product range, helped us in developing our system.”

Safety thanks to sustainable post processing The production laser melting technique leaves the completed work-piece coated in a thick powder cake. The excess fine powder makes unpacking it from the materials left from production difficult.

Besides the health risks, stirring ultra-fine particle materials made of aluminum or titanium for example can form explosive atmospheres.

Emerson’s AVENTICS AV05 valve system is used to control the pneumatic components, the manifold is easily split into compressed air and inert gas control.

Sold by Lineal Foot Available with adhesive No minimum orders

800-461-4161 sales@cshyde.com www.cshyde.com 74

June 2019 www.makepartsfast.com

EMERSON MPF 6-19_Vs3.LL.indd 74

DESIGN WORLD

5/31/19 1:08 PM

Pneumatics in the cleaning chamber prevent risk of explosion when it is flooded with inert gas.

To make post processing safe, two years ago machine manufacturer Solukon developed a cleaning booth that was then unique to the market. The process chamber with an integrated three-dimensional swivel device automatically removes virtually all metal residues in a closed circuit.

The SFM02-AT800 cleaning booth makes it possible to safely and efficiently clean metal components with dimensions of up to 800 x 400 x 500 mm. Cleaning is performed within a sealed process chamber flooded with inert gas. In this chamber, the component is swiveled in three dimensions and stimulated with targeted vibrations so that the powder residues come free and gather at the bottom of the chamber. The powder residues are then removed through a funnel.

A 3D swivel device continually moves the components including build platform around two axes. Even complex cavities, indentations, and supporting structures can be freed completely from the loose building material. The gentle cleaning process in an inert gas atmosphere prevents

explosive atmospheres from forming, also protecting the construction material against oxidation.

One clear advantage of these automated processes lies in the many hours of post processing saved. Customers in the aviation and aero-nautics industries are especially pleased with this new reproducible possibility to clean complex internal structures.

The relevance of pneumatics To prevent any risk of explosion, the process chamber must be securely flooded with inert gas and totally free of ignition sources. Pneumatic components play a major role in the fully automated cleaning booth.

The CCL-IC compact pneumatic cylinder features clean surfaces making it ideal for the process chamber.

Actuators controlled by compressed air offer the only option to design an efficient and risk-free machine. AV series valve systems control the pneumatic components, the manifold can easily be split into compressed air and inert gas control. The AV05 series valves were chosen due to the combination of compact size, high flow (up to 0.7Cv), and extremely flexible options and accessories.

The CCL-IC series pneumatic cylinder (ISO 21287) suits the process chamber, as it is intended for use in explosive areas. The smooth surface of the CCL-IC compact cylinder, available in bore sizes from 16 mm to 100 mm, also makes cleaning the booth easy.

“With the Solukon cleaning booth, the challenge was to develop a technology that could meet a range of requirements,” comments Michael Lehner, longstanding sales partner of Emerson’s AVENTICS. “This is why it was really important to be involved in the design process from the beginning.”

Added Hartmann, “thanks to the excellent collaboration, we quickly and easily found a convincing system solution that also benefits our customers in additive manufacturing.” n MPF

Emerson AVENTICS www.emerson.com/en-us/automation/brands/aventics

DESIGN WORLD

EMERSON MPF 6-19_Vs3.LL.indd 75

www.makepartsfast.com

June 2019

75

5/31/19 1:08 PM

A d d i t i v e

T e c h n o l o g y

How small

can additive technology build?

A new technology exists at the intersection of additive manufacturing and micro

manufacturing. It is opening up the possibility

Jon Donner â&#x20AC;˘ CEO â&#x20AC;˘ Nanofabrica

for manufacturers to take advantage of the inherent advantages of AM while achieving micron level accuracy over a build envelope of

T 5 x 5 x 10 cm.

There are two current global trends in manufacturing. The first is the trend towards miniaturization, which demands parts and components with highly precise micron and sub-micron level resolution. The other trend is the move towards digital manufacturing referred to as Industry 4.0. Additive Manufacturing (AM) is a key enabling technology catering for the move towards shorter product life cycles, and allowing mass customization.

The low set up costs associated with AM when compared to traditional manufacturing processes explains why a growing number of blue-chip companies across the world are adopting it as a manufacturing technology.

Now, a new technology exists at the intersection of AM and micro manufacturing, opening up the possibility for manufacturers to take advantage of

the inherent benefits of AM while achieving micron level accuracy over a build envelope of 5 x 5 x 10 cm.

The discipline of Additive Manufacturing (AM) or 3D Printing (3DP) is regularly cited as being disruptive to traditional manufacturing processes. Indeed there are existing AM production applications across varied vertical sectors that support this position-optimized components and parts that would be either

76 June 2019 www.makepartsfast.com

NANOTECHNOLOGY MPF 6-19_Vs3.LL.indd 76

DESIGN WORLD

5/31/19 1:11 PM

impossible or uneconomic to produce using traditional methods that are better made using AM technologies. In this way AM is disruptive and promotes innovation across many industry sectors.

For some OEMs throughout the automotive, aerospace, medical (and other markets), AM has already

DESIGN WORLD

NANOTECHNOLOGY MPF 6-19_Vs3.LL.indd 77

become an established production process, including some instances of mass manufacturing. However, some barriers to entry for adoption of AM as a production technology still exist, key among these being the requirement for high initial capital investment and expensive on-going running costs; consumable costs (particularly for

www.makepartsfast.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

A micro gear made from ABS used in an inkjet wide format industrial 2D printer. Part size 1.3 x 1.3 x 0.4 mm3, print time 35 minutes, and print layer 2 microns.

June 2019

77

5/31/19 1:11 PM

Additive Technology

g

A diamond shaped lattice in ABS, a shape that is only possible to manufacture using additive manufacturing, and impossible using CNC machining or injection molding. The structure has ultra-high surface area and is therefore useful in heat dissipators. Part size 0.3 x 0.3 x 1 mm³, print time 45 minutes, and print layer 3 microns.

refined materials); inconsistent material properties which are a significant prohibitor for critical components; extensive pre-and post-processing requirements (and costs); and, often, a failure to understand when and how to apply AM to maximize its benefits.

The final reason is the focus of much attention today. AM is making the shift from a prototyping technology to a true production technology, but many lack the insight about what can really be produced on AM platforms, and the inherent characteristics of the process that add significant advantages when it comes to cost, complexity, and timeliness of manufacture.

The manufacturers of additive platforms are aware of these barriers to adoption, as many — mainly at the highend of the system spectrum — have been refining and developing their respective processes by adding value propositions pre-, in- and post-process

Additive Manufacturing Systems

Industrial Size

LARGE

100

200

300

Build Area

Build Area

Build Area

1000 mm x 1000 mm x 500 mm

NANOTECHNOLOGY MPF 6-19_Vs3.LL.indd 78

1000 mm x 1000 mm x 500 mm

1000 mm x 1000 mm x 700 mm

5/31/19 1:12 PM

specifically for production applications.

The corresponding vernacular that has emerged and is increasing in use across AM marketing campaigns and in-depth conversations about AM for production applications is “end-to-end manufacturing solutions.”

In addition, serious players in the AM sector are seeking out niches that are either under-served, or indeed in some instances completely un-served.

One example is the area of micro manufacturing which until recently has had no viable AM technology that can reach the resolutions required.

When viewed from the perspective that across industry there is a shift towards miniaturization, with many applications demanding extremely exacting levels of micron and submicron precision on macro and micro parts, there is huge potential for an AM platform that can service this trend.

A whole raft of traditional production

platforms have developed to cater for this demand, but until recently, the ability for AM to produce such precision at all — let alone at volume production levels — has been impossible.

An AM platform tailored for micro / nano manufacturing Nanofabrica, founded in 2016, recently developed a micron-level resolution AM platform for this sector. The company produced a technological solution that provides an end-to-end solution bespoke to manufacturers requiring micron and sub-micron levels of resolution and surface finish.

To date, key AM platform developers struggle to get resolution under 50 microns, and the few companies that have strived to provide a micro manufacturing AM solution are either expensive in terms of machine costs and cost per part, or slow, or can only print parts that are restricted in size.

Successful AM platform developers need to focus technological advances on areas that open up innovation and the manufacture of products and components hitherto impossible using AM. It is here that Nanofabrica has identified a series of applications where there is growing market demand, where the only route to market at the moment is through disproportionately expensive or restrictive traditional manufacturing technologies, and where the use of AM can open up significant advances in terms of design and function.

These applications exist in the area of optics, semi-conductors, microelectronics, MEMS, micro fluidics, and life sciences. Products include casing for microelectronics, micro springs, micro actuators and micro sensors, and many medical applications such as micro valves, micro syringes, and micro implantable or surgical devices.

Microfluidics is a good example

Flexibility to Address Fidelity & Speed FINE

XLARGE

400

Throughput Speed

Industry Baseline

VOLCANO

1000 mm x 1500 mm x 700 mm

Build Area

NANOTECHNOLOGY MPF 6-19_Vs3.LL.indd 79

See more at

NEW HFA

FAST

NEW HFE300

NEW HFE900

3dplatform.com

3DPlatform • 6402 East Rockton Road, Roscoe, Illinois 61073 USA • +1.779.771.0000 5/31/19 1:13 PM

Additive Technology of how a true micro AM technology can outcompete traditional manufacturing processes. Microfluidic channels are used to move incredibly small volumes of liquid, and many of them incorporate functioning components such as filters and pumps.

Traditional micro manufacturing processes such as micro molding hugely limit the freedom of design for such microfluidic channels, and it is almost impossible to manufacture functional substructures in them using such processes.

How the process works The first breakthrough of Nanofabrica’s technology enables high precision at a cost required for industrial manufacturing.

The AM process is based on a Digital Light Processor (DLP) engine. But to achieve repeatable micron levels of resolution, it combines DLP with the use of adaptive optics. This tool in conjunction with an array of sensors, allows for a closed feedback loop.

Nanofabrica tackles precision with software where solutions are easier, more robust, and less expensive. Adaptive optics have been used in other areas of technology, but this is the first time that they have been applied to an AM technology.

This technology can achieve micron resolution over centimeter-sized parts.

A number of technologies have been combined. Specifically, the developers has taken adaptive optics and enhanced this imaging unit with technology and knowhow used in the semiconductor industry (where the attainment of micron and submicron resolutions over many centimeters is routine.) By working at the intersection of semiconductors and AM, the developers built large “macro” parts with intricate micro details. It can also do this at speed by introducing a multi resolution strategy, meaning that the parts where fine details are required are printed relatively slowly, but in the areas where the details aren’t so exacting, the part is printed at speeds 10 to 100 times faster. This makes the entire printing speed anything from 5 to 100 times faster than other micro AM platforms.

Precision Welding For Critical Plastic Components The Branson GSX Ultrasonic Welding Platform meets the growing demand for the assembly of smaller and more complex plastic components.

Precision welding control and accuracy Precise welds are achieved utilizing an advanced electro-mechanical actuation system that provides unprecedented control and position accuracy, while applying an industry low trigger force.

Real-time monitoring across multiple parameters The Branson GSX can also weld across multiple parameters, monitored in real-time to ensure quality. This is possible with a wide range of input materials and first class repeatability, across multiple Branson GSX welders.

Visit us at MD&M East, Booth #1839 The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2019 Emerson Electric Co.

For more information: Emerson.com/Branson

80

BRN_GSX-halfpg-island-Ad_5-24-19.indd 1 NANOTECHNOLOGY MPF 6-19_Vs3.LL.indd 80

5/24/19 2:15 PM

June 2019

DESIGN WORLD

5/31/19 1:15 PM

Additive Technology For OEMs requiring small parts, thousands of parts can be printed in a single build, making it a mass manufacturing technology for micro product or component manufacturers.

The multi resolution capability is possible through the use of hardware that enables a trade off between speed and resolution, and software algorithms which prepare the part and printing path by defining and sectioning it into low and high resolution areas, which are then fed into the printer path and machine parameters. Of course there are not only two resolutions, but a spectrum of resolutions that allow speed to be optimized while maintaining satisfactory results throughout the part.

The final algorithm family focuses on file preparation, optimizing parameters such as print angle build plate, supports etc…, which ensure a precise, optimized, and reliable print process.

The materials are proprietary but based on the most commonly used industry polymers, which enable high resolution in parts built.

What does this mean for manufacturers?

Additive manufacturing in the micro space offers several advantages. AM requires no set up costs. The tooling required for traditional manufacturing processes can have a negative impact on time to market. It can also be uneconomical for small or medium sized production runs. For AM technologies, small and medium sized runs are cost-effective, and indeed it is fair to say that today, represent the sweet spot for the technology.

Add into the mix that AM allows for mass customization, personalization, and the ability to use the same manufacturing platform for prototyping, small batches, and mass manufacturing, which enables multiple possibilities for micro manufacturers. n MPF Nanofabrica | www.nano-fabrica.com Jon Donner earned his PhD in nano optics in the Romain Quidant Plasmonics group at ICFO Barcelona, Spain.

Before his PhD, he earned a double degree at TAU (Tel-Aviv University) in physics and electrical engineering and worked in an electro optics lab.

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

DESIGN WORLD

NANOTECHNOLOGY MPF 6-19_Vs3.LL.indd 81

A micro honeycomb structure in PP, with wall thicknesses of ~20 microns over a height of a few mm. The part is made for a company that specializes in micro batteries. The ultra-high surface area is used to increase battery storage with minimal footprint. Part size 1.6 x 1.8 x 2.3 mm³, print time 80 minutes, and print layer 2 microns.

www.makepartsfast.com

June 2019

81

5/31/19 1:17 PM

Medical www.designworldonline.com

A Supplement to Design World - June 2019

How to design

for home healthcare

Medical Tips cover 6-19_FINAL2.indd 82

5/28/19 10:36 AM

ISO 9001 • ISO 13485

EAGLE STAINLESS

Medical

Tube & Fabrication, Inc.

C O N T E N T S

With the advanced technology and the expertise to deliver stainless steel exactly as you want it.

Extensive tubing inventory Eagle stocks stainless, copper, brass and aluminum in metric, hypodermic and fractional tubing in an extensive assortment of grades.

Features 84 How to design for

home healthcare

Cut-to-length tubing - Eagle can cut and de-burr any diameter in quantities from 1 piece to millions from lengths of .040” and longer with a standard tolerance of ±.005 on diameters of less than 1”. Closer tolerances are met quite often.

Talk to us!

87 Product Development 90 Tubing 92 Medical Tips

Bending / Coiling - Eagle craftsmen working with state-of-the-art machinery supply uniformly smooth bends, meeting the tightest customer specifications.

Wire EDM & Laser Machining enables Eagle to produce some of the mosdt exotic parts imaginable.

CNC Machining Centers - enable machining some of the most intricate parts imaginable. Working in diameters from .030” to 2”, we’re ready to meet your most demanding requirements!

Assembly - Custom tube drawing and assembly of multiple parts to achieve a single component.

End reduction Bulging Flaring

DESIGN WORLD

Medical Tips_CONTENTS_6-19.indd 83

June 2019

83

End Forming - Robotic machine centers speed production and reduces cost.

www.eagletube.com 10 Discovery Way Franklin, MA 02038 Phone: 800-528-8650 Fax: 800-520-1954

5/31/19 1:24 PM

M e d i c a l

T i p s

How to design

for home healthcare Meeting consumer demands for home healthcare technology requires a keen knowledge of user behavior.

Athelasâ&#x20AC;&#x2122; home blood testing device resembles the Amazon Echo.

Image courtesy of Athelas

The global smart home healthcare market is exploding as more medical devices are designed for use wherever the patient is, including at home. A report by Research and Markets predicts sales of these devices to reach $30 billion by 2023, up from $4.5 billion in 2017. Fall prevention and detection devices hold the largest share of the market, which is expanding to include safety & security and health status monitoring, compliance aids and nutrition monitoring.

Scott Thielman Product Creation Studio

84

Developing these devices is one thing. Designing them so users find their technology intuitive, accessible and easy to use is another. Patients and caregivers who are comfortable with digital consumer products expect their healthcare devices to be just as user-friendly. Ease of use boosts compliance â&#x20AC;&#x201C; and in the world of consumer health, compliance is everything.

A deep understanding of user behavior can have a significant impact on compliance. Here are some behavioral strategies that can improve compliance and create the ideal at-home healthcare experience.

Make the technology invisible Developers are exploring ways to make home digital devices automatic and able to blend seamlessly into consumersâ&#x20AC;&#x2122; lives.

One example is Athelas, a next-generation immunity monitor that mimics technology already found in many homes. Athelas measures neutrophils, lymphocytes, platelets, white blood cells,

June 2019 www.designworldonline.com

Design_Vs3_Med Tips Supp 6-19.LL.indd 84

DESIGN WORLD

5/31/19 1:29 PM

STANDARD AND CUSTOM MOTION CONTROL PRODUCTS FOR DRUG DELIVERY & LIQUID HANDLING morphology and cell activation within minutes from a finger-prick of blood. Its unobtrusive design as a 3-D printed black cylinder is reminiscent of Amazon’s Alexa device, featuring a small window to insert the test strips.

Instead of focusing on flashy design, the developers tout the device’s transparent accuracy and scientific validity.

Though not very “sexy,” another attention-grabber is a smart toilet seat. Developed by the Rochester Institute of Technology, this toilet seat measures diastolic and systolic blood pressures, stroke volume, blood oxygenation, heart rate, heart rate variability, QRS duration, corrected QT interval and patient weight. The device’s design uses an everyday activity to capture data that would otherwise require multiple devices that aren’t as easy to use.

FOR USE IN: automated work stations | sample movement drug discovery systems | robotics peristaltic and syringe pumps digital and automated pipetting

Make the technology automatic Diabetes treatment has made significant leaps with continuous glucose monitors. For example, Abbott’s FreeStyle Libre replaces a finger stick with a 14-day sensor patch worn on the upper arm. It automatically measures glucose readings and transmits them to a smartphone or reader for accurate insulin dosing.

Remove barriers to use Anything that introduces a user roadblock can deter a device’s adoption, so detecting and eliminating those barriers is essential. As an example, ResMed’s human factors research revealed that even processes such as registering a new device could interrupt compliance.

“You lose health adopters every time you ask a patient or provider to perform a set-up step, select a network or flip a switch,” ResMed CEO Mick Farrell told Medical Design & Outsourcing.

ResMed connects each of its continuous positive air pressure (CPAP) sleep apnea treatment devices to the cloud before patients begin to use them. In-house research revealed that once the device gave users feedback, it improved patient compliance. Use of the company’s MyAir smartphone app helped nearly 84% of new CPAP users reach the necessary usage threshold for Medicare adherence in the first 90 days of treatment, according to the company.

Make user feedback part of the business model User feedback can reduce user errors and improving the user experience in a way that ties a patient population to a product.

Clarify Medical believes so strongly in user feedback that it built it into its business model. Clarify makes a phototherapy tool for treating psoriasis and vitiligo (loss of skin pigment). Activating the device puts the Clarify team in

DESIGN WORLD

Design_Vs3_Med Tips Supp 6-19.LL.indd 85

June 2019

85

fully customizable rotary and linear stepper motors for precision positioning, dispensing and diluting ultra-precise Linear Shaft Motor servos linear stages, driven by linear steppers or servos and configured for simultaneous multi-axis movement

DOWNLOAD MORE INFORMATION

nipponpulse.com/lab-automation-market

Nippon Pulse Your Partner in Motion Control nipponpulse.com | info@nipponpulse.com ISO 14001:2015 & 9001:2015 certified

5/31/19 1:30 PM

M e d i c a l

T i p s

acquired the behavioral health-focused myStrength to add digital tools for conditions such as depression, chronic pain, and opioid addiction. Moves like this signal that designing digital devices for user behavior may be critical to the success of a home medical product.

Perhaps for the first time, the industry is seeing that in a competitive environment, focusing on user behavior is essential to innovation.

While it raises the risk factor in developing medical devices, it also boosts the potential rewards. The design tips presented here are not new, but they are essential steps in gaining market share. M

close contact with the patient through a company-based (rather than outsourced) customer care center and a smartphone app. The email and phone calls Clarify employs to train users have also led to bug fixes, app refinements and even firmware updates. The app allows the company to monitor patient usage; noncompliant users receive additional coaching and training.

User behavior is key In many ways, the medtech industry is playing catch-up with consumer technology. The stakes are high, so getting the experience right is critical.

Forward-thinking companies of all sizes are investing in user behavior.

Consider that consumer digital health company Livongo Health recently

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

MEDICAL MOLDED CABLE ASSEMBLIES

Cables:

Turn your design challenges into next-generation, marketleading medical devices with our extensive manufacturing capabilities and engineering expertise. We have facilities in Fremont, CA and Santa Ana Sonora Mexico.

Cardiac Monitoring Device Generator Interface Cable

46840 LAKEVIEW BOULEVARD, FREMONT, CA 94538

86

•

510-933-3800

Molding Materials Include: • Silicone Rubber • PVC • Polyurethane • TPE • Polyester • Santoprene

Product Categories: • Video Cables • Patient Monitoring Cables • Sensor Probe Cables • RF Generator Cables • Robotic Surgery System Cables • Aesthetic Surgery Cables • Single Use Cables

•

•

bayinfo@baycable.com

June 2019 www.designworldonline.com

Design_Vs3_Med Tips Supp 6-19.LL.indd 86

Endoscopy Camera

ISO 9001:2015; ISO 13485:2016 WWW.BAYCABLE.COM

DESIGN WORLD

5/31/19 1:29 PM

M e d i c a l

T i p s

9

human factors

pitfalls to avoid for safer orthopedic surgical devices A human factors engineering (HFE) process provides important safety benefits during orthopedic device design and development and may help smooth the regulatory process..

Pragadeesh Thirumurugan Loren Kim Kaleidoscope Innovation

Human factors engineers conduct a formative usability test.

Image courtesy of Kaleidoscope Innovation

Orthopedic surgical device manufacturers are increasingly taking advantage of HFE, but they may not know how to most effectively incorporate it into product development. Not engaging human factors specialists or doing so incorrectly has the potential to lead to setbacks in submissions to the FDA, delays in product launches â&#x20AC;&#x201C; and, more importantly, serious harm to patients.

While the mortality rate due to medical mistakes in orthopedic surgery is low, preventable human use-related errors could potentially contribute to serious or catastrophic post-operative complications. In fact, 13% of orthopedic surgical

DESIGN WORLD

Product Development_Vs2_Med Tips Supp 6-19.LL.indd 87

www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

June 2019

87

5/31/19 1:32 PM

BIOCOMPATIBLE LED Curable Adhesive

M e d i c a l

Nanosilica Filled LED405Med

errors were classified as errors in technique, according to an article in the International Surgery Journal. These errors have the potential to be reduced by examining and understanding common use errors and “designing them out.” The goal would be a better user/device interaction, fewer errors and fewer complications and risk to patients.

Strong HFE capabilities and support can help manufacturers avoid these nine pitfalls when developing orthopedic surgical devices:

Meets ISO 10993-5 for cytotoxicity Outstanding optical clarity Refractive index 1.50 High dimensional stability Coefficient of thermal expansion 35-40 in/in x 10-6/°C Cures by LED light Suitable for heat sensitive components

154 Hobart Street, Hackensack, NJ 07601 USA +1.201.343.8983 ∙ main@masterbond.com www.masterbond.com

If left to your own devices, this is where you hope the pumps & compressors were sourced.

NittoKohki.com

Take heart engineers: • Exceptional reliability y • Low noise & vibration n • Long service life • DC-motor driven

1. Minimal or no HFE considerations in early development Waiting to incorporate HFE until the later stages of development, such as during the FDA-required validation study, might turn up use errors that could have been mitigated during the design and development process.

The FDA might require changes in design, prolonging the device’s market launch. Usability testing done earlier in the design process opens a new dimension of product use and could reveal use errors with more time to make design improvements.

2. No anthropometric and ergonomic considerations While surgeon input is important, it’s also important to consider other user groups such as circulating nurses, scrub nurses and technicians. Issues can arise when all relevant individuals’ hands, fingers, degrees of freedom of movement, gender and other anthropometric considerations are not studied.

Device designers should also consider users’ ergonomic preferences. The device should not only be intuitive but comfortable to all who need to use it. This should help mitigate issues that might lead to someone using a device incorrectly or choosing not to use it at all.

3. Insufficient pre-assessment and assessment of usability risk Sometimes problems and complaints with predicate and/or similar devices are repeated in new designs. Use-related risk analyses can help manufacturers to predict potential errors and design to avoid these issues.

4. Failure to do formative evaluations Not taking advantage of exploratory formative evaluations could lead to discovering errors or design flaws when it is too late in the process. Performing formative evaluations can reveal ways to improve the design to help ensure the product is safe and effective to use.

5. Unrealistic training for usability testing During validation testing, training must reflect the real-world scenario, as it may affect the participant’s performance.

88

Product Development_Vs2_Med Tips Supp 6-19.LL.indd 88

T i p s

June 2019

DESIGN WORLD

5/31/19 1:34 PM

6. Ignoring supporting materials and processes Packaging and product labeling are as important to assess as the product itself. Some examples of this include misread or complicated instructions for use, and crowded text that may deter a user from thoroughly reviewing product support and instructions for transporting, cleaning and/or discarding the product.

7. Designs based on stakeholders rather than end users Instead of designing for the actual users, companies may defer to stakeholders such as the orthopedic sales rep, marketer or orthopedic engineer. Further, while orthopedic surgeons can be involved in a product’s invention, it is important to obtain wider surgeon input rather than default to an orthopedic surgeon-inventor’s individual preferences.

8. Disregard for surrounding tissues/muscles Sometimes overlying structures like soft tissues and muscles on the body around the bones are overlooked while testing on plastic models. It is critical to consider the actual complications or serious consequences that could occur in real surgery.

9. Cutting tools similar in appearance but different in performance Understanding the differences between cutting tools is imperative. Designing to differentiate cutting tools that look similar but do not perform alike is a critical HF input.

Ultimately, a solid HFE team focused on making orthopedic products more intuitive may contribute to improved patient care. For example, the intended users might be able to perform their tasks with less distraction from device designrelated challenges. Implementing HFE principles early may help to inform the design of safer and more effective devices. M

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

DESIGN WORLD

Product Development_Vs2_Med Tips Supp 6-19.LL.indd 89

SDP/SI develops and manufactures

ENGINEERING

Precision Gears Mechanical Components Complex Assemblies for aerospace, medical, defense, and industrial applications

Custom Solutions Prototype to HighVolume Production Est. 1950 AS9100 Registered RoHS | REACH | ITAR

www.sdp-si.com 250 Duffy Avenue, Hicksville, NY 11801 800-819-8900 www.designworldonline.com

MANUFACTURING ASSEMBLY

DOWNLOAD: - Product Specifications - 3D CAD Models REQUEST A CATALOG

June 2019

89

5/31/19 1:34 PM

M e d i c a l

T i p s

Could this

old-school manufacturing tech enable better catheter designs?

Excimer lasers took a back seat to femtosecond and picosecond lasers in catheter manufacturing. It may be time to give this decades-old technology a second look.

Serial medical device manufacturing entrepreneur Brady Hatcher still remembers the moment years ago when he first saw Daryl Kiefer use an excimer laser to drill a hole only a few thousandths of an inch across into a polymer catheter.

Chris Newmarker Managing Editor Medical Design & Outsourcing

90

“It looked like it was magically removed, without heat effect – like it was molded that way,” Hatcher recently told Medical Design & Outsourcing.

“Like it was made that way,” Kiefer added.

It’s that type of miniature magic that has Kiefer and Hatcher betting that excimer lasers will have an important role to play as catheters grow increasingly smaller and more complicated to suit neurological applications and a host of other delicate medical procedures.

Hatcher’s Twin Cities medical device design startup Switchback Medical last year bought Kiefer’s five-person Kiefer Manufacturing operation. Daryl Kiefer now runs Proto Lase, a quick-turn laser processing service that utilizes 4,000 square feet of space adjacent to Switchback in the Minneapolis-St. Paul suburb of Maple Grove.

With an excimer laser, Kiefer boasts that he is able to use his roughly 20 years of experience with the technology to get detailed jobs done in days that would take a larger outfit weeks to complete.

Excimer lasers have been around for more than 40 years and work well for highprecision polymer ablation. The technology fell out of favor in catheter and other medical device manufacturing as cheaper manufacturing methods like femtosecond and picosecond lasers came along, Kiefer explained.

June 2019 www.designworldonline.com

Tubing_Vs2_Med Tips Supp 6-19.LL.indd 90

DESIGN WORLD

6/4/19 8:24 AM

The view down the barrel of an excimer laser | courtesy of Proto Lase

Excimer lasers are high maintenance because they use a fluorine-and-neon gas mix that eats away at parts. Kiefer himself has to tear down Proto Lase’s machine every eight to 12 months.

Still, an excimer laser in the hands of an experienced technician can accomplish design feats that would be extremely difficult if not impossible with other manufacturing technologies, he told us.

Kiefer can use an excimer laser to ablate a design you’d need an electron microscope to see.

“The detail that you can produce on a catheter tube is incredible. You could ablate your logo or name on it,” Hatcher noted.

It really comes down to the development engineer’s understanding of excimer laser capabilities, Kiefer added. “There are a lot of ways that we can help them with design, and the excimer tool is a great tool to do that.”

Kiefer listed three things that excimer lasers are especially good at when it comes to catheter and medical tubing manufacturing:

long and a half inch tall – to create a specific type of hole in a single shot.

“We can do any type of hole pattern you want: rectangular, square, round, oval,” he said. “Whatever we put on that mask, that’s what you’re going to get. You can shoot that.”

One customer wanted a design on a polymer surface that would reduce surface contact between two substrates.

“We designed a custom screen to place in front of the path, and what comes out on the part is the exact same thing. It’s like milling on a lathe.

It’s the same effect,” Kiefer said.

It’s possible to create such effects at sizes as small as 0.002 in., or roughly 50 microns, according to Kiefer.

“Femtosecond – there’s just so much energy that you’re not going to have that type of detail,” Kiefer said.

Some manufacturers have started using mirrors to scan out a hole using femtosecond lasers, but it’s not the one-shot process you get with an excimer laser, he said.

2 Reducing outside diameter 1 Detailed holes and surface patterns Kiefer can create a stainless steel mask to place in the path of the laser – which comes out about an inch

DESIGN WORLD

Tubing_Vs2_Med Tips Supp 6-19.LL.indd 91

Another great excimer laser application involves reducing the outside diameter on a catheter shaft to a controlled depth – for example, going down from 100 thousandths of www.designworldonline.com

an inch to 90 thousandths of an inch.

“We’re going to ablate it down to a certain diameter and over a certain length,” Kiefer said.

Perhaps there’s a catheter shaft with a PTFE liner with a polyamide layer on top. It’s possible to reduce the diameter down to the PTFE for a certain length and then replace the polyamide along the length with another material that accomplishes a particular design goal along the particular length of catheter, he explained.

This type of capability makes excimer layers useful in stripping extremely tiny wires before welding them to onto an electrode for, say, a pacemaker, he added.

3 Surface finish It’s also possible to add extremely tiny surface patterns or to roughen a tubing surface in an extremely controlled way, according to Kiefer.

This surface preparation can be beneficial when bonding materials together, as it adds surface area to increase bond strength. It can also benefit in the reduction of surface tension when the product needs to release or slide over the finished surface. M

June 2019

91

5/31/19 1:39 PM

MEDICAL MEDICAL 92

BAYCABLE BAYCABLE is vertically integrated and can offer a wide range of manufacturing capabilities including custom cable constructions, full turnkey cable assembly and molding services, component customization, specialized testing, and in house mold tool manufacturing.

BAYCABLE delivers unparalleled engineering expertise “an integrated solutions partner” that can help skillfully create the optimal interconnect system for your application.

Early design collaboration with our Silicon Valley based engineering group takes you from concept through pre-production into the initial production runs quickly, and we provide medium to higher volume production by transferring production to our plant in Sonora, Mexico. Both manufacturing locations are ISO Registered.

BAYCABLE has a long legacy of delivering high performance reliable interconnect solutions to our customers.

Bay Associates Wire Technologies 46840 Lakeview Blvd Fremont, CA 94538 Tel: 510-933-3800 Email: bayinfo@baycable.com www.baycable.com

Master Bond Inc. Ultra Low Viscosity Biocompatible Epoxy for Medical Electronic Applications Formulated for medical electronic applications, Master Bond EP621LPSPMed is a biocompatible two part epoxy that has a mixed viscosity of 150300 cps. Its ultra low viscosity makes it ideal for use in underfill, impregnation and porosity sealing applications, while it also performs well in bonding, coating or encapsulation. This product exhibits excellent wetting properties and can readily flow by capillary action in tight clearances or beneath devices. It adheres well to metals, plastics, composites, polyimides, glass and ceramic substrates.

EP62-1LPSPMed has an advantageously long working life of 12-24 hours for a 100 gram mass and requires moderate heat for curing. Cure schedule is overnight at room temperature followed by 60-90 minutes at 80-100°C. The higher the temperature the faster the cure. Post curing at 100-150°C for 3-4 hours will optimize its properties.

Master Bond EP62-1LPSPMed passes USP Class VI and ISO 10993-5 cytotoxicity requirements. It also has been tested for 1,000 hours at 85°C/85% RH. It has excellent toughness, tensile strength of 11,000-12,000 psi and resists repeated cycles of ethylene oxide, radiation, and chemical sterilization. This compound has volume resistivity of more than 1014 ohm-cm, withstands mechanical shock/vibration and is serviceable from 4K to +400°F. In very thin sections it will transmit light, but in

June 2019 www.designworldonline.com

Medical Tips 6-19_Vs1.indd 92

thicker sections it is opaque. Shore D hardness is 75-85 and its glass transition temperature is 125-130°C. EP62-1LPSPMed has a 100 to 25 mix ratio by weight and can be supplied in standard sized units: ½ pint, pint, quart, gallon, 5 gallon kits. It can also be packaged in premixed and frozen syringes, as well as in cartridges for gun dispensers. Shelf life in original unopened containers is 6 months.

MASTER BOND INC. 154 Hobart Street Hackensack, NJ 07601-3922 +1-201-343-8983 www.masterbond.com main@masterbond.com

DESIGN WORLD

5/31/19 1:21 PM

MEDICAL MEDICAL

DESIGN WORLD

Medical Tips 6-19_Vs1.indd 93

Nippon Pulse Nippon Pulse offers a variety of motion control products that are perfect for the lab automation market. We offer standard and custom tin-can stepper motors, linear servo motors and linear stages, as well as electronics to drive them. Our products are designed for easy modification, in order to provide you with custom solutions at off-theshelf prices.

Check out our new, smallest-ever linear stepper motor, the PFL20! Our Linearstep motors reduce the number of mechanical parts needed for rotary-to-linear motion, reducing design time and cost. Now available in 25, 35 and new 20mm diameter sizes!

Since 1952, Nippon Pulse has built state-of-the-art motion control products. We provide solutions for lab automation OEMs, including products that accomplish sample handling, microscope automation, medical robotics, drug delivery, surgical tools, pharmaceutical dispensing and other healthcare technologies.

Nippon Pulse America, Inc. 4 Corporate Drive Radford, VA 24141 540-633-1677 www.nipponpulse.com info@nipponpulse.com

DC Motor-Driven Pumps Nitto Kohki’s DC motor-driven air compressors and vacuum pumps are ideal for applications requiring exceptionally reliable air flow, pressure or vacuum performance.

Featuring oil-free operation, a single moving part, low noise, and low vibration, this line of linear air compressors comes in 12V and 24V models. Other benefits include: • • • •

Very low power consumption Self-cooling design Exceptional service life (rated at 10,000 hours) Easy maintenance

Ideal for demanding applications in the medical device and laboratory equipment industry, including dialysis machines, blood separators, blood analyzers, incubators, heart assist devices and more.

NITTO KOHKI U.S.A., INC. 46 Chancellor Drive Roselle, IL 60172 Toll Free: (800) 843 6336 Phone: (630) 924 8811 Fax: (630) 924 0808 E-mail: info-pumps@nittokohki.com www.nittokohki.com

www.designworldonline.com

June 2019

93

5/31/19 1:22 PM

MEDICAL

SDP/SI Comprehensive Engineered Mechanical Solutions SDP/SI’s combination of design, manufacturing and assembly capabilities allows us to meet the critical tolerances and functionality needs that the medical device and healthcare industries demand.

Manufacturing high-precision gears, gear drives, high-quality machined parts, and molded components; our customers include many of the top medical device manufacturers in the world.

• Extremely high accuracy and tight tolerance machining • Lights-out manufacturing • High efficiency/low cost volume production • Low-volume prototype machining • 5-axis machining capability • 9-axis Swiss turning

• ITAR compliant – DDTC registered • RoHS compliant • R.E.A.C.H. compliant • ISO 7 Class 1000 Cleanroom • World class quality • Established 1950

Engineered Mechanical Solutions and Component Choices – See what SDP/SI can do for you.

Stock Drive Products/Sterling Instrument (SDP/SI) 250 Duffy Avenue Hicksville, NY 11801 516-328-3300 http://www.sdp-si.com sdp-sisupport@sdp-si.com

It’s not a web page, it’s an industry information site Stay current with the latest electronic tips, resources, and news, visit eeworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the electrical design engineering community.

eeworldonline.com

94

June 2019 www.designworldonline.com

Medical Tips 6-19_Vs1.indd 94

DESIGN WORLD

5/31/19 1:22 PM

YES,

Development delays can be costly

YOU KNOW

Compromises on linear motion technology can be risky

WHAT TO DO

Schneeberger will customize the right linear solution so you can move on

We’re ready to help you meet your goals.

Call us at 800-854-6333 — or email info-usa@schneeberger.com

SCHNEEBERGER | www.schneeberger.com Visit www.schneeberger.com/pitfalls to claim your guide to the Five Pitfalls of Component Specifying Schneeberger_ad_select_no_shading.indd 1 Schneeberger 5-19.indd 95

4/2/19 1:45 PM 5/31/19 2:44 PM

M o t i o n

C o n t r o l

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

VFDs

with integrated motion and machine controls

By Jeff Payne • AutomationDirect

Today’s ac drives can be controlled by either an external or internal PLC. Those with built-in controls move machine intelligence to the edge.

Though ac drives can operate as standalone components, they often integrate into automation systems to control speed of three-phase ac motors that commonly run conveyors, fans, and pumps. For such speed control, ac drives most often pair with PLCs. But ac drives are becoming more intelligent … and some now include built-in PLCs to work as smart drives. These smart ac drives are compact; add intelligence at the edge of machinery; include inverters capable of more than just typical speed control; and accept the setting of myriad parameters.

In this feature, we’ll detail how to integrate smart ac drives and the

applications for which they make the most sense.

Review of how ac drives work An ac drive is often called a variable frequency drive (VFD), adjustable frequency drive (AFD), or frequency inverter. We use the term VFD for its main function of varying the speed of a three-phase ac induction motor. VFDs 96

June 2019

Motion Control 6-19_Vs3.LE.LL.indd 96

DESIGN WORLD

5/31/19 1:52 PM

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

•• ••

Many VFDs, such as this AutomationDirect DURApulse GS4 series AC drive, can be controlled and monitored by an external PLC.

Motion Control 6-19_Vs3.LE.LL.indd 97

June 2019

97

5/31/19 1:51 PM

•• ••

M o t i o n

C o n t r o l

also provide motor overload protection, non-emergency starting and stopping, and control of acceleration and deceleration.

VFD benefits significantly boost the efficiency of many applications. In addition, they gradually accelerate the motor — which in turn reduces inrush current during motor startup. This minimizes both electrical and mechanical stress on the system.

VFDs operate by rectifying incoming ac power to dc and then inverting it back into three-phase ac output power. The voltage and frequency of this inverted output is controlled by the drive to vary the speed of a three-phase ac induction motor.

Control modes include volts per Hz (V/f), V/f with encoder, open-loop vector, and closed-loop vector control. These methods all use a pulse-width modulation (PWM) voltage waveforms; they’re well-developed motor control methods needing some level of automation to control the drive.

VFD control methods A VFD is controlled by discrete inputs (two or three-wire control), analog inputs and/or digital communications. In its simplest form, a VFD can be manually controlled using the built-in digital keypad’s run/stop buttons.

Two-way digital communication often allows drive commands to be controlled by a PLC — and allows for the monitoring of all drive parameters.

98

These WEG-CFW300 ac drives from AutomationDirect offer high performance in a compact size, along with a built-in operator interface and a SoftPLC. They eliminate the need to purchase, install, and integrate an external PLC with the drive.

This keypad also allows setting of the drive speed and other parameters, as well as monitoring of drive status variables. Manual pushbuttons can also be wired to the drive in a two or three-wire configuration to control basic functions.

A two-wire control setup provides a run command input and a direction input to the drive. The run command must remain high (on) for the drive to run the motor. The direction command controls forward and reverse motor rotation. Deactivating the run command stops the motor.

With three-wire control of a drive, a stop command is added to the drive control inputs. To activate the drive, the stop command must be high, often through use of a normally closed (NC) pushbutton or an NC relay contact. A momentary run command is all that is needed to activate the drive.

Both two or three-wire drive control methods can be via manual pushbuttons,

June 2019 www.designworldonline.com

Motion Control 6-19_Vs3.LE.LL.indd 98

PLC-activated relay outputs, or PLC discrete signal outputs. Some drives also have programmable functions such as jog, speed change, and acceleration and deceleration control.

Analog signals can also help control drives to deliver speed-control or tensioncontrol functions. Signals take the form of analog 0 to 10 Vdc voltages, analog 0-to-20-mA or 4-to-20-mA current, or potentiometer signals. A two or three-wire discrete control method is still needed to start and stop the drive.

Digital communications between PLCs and VFDs In addition to discrete and analog inputs, PLCs often control VFDs using digital communications such as Modbus ASCII and Modbus RTU, or via industrial Ethernet protocols specifically created for real-time control. These digital communications can control all drive functions or work in DESIGN WORLD

5/31/19 1:53 PM

maxon motors 5-19_Robot Report.indd 99

5/31/19 2:45 PM

M o t i o n

C o n t r o l

A VFD with a built-in soft PLC can monitor sensors and run programmed logic to properly convey products.

concert with discrete and analog signals. Two-way digital communication often allows drive commands to be controlled by a PLC — and allows for the monitoring of all drive parameters ... including the reading of drive variables, statuses, and fault codes. This can include more than 100 commands, parameters, and statuses, and fault codes.

Serial or Ethernet communication from the PLC can issue speed references, run, direction and jog commands. It can also adjust motor parameters such as voltage and amps and run parameters associated with set acceleration and deceleration times, S curves, and skip frequencies. Other digital parameters include the issuing multi-function input commands and triggering functions just as a discrete input would. Target frequency and current (and many other analog and preset parameters) are also available for control and monitoring using digital communication.

Where the PLC communicates with the drive to monitor status and fault codes, it might compare the frequency command to output frequency or the output current to rated current or motor rpm.

The monitoring of drive faults is also enhanced by digital communication. Instead of just a ‘fault present’ discrete signal, the system can register dozens of error codes — including overcurrent, overvoltage, overtemperature, overload, low voltage, and more.

Upfront programming of the drive’s monitoring and control functions (through discrete communication) makes for a more intelligent system. A serial or Ethernet link between the PLC and drive(s) is required; with Ethernet, a hub or a switch is also needed. The ability to configure, control, and monitor the drive from the PLC via digital communications helps futureproof automated systems.

Programming ac drives with built-in PLCs As mentioned, PLC control of VFDs is well-developed with many configuration and monitoring options.

But devices at the machine edges are becoming 100

June 2019 www.designworldonline.com

Motion Control 6-19_Vs3.LE.LL.indd 100

DESIGN WORLD

5/31/19 1:53 PM

smarter … and VFDs with built-in PLCs are no exception. These VFDs provide all the precise variable speed-control functions of separate PLC-controlled drives, but in one compact package. Such smart drives typically have a built-in operator interface panel and a soft PLC. Via the interface panel, it is possible to control the VFD and view (and adjust) its parameters. A typical keypad toggles between parameter numbers to show position or value.

Up and down buttons let operators change the parameter number or its value. Another button lets operators run and stop the drive and reset drive faults. A variety of plug-in option modules are typically available for additional I/O … and to add additional communication protocols.

Some vendors provide free PC-based programming software for the soft-PLC portion of the drive — to let design engineers create custom-tailored control schemes. These then download from the PC to the drive (often via a USB connection). Such software typically includes ladder-diagram programming for the creation of function blocks to monitor inputs, operate the drive, and control outputs. Besides controlling the VFD housed in the same package, the soft PLC can also work to monitor additional components on the plant floor — including other VFDs.

Driving conveyor, mixer, and other applications Common applications for smart drives include packaging machines, mixers, kneaders, and dosing pumps. Other applications include the control of fans, exhausts, centrifugal pumps, granulators, palletizers, stirrers, and conveyor belts. Many conveyor or gate applications need to monitor inputs from a few sensors to properly control a VFD as well as an output to trigger a solenoid. Here a carefully selected smart drive having a built-in PLC (meeting full-load amperage, overload, and temperature requirements) can monitor sensors; make programmed decisions; and control field devices. DW AutomationDirect automationdirect.com/adc

Ball & Crossed Roller Linear Slides

Carry loads up to 779 lbs!

CUS TO SLID M ES AVA ILAB LE

Del-Tron Precision, Inc. is now ISO 9001:2015/AS9100D CERTIFIED

Other

Precision Linear Motion

Products

Del-Tron’s

Ball & Crossed Roller Linear Slides • Accuracy ranging from 0.0005”/” to 0.0000040”/” of travel.

Non-Magnetic Ball Slides

• Low friction straight-line design reduces the coefficient of friction to 0.003.

• Factory preload adjustment prevents side-play and backlash.

• Lightweight aluminum carriage and base with high load capacity.

• Inch or Metric built-in holes simplify installation and component mounting.

• Available with ball slide or crossed roller slide technology, varying precision grades and corrosion resistant materials.

Order Today!

800.245.5013 DESIGN WORLD

Motion Control 6-19_Vs3.LE.LL.indd 101

June 2019

Micrometer Positioning Stages Micrometer Driven Ball & Crossed Roller Stages

MADE IN USA

Solid Models Available for all Del-Tron Model Numbers

DL Linear Actuators Lead Screw/Ball Screw Driven

www.buydeltron.com

101

5/31/19 1:54 PM

L i n e a r

M o t i o n

Up your conveyor

Game

New alternatives to traditional conveyor systems offer better efficiency and more flexibility, helping to boost manufacturing throughput.

Reid Schook • OEM Segment Business Manager • Rockwell Automation

W

When moving product through a manufacturing or assembly process in a plant, conveyors have been a traditional choice. A typical conveyor can consist of individual roller axes mounted between a metallic frame or conveying belts that move objects along a beltway. There’s also a power source such as a motor to actuate the conveying process. While these traditional methods have been the workhorse of conveying systems, recent years have seen an influx of new technologies that improve performance.

Older more traditional conveyors are generally less flexible and more rigid and therefore more inefficient than some of the newer technologies available. A good example is the use of roller beds, overhead conveyors and skillet conveyors in automotive assembly. These mechanical systems have inherent inefficiencies that waste energy and slow production. And the configuration and preventive maintenance they require can slow operations.

Newer systems offer more efficient ways to move parts. For instance, intelligent conveyor systems (ICS) offer added control over positioning while also offering more flexibility. These systems use independent carts that ride on a magnetic track, allowing for assembly of multiple products

102

June 2019 www.designworldonline.com

Linear Motion 6-19_Vs3.indd 102

DESIGN WORLD

5/31/19 1:57 PM

on the same line. Replacing the rotarydriven chains, belts and gears of traditional conveyance systems reduces the number of jams, breaks and failures that can occur while reducing required maintenance.

Besides increasing production flexibility and speed, intelligent conveyor systems can also help to decrease the number of products needed to be kept in stock while reducing floor space and eliminating the extra equipment required for roller beds and

DESIGN WORLD

Linear Motion 6-19_Vs3.indd 103

skillet conveyors. All of this decreases cost of ownership as well…

Technology overview Intelligent conveyor systems offer designers flexibility and quick product changeover by allowing individual product control throughout an application.

Permanent magnet arrays on each cart are driven by independently energized coils in the stationary motor modules. Positive

www.designworldonline.com

Modern manufacturing plants use robots and conveying systems to increase their efficiency. Automotive assembly plants especially benefit from new conveying technologies, helping to save time and increase throughput.

June 2019

103

5/31/19 1:57 PM

L i n e a r

M o t i o n

Payload

2

N

3

4

t

t

N

N

5

6

7

8

9 10

t

t

1

N

S

t

t

N t

Magnet array on carts

Connect motors to control multiple carts simultaneously

Motor Windings or negative currents of varying magnitude are driven to create a local magnetic field producing a net force to the cart. Carts are passively controlled via closed-loop servo control with no on-cart power required, eliminating the need for traditional flex cabling and/or slip rings.

Integrated sensors in each motor continuously monitor the unique position of each cart in the system. This eliminates the need for external encoders that are often difficult to align, require tight installation tolerances and are sensitive to debris. This can reduce or eliminate the need for external identification devices.

Those devices can only monitor in discrete locations versus persistent monitoring with ICS. Magnet arrays are available in a variety of configurations based on the application requirements. Thrust is based on the

overlapped area of the magnet and coils.

Applications requiring small, tightly spaced payloads are able to use short arrays while larger, heavier payloads typically use longer arrays and/or wider coils. Modified Halbach arrays provide a higher performance design used to achieve higher force densities and enable air gaps of up to 20 mm. Larger air gaps enable more generous mechanical tolerances and the unique ability to isolate motors for harsh environments.

Motors are designed with coils around a traditional iron core to focus the field strength or as an air core motor without iron lamination. Iron core motors offer higher force density where air core configuration

Intelligent conveyor systems are based on electromechanical principles.

Varying positive or negative currents drive independent coils to create a local magnetic field. As the cart moves along the track, current magnitudes and polarity are adjusted to deliver the required thrust.

eliminates the attractive force between the magnet array and the cart. Air core systems typically enable lower-cost sliding carts where wheels are required for iron core motors.

Systems are organized into groups of motors connected to a PLC via lower-level node controllers. These node controllers monitor cart positions along each path, manage traffic flow, and pass commands from the PLCs to individual motors.

Brick-wall headway (the stopping distance required to avoid a collision if the lead vehicle hits an obstacle) is continuously monitored for each vehicle based on the known mass and acceleration. Depending on the programming approach taken, this can be used to automatically avoid

New intelligent conveyor systems, such as these from MagneMotion, use linear motors to provide magnetic propulsion and control of multiple cars on a track. They offer engineers greater flexibility by controlling individual carts on the line, allowing for quicker changeover for differing manufacturing requirements.

104

June 2019 www.designworldonline.com

Linear Motion 6-19_Vs3.indd 104

DESIGN WORLD

techno

5/31/19 1:57 PM

ULTRA-PRECISE POINTING OF ELECTRO-OPTIC DEVICES Continuous 360° Direct-Drive AZ/EL Rotation Aerotech direct-drive AZ/EL mounts provide ultraprecise angular position, rate, and acceleration for development and production testing, and are ideal for directing optics, lasers, antennas, and sensors at high speed to very precise pointing angles. Typical applications include missile seeker test and calibration, LIDAR, electro-optic sensor and FLIR testing, airborne target tracking, optical testing of space-based sensors in a vacuum, and angular testing of inertial sensors such as gyros, MEMS, accelerometers, and inertial reference units. Contact an Aerotech Application Engineer to discuss how an Aerotech gimbal can give you a competitive advantage.

AMG-600

AOM360D

IP-66 Rated

Custom Design

AMG and AMG-LP

Visit aerotech.com or Call 412-963-7470 Since 1970, Aerotech has designed and manufactured the highest performance motion control, positioning tables/stages, and positioning systems for our customers in industry, government, science, and research institutions around the world.

AF0519A-RAD

AF0519A-RAD-AMG-Gimbals-9x10_875.indd 1 Aerotech 6-19.indd 105

5/7/2019 11:41:53 AM 5/31/19 2:46 PM

L i n e a r

M o t i o n

collisions, protecting the pallets and product being transported.

Users are able to control their system using destination-based or motionprofile programming. Destination-based (asynchronous) programming is akin to using a taxi where the cart is commanded to a specific location and the system routes it along the most efficient path while leveraging brick-wall headway to avoid collisions, automatically queuing where required. This significantly reduces the amount of programming and traffic management the user needs to manage.

Motion-profile (synchronous) programming is akin to driving a car where the user fully programs the motion profile the cart takes. This approach is beneficial when synchronizing carts to external axes for on-the-fly processes.

DEVELOP TOMORROW’S

PRODUCTS IN-HOUSE Take control of your process by cutting prototypes with affordable CNCs.

Flexibility for faster changeovers Assembly lines that handle multiple parts with traditional conveyance systems often require multiple mechanical adjustments and physical intervention to conduct changeovers. This can impact production by slowing it down.

An intelligent conveyor system uses operator stations and system programming to make those changeovers, so that production can quickly move from one part to another. In the automotive manufacturing world, this makes it more feasible to produce multiple vehicle models in one plant.

Linear synchronous motors, with intelligent controllers, enable this capability. They allow carts to move independently and operators can adjust the distance between carts through programming. This is a key advantage and allows for changeovers with the push of a button.

An intelligent conveyor system can also handle parts of all sizes, with a fully adjustable conveyor pitch, or distance between carriers.

The system can operate from the ceiling, at an inverted angle or upright. Because of the elimination of belts, brakes and chains, an ICS frees up space on the plant floor.

Instead of farming your parts out to a job shop and playing the waiting game, get in on the accessible and easy-to-learn modular machines from Tormach.

ERVO M+ S E KIT AD UPGR W NO E LABL V A AI

×

Engineered and Supported in the USA

×

770M Redesigned with 50% More hp

×

Small Footprint Fits Almost Anywhere

×

Plug into Standard Single-Phase 120Vac Outlet

×

Free Standard Shipping within the Continental USA

Keep things moving Roller bed and skillet conveyors can only move as fast as their slowest station. An intelligent conveyor system breaks operations free from this constraint. It allows carts to operate at

TORMACH.COM

106

Linear Motion 6-19_Vs3.indd 106

June 2019

DESIGN WORLD

5/31/19 1:59 PM

independent speeds and accelerations.

This can increase operating speeds and productivity throughout a plant, because each part is able to move at the optimal pace.

And increased production speeds can open the door to other improvements.

For example, auto makers that have implemented intelligent conveyor systems in their plants have seen up to a 25% increase in the efficiency of their use of robots.

The reason is that moving at a faster pace reduces non-value adding activities and increases use of value adding assets, like robots. This focuses operations on getting more use out of flexible production lines.

More robust track and trace Keeping track of each part that goes into a vehicle is even more difficult when multiple models are produced in a single plant.

Traditional conveyor systems can track parts at discreet locations. But they require workers to scan barcodes or RFID tags, then enter the data in the system. This task is time-consuming and leaves room for human error.

An intelligent conveyor system can continuously identify each piece of equipment it transports. The information is automatically logged in the control system with timing and destination information.

This gives operators a list of what’s in each vehicle along with production time stamps.

When parts are tracked and traced on an assembly line, the operation can also be more responsive in the event of a recall. Rather than generalizing where a problem could have occurred in production, operators are able to pinpoint exactly where and when it took place. Additionally, they can isolate impacted vehicles faster and more efficiently.

reduce maintenance and downtime costs.

Carts are magnetically propelled so there is no contact required to propel the carts, reducing wear and increasing uptime.

In addition to reducing space, an ICS can save energy by only applying power when necessary to move a vehicle. Traditionally, belts or chains have to energize and move an entire 50-foot conveyor section just to transport one part mere inches.

Traditional conveyance systems don’t offer the agility and efficiency needed to produce multiple vehicles in the same plant.

An intelligent conveyor system can provide agility and efficiency, reduce the number of physical interactions and spare parts needed, and deliver more visibility into the assembly process. DW MagneMotion, a Rockwell Automation company www.magnemotion.com

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

Lower cost of ownership Not only do extra components make mechanical conveyors less flexible, they require upkeep and spare parts. They also create a higher chance for something to go wrong or break during production. An intelligent conveyor system can significantly

DESIGN WORLD

Linear Motion 6-19_Vs3.indd 107

www.designworldonline.com

June 2019

107

5/31/19 1:59 PM

Step into

CAD

Immersive design technologies make CAD models uniquely interactive Jean Thilmany | Senior Editor

Designers who can call upon virtual reality (VR) technologies to immerse themselvesâ&#x20AC;&#x201D;become partâ&#x20AC;&#x201D;of their designs get a good understanding of their products and of ways to address potential flaws and issues early in the design cycle. VR helps tell a story about a product in more ways than one. But at least one of those ways can be tied with CAD to improve design, says Elizabeth Baron, who founded her consulting practice, Immersionary Enterprises, after a 30-year career at Ford Motor Company developing VR and immersion tools and outlining ways they can be best used in the automotive design process.

VR gives engineers a way to get handson with their early-stage product designs, when those designs exist only within a CAD software program. This helps engineers visualize how tweaks and changes to one part of the design would affect the overall layout.

108

June 2019 www.designworldonline.com

3D CAD 6-19_Vs3.LL.indd 108

DESIGN WORLD

5/31/19 2:01 PM

3 D

C A D

Virtual Reality helps designers get a better understanding of their designs and address potential flaws early. | istockphoto.com

DESIGN WORLD

3D CAD 6-19_Vs3.LL.indd 109

www.designworldonline.com

June 2019

109

5/31/19 2:03 PM

3 D

C A D

You can meld the worlds of virtual reality and CAD together— the analytical and the immersive—and see engineering data in the context of design, says Elizabeth Baron of Immersionary Enterprises.

Elizabeth Baron • ford

Using immersive computing methods to rotate a model, you can reach out with your hand, select the model and move it as if it were a real object in your hand. The physiological response of interacting with your body is inherently different than using a mouse and keyboard.

110

They could also get a better idea as to how the finished product will look, she says.

Immersive technology can reduce time to market and save organizations money in developing aircraft and automobiles, she adds.

One use, for example, is to determine how the windows of a potential vehicle will look when defrosting.

“You can immerse yourself inside the vehicle and look around and watch the defrost pattern,” Baron says. “You can choose the best results and work with those in the CAD system.

The defrost patterns seen while immersed in the VR environment come from analysis software applied to the model and the material and then accessed by the VR software, she says.

“So you can meld these worlds together— the analytical and the immersive—and see engineering data in the context of design,” she adds.

Immersive computing presents a sharp contrast to existing two-dimensional computer interfaces used with CAD software programs.

Currently, all digital objects, no matter what the actual size, are scaled to the size of the computer monitor. Interacting with these objects is done through short-cut keystrokes and mouse interaction. To rotate a model, certain functions of the keyboard and mouse are combined to allow you to rotate, says Judy Vance a mechanical engineering professor at Iowa State University in Ames.

Currently, engineers use computer-aided design programs to design products in three-

June 2019 www.designworldonline.com

3D CAD 6-19_Vs3.LL.indd 110

dimensions, but they view, modify, and interact with our CAD models using twodimensional interfaces such as the monitor, keyboard and mouse. But wouldn’t it be more effective to use our ability to reach out, move around, look under and through objects, even when they’re still in their digital form, to help us design products and manufacturing facilities? Immersive systems can bring that effectiveness about, Vance says.

The underlying technology includes electrical, mechanical, or optical sensors that sense a person’s position and relay that position to a computer. Those sensors help detect interactions so resultant action can be simulated.

Immersive computing technologies track the user’s head or body position. The digital objects are drawn with a fixed position in a 3-D computer generated environment. The computer environment is mapped to the real environment such that a person’s movement in the real environment corresponds to a movement in the computer environment, Vance says.

But using immersive computing methods to rotate a model, you can reach out with your hand, select the model and move it as if it were a real object in your hand. The difference is significant. The physiological response of using your body to interact with the object is inherently different than using the mouse and the keyboard, she adds.

DESIGN WORLD

techno

6/3/19 9:25 AM

3 D

Baron spoke to her experiences developing immersive software at Ford.

Engineers can immerse themselves in the virtual world of their designs to look at all types of engineering data in the context of design, Baron says.

In automotive design, for example, “you can look at where the phone jack and the cupholders are placed and test them out to see if they’re an ergonomic fit,” she says. “You can look at the continuity of a surface to understand it in different way.”

Baron spoke at the Conference on the Future of Engineering Software, held earlier this year. The event brings professionals together to talk about the role engineering technology could play in the future of the engineering, design, and architectural realms.

Many software makers are moving to marry CAD and immersive, technology.

Today, to bridge the gap between CAD and fully immersive virtual environments, 3D design and visualization software packages have begun to incorporate immersive capabilities through software plugins. Designers and engineers can make precision design changes on the desktop and then move into the immersive environment to understand the implications of their proposed changes. In some cases, transitioning from the desktop environment to the VR environment requires only minimal effort on the part of the user.

For example, Autodesk, a maker of engineering applications, is working to pair its Fusion 360 design software with the Microsoft HoloLens, which engineers wear to see the design hovering near them in three dimensions. If they decide, for example, they need a flange on the piece to be a little larger, they make the change on the software, which is also part of the virtual reality display. They can then rotate the image, walk around it and see it from all angles; they see exactly how the change would affect all aspects of the design.

And late last year, Tech Soft 3D, which makes engineering 3D developing tools, announced augmented reality and VR support for Hoops Visualize, a graphics engine for developing highperformance applications. HOOPS Visualize now enables rapid development and deployment of 3D engineering applications on the HTC Vive, Microsoft HoloLens, Oculus Rift and Meta 2.

A difference you can see and feel Baron had a big hand in bringing those immersive benefits to Ford. She had long been interested in the topic.

IN STOCK NOW! Eighty New 90V and 180VDC PMDC Gearmotors. SCR Speed Control Compatible.

With maximum rated armature speed of 2500 rpm, Bodine SCR rated gearmotors provide reliable performance, adjustable speed, and quiet operation.

These new stock models can replace gearmotors sold by Baldor, Bison Gear, Leeson, or Grainger.

Visit our new website at: bodine-electric.com info@bodine-electric.com

DESIGN WORLD

3D CAD 6-19_Vs3.LL.indd 111

June 2019

C A D

•

773.478.3515 (USA)

111

5/31/19 2:04 PM

3 D

C A D

Autodesk is working to pair its Fusion 360 design software with the Microsoft HoloLens, which engineers wear to see the design hovering near them in three dimensions.

Currently, engineers use computeraided design programs to design products in three-dimensions, but they view, modify, and interact with CAD models using twodimensional interfaces such as the monitor, keyboard and mouse. Wouldn’t it be more effective to use the ability to reach out, move around, look under and through objects, even when they’re still in their digital form? Immersive systems can bring that effectiveness about.

112

Ivan Sutherland, often regarded as an inventor of computer graphics and of early CAD systems themselves, described in 1965 a concept he called an “ultimate display,” which could simulate reality by means of a 3D virtual world viewed through a head-mounted display. In he created the first virtual reality head mounted display connected to a computer and not a camera, which he called the Sword of Damocles.

“He thought we had a way to understand physical world quite well, but we still didn’t know particles and forces and esoteric things that aren’t touchable,” Baron says. “And he thought that getting immersed in something could provide looking glass into mathematical world.”

June 2019 www.designworldonline.com

3D CAD 6-19_Vs3.LL.indd 112

But the large, cumbersome system, suspended from the ceiling, was too heavy for any user to realistically wear, Baron says.

“You put something on your head, so it was a head mounted display, but you couldn’t move a whole lot because the system had a huge boom attached and the area you had to walk in was not very large,” she says.

Her goal was to make VR systems useful and feasible for Ford.

In the late 1980s, Baron worked as programmer on the automaker’s custom-built CAD system. It was then she came to realize that by using CAD data to create real-time simulations, the company could create representations of different parts of the vehicle, as well as the vehicle as a whole, that would help designers and manufacturers streamline their own processes.

“That’s what I was doing at Ford, taking engineering data and mixing it with the other data we have to allow for high-throughput discovery,” she says.

“With an immersive experience, we can get a better emotive and scientific experience of the data because this is how we go about in the world every day—being visually and tactically immersed in our world.”

“If you take a lot of geometrical and other data into an immersive system, you can provide a broad understanding to a DESIGN WORLD

5/31/19 2:05 PM

MOVE YOUR

ROBOT

*

Robot not included

Seven axes, infinite possibilities. Rollon’s Seventh Axis expands your work area and enhances your automation system—from painting to palletizing. Integrate this shuttle system with any robot up to 2,000 kg.

LEARN MORE AT MOVEYOURROBOT.COM

Seventh Axis

Rollon 1-19.indd 113

5/31/19 2:47 PM

3 D

C A D

multitude of people who you would have a hard time reaching in the immersive space,” Baron adds.

At Ford, for instance, designers can use immersive tools to find the best location for the radio knobs within a particular design for an automotive dashboard. Designers could enter a VR simulation. They could reach out as if to touch the knobs while Baron tracked how their hands moved. Designers feel whether a particular placement worked and, using Baron’s tracking information, bring more mathematical and ergonomic information to the issue, Baron says.

The systems are also useful in looking at different build considerations, such as depicting the errors in where two parts come together.

“You get a graphic example of what is wrong,” she says. “You can also see what parts look like as installed and then that morphs into seeing how they would work together.”

And yet these immersive applications are quickly moving beyond straight mechanical engineering uses.

Immersive systems can also bring CAD geometrical and analysis data alive for engineers, marketers, and others involved in the design process in a way not possible in the past, Baron says.

“You can also understand design, ergonomics and crafted quality, manufacturing methods, among many other areas,” she says.

For her part, Baron expects that in the near future immersive technologies will help engineers better understand generative design data. Generative design entails having the CAD system generate the designs based on engineering inputs such as the materials to be used, how parts need to connect, and other design specifications.

The computer can then return some fairly unorthodox designs that engineers likely hadn’t considered.

Interacting with those new designs in virtual reality will allow engineers to better weigh their pros and cons, Baron says.

“And you’ll get insight from how it’s generated so you can maybe train your model better,” she says.

In other words, designers can see what’s working and what’s not working with their generated models so they can supply new constraints for the next generated-design go-round.

“What can we learn from this type of data—data we would otherwise throw out— when an engineer can immerse itself in the data?” Baron asks.

She’s helped answer that question, along with many others during her long career developing immersive technologies for the automotive industry. And yet she continues to come up with—and work toward answering—other questions, and other uses for the technology that, as Vance says, is poised to revolutionize the engineering industry. DW

The future for immersive Vance is seeing those immersive tools move from development at companies like Ford and Boeing and into more mainstream applications. In fact, they may become as ubiquitous in the design world as CAD is today, she says.

We’re at the revolution of virtual reality both in the workplace and in the home and it’s going to affect us all. I expect to see virtual reality tools onto every engineer’s desktop just like the emergence of personal computers in the 1980s. The result will be better products produced more economically resulting in increased national competitiveness.

Autodesk www.autodesk.com

114

Immersionary Enterprises www.immersionary.net/about Tech Soft 3D www.techsoft3d.com

June 2019 www.designworldonline.com

3D CAD 6-19_Vs3.LL.indd 114

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

DESIGN WORLD

5/31/19 2:05 PM

POWER We stock enough power to brew a 12 oz. cup of coffee for the entire population of New Orleans.

Put that in your mug and drink it.

Š Allied Electronics & Automation, 2019

Allied Electronics - AC Power_5-19_DW.indd 115

Get your A&C fill at

alliedelec.com

1.800.433.5700 5/31/19 2:48 PM

Product World Brushless servo motor with integrated electronics Maxon maxonmotorusa.com Maxon have released the EC-i30 20 W Brushless Servo Motor with Integrated Electronics. With an integrated 4 Quadrant speed controller, this latest addition to the EC-i portfolio is available as a 5-wire version. Both enable and direction versions of the motor are offered.

This high torque 20 Watt 30 mm diameter motor is suitable in microfluid pump (air/gas) and medical applications such as:

• Vacuum wound therapy

• Anesthesia and gas monitoring

• Blood analyzers

• Haemodialysis

• Gas detection and analysis

• Surgery training systems

Snap-action micro limit switches AutomationDirect automationdirect.com IDEM high precision, snap-action, 15 A-rated micro limit switches are now available in plunger and lever actuator styles. Plunger Series types include pin plunger, spring plunger, and roller plunger actuator.

Lever Series types include lever, hinge lever, and roller lever.

These micro limit switches are suitable for a range of operating conditions. Snap action assures

reliable, repeatable contact closure regardless of actuation speed, and provides extremely long service life. Panel mount options are available and screw terminals provide easy connection. These limit switches are suitable for a range of operating conditions. A terminal enclosure with cable strain relief is available to cover and protect the terminals.

116

June 2019 www.designworldonline.com

Product World 6-19 Vs4.LL.indd 116

DESIGN WORLD

6/3/19 8:47 AM

congratulates

Protolabs is a digital manufacturer of custom prototypes and on-demand production parts, serving as a product development tool for engineers and a supply chain resource for companies large and small. Our 3D printing, CNC machining, sheet metal fabrication, and injection molding services have continuously evolved to meet the ever-changing needs of our customers around the world.

In 2018, we served nearly 46,000 product developers globally. We now have twelve manufacturing facilities located around the world and continue to explore new ways to accelerate product development, reduce costs, and optimize our customersâ&#x20AC;&#x2122; supply chains with rapid manufacturing technologies.

1.877.479.3680 â&#x20AC;˘ protolabs.com

PROTOLABS 20 YEAR ANNIVERSARY AD_6-19_Vs1.indd 117

5/31/19 2:51 PM

Product World Wireless encoder service

Compact controller with integrated switch

Leine Linde leinelinde.com

B&R br-automation.com

ADS Uptime is the next generation of condition monitoring system for encoders.

At a width of 37.5 mm, including the power supply, the X20CP0420 is quite compact. The

The Advanced Diagnostic System (ADS)

controller achieves cycle times down to 4 ms and is equipped with 128 MB RAM and 256

retains the core features of its previous

MB internal flash memory. With Ethernet, USB and RS232, the controller offers plenty of

generation (ADS Online), and also

communication options. An optional CAN bus interface is also available. With no fans or

introduces new features such as a wireless

batteries, the compact controller is also maintenance free.

service check-up through Bluetooth and

X20 I/O modules can be connected directly to the controller and line up seamlessly.

single cable support for diagnostic and

The entire system saves significant space in the control cabinet. Even with its narrow

control loop feedback information.

dimensions, the controller has a built-in power supply for itself and the connected I/O

modules. There is no need for a separate power supply module.

As with its previous generation,

ADS Uptime continues to offer system monitoring features on parameters such as vibration and temperature. It also provides the ability to set various alarms and warning, as well as record and access information over the encoderâ&#x20AC;&#x2122;s lifetime.

The new features of ADS Uptime

such as wireless encoder service checkup, through Bluetooth connectivity, will create simplified maintenance routines in production lines and allow quick access to important factors affecting the encoder.

Users can now perform service check-ups on the go via the ADS Uptime app on their mobile device or tablet.

118

Product World 6-19 Vs4.LL.indd 118

June 2019

DESIGN WORLD

6/3/19 8:49 AM

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

Rugged sensors for small-scale process technology Balluff balluff.com Depending on the version, the BFT sensors provide PNP switching outputs, analog signals 0...10 V /4...20 mA or work as a PT1000 sensor. They are simple to install by threading into the process using a standard process connection with G- and NPT threads. Integrating them requires just a 4-pin M12 plug on the sensor.

Continuous monitoring of process media on machines and equipment contributes significantly

to process security. Values that need to be maintained are pressure, level and temperature. In a hydraulic system, if you need to monitor the temperature of the hydraulic fluid, you can do this reliably using our BFT media-contacting temperature sensors. Monitoring the temperature within the hydraulic loop guarantees correct fluid viscosity and thereby, the best performance of a machine. Critical process conditions such as a temperature limit can be controlled directly via the switching output. An analog output provides continuous measurement results. The BFT temperature sensors also stand out when it comes to monitoring the cooling water, lubricants, and compressed air, making them suitable for a variety of applications.

Stainless steel Oldham couplings

Flexible, electrically conductive silicone adhesive

Ruland ruland.com

Dow dow.com

These Oldham coupling hubs are now made

DOWSILTM EC-6601 Electrically Conductive Adhesive is engineered for electromagnetic compatibility (EMC) in demanding electrical and electronics applications in the transportation, communications and consumer markets. This novel adhesive combines strong electromagnetic interference (EMI) shielding capabilities across a range of frequencies with durable mechanical and conductive properties over time, underscoring how Dow is further growing its highly differentiated EMI shielding solutions portfolio.

from 303 stainless steel. This addition gives designers an off-the-shelf coupling to choose from when designing systems in corrosive, vacuum, or cleanroom environments. Stainless steel Oldham couplings are zerobacklash, can accommodate all forms of misalignment, and have a balanced design, making them suitable for a variety of servo driven applications.

Oldham couplings are comprised of two hubs that mate to a center

disk. This three-piece design allows users to easily customize Oldham couplings with clamp or set screw hubs with inch, metric, keyed and keyless bores. They have a balanced design for reduced vibration at high speeds of up to 6,000 rpm and operate with low bearing loads, protecting sensitive system components such as bearings from premature failure.

The Oldham disk is available in acetal for zero-backlash and high

torque capacity, PEEK for high temperature and low outgassing, and nylon for dampening and noise reduction. In the event of failure or wear the disk can be replaced, restoring the original performance characteristics of the coupling.

DESIGN WORLD

Product World 6-19 Vs4.LL.indd 119

www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

June 2019

119

6/3/19 8:51 AM

Ad Index Aerotech ...................................... 105 Allied Electronics .................... 3,115 AllMotion .......................................... 4 Altech Corp. ..................................... 1 Altra Industrial Motion Corp. ....... .........................................25,26,27,28 Aurora Bearing Company ........51 Automation24, Inc. ....................... 7 AutomationDirect ........... .Gatefold Beckhoff Automation ................61 binder USA ...................................55 Bison Gear and Engineering ............................59 Bodine Electric Company .........111 Caddock Electronics, Inc. .........16 Cadence Inc. ................................39 Canfield Connector .................. 118 Carlyle Johnson ..........................35 CGI Motion ....................................49 CIT Relay & Switch .....................47 Clippard ........................................ BC Cornell Dubilier Electronics, Inc. .....................43 Del-tron ......................................... 101 Diequa .......................................... IBC Digi-key ........................................... 13 Elesa U.S.A. Corp ........................29 Emerson - Aventics ...................23 Encoder Products Company .................................62

SALES

EZAutomation ................. 15,Insert Fixtureworks ..................................14 Harwin ............................................. 31 icotek Corp .....................................51 igus .................................................... 2 Interpower .....................................53 ITT Enidine ....................................65 J.W. Winco, Inc. ............................57 Keller America ............................. 66 Key Bellevilles ..............................57 LAPP USA ..................................... 9 LEMO USA, Inc. ........................... 24 maxon precision motor ........... 99 Miki Pulley US ..............................44 MW Industries - Helical .............. 21 OKW USA ........................................ 17 Oriental Motor .............................38 Phoenix Contact .........................64 Protolabs, Inc. ..............................117 Rollon ..............................................113 Rotor Clip Company, Inc. ..........45 Schneeberger ............................95 Smalley Steel Ring ......................10 The Lee Company ......................41 Tormach ....................................... 106 Trim Lok ..........................................33 Vlier .................................................52 Whittet-Higgins ........................... 37 Zero-Max, Inc. ................................ 5

Jami Brownlee

jbrownlee@wtwhmedia.com 224.760.1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Bill Crowley

bcrowley@wtwhmedia.com 610.420.2433

Michael Ference

mference@wtwhmedia.com 216.386.8903 @mrference

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Nagle

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com mfrancesconi@wtwhmedia.com 508.446.1823 @wtwh_memich 630.488.9029

Mike Francesconi

David Geltman

dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

FOLLOW US ON

Follow the whole team on twitter @DesignWorld

Medical Tips Supplement Bay Associates Wire Technologies, Inc. ........................ 86 Eagle Stainless ...................................83 Master Bond ....................................... 88 Nippon Pulse Americas, Inc. ...........85 Nitto Kohki USA ................................ 88 SDP/SI-Stock Drive Product ........... 89

Medical www.designworldonline.com

A Supplement to Design World - June 2019

Make Parts Fast Supplement

A supplement of Design World June 2019

CS Hyde Company .......................74 Emerson ..........................................80 3D Platform .....................................78,79

How to design

for home healthcare

Medical Tips cover 6-19_FINAL2.indd 82

ensures safe post processing of metal 3d printed models 72 68

5/28/19 10:36 AM

76

A spotlight on AM

How small can additive

partnerships

technology build?

COVER_MPF 6-19_Vs1.indd 67

5/28/19 8:17 AM

DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. CopyrightŠ 2019 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

Subscriber Services: To order a subscription or change your address, please email: designworld@omeda.com, or visit our web site at www.designworldonline.com

DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, OH 44114.

Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Design World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

120

June 2019 www.designworldonline.com

AD INDEX_6-19_Vs1.indd 120

DESIGN WORLD

6/3/19 9:01 AM

Motion Components

to Automate any Industry

Right Angle Precision Servo Gearheads with Single or DUAL Output Options

800-430-1439

diequa.com/dw

Diequa 6-19 - IBC.indd 1 full page print ad.indd 1

5/28/19 12:29 PM 2/27/19 2:13 PM

Miniature Solutions for Today’s Packaging Challenges

Air Cylinders • Electronic Valves • Isolation Valves • Control Valves • Custom Assemblies A leader in miniature pneumatics, Clippard

877-245-6247

www.clippard.com provides quality products and complete design Cincinnati, OH 45239

CINCINNATI • BRUSSELS • SHANGHAI

solutions for today’s engineering challenges!

Innovative solutions for today’s engineering challenges.

877-245-6247 • www.clippard.com

Clippard 6-19.indd 1

5/28/19 12:31 PM