DESIGN WORLD JUNE 2020

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June 2020

inside: MOTION CONTROL: Big world of miniature brakes

p. 116

LINEAR MOTION: Encoders endure in tough applications

p. 124

3D CAD: Look up in the sky; it’s CAD software

p. 136

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The era of social distancing has not been a good one for trade shows and conferences, including those that we attend across the design engineering, fluid power, R&D and related spaces. The big news earlier this Spring was Hannover Fair moving om its traditional April dates to mid-July. One of the largest industrial trade shows in the world, this was no small undertaking. And yet, several weeks later, show organizers had to switch course again and decided to cancel the 2020 iteration altogether.

A handful of other events were outright cancelled, such as annual meetings of associations like NAHAD and the CFPA, as well as the Brooklyn 5G Summit and Houston’s enormous Offshore Technology Conference, which focuses on the lucrative oil & gas market.

Meanwhile, there are a good number of Spring shows that have postponed and rescheduled for the Fall months — already a busy time on the annual calendar. AUVSI XPONENTIAL, originally scheduled for May 6-7 in Boston, moved back to August 9-12 before deciding that a better bet was to move to Dallas om October 5-8.

Similarly, MD&M East moved om New York in June to a Philadelphia in August. The months of August through October all look to be jam-packed with industry events, assuming that the situation in various states allows them to actually take place.

I spoke with Travis Stanton, who is the Editor of EXHIBITOR Magazine, about what he’s seeing om his end of the trade show industry. Stanton said he thinks it’s unlikely that any of the large trade shows or events will occur in June, for two reasons.

“First, less than 5% of corporate exhibit managers have plans to participate in any live events prior to July 1, and some of those plans are still very tentative at the moment,” he said. “Second, 90% of our readers are under company-imposed travel restrictions that preclude them om attending trade shows and corporate events,

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only a tiny action of which are set to expire by June 1. Also, om a personal standpoint, all of the June trade shows and conferences I’ve been invited to speak at or attend have been cancelled, postponed, or converted into virtual events.”

Stanton said that his publication’s research shows that based on their current plans, most exhibiting companies plan to return to the show floor by the end of September, but about one-fi h have no plans to exhibit at any upcoming 2020 shows.

“Having said that, plans could shi considerably if a treatment or vaccine is made available,” he said. “Currently, 63% of exhibit managers say that a COVID-19 treatment would make them feel more comfortable about exhibiting

Stanton said that his publication’s research shows that based on their current plans, most exhibiting companies plan to return to the show floor by the end of September, but about one-fifth have no plans to exhibit at any upcoming 2020 shows.

DESIGN WORLD

DW.Insights.6-20_Vs2.LL.indd 5

at a trade show, while 81% say a vaccine would ease their concerns over mass gatherings.”

Last month, igus, a Cologne, Germany based manufacturer, held a livestreamed press event, where product managers in multiple stations talked about the latest innovations. All of this occurred with social distancing and face masks — and was held in the company’s enormous booth that was to have been at Hannover Fair. Instead, the company built out the booth in their headquarters facility. Could this sort of thing be the new normal for a while?

Stanton said that about threequarters of exhibit managers anticipate an increase in virtual/hybrid events, while a slight majority foresee developments such as decreased trade show attendance, fewer events, and a shi om large national events to small/regional alternatives. Just under half of them expect to see wider aisles and temperature checks on the show floor when events do resume.

“Interestingly, eight out of 10 also report that enhanced cleaning/ sanitation policies at hotels, convention centers, and on airplanes would make them more likely to return to the show floor,” Stanton said.

Once things begin to open up, will we actually see the clustering of shows happening in the Fall months? Stanton thinks it’s possible, but only to an extent.

“Many shows scheduled for the second and even third quarter have been postponed until later in the year.

In many cases, this has caused show organizers to truncate their timelines, at the very least shaving off time that would previously have been dedicated

to exhibitors’ installation and dismantle — largely because venues are booked fairly solid with organizers clamoring for fall dates.

But my gut tells me that only a action of those shows will happen, and many will be far smaller in scope, as a result of fewer exhibitors participating and a scaling back of exhibitors’ investments,” he said.

Stanton said that trade show exhibitors and vendors/suppliers to the trade show industry, including exhibit designers and producers have a bit of a dismal outlook for 2020, with only about one-fi h of them believing that the industry will rebound in 2020.

“The majority predict it will be at least second-quarter 2021 before the industry will return to normalcy and 13% of them anticipate that won’t occur until 2022 — while 5% question whether the industry will ever return to business as usual,” Stanton said.

In covering engineering and manufacturing over the past two months, however, one thing is clear. Strange times do seem to breed creativity and innovation.

So, while we don’t know what will happen to the industrial tradeshow landscape in the months ahead, I’m confident that we’ll find a way to move forward and create something new and better. Maybe the typical conference or show of 2021 won’t look like those we had in 2019, but the right answer to connect sellers and buyers will find a way.

“I have no doubt that trade shows and face-to-face marketing will survive,” Stanton said. “The industry made it through 9/11, SARS, MERS, and the Great Recession — all of which felt insurmountable at certain moments. So, while prognosis for the immediate future is gloomy, you can mark my words. Trade shows will resume. The question is precisely when, and what will they look like.” DW

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

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Teschler on Topic Uncritical thinking about thinking critically Headlines were made recently when numerous universities announced they would no longer require students applying for admission to take ACT and SAT tests. But there is a lesserknown test, the Collegiate Learning Assessment (CLA+), that may be a better indicator of academic learning than either of these two tests. CLA+ claims to measure how much an educational institution enhances the critical thinking skills of its students.

One part of the CLA+ requires testtakers to read about a hypothetical situation involving an issue, problem, or conflict, then suggest a solution or recommend a course of action based on the information provided in a document library. (One example question calls for evaluating claims of political candidates and endorsing one of them; another involves deciding whether to continue an ad campaign for a product that seriously injured someone.) The library typically contains six to twelve documents that can be technical reports, data tables, newspaper articles, e-mail, and other every-day materials. Students have 90 minutes to make sense of it all and suggest what to do.

Results of the CLA+ test for 2016-17 showed that college seniors generally did, in fact, do better on the test than did incoming eshman. But the range of improvement om eshmen to seniors varied widely depending on the academic institution. This fact caused the Wall Street Journal to say the test found “students o en gain little ability to assess evidence, make cohesive argument(s).” The WSJ also came up with a graph showing the average point difference between eshman and senior CLA+ test takers which ranked educational institutions om highest to lowest.

Several big-name academic institutions didn’t come out looking good in this graph. They were clustered at the end with the least improvement.

Of course, the WSJ asked several institutions about their results. We might speculate that these inquiries may have gotten the institutions involved to wonder more about the critical thinking skills of the reporters asking the question than about those of their own students. In what may well have been a “Well, duh” moment, educators om elite institutions were reported to have explained that the hyper-competitive nature of their admissions policies meant that most of their incoming eshman were already pretty good at critical thinking when

they first set foot on campus-- and their CLA+ scores were, in fact, relatively high. So, it would stand to reason their CLA+ scores wouldn’t improve much a er four years.

The institutions that came out looking great in CLA+ point gains tended to be small schools without a national reputation. New Hampshire’s Plymouth State University was at the top of heap in 2014. We might also speculate the result is understandable given that schools of PSU’s stature probably don’t have many applicants who scored 1,600 on the SAT. I suspect PSU faculty members might say a number of their eshman have nowhere to go but up.

Of course, colleges that no longer require SAT or ACT testing may won’t be able to use test scores to distinguish stand-out applicants om the masses.

Time will tell what effect this will have on the caliber of incoming classes. At worst, it might be a good way for an institution to show bigger improvements in student CLA+ scores. DW

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

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Technology Forward Metal additive manufacturing’s effect on the automotive industry In automotive applications, additive manufacturing (AM) will be both a tool and a game changer, noted Jonah Myerberg, co-founder and CTO of Desktop Metal in a recent interview.

It will be a tool necessary to do a job efficiently and competitively.

Designers will need 3D printing to react quickly to customer demands, prototyping components and parts to change and innovate, as well as to produce low volume components, and to remain flexible for customers.

But as a game changer, additive manufacturing will aid upcoming industries, such as electric vehicles, through its ability to deliver lightweight components and systems. “Plus,� noted Myerberg, “it’s going to be a great equalizer for small companies trying to compete with the big ones. So, you will see the birth of new tier one suppliers who are focused on AM that may not have been able to compete in the past.

And it’s going to change the way that designers think about automotive design forever, so in that way it’s really going to be a game changer.�

Metal AM can be applied to any component within a car, claims Myerberg. Materials are available that can tolerate the temperatures and offer the strengths of more

traditional alloys used in the engines, suspension systems, and transmissions. “We’re going to see additive manufacturing playing in every aspect of a vehicle now,� he added.

One of the more important roles that metal AM will play will involve enhancing the recyclability of cars.

The automotive industry is focusing on how to make transportation systems more efficient and less impactful on the environment.

Electric vehicles, hybrid vehicles, and hydrogen vehicles will play a part, but so will the use of AM and new materials that can be recycled at the end of a car’s useful life.

The Circular Car Initiative is looking for ways to make vehicles fully recyclable. In some cases, this involves repurposing automotive components to reduce the impact a vehicle has on the environment a er its death.

Another focus involves taking advantage of 3DPs ability to place mechanical characteristics exactly where you want them. “Parts can be flexible in one area and stiff in another,� noted Myerberg. “They can be designed as much for performance on the road as for manufacturability. “To be able to design an entire vehicle at one time and then print it out and have it be optimized

for crashing, impact, suspension, performance all in one, that’s really exciting, but we’re certainly not there yet,� he added.

One issue is current manufacturing processes focused around sheet metal. 3D printing something that simulates sheet metal has many challenges. “Sheet metal is not 3D printable iendly, so if designers are going to replace a sheet metal fabricated assembly with a 3D printed part, they will have to go back to the drawing board and redesign it under the loads that are being placed on it.�

One of the tools that will help is generative design, because it lets AI do the heavy li ing.

One of the stronger roles of metal AM in automotive will be as a bridge between concept and final mass production. “We see this all the time.

Designers may not have the time or money to invest in the tooling that’s required for the part. 3D printing is an alternative, enabling designers to jump in and test a design without having to invest in that tooling.�

Another interesting aspect is how metal AM will affect the supply chain and worldwide manufacturing.

Myerberg sees AM helping to reshore automotive back to the United States.

Bring manufacturing closer to the point of production instead of have these long-distance supply chains.

DW

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

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Green Engineering

Innovations in plastic packaging are

contributing to a circular economy Sheldon Yourist Senior Director of Global Design Graham Packaging and

Balaji Jayaseelan Director of Sustainability and Regulatory Affairs Graham Packaging

In recent years, plastic has come under increased scrutiny due to low recyclability rates and the growing amount of plastic waste in the natural environment. While manufacturers are stepping up efforts to meet consumer demand for more sustainable solutions, there are still significant challenges at every level of the recycling process that build barriers to recyclability.

Over the years, package designers have seen additional demands placed on their talents and skill set. Not only are they tasked with cra ing eye-catching designs that differentiate products at point of sale, but they are also under increased pressure to create sustainable solutions that offer additional shelf appeal to environmentally conscious consumers. There is no one solution to success. It involves the use of art, communication, engineering, technology and manufacturing to optimize the development of customized, sustainable packaging solutions.

Packaging manufacturers should broaden their perspectives beyond just recyclability to complete sustainability.

What used to be considered a cradle-to-grave process is now a cradle-tocradle solution that evaluates and optimizes every aspect of the supply chain to improve circularity. Many consumer brands and manufacturers have signed

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Green Engineering

the Ellen MacArthur Foundation pledge to ensure plastic materials used in new packages are 100% reusable, recyclable or biodegradable by 2025.

Beyond post-consumer recycling One of the greatest challenges packaging companies face is the lack of access to recycled content — particularly post-consumer recycling (PCR). Low recycling rates and a lack of consumer education regarding how to recycle properly has made PCR a scarce commodity. Luckily, there are alternative sources for obtaining recycled content.

Post-industrial recycling (PIR) is another source of recycled content that is equally important in reducing the carbon footprint and lowering greenhouse gas emissions. PIR is derived om the waste generated om the original manufacturing process that is used again in the same material. Although PIR is o en seen as a less attractive solution for brands, it allows for more recycled content to be used in the manufacturing process at a lower carbon footprint.

For the manufacturer, post-industrial recycling (PIR) o en requires less energy to convert material into a new, usable package. Additional benefits include eight savings, less mixed-material contamination and lower cost for conversion (saved energy for cleaning, sorting and interim conversion of flakes to pellets). PIR can offset the demand for virgin materials and the added eight to sell off PIR and bring in new materials.

A tremendous advantage of PIR is the ease of access to a distribution network. Scrap material can be easily collected and sorted in the facility that it comes out of and quickly sent to be reprocessed into a raw material form.

Keeping oceans clean starts with preventing waste — including plastic — om entering them. Having the ability to recycle salvaged plastics is even better.

Rescuing ocean-bound plastics (OBP) involves taking materials that are at risk of becoming ocean pollution and turning them into a reusable plastic resin.

Every pound of rescued OBP is pollution transformed into a recyclable resource. OBP can be refined to quality levels with up to 100% inclusion in nearly any application where HDPE/PET is the preferred material. This versatile resin can be used for both injection and blowmolding products, making it suitable for a wide range of packaging applications.

Reducing plastic in bottles Due to the challenges of securing recycled content — particularly foodgrade material — manufacturers are finding innovative ways to lightweight their packaging in an effort to significantly reduce the amount of material needed in each package. In addition to shrinking package weight, lightweighting allows more product to be shipped in one truck.

There are several ways companies like Graham Packaging are reducing plastic content, including: Vertically Applied Processing (VAP) — This process involves extrusion blow molding with vertical bands that can be adjusted to increase or decrease bottle wall thickness in desired locations. It allows polyolefins to be strategically placed throughout the bottle.

Concentrating vertical stripes around the corners allows it to take on more weight while reducing the amount of material needed at the base and throughout the entire bottle.

ThermaSet — Lightweighting has also been proven to be successful in hot-fill food processes. This heat-set process allows PET containers to be used in challenging fill processes like hot fill, pasteurized and retort where glass is typically used. Because of its lighter weight and smaller footprint than current glass jars, 40% more ThermaSet PET jars can be put on a single truck. They also

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need less packaging and fuel during transport while being fully reusable and recyclable.

Eliminating Grips and Handles — By simply removing the grips and handles om plastic bottles, companies can significantly reduce package weight. One spirits company decided to remove the handle om its bottle, resulting in a 15% weight reduction. By making this simple change, the annual material savings for this single product was equivalent in weight to seven Boeing 747 jets.

While taking weight out of bottles is one way to promote sustainability, manufacturers are also seeking out alternatives that encourage consumers to reuse bottles in an effort to eliminate downstream waste. One way to promote reuse is to add texture. This process helps extend the “like new” appearance of a bottle and is less likely to be discarded a er a single use.

Adding texture that takes on the appearance of bubbles at the base of a bottle helps to heighten shelf appeal, while also boosting reuse.

Bottles with added texture have shown to reduce scuffing by 75% and can be reused up to 25 times compared to non-textured counterparts.

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Mixed material recyclability Plastic packaging o en includes various other materials that complement the product both aesthetically and functionally. To make sure a product is completely recyclable, plastic manufacturers must work with their vendor partners to ensure packing will not be rejected in recycling streams because of labeling, coloring, adhesives or attachments. Knowing this, plastic packaging manufacturers are now taking steps to proactively address these concerns with customer in order to guarantee a more sustainable outcome.

Changes to packaging design never occur in a bubble. Insights and data, driven by a consumer lens, contribute to research and development, technology and future innovations. Understanding what motivates consumers at the point of sale helps drive advancements in sustainable design.

Supporting a circular economy requires bringing together customers, suppliers and manufacturers to create sustainable products that are good for the environment and future generations. By exploring new shapes, processes and technologies, designers can increase recyclability and lightweighting while creating functional features that minimize the environmental impact of packaging. These efforts allow manufacturers to deliver on customers’ design goals while reducing their overall environmental footprint. DW

DESIGN WORLD

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June 2020

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Contents 6 • 2020

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vol 15 no 6

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116

A supplement of Design World June 2020

A new approach to makes more materials available for additive manufacturing 144

141 150 Designing medical devices for Combining additve and additive manufacturing subtractive technologies for metal digital manufacturing

COVER_MPF 6-20_CONCEPT2.indd 140

116 _MOTION CONTROL

130 _INTERNET OF THINGS

Big world of miniature brakes

Industry 4.0 and the Factory of the Future: Insights for new engineers

Many industries have come to employ the compact cameras, sensors, batteries, processors, and communications technologies made ubiquitous by consumer products.

Electromagnetic brakes complement such designs with miniature formats.

136 _3D CAD

Encoders endure in tough applications

Look up in the sky it’s CAD software

A combination of mechanical and electrical resiliency along with design for impermeability makes for truly heavy-duty encoders.

Medical www.designworldonline.com

Whether you’re an experienced engineer or a member of a new generation just launching your professional career, you can make full use of Industry 4.0 technology through a step-by-step approach.

124 _LINEAR MOTION

6/8/20 4:38 PM

140-152

A Supplement to Design World - June 2020

How are alternative during ventilators helping the COVID-19 pandemic

Medical Tips cover 6-20_FINAL.indd 153

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A major CAD vendor is betting the modeling so ware’s future is in the cloud

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Precision Control for Your Operations

6.20

• contents departments 04

Insights

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Teschler on Topic

08

Technology Forward

10

Green Engineering

18

Design For Industry

32

Design Notes

40

CAE Solutions

46

Internet of Things

168 Product World

Clutches, Brakes and Motion Control Products

176

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Design for Industry Aerospace

Fire seal enables aircra engines to run hotter

The Ultra High Temp Seal enables aircra manufacturers to develop engines that run more efficiently and, by achieving lower fuel consumption, more sustainably.

Quinn Collett, Air ame General Manager, says: “The hotter an engine runs, the more thrust is obtained om the same amount of fuel, making the engine more efficient with lower fuel consumption. Aircra designers aim to run engines at continuously higher temperatures with the latest options operating at +600 °F and beyond, significantly higher than their predecessors.”

At these extreme temperatures, specialized fire seals help ensure the safety of passengers onboard. Used in the fuselage, pylons, thrust reversers and engine applications, they act as a barrier to prevent airflow om one area of a plane to another during normal operating conditions. This is an important function. However, even more crucially, they serve as a precaution in incidents that lead to fire. Then they act to contain the fire to one section of an aircra and enable the airplane to land safely within a 15-minute period.

The design of the Ultra High Temp Seal overcomes the inherent silicone characteristic of relaxation and compression set at elevated temperatures; a major cause of failure in a fire seal’s ability to perform against all requirements. This means

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seal can also be a drop-in replacement for seals that do not currently meet all fire seal requirements, such as high temperature operation, or for customers seeking extended life than that provided by their existing seals.

The seal meets the requirements of US Federal Aviation standard AC20-135 Powerplant Installation and Propulsion System Component Fire Protection Test Methods and Standards and Criteria, as well as ISO 2685:1998 Aircra – Environmental Test Procedure for Airborne Equipment – Resistance to Fire in Designated Fire Zones. DW

that the seal can successfully operate in high temperature aircra engine applications.

Trelleborg performed a full test program to prove the product’s capabilities at different compression loads. In heat soak tests, the seal performed better than other fire seals. In all cases it was below a 15% permanent set target.

The seal eliminates the need for thermal protection of sealing elements, reducing weight and part count, making assembly easier.

The seal operates at a temperature range om -40 °C/ -40°F to up +315 °C/ +600 °F while meeting all customers’ fire seal requirements. It is engineered to have a life time of 60,000 flight cycles (take off, flight and landing), dependent on application. The Ultra High Temp TL Design World V1.pdf

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Trelleborg Sealing Solutions www.tss.trelleborg.com

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Design for Industry Medical

Improvising and 3D printing PPE

The additive community has really stepped up to help healthcare workers who are facing shortages of Personal Protection Equipment (PPE), such as face masks, and components for ventilation systems. While professional engineers and hobbyists alike are either creating designs or using CAD files available on various sites, it’s important that these efforts are done using the right materials. Healthcare workers need to feel safe and protected using these solutions. Safe improvised alternatives do exist.

According to 3D Systems, face masks intended for a medical purpose in the United States are regulated by FDA (see guidance). When FDA-cleared masks or respirators are unavailable, healthcare professionals may choose to improvise PPE. Similar situations are likely to arise in jurisdictions not regulated by FDA. 3D Systems worked with engineers and clinicians at the Veterans Health Administration to develop an emergency Stopgap Face Mask (SFM). The SFM is available in multiple sizes and is printed om a biocompatible nylon material using selective laser sintering technology.

The SFM is comprised of the 3d printed mask and filter cover, two elastic strips, and a rectangular patch of filter material.

The SFM can be reprocessed using disinfectants and/or autoclaved.

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The Stopgap Face Mask is to be used for medical purposes when standard PPE is unavailable or for less critical non-medical environments that do not require compliant PPE. The SFM design has undergone review in a clinical setting and is recommended for use when manufactured according to the guidance and used as instructed in the IFU. Included with the download are the 3d printable files, the instructions for use (IFU), and a manufacturing guidance document for printing om a 3D Systems Selective Laser Sintering machine in Duraform PA or Duraform ProX PA. Selective laser sintering can be used to manufacture volume quantities of the mask and filter cover. DW

3D Systems www.3dsystems.com DESIGN WORLD

6/11/20 1:54 PM

Power REVIEW THE POWER BRANDS IN POWER TRANSMISSION

Vol. 9 | No. 2 | 2020

www.AltraMotion.com

Follow Altra Motion on:

INSIDE THIS ISSUE:

Visit Altra’s Virtual Trade Show

Scan to download the interactive version of the Power Review

Altra Industrial_#1_6-20.indd 21

Visit Altra’s Virtual Trade Show Exhibit!

Warner Electric Electromagnetic Spring-Set Pulse™ Brakes

Altra Certified Rebuild Services Marland, Formsprag, & Ameridrives

Twiflex USA Brake Calipers

6/11/20 12:29 PM

Visit Altra’s Virtual Trade Show Exhibit!

Some of the world’s largest trade shows have been canceled or postponed due to the unprecedented impact of the COVID-19 pandemic.

Altra’s immersive and interactive trade show environment provides visitors around the world with convenient 24/7 access to browse the extensive portfolio of motion control and power transmission products offered by our 27 global brands.

You can quickly and easily navigate through the intuitive virtual exhibit area by clicking on various primary hotspots, including clutches & brakes, couplings, gearing, automation & specialty, PT components, brand websites and a media tower.

Search the virtual trade show by sections or hotspots.

Interactive product category kiosks are located within each major section of the exhibit. Users can select specific Altra brands on each kiosk which reveal a series of product family hotspots that link to specific product screens where related literature pdfs can be downloaded.

The media tower features links to various videos as well as the Altra literature portal.

Altra is a premier global designer and producer of a wide range of motion control and power transmission solutions. With engineered components and systems that provide essential control of equipment speed, torque, positioning, and other functions, Altra products are utilized globally in thousands of machines, processes and applications involving motion.

For more information, visit www.AltraEx.com

Altra Industrial_#2_6-20.indd 22

Scan the QR code to visit Altra’s Virtual Trade Show Booth

6/11/20 12:30 PM

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 like-new 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. n Altra Industrial Motio

I N T R O D U C I N G

Ameridrives Rebuild Service

Ameridrives remanufactured couplings look like new, perform like new and are warrantied like new For more information call (814) 480-5095 or visit www.Ameridrives.com.

The Ameridrives Rebuild Service Team will conduct a comprehensive inspection of your coupling and perform the following to restore your coupling to its original specifications with a new coupling warranty: • All potential wear components – metallic and gear flex elements, shims, and fasteners are refurbished or replaced to new performance standards.

• Magnetic Particle Inspection (MPI) on all torque transmitting

your old, worn couplings for Ameridrives Rebuild Service can refurbish replacement coupling. The economical ® substantially less than the cost of a new , Ameridrives couplings including Ameridisc rebuild service applies to all ® high speed couplings used primarily Ameriflex® and Amerigear high performance, applications in the power generation, on turbomachinery, compressor and pump brands are accepted on a case-byoil & gas and marine industries. Other coupling case basis.

Ameridrives has the team, facilities, As a leading global coupling manufacturer, experience to rebuild and replace and nearly 100 years of inspection and repair are completed to meet the exacting all coupling components as required. Repairs standards of the original coupling.

components.

• Removal and repair of surface defects on a lathe and glass bead blasting as appropriate while maintaining original coupling integrity.

• Precision dimensional and Total Indicator Run-out (TIR) measurement • Rebalancing to original API 671 certification if applicable. This recertification requires the return of the entire coupling structure.

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.

in the shortest possible time frame.

Couplings are received, inspected and rebuilt down schedule.

We will work to accommodate your shut call (814) 480-5095 or visit For details on our cost-saving program www.Ameridrives.com. www.ameridrives.com 1802 Pittsburgh Avenue Erie, PA 16502 - USA 814-480-5000 Fax: 814-453-5891

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Warner Electric Electromagnetic Spring-Set Pulse™ Brakes Warner Electric Electromagnetic Spring-Set Pulse Brakes require NO ELECTRICAL POWER to hold in either a clamped or released model.

Warner Electric can make all sizes and custom fit to meet specific application requirements.

• • • • • • • • • •

Brake remains Locked or remains Released without power consumption.

Lower release drag allows operation at high speeds.

Can be made into hundreds of existing configurations.

Mechanical Springs clamp the brake disc like conventional Spring-Set Brakes.

Can be custom made to fit most applications.

Can be Steel on Steel or smooth friction lining.

Controlled soft stop for sensitive applications.

Longer wear life.

Replaceable friction component.

Uses common DC Voltage. Simply apply a DC pulse to release the brake then a reverse DC pulse to engage the brake.

otion Altra M

etic ™ Electromagn Pulse Spring-Set Brakes hold CAL POWER to ELECTRI Requires NO or released mode! in either clamped

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Spring-Set Brakes. any application made to fit most • Can be custom friction lining. on Steel or smooth • Can be Steel applications. sensitive for stop soft • Controlled life.

• Longer wear t. componen friction to • Replaceable apply a DC pulse the DC Voltage. Simply to engage • Uses common then a reverse DC pulse release the brake brake.

For more information, download P-8840-WE from www.AltraLiterature.com

Twiflex USA Brake Calipers Twiflex offers the largest range of industrial disc brake calipers in the world. Spring applied units may be retracted pneumatically, hydraulically or electrically (depending on caliper design) while most direct acting brakes have some form of positive retraction device.

Pneumatically Applied Brakes are best suited for light to medium stopping duties and for tensioning applications where a high degree of control is required.

Hydraulically Applied Brakes address higher torque requirements, while spring applied calipers are essential where braking must be maintained in the event of supply system failure.

Mechanically Applied Units are suitable for light tensioning duties or where no external power is available; they may also be specified when designers wish to use their own means of actuation.

For more information download P-1648-TF from www.AltraLiterature.com

Call Twiflex Toll-Free: 844.723.3483

Founded in 1927, Warner Electric has grown to become a global leader in the development of innovative electromagnetic clutch & brake solutions.

Warner Electric engineers utilize the latest materials and manufacturing technologies to design long life, easy-to-use clutches and brakes that provide improved accuracy and repeatability. Warner Electric offers the broadest selection of industrial clutches, brakes, controls and web tension systems available from a single manufacturer.

Products: • Clutches • Brakes • Clutch/Brakes • Torque Control • Linear Products • Coils • Clutch/Brake Controls • Sensors/Switches

Key Markets: • Elevator • Turf & Garden • Mobile Off-Highway • Packaging Machinery • Food & Beverage • Medical & Mobility • Forklift Truck • Material Handling • Farm & Agriculture

Altra Industrial_#4_6-20.indd 24

www.warnerelectric.com

6/11/20 12:31 PM

Design for Industry Medical

3D printing aids the development of a ventilator splitter with individual pressure capability

Researchers at the University of Michigan, collaborating with Autocam Medical, have tackled the COVID-19 crisis of potential ventilator shortages globally and developed VentMI in remarkable time— om prototype to available for use in under a month. This new ventilator splitter overcomes a previously critical limitation for shared use of these devices. Previous splitters could deliver only one pre-set pressure to patients even though each patient requires a unique pressure tailored to their lung size and degree of disease. Excessive volume or pressure can cause lung trauma, thereby limiting the ability to share a ventilator.

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

Conceived only weeks ago by Dr. Kyle VanKoevering of the Department of Otolaryngology-head and neck surgery at Michigan Medicine and an associate faculty member in the Department of Biomedical Engineering, the new splitter was designed, prototyped, tested and received Emergency Use Authorization (EUA) from the FDA. In less than a week, Autocam Medical was mobilized to implement Design for Manufacturing (DFM) processes and started manufacturing the VentMI. A new company formed by U-M inventors, MakeMedical LLC, has licensed the technology from U-M and will provide VentMI at cost to other institutions. Autocam Medical is providing its manufacturing services at cost, as well. The VentMI costs only one-hundredth that of a new ventilator, thereby helping to reduce vent costs into the future as well. “We’re extremely grateful to have been asked to participate in the creation of this vital new product,� commented John Kennedy, CEO of Autocam Medical. “And we’re very proud of our team’s ability to go from prototype through manufacturing, engineering, to finished product in a matter of days to help meet this crucial need for the healthcare community.�

According to Owen Tien, CEO of 3-D printing company, Thingsmiths, a co-developer of VentMI and co-founder of MakeMedical, “Autocam Medical’s professionalism, speed, and quality of work is world-class. Their ability to move our components beyond 3D-printed prototypes has resulted in a product we can stand behind, and we are proud to partner with them.�

Added Kennedy, “This is truly a great example of the power of innovation and collaboration between multiple partners in successfully tackling an important challenge under the most difficult circumstances presented by the pandemic.� DW

Autocam Medical autocam-medical.com

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

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

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

Servomotor encoder combination aids in the development of ventilator components

Even the machine tool industry is working to develop critical components needed during this COVID-19 crisis.

HEIDENHAIN is working with Applied Motion Products, Inc. to expedite components to a large manufacturer of ventilators.

Now in various stages of delivery, the Applied Motion Products’ StepSERVO Integrated Motors equipped with HEIDENHAIN’s RENCO encoders are making their way into the production of 5,000 new life-saving medical devices.

StepSERVO Integrated Motors combine an integrated motor design with a high-resolution incremental encoder and closed-loop firmware. This combination provides users with the ability to create peak torques up to 50% higher than open loop motors, as well as operate cooler and quieter – especially important to ventilator manufacturers. The incremental RENCO RCML 15 rotary encoders used in the design are compact and reliable and continue to provide easy-to-integrate motion control performance. DW

HEIDENHAIN www.heidenhain.us/about-us

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6/8/20 3:02 PM

YOUR CUSTOM SOLUTIONS ARE CGI STANDARD PRODUCTS

Advanced Products for Robotics and Automation 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©2018 cgi inc. all rights reserved. 0516spd

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

Linear positioning stages ensure

accurate motion

Five new profile single axis positioning stages have been added to ther AQ150 Series of linear stages. Available off-the-shelf in travel lengths of: 600 mm (23.622 in.), 700 mm (27.559 in.), 800 mm (31.496 in.), 900 mm (35.433 in.), and 1000 mm ( 39.370 in.), these stages are available with either a Two-Phase Stepper Motor or with a Three-Phase Brushless Motor with a Quadrature Incremental Optical Encoder.

Stepper Motor driven models feature a resolution of 2.1 micron (achieved with a 10 microsteps per step stepper motor driver), additionally, the knob on the AQ150 Stepper Motor series can be replaced with an optical encoder for position verification. For Closed Loop Operation, high precision, higher travel speeds, and greater throughput, the stepper motors are replaced with Three Phase Brushless Servo Motors and Quadrature Encoders.

The tables of each stage measures 150 mm x 150 mm (5.90 in. x 5.90 in.) and has a precision pattern of threaded holes for mounting fixtures or other tooling. These high precision low profile rail stages have top and side rail covers. Featuring a 5 mm perturn, lead screw, these have a positional accuracy of 10 microns.

These low profile, aluminum and black anodized stages can handle loads to 50 kg (110.2 lbs.), and can also be ordered in an XY or XYZ configuration. These compact linear stages are easily integrated into new and existing systems and are available as complete plug-and-play systems including a single or multi axis controller. DW

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6/8/20 3:02 PM

M a c h i n e To o l

Smart vibration sensor for preventative maintenance

The development of smart manufacturing relies on sensors, which acquire data, which automate the manufacturing process and thereby enable predictive maintenance.

The WISE-2410 LoRaWAN smart vibration sensor monitors surface temperatures of machines and autonomously calculates their vibration characteristics. This helps factory owners and admins to analyze data and plan for proactive maintenance or take preventative measures that predict events before they happen.

WISE-2410 is equipped with the latest ARM Cortex-M4 processor, which is used to transform original vibration data into spectral information via fourier transformation functions to calculate vibration values. Users can estimate the operational status of any motor-powered mechanical equipment such as pumps, air compressors, and fans by cross-comparison of RMS speeds and eigenvalues against ISO 10816-3 standards. The WISE Studio utility helps users set operation parameters through a user iendly GUI, whether it’s reading reports, getting temperature values, vibration info, setting alarms etc., all can be done using the WISE Studio utility.

WISE-2410 LoRaWAN Smart Vibration Sensor can monitor fixed or mobile devices and collect data 24/7. Operators can quickly view and understand the utilization rates of all devices to maximize their capacity.

What’s more, through RMS, Peak, Kurtosis, and other vibration characteristic values, operating trends can be analyzed and equipment can be proactively tracked to discover the health and status of production lines and machines, preventing unwarned downtimes and learning root causes of problems to plan better preventive maintenance.

WISE-2410 is easy to set up and supports plug and play. The product can withstand wide-temperature ranges om -20 °C to 85 °C and has an IP-66 rating for dust and water ingress resistance. Even in harsh environments, collecting, calculating, and transmitting data is still unhindered. In terms of the power supply design, WISE-2410 uses a low-power consumption IC solution and is driven by two 3.6V AA lithium batteries. Under regular operating conditions (returning a packet of data every 15 minutes), the battery life can be as long as two years. Even under low power warning conditions, the power supply can still operate for up to three months. DW

Advantech www.advantech.com

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June 2020

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Design Notes

Pneumatic and electric drive technology help fight COVID-19 Lisa Eitel • Executive Editor

Festo LifeTech Business Unit components are used in highspeed automated laboratory devices that are essential for the types of screening envisioned for sample analysis during the pandemic.

Festo North America and subsidiary Fabco-Air Inc., classified as essential businesses, are supplying pneumatic and electric drive technology to distributors, equipment manufacturers, and end-users in North America.

“Festo has launched focused coronavirus mitigation projects,” said Craig Correia, Director of Life Science & Process Industries, Festo North America.

“Among several initiatives, the first is to ensure that orders for components and systems used in medical devices receive priority treatment and are processed and shipped rapidly.

“A large research and development team is working full time on a design for a quick-to-manufacture emergency respiratory ventilator. Another team alongside a partner firm is developing a concept for automated production of protective masks. This team envisions a complete production system that

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can be set up and shipped within a standard transport container.”

The company’s LifeTech Business Unit components are used in highspeed automated laboratory devices that are essential for the types of screening envisioned for sample analysis during the pandemic.

LifeTech components are also used by certified respiratory equipment manufacturers. Festo does not manufacture that equipment itself.

In addition to the medical and manufacturing sectors, Festo is keeping its overall production and logistics systems sound for the pharmaceutical, food and beverage,

www.designworldonline.com

and packaging industries, as well as for washing systems for hospitals and care facilities.

Festo encourages the use of the company’s online resources, including the 24/7 online shop, for placing orders and checking delivery status, and online product configuration and engineering tools. The company continues to take measures to ensure continuity of production while protecting the health and safety of employees, suppliers, and the public. DW

Festo | festo.com/us/en

DESIGN WORLD

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Design Notes

Could coating surfaces with copper kill the SARS-CoV-2 virus?

Edited by Mike Santora • Associate Editor

Copper parts are difficult to produce using traditional methods — 3D printing may be the only tool available to deploy copper rapidly. The technology used in printers like this LighSPEE3D metal printer makes copper printing fast and affordable.

Australian company SPEE3D is reporting that it has successfully developed and tested a fast and affordable way to 3D print anti-microbial copper onto metal surfaces. Laboratory tests have shown that touch surfaces modified by this process “contact kills” 96% of SARS-CoV-2, the virus that causes COVID-19, in just two hours.

The process, known as ACTIVAT3D copper, has been developed by modi ing SPEE3D’s 3D printing technology using new algorithms for controlling their metal printers to allow existing metal parts to be coated with copper. Copper parts are difficult to produce using traditional methods — 3D printing may be the only tool available to deploy copper rapidly. SPEE3D technology makes it fast and affordable.

Australian NATA-accredited clinical trial specialty laboratory, 360Biolabs, tested the

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COVERED BEARINGS. effect of ACTIVAT3D copper on live SARSCoV-2 in their Physical Containment 3 (PC3) laboratory. The results showed that 96% of the virus is killed in two hours and 99.2% of the virus killed in 5 hours, while stainless steel showed no reduction in the same time ame. Stainless steel is currently the material typically used in hygiene environments.

With laboratory testing complete, it is hoped that this development can be applied to common touch items like door handles, rails, and touch plates in hospitals, schools, and other public places.

SPEE3D CEO, Byron Kennedy, said the company has focused on developing a solution that can be rapidly deployed and is more efficient than printing solid copper parts om scratch. “The lab results show ACTIVAT3D copper surfaces behave much better than traditional stainless, which may offer a promising solution to a global problem.

The technology can be used globally, addressing local requirements, be they in hospitals, schools, on ships or shopping centers.”

The technique was developed to harness copper’s proven abilities to eradicate bacteria, yeasts, and viruses rapidly on contact by breaking down the cell wall and destroying the genome.

This is compared to traditional surfaces like stainless steel and plastic, with recent studies showing that SARS-CoV-2 can survive on these materials for up to three days.

Stainless steel and plastic surfaces can be disinfected; however, the problem with these surfaces is that even with rigorous protocols, it is impossible to clean them constantly.

When surfaces become contaminated between cleans, touching them may contribute to superspreading events. Touching contaminated objects, known as fomite transmission, was suspected during the 2003 SARS-CoV-1 epidemic and analysis of a nosocomial SARS57 CoV-1 superspreading event concluded that touching contaminated objects (fomites) played a significant role.

To validate its abilities to combat COVID-19, copper samples printed by SPEE3D have been lab-tested and shown to kill SARS-CoV-2. The SPEE3D team developed a process to coat a stainless-steel door touch plate and other handles in just 5 minutes.

The digital print files were then sent to participating partners around the globe, allowing the simultaneous installation of newly-coated parts in buildings in the USA, Asia, and Australia. In a matter of days, copper fixtures were installed in buildings at Charles Darwin University (CDU) in Darwin, Swinburne University in Melbourne, the University of Delaware in the USA, and in Japan.

Assistant Director of Digital Design and Additive Manufacturing at the University of Delaware, Larry (LJ) Holmes said, “Scientists and engineers at the University of Delaware were honored to be part of this global

The SPEE3D team developed a process to coat a stainless-steel door touch plate and other handles in just 5 minutes. The digital print files were then sent to partners around the globe, allowing the simultaneous installation of newlycoated parts in buildings in the USA, Asia, and Australia.

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MOLDED NEOPRENE & URETHANE SURFACES

SINGLE & DOUBLE BEARINGS

IN STOCK! ROLLERS & BUMPERS

LOCATE YOUR DEALER ONLINE!

June 2020

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www.fairlaneproducts.com 800.548.2935 6/9/20 8:02 AM

Design Notes research collaboration. We recognized the importance of developing simple yet highly impactful solutions that have been proven effective on COVID-19.

Recognizing supply chain shortfalls over the last couple of months, it was clear to this team that fabrication speed was a priority. Using this technology, we can rapidly transition safe options for hightouch surfaces.”

The company has worked in close collaboration with the Advanced Manufacturing Alliance (AMA) at CDU. The initial testing of ACTIVAT3D copper and future studies have been funded and supported by the National Energy Resources Australia (NERA). NERA CEO Miranda Taylor said the company’s ability to successfully adapt their technology and pivot their business model demonstrated the resilience of Australian

businesses and their potential to help the world combat COVID-19. “NERA has supported SPEE3D to develop marketleading technologies to help our national energy sector, and we’re committed to assisting them to leverage their skills and expertise into this important new paradigm to help our country and many others curtail the devastating impact of this global pandemic.” DW

SPEE3D | spee3d.com

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Design Notes

Air-purification systems (and their terminal blocks) help battle COVID-19 Barry Nelson of WAGO

GreenTech uses WAGO’s picoMAX pluggable PCB terminal blocks for reliable connections in its design.

As doctors and medical experts continue to try and find a vaccine for COVID-19, one company is looking to help control the spread — especially in medical facilities. For the past ten years, GreenTech Environmental has been at the fore ont of producing residential air-purification systems. Now with the help of CASPR Medik, they have created an air-purification system for hospitals and medical centers that has demonstrated effectiveness against viruses similar to COVID-19.

It should be noted that their system has not been tested directly against the COVID-19 strand, but CASPR Medik has tested it against similar viruses on hard and absorbent surfaces. CASPR Medik has also conducted testing of this system against the Feline Calicivirus. This is a highly contagious virus that is one of the major causes of upper respiratory infections in cats. Feline Calicivirus is a well-known surrogate for Norovirus and COVID-19. It is a virus that

CASPR designs install into HVAC systems to continually disinfect public and patient areas in healthcare settings. Billed as an alternative to hydrogen misters and ultraviolet light, the technology employs oxidizing molecules to disinfect closed areas.

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spreads through airborne particles when coming in contact with infected surfaces or by coughing or sneezing. With the technology developed by GreenTech and the testing done by CASPR, both strands were significantly reduced or eliminated.

Medical facilities are taking precautions at every turn to stop the spread of COVID-19. They use hand sanitizer, disinfecting wipes, and other materials to try to keep rooms and surfaces clean.

However, as GreenTech founder and CEO Allen Johnston explains, “There are a lot of liquid sanitizers that do a great job and kill pathogens. But within a short time, people reenter the room and the area becomes contaminated again.”

GreenTech’s proprietary photocatalyticbased air-purification technology continuously sanitizes and purifies the room as people come in and out. “It’s a slower process,” Johnston says, “but much more effective because it works continuously.”

With the outbreak of COVID-19, Johnston says that orders om medical facilities all across the world have been pouring in. GreenTech had planned for 6,000 purifiers to be manufactured throughout the year, but due to the virus, DESIGN WORLD

6/8/20 3:16 PM

The GreenTech manufacturing facility connection. Against tremendous odds, questions remained — Could WAGO produce a mass number of these PCB connectors in such a short time? If so, could they get them to GreenTech quickly?

With strong communication, WAGO could answer yes to both questions.

WAGO Regional Sales Manager Mitch McFarland said it was a team effort and realized emphasizing the importance of the product and the parts needed really helped.

“Communication was key,” says McFarland. “We needed the support of WAGO US and we also needed to work with WAGO Germany to get this done.”

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that process needed to be expedited.

A plan for another 10,000 was put in motion as well. However, there was just one issue: there were not enough parts to manufacture so many products in such short time.

One component, in particular, was a part that connects the ballast (power module) to the UV light output. From the beginning, GreenTech had been using WAGO’s picoMAX pluggable PCB terminal block to ensure a high-quality

Customer Operations Manager Scott Schauer of WAGO Germany was able to push these parts to the ont of the line and get them manufactured quickly. “The order came across my desk on March 30th. Thanks to everyone, we will be shipping the first 6,000 parts out om Germany by April 8th.” Understanding the gravity of the situation, FedEx said that they would be expediting shipping om Germany to GreenTech and get them to their Johnson City, Tenn. manufacturing plant within a couple of days.

Communication, teamwork, and technology are the backbone that will help get us through these unprecedented times. Thanks to companies like GreenTech Environmental, CASPR, and WAGO, we are one step closer to lessening, and eventually, eradicating the threat of COVID-19. Hopefully, with innovations such as these, we are on the cusp of returning to normalcy. DW

WAGO | wago.com/us

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CAE Solutions

Reduce overall simulation time The latest release of Simcenter FLOEFD so ware om Siemens Digital Industries So ware is a CAD-embedded computational fluid dynamics (CFD) tool. Simcenter FLOEFD is part of the Simcenter portfolio of simulation and test solutions that help engineers simulate fluid flow and thermal problems quickly and accurately within their preferred CAD environment. The latest version offers new modules and

M

improvements that can improve accuracy and solve rates.

Simcenter FLOEFD helps users ontload CFD simulation early into the design process to understand the behavior of their concepts and eliminate the less attractive options. The so ware can reduce overall simulation time by as much as 65-75% and offers up to 40 times user productivity enhancement. Part of the Xcelerator portfolio, Simcenter FLOEFD also helps design engineers contribute to the creation of a highly accurate digital twin.

The new Electronics Cooling Center module combines existing best electronics-specific capabilities and integrates new ones om Simcenter Flotherm so ware inside the CAD-embedded interface to enhance electronics cooling functionality. A second new module helps users create a compact Reduced Order Model (ROM) that solves at a faster rate, while still maintaining a high level of accuracy. The Power Electrification module can now simulate an electrical device as an electro-thermal compact model, which can save significant user and computational time. DW

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DESIGN WORLD

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Accelerate spatial AR programming of machines and robots Vuforia Spatial Toolbox platform, created by the PTC Reality Lab, is an open-source platform that helps developers create, innovate, and solve spatial computing problems in a new way. Innovators can explore Industrial Internet of Things (IoT) and Spatial Computing, accelerate prototyping for machines, and develop leading-edge spatial Augmented Reality (AR) and IoT use cases to support digital transformation initiatives.

With this spatial computing platform, teams can improve the operation of complex manufacturing environments and make IoT-enabled machines easier and more intuitive to control with onthe-fly programming. Robots can be operated and controlled through more

intuitive user interfaces (UIs), and intuitive Human Machine Interfaces (HMIs) can be quickly built, enabling improved humanmachine interaction and merging the digital world and physical screens.

As the newest addition to the Vuforia AR product portfolio, Vuforia Spatial Toolbox complements the current commercial Vuforia offering. The Vuforia Spatial Toolbox is a system consisting of two components which combine to provide an industrial AR/ Spatial Computing prototyping environment with pre-built UI/UX elements, spatial programming services, an intuitive UI app, and simplified connectivity to IoT with the Vuforia Spatial Edge Server. The open-source environment is designed to drive further exploration around the convergence of the physical and digital worlds and help to push

the boundaries of innovation.

To enable users to take advantage of the new Vuforia Spatial Toolbox while working om home during this crisis, PTC created a basic hardware interface add-on that allows them to connect the Vuforia Edge Server with Arduino projects, children’s LEGO BOOST and LEGO Education WeDo 2.0 sets, and the Philips Hue smart lighting system.

The technology is the brainchild of Valentin Heun, Ph.D., vice president, Innovation Engineering, PTC, and former scientist at the MIT Media Lab’s Fluid Interfaces Group, where he led the Reality Editor human-machine interface research. Dr. Heun is a leader in the AR industry, and an active author and speaker on topics related to AR. DW

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CAE Solutions

So ware supports powder bed fusion additive manufacturing DP Technology is enhancing its support of additive manufacturing processes with so ware specifically for the powder bed fusion market.

Called ESPRIT Additive for Powder Bed, the program comes as an addin application for SolidWorks.

ESPRIT Additive for Powder Bed Fusion is compatible with any file supported by SolidWorks. One feature of the new so ware is the patented Part-to-Build. When preparing a part for manufacturing, the program automatically assigns exposure strategies based on simple inputs om the user.

ESPRIT Additive for Powder Bed Fusion also introduces an accurate slicer that uses parametric workflow modeling. Once the part is ready to slice, it may be imported to the job environment as many times as needed.

“This optimized workflow saves our users even more time by eliminating the need to repeatedly define the manufacturing information,” says Clement Girard, Product Manager for Additive Solutions for DP Technology. “Additive for Powder Bed Fusion improves consistency by ensuring a part is built the same way each time and maintains traceability by recording each step om the original 3D CAD file.” DW

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CAE Solutions

Generative design for flow applications

In Flow driven generative design, once the designer is satisfied with the initial iteration of the design, they simply click a button to begin a simulation. Then, they can run a flow analysis without leaving the design program.

Flow driven generative designer is a new application om Dassault Systèmes. Its intended use is to give users or designers access to simulation capabilities for fluid optimization.

As many designers know, the process of creating a part is typically based on experience and intuition. Generative design, however, offers a different approach. Generative design programs use boundary conditions, set by the designer, to drive and simulate how a part should look. Applications for flow driven generative design include powertrain design, HVAC, jet propulsion, injection molding, and valve and piping design.

Within the program, designers are encouraged to ask different questions. For example, rather than ask, ‘Does this shape meet the requirements?’, the question changes to ‘Which shape best meets the requirements?’

According to Colin Swearingen, generative design expert at Dassault Systèmes, “optimizing fluid flow for a particular component is a difficult process as it incorporates a number of aspects of engineering.” These aspects create an “over-the-wall” process where various engineering disciplines such as CAD, analysis, simulation, manufacturing, PLM and so on, are siloed and there is little collaboration.

One of the risks of siloed engineering is an increase in the number of data translation errors that can compromise a design. Another drawback is the lack of expertise in more than one engineering discipline. Few companies have designers who are experts in CAD, CFD, and analysis.

Thus, in a typical traditional design process, a designer begins with a design space and sets up boundary conditions. In the case of fluid,

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what are the inlet conditions and what are the outlet conditions? Are there any other restraints that need to be applied to the model?

Then the design is handed off to an analyst, who must then mesh the data and prepare it for a CFD model run.

The new shape also needs to be validated. In a typical design process, that’s a different tool that is used to compute the flow analysis as opposed to optimizing the shape to begin with.

So, designers do their best version of the design.

However, it quickly becomes an iterative process every time a change is made.

The flow driven generative program is in the 3DEXPERIENCE platform, which also includes other engineering tools, such as CAD, simulation, analysis, optimization, and manufacturing. All of these are unified into one environment so that a designer can streamline the design process. This platform makes the process intuitive, helping users optimize the design earlier and eliminates all the data translations required in other tools and platforms.

In Flow driven generative, once the designer is satisfied with the initial iteration of the design, they

DESIGN WORLD

6/8/20 3:42 PM

In a typical traditional design process, a designer begins with a design space and sets up boundary conditions.

Once the designer is finished, they had it off to an analyst, who must then mesh the data and prepare it for a CFD model run. simply click a button to begin a simulation.

Then, they can run a flow analysis without leaving the design program.

File exchange is not needed in this process, and no data translation is necessary. Said Swearingen, “It’s intuitive, easy to use, and we really streamline the process. What we see is about a 10-times faster turnaround time.”

The program includes a design assistant that prompts the designer to answer specific boundary questions that help the

CAE.Solutions%206-20_Vs4.LL.indd 45

program create a design.

Noted Swearingen, the program leverages best in class TOSCA fluid technology in the background. Tosca fluid and many of the Tosca applications are typically known as an expert tool. However, that’s being run in the background here.

The designer is getting access to this simulation capability without needing to be a full-fledged expert in the program.

The goal of the Flow driven generative program is to remove the bottlenecks that

make it cost prohibitive to explore optimized parts. Another goal is to develop a seamless collaboration with design and simulation departments. “In a unified environment,” said Swearingen, “it’s enabling collaboration and opening doors for users in a much more streamlined and efficient manner, to tackle the problems that arise with this type of workflow.” DW

Connec engin thousa

Dassault Systèmes www.3ds.com

6/8/20 3:42 PM

Internet of Things

The edge is modular Dan Demers • congatec

Industrial edge server designs must be flexible to perform diverse tasks. Increasingly, virtual machines are used to consolidate a variety of Industry 4.0 workloads. In addition, Computer-on-Modules offer the flexibility to scale the computing power to fit the application, enabling application-specific price and performance balancing next to load balancing.

Fully modular edge and fog servers offer realtime hypervisor support and are based on Server-on-Modules to enable applicationspecific price and performance balancing in addition to load balancing.

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Workload consolidation, which was mainly reserved to data center server virtualization in the past, has long ceased to be confined to wellconditioned server cabinets. Demand is now increasing at the rough industrial edge: Machine and systems manufacturers as well as industrial end users want to virtualize their Industry 4.0 applications on local edge servers. At the same time, they also want to consolidate the various controls distributed across a manufacturing cell on these edge servers instead of assigning the control tasks to multiple dedicated systems. Such an approach makes it possible to use the combined computing performance better, which ultimately saves costs.

Next to system costs, the maintenance and administration efforts are also reduced. What is more, workload consolidation on redundantly

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designed edge and fog servers also helps to increase reliability and failsafety. This is because with multiple distributed systems, there is a higher probability that a link in the chain, and therefore the entire chain, will fail.

To be able to develop heterogeneous and application-specific edge and fog servers, OEMs need a powerful realtime hypervisor as well as a multicore platform that’s right for the particular application. Since it doesn’t tend to make a difference on which server platform the hypervisor runs, a modular hardware design is the first step to enable application-specific price and performance balancing in addition to load balancing. Such a modular hardware approach can already be found in numerous edge systems, om the smallest gateways to large industrial servers.

DESIGN WORLD

6/8/20 3:44 PM

The real-time workload consolidation starter kit from congatec is based on a COM Express Type 6 module with Intel® Xeon® E2 processor and the RTS Hypervisor from Real-Time Systems. (Copyright ©Intel)

LPWAN gateway for LoRa A good example from the lowpower segment is the LoRa gateway from Expemb. Designed for use in a variety of LoRa scenarios, it allows

the implementation of an equally wide variety of edge logic. For example, in factory environments LoRa is used to connect autonomous smart IoT sensors or track load carriers to monitor and optimize the internal

flow of goods. Because the gateway integrates Computer-on-Modules – in this case, Qseven modules with Intel Atom processors – it offers a flexible hardware setup that can be customized both on the hardware and the software side to meet the most heterogeneous technical requirements for LoRa-based IoT applications.

Next to load balancing, this makes application-specific price and performance balancing possible, too.

Edge servers for smart grids High flexibility is also required for box PC-like edge servers. China, for example, is currently rolling out an edge layer for a distributed smart grid management system in cooperation with Tencent’s IoT partner for the energy market. An edge server design of this kind should manage distributed

A number of manufacturers have already built innovative modular edge server systems, from small LoRa gateways to smart grid edge servers and industrial rack servers.

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Internet of Things

power generators and consumers in factories and industrial parks, and since the installed base is always heterogeneous, the hardware design should also be modular. In this case, COM Express Type 7 Computer-on-Modules are used. First systems integrate modules with Intel Xeon D15xx processors with up to 16 cores and 32 threads. Alternative configurations are based on Intel Atom C3xxx processors. With up to 16 cores, these processors are ideal for all installations where diverse workloads must be consolidated.

Obviously, it makes a significant difference both in terms of energy consumption and cost whether the system uses a Xeon or Atom processor.

Modular rack servers for harsh environments It is, of course, also possible to build more powerful modular rack server designs that use standard Computer-on-Modules to reduce investment costs for the control of robotic systems, production cells as well as complex packaging and machine tools.

An example of such modular designs are servers om suppliers such as Christmann, which has successfully integrated COM Express Type 7 Server-on-Modules and is already planning designs based on the new COM-HPC module standard. Next to providing the perfect design basis for the specific task, what speaks in these servers’ favor is the high scalability that enables performance upgrades for future needs: The second server generation, which will doubtlessly be required a er three to five years due to rapid technological progress, is expected to cost only roughly half of the initial investment. This is because in most cases all that will need replacing is the processor module. To fully leverage the significant TCO savings this yields, Christmann rackmount servers can be flexibly equipped with up to 27 CPU microservers. These three examples illustrate the enormous advantages that Computer-onModules and Server-on-Modules offer for edge gateways and edge servers.

Real-time workload consolidation kit But without real-time hypervisor support, this is only half the solution. It is also necessary to provide appropriate so ware support for the hardware. For this purpose, congatec cooperated with Intel and Real-Time Systems to develop an Intel certified RFP (ready for production) kit for workload consolidation. The kit, Intel certified since March 2020, is aimed at the next generation of image-based collaborative robotics, automation controllers and autonomous vehicles that need to perform multiple tasks in parallel, including situational awareness using deep-learning based AI algorithms. The solution-ready platform is based on a COM Express Type 6 module with Intel Xeon E2 processor and integrates three preconfigured virtual machines to demonstrate that it is possible to run real-time applications on a virtual machine even while another system application is being rebooted.

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Time-sensitive networking is the complementary counterpart of workload consolidation.

It enables realtime control over standard Ethernet networks as well as tactile Internet sessions over realtime 5G

But to ensure that the platform is future proof and able to support workload consolidation most efficiently, it also provides all the basics needed for flexible connectivity via customer-specific carrier board designs.

Time-sensitive networking support included The kit supports time-sensitive networking (TSN), which is becoming essential for real-time processing in tactile Internet environments with the emergence of 5G technologies and 10+ GbE networks in the factory. TSN technology comprises a number of standards, such as IEEE 802.1q for virtual LANs over Ethernet, time aware shaping (TAS) as standardized in IEEE 802.1Qbv for guaranteed minimum transmission latency, or real-time synchronization via the precision time protocol (PTP)

DESIGN WORLD

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defined in IEEE 1588. PTP is responsible for time synchronization between nodes. A master sets the time. The individual slaves synchronize their clocks with two-digit nanosecond accuracy.

Based on these synchronized clocks, packets can be time stamped and sent. This means PTP networks can synchronize themselves with twodigit nanosecond accuracy, whereby the travel time of the IP packets naturally also impacts the ultimate real-time behavior of the application.

In case of the I219 Intel Ethernet interface, the clock synchronization is based 100% on this standard component. This gives it the dual advantage of being cast in hardware and not requiring any additional proprietary applications or dedicated hardware. DW

congatec www.congatec.com

www.designworldonline.com

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June 2020

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6/10/20 9:22 AM

Internet of Things Ethernet/IP enhanced to further address Industry 4.0 and IIoT ODVA announced the latest enhancements to The

diagnostic assembly definition for diagnostic connection points defined by other objects will enable these new statistics to help assist in network troubleshooting. Additionally, new provisions diagnostics, new methods to lower bandwidth and resource for aggregation of multiple I/O connections will provide a requirements for devices, and the addition of IIoT building block mechanism to multiplex many individual connections into one, in astructure. which will significantly reduce network bandwidth. Runtime reconfiguration will be seamless and efficiency will be improved In addition to the recent enhancements to EtherNet/IP to across the board, especially in instances where IO-Link or HART allow users to obtain device diagnostics pursuant to the NE107 translation or modular I/O is used. standard, ODVA enhanced EtherNet/IP further to provide Updates allow for constrained devices running on EtherNet/ overall system diagnostics. The additional EtherNet/IP system IP to enable UDP-only device communication with the goal diagnostics will enable a better understanding of the number of lowering resource and hardware requirements. Constrained of connections, resource usage, the number of Ethernet errors, devices are anticipated to significantly lower the cost barrier missed packets, and overall CPU use. A common, scalable network thereby further strengthening the business case to add EtherNet/IP to in-cabinet, small sensors, and other simple devices. Ethernet will be possible all the way to edge devices, including use of Single Pair Ethernet (10BASE-T1S), enabling end to end IIoT communication. EtherNet/IP, including CIP Security, has been enhanced to include constrained device definitions.

Furthermore, the addition of the option to use Link Layer Discovery Protocol (LLDP) will enable nodes and in astructure to detect other devices in near proximity, and for the physical network topology to be discovered and visualized. As a required component for TSN, the addition of LLDP lays the ground work for easier adoption of TSN into the EtherNet/IP Specification.

Standard Parts. Winco.

Along with existing network extensions, the TSN standards for sending time critical data via industrial Ethernet will be an option to meet the needs of high determinism applications, to add network design options, and to plan for the significant future increases in data traffic brought about by IT and OT convergence.

The latest enhancements to the EtherNet/IP Specification are enabling enhanced understanding and therefore performance of the broader network, driving EtherNet/IP down to the lowest capacity devices through reducing resource requirements, and are laying the foundation for TSN. ODVA is continuing to drive the advancement of EtherNet/IP to meet 800-877-8351 the evolving requirements of IIoT and Industry 4.0 to meet the sales@jwwinco.com needs of CIP technology users both today and tomorrow. DW EtherNet/IP Specification to provide improved network

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ODVA www.odva.org

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The Robot Report

The 2020 RBR50 robotics innovation awards The annual RBR50 list, a leading indicator of robotics leadership, has been broadened in 2020 to celebrate a wider range of technology and business innovation.

The 2020 RBR50 Innovation Awards Judges

DAN KARA VP, Robotics

STEVE CROWE Editor, Robotics

For nearly a decade, Robotics Business Review has produced the RBR50 robotics innovation awards, which recognize and celebrate forward-thinking companies and the original, impactful solutions they have created. Widely recognized throughout the world as a leading indicator of robotics innovation leadership, the RBR50 is also a critical measure of robotics sector growth.

For the robotics industry, the role, importance, and impact of innovation has never been greater. Moreover, multiple types of innovation -- technological, business, and market -- have converged to accelerate robotics sector growth overall.

Accordingly, for 2020, the criteria for the RBR50 awards has been reworked and extended to celebrate robotics innovation over a wider range of forms, including the following: • Business and management innovation -- Business and management initiatives or practices that enhance a company’s commercial standing, foster robotics sector growth, or improve society.

• Technology, products, and services innovation -- New commercial solutions that that have the potential to benefit markets or the whole robotics and automation industry.

• Application and market Innovation -- Industry-specific, newly developed applications that deliver value, provide entry to new markets, or improve performance over existing approaches (i.e., improve productivity, increase quality, or reduce cost).

THE ROBOT REPORT

EUGENE DEMAITRE Senior Editor, Robotics Methodology Applications for the 2020 RBR50 robotics innovation awards came om multiple sources.

WTWH Media’s Robotics Group sought submissions om companies, businessdevelopment entities, research and investment groups, and others for innovations that were released, initiated, or executed since January 2019.

In addition, the RBR50 judges communicated with the leaders of major robotics clusters and other groups for submissions. The judges also reviewed announcements om investment groups, corporate briefings, and association and industry publications, as well as sessions at conferences and seminars.

Private interviews with industry representatives, investors, and other analysts also played a part in the submission and verification process.

Many factors were used as a basis judging RBR50 entries, including the originality and significance of the innovations and their business or technical merits.

Entries were also judged on their impact, or potential impact, on markets and the global robotics ecosystem. RR

www.therobotreport.com

June 2020

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Spotting trends among the RBR50 innovation award winners This year’s honorees were not only innovators, but also leaders in robotics trends.

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SSI and BiSS-C interfaces

Cruise raised $1.1 billion last year.

Dust and moisture tolerant Factory-friendly assembly tolerances

Each year, the RBR50 innovation awards receive many more nominations than can fit in the annual list. This year, the final selection reflects more rigorous judging criteria, current technological and business trends in robotics, and reactions to the COVID-19 pandemic.

Since companies of different sizes build robots for widely differing applications, it is difficult to compare them directly. Add to that regional clusters, universities and research institutions, and new business models, and it becomes clear that the best way to analyze robotics leadership is to see what categories and industries they fit into.

www.posital.com

Innovation classes A renewed emphasis on innovation in the 2020 RBR50 criteria led to half of this year’s winners being recognized for the introduction of new products and technologies. This included both hardware and so ware for autonomous systems.

Fourteen companies were recognized for novel business management, with six in leadership, six in market engagement, and one organization, MassRobotics, for business model.

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THE ROBOT REPORT

While several companies serve the healthcare industry, only one company was recognized for social good.

AutoGuide Mobile Robots earned honors for participating in a program to retrain and hire former coal miners as robotics technicians.

Eleven companies were recognized for innovation in applications and markets, reflecting seven industries ranging om healthcare and manufacturing to forestry, logistics, and retail. AMP Robotics made the list for its development of a dualrobot recycling system.

Technologies and industries Nearly half of this year’s RBR50 innovation award winners, 21, were involved in industrial automation and manufacturing. This included nine companies making industrial or collaborative robot arms or end effectors, as well as Sarcos, which has developed an industrial exoskeleton.

Some of the biggest and best-known robotics makers in the world are in the industrial space, including ABB Robotics and Yaskawa Motoman, as well as cobot leader Universal Robots. Gripper makers OnRobot and So Robotics also came out with new products this past year.

Ten component suppliers made this year’s RBR50 list, including drive makers FAULHABER MICROMO and Harmonic Drive, as well as processor makers Intel and NVIDIA. While it may come as no surprise that Formant and Microso are among the six listees for robot so ware, Vecna Robotics also made the list for its Pivotal “orchestration engine” rather than its autonomous mobile robots (AMRs). Many submissions claimed to apply artificial intelligence to robotics and automation, but relatively few could demonstrate true innovation in the past year.

AMRs were well-represented, with nine organizations supporting supply chain and logistics operations, such as 6 River Systems, Geek+, Locus Robotics, and Waypoint Robotics.

Six companies in autonomous vehicles and transportation also made the 2020 RBR50, including Cruise, Nuro, and Waymo. Even with testing paused in the past few months, these companies have advanced the state of driverless technology.

THE ROBOT REPORT

AutoGuide helped coal miners become robotics technicians. | Source: AutoGuide Mobile Robots

By innovation class: 11 Application & Markets 14 Business & Management 25 Product, Technology & Services

The novel coronavirus crisis has increased interest in robotics for healthcare, which is the focus of September’s Healthcare Robotics Engineering Forum. Three organizations -- Blue Ocean Robotics, Diligent Robotics, and Worcester Polytechnic Institute -were winners this year.

Where the innovators are Four robotics clusters and organizations won 2020 RBR50 awards: the Advanced Robotics for Manufacturing (ARM) Institute in Pennsylvania, MassRobotics in Massachusetts, Silicon Valley Robotics in California, and the Commonwealth Scientific and Industrial Research Organisation (CSIRO) in Australia. The ARM Institute and CSIRO are national rather than regional groups.

All have both nurtured startups and led robotics development, which is the focus of the annual Robotics Summit & Expo in Boston.

While the majority of RBR50 winners this year happened to be based in the U.S., other countries represented included Canada, China, Denmark, Germany, the Netherlands, New Zealand, and Switzerland. Japan and South Korea, both leaders in the use of robotics and automation, were under-represented in nominations.

Within the U.S., organizations in 12 states qualified for this year’s list, with Massachusetts and California leading with 15 and 14, respectively.

Nearly half (21) of this year’s RBR50 winners have been on the list before, with ABB and Universal Robots each being

www.therobotreport.com

Some of the biggest and best-known robotics makers in the world are in the industrial space, including ABB Robotics and Yaskawa Motoman, as well as cobot leader Universal Robots. Gripper makers OnRobot and Soft Robotics also came out with new products this past year.

June 2020

55

LEADING

THE WAY

To Faster Fulfillment

“We found a great partner in 6 River Systems and a great technology in Chuck.

We depend on that relationship in our operations.”

– Bob Abbondanza, Office Depot

Scalable. Flexible. Available.

Now backed by Shopify

“We will continue to operate, build and sell the 6 River Systems solution.” – Tobi Lütke, CEO, Shopify

LEARN MORE 6river.com

6RS UK pub AD.v2.indd 1

6/4/20 10:16 AM

RBR50 Introduction honored nine times in the past decade. On the other hand, more than half of this year’s innovators are new to the list, so organizations should not miss the annual call for submissions.

THE NEW MUST HAVE FOR ROBOTS!

By the numbers: 21 Repeat honorees 21 Industrial automation/manufacturing leaders 12 U.S. states represented 11

Organizations om outside the U.S.

9

Supply chain/logistics companies

8

Countries of origin

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Investment in innovators Investors, partners, and acquirers also recognized the 2020 RBR50 organizations, investing about $3.2 billion in them over the past year.

Innovative companies received money to develop and deploy autonomous mobile robots, self-driving cars, end-of-arm tooling, sensors, and industrial automation.

Top 12 transactions among 2020 RBR50 winners Amt. ($M)

Type

Date

Cruise

1,150

Funding

5/7/2019

Nuro

940

Series B

2/11/2019

6 River Systems

450

Acquisition 9/10/2019

AutoGuide Mobile Robots

165

Acquisition 10/21/2019

Organization

Geek+

150

Series C1

6/13/2019

Vecna Robotics

50

Series B

1/7/2020

Fetch Robotics

46

Series C

7/23/2019

Boston Dynamics

37

Venture funding

2/6/2019

Built Robotics

33

Series B

9/19/2019

OnRobot

27.4

Early stage VC

12/19/2019

Locus Robotics

26.2

Series C

4/22/2019

26

Series A

6/11/2019

Sense Photonics

The Ensenso XR 3D camera system

In addition, autonomous vehicle company Waymo raised $3 billion in funding last month, a er the period covered by the 2020 RBR50 list.

For more detailed discussions of why each organization is in the 2020 RBR50, please see the individual descriptions of their innovations. RR

ÂŽ www.ids-imaging.com THE ROBOT REPORT

June 2020

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RBR50 CHART

58

6 River Systems Inc.

6 River Systems helps fulfillment operations scale with Chuck mobile robots, scales quickly to serve market

Business & Management Innovation

Leadership

ABB Robotics

ABB opens global research hub for robotics at the Texas Medical Center

Business & Management Innovation

Leadership

ACEINNA Inc.

ACIENNA releases OpenRTK33L guidance module for robots, drones, and autonomous vehicles

Product, Technology & Services Innovation

Product Introduction

Advanced Motion Controls

Advanced Motion Controls adds 15 new models of FlexPro high-performance servo drives

Product, Technology & Services Innovation

Product Introduction

Agility Robotics

Agility Robotics announces the commercial availability of Digit humanoid robot

Product, Technology & Services Innovation

Product Introduction

AMP Robotics

AMP Robotics launches AMP Cortex Dual-Robot System for rapid recycling

Applications & Markets Innovation

Waste management

Apex.AI Inc.

Apex AI releases Apex.OS, a software framework based on ROS 2 designed to ease and speed software development for autonomous vehicles

Product, Technology & Services Innovation

Product Introduction

ARM Institute

The ARM Institute relocates to offer expanded offices and labs optimized for robotics development, co-locates with Carnegie Mellon University’s Manufacturing Futures Initiative

Business & Management Innovation

Market Engagement

AutoGuide Mobile Robots

AutoGuide Mobile Robots hires retrained coal miners as robotics technicians

Business & Management Innovation

Social Good

Blue Ocean Robotics ApS

Blue Ocean Robotics produces a UV-D disinfection robot, aiding in COVID-19 response worldwide

Applications & Markets Innovation

Healthcare / Rehabilitation

Bossa Nova Robotics

Bossa Nova Robotics announces deployment of self-scanning inventory robots in 1,000 Walmart stores in the U.S.

Business & Management Innovation

Market Engagement

Boston Dynamics Inc.

Boston Dynamics commercializes its Spot quadruped robot

Product, Technology & Services Innovation

Product Introduction

Built Robotics Inc.

Built Robotics partners with International Union of Operating Engineers for robotics training

Business & Management Innovation

Leadership

Commonwealth Scientific and Industrial Research Organisation

CSIRO opens new Robotics Innovation Centre in Australia

Business & Management Innovation

Leadership

Cruise LLC

GM unit Cruise unveils Origin, a driverless ride-sharing vehicle challenging transportation paradigms

Product, Technology & Services Innovation

Product Introduction

Diligent Robotics Inc.

Diligent Robotics introduces the Moxi mobile manipulation assistance robot in hospitals

Applications & Markets Innovation

Healthcare / Rehabilitation

Energy Robotics & ExRobotics BV

Energy Robotics and ExRobotics launch mobile robots for remote oil and gas site inspection

Applications & Markets Innovation

Energy

Exyn Technologies Inc.

Exyn Technologies offers aerial imaging and mapping system for surveying mines in GPSdeprived environments

Applications & Markets Innovation

Mining / Quarrying

FAULHABER MICROMO LLC

FAULHABER MICROMO releases compact BXT flat brushless DC motors

Product, Technology & Services Innovation

Product Introduction

Fetch Robotics Inc.

Fetch Robotics releases Workflow Builder to facilitate the design and implemention of workflows for robotic fleets

Applications & Markets Innovation

Product Introduction

Formant Inc.

Formant includes ease of use, remote control, and analytics in cloud-based robot management platform

Product, Technology & Services Innovation

Product Introduction

June 2020 www.designworldonline.com

DESIGN WORLD

Gatik

Gatik provides so ware stack for autonomous vehicles for middle-mile delivery applications and partners with Walmart

Applications & Markets Innovation

Logistics

Geekplus Technology Co.

Geek+ deploys more than 10,000 mobile robots as a service around the world, expands into the U.S.

Business & Management Innovation

Leadership

Harmonic Drive LLC

Drive leader Harmonic Drive opens a new manufacturing and R&D facility

Business & Managemen Innovation

Leadership

Intel Corp.

Intel RealSense L515 lidar camera brings high resolution and depth perception indooors

Product, Technology & Services Innovation

Product Introduction

iRobot Corp.

iRobot diversifies its manufacturing supply chain, reducing exposure to ongoing trade issues

Business & Management Innovation

Leadership

Kinova Inc.

Kinova's Gen3 robotic arm family supports research and spurs commercial development

Product, Technology & Services Innovation

Product Introduction

Locus Robotics Inc.

Locus Robotics launches so ware and hardware suite optimized for omnichannel fulfillment and expands its partnership with DHL

Applications & Markets Innovation

Logistics

MassRobotics

MassRobotics expands its robotics innovation center to nurture innovations in industrial automation, human-machine interaction

Business & Management Innovation

Business Models

maxon motors

maxon motors opens a new engineering and manufacturing facility, expanding its North American footprint beyond sales and distribution to better serve customers and partners

Business & Management Innovation

Market Engagement

Microso Corp.

Microso releases Robot Operating System (ROS) for Windows 10.

Product, Technology & Services Innovation

Product Introduction

New Scale Robotics

New Scale Robotics' Q-Span Automated Small-Part Measurement System enables robotic inspection in manufacturing environments

Applications & Markets Innovation

Manufacturing

Nuro

Nuro upgrades R2 autonomous vehicle development platform, obtains dual exemptions for on-road testing

Applications & Markets Innovation

Transportation

NVIDIA Corp.

NVIDIA launches the Jetson Xavier NX, a small, high-performance compute platform that supports all popular AI ameworks

Product, Technology & Services Innovation

Product Introduction

OnRobot A/S

OnRobot's One System Solution allows its end-of-arm tools to work with a range of collaborative and light industrial robots

Product, Technology & Services Innovation

Product Introduction

Robotics Plus Ltd.

Robotics Plus introduces automated log-scaling system designed to increase productivity and reduce injuries

Applications & Markets Innovation

Forestry

Sarcos Corp.

Sarcos Robotics commercializes Guardian XO full-body exoskeleton for industrial use

Product, Technology & Services Innovation

Product Introduction

SCHUNK GmbH

Schunk EGL-C enables robots to handle up to 8 kg while collaborating with humans and conforming to international safety standards

Product, Technology & Services Innovation

Product Introduction

Sense Photonics Inc.

Sense Photonics launches Osprey, a 3D Flash LiDAR solution for automotive applications

Product, Technology & Services Innovation

Product Introduction

Sevensense Robotics AG

Sevensense Robotics provides a 360-degree view with newly released Alphasense Core system

Product, Technology & Services Innovation

Product Introduction

DESIGN WORLD

www.designworldonline.com

June 2020

59

RBR50 CHART

60

SICK Inc.

SICK's nanoScan3 laser scanner combines compact design, environmental resistance, and high performance

Product, Technology & Services Innovation

Product Introduction

Silicon Valley Robotics

Silicon Valley Robotics celebrates 10 years of community building and leadership

Business & Management Innovation

Market Engagement

So Robotics Inc.

So Robotics' SuperPick Polybag Picking System addresses complexity, variability in the unstructured environment of reverse logistics

Product, Technology & Services Innovation

Product Introduction

Universal Robots A/S

Universal Robots launches UR+ Application Kits to remove barriers to integration of UR collaborative robots

Product, Technology & Services Innovation

Product Introduction

Vecna Robotics Inc.

Vecna Robotics introduces Pivotal, a “multiagent orchestration engine� that integrates into WMS / ERP systems and optimizes workflows among automated systems and manual activities

Product, Technology & Services Innovation

Product Introduction

Veo Robotics Inc.

Veo Robotics launchs FreeMove, a safetyrated vision system that allows standard industrial robots to operate more collaboratively with humans

Product, Technology & Services Innovation

Product Introduction

Waymo LLC

Waymo pulls ahead in autonomous vehicle race

Business & Management Innovation

Market Engagement

Waypoint Robotics

Waypoint Robotics builds MAV3K, an omnidirectional, heavy-duty autonomous mobile robot

Product, Technology & Services Innovation

Product Introduction

Worcester Polytechnic Institute

WPI opens the PracticePoint facility to foster innovation and commercialization of medical robotics

Business & Management Innovation

Market Engagement

Yaskawa Motoman

Yaskawa Motoman releases the HC20XP, the first food-grade collaborative robot

Product, Technology & Services Innovation

Product Introduction

June 2020

www.designworldonline.com

DESIGN WORLD

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Medical

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Tra n s fe r L i n e s

BUSINESS & MANAGEMENT INNOVATION — Leadership

6 River Systems helps fulfillment operations scale with Chuck mobile robots Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

6 River Systems Inc. U.S. www.6river.com 2015 140+ Business & Management Innovation Leadership

Description: 6 River Systems’ (6RS) Chuck is an autonomous mobile robot (AMR) that is designed to work with human pickers for e-commerce order fulfillment.

In March 2020, Waltham, Mass.-based 6RS unveiled enhancements to Chuck including increased capacity, expanded compliance with international safety standards, and features such as globally recognized lighting for improved usability and faster training of associates. The robot won two Red Dot Awards for product design in April.

Not only is Chuck able to continuously improve, thanks to cloud-based so ware updates, but it is also able to operate without extensive physical in astructure. 6RS said its AMRs can deliver a return on investment in as little as nine months and increase productivity by 10% year over year.

Analysis: 6 River Systems’ leadership has deep experience in the competitive market for AMRs. Co-founders Jerome Dubois and Rylan Hamilton had been executives at Kiva Systems, which was acquired by Amazon. com Inc. in 2012. They were joined by Chris Cacioppo, who designed electrical and mechanical systems.

In September 2019, Shopi Inc. validated 6RS’s innovative approach by acquiring it for $450 million. The multi-channel

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June 2020

e-commerce provider said Chuck will help it and its customers scale to meet demands for reliability and speed.

Unlike Kiva, which was later renamed Amazon Robotics, 6RS will continue providing Chuck to other companies, including DHL, Lockheed Martin, Office Depot, and XPO Logistics.

In just four years, 6RS has gone om being a startup to a major player in AMRs for e-commerce. RR -- Eugene Demaitre

www.designworldonline.com

DESIGN WORLD

BUSINESS & MANAGEMENT INNOVATION — Leadership

ABB opens global research hub for robotics at Texas Medical Center Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

ABB Switzerland www.new.abb.com 1988 144,000 Business & Management Innovation Leadership

Description: ABB’s healthcare research center opened in October 2019 at the Texas Medical Center in Houston. The facility is using ABB’s collaborative robots to explore the development of non-surgical medical robotics systems, including logistics and next-generation automated laboratory technologies. This is ABB’s first dedicated healthcare research center. A 20-strong team om ABB Robotics will work in the research facility, which includes an automation laboratory and robot training facilities, as well as meeting spaces for co-developing solutions with innovation partners.

Analysis: A key element of ABB’s long-term growth strategy is to continue to invest and innovate in underserved robotics sectors.

ABB’s healthcare research center could fuel its collaborative robotics business by bringing its automation expertise to new areas such as healthcare.

Throughout the world, the healthcare sector is struggling om the combined pressures of skyrocketing costs, the need to improve the quality of services and results, rapidly aging

THE ROBOT REPORT

populations, and a shortage of qualified workers.

Many highly skilled medical workers also spend a large part of their days doing repetitive and low-value tasks.

ABB said its analysis showed that repetitive tasks could be completed up to 50% faster with automation in comparison wth current manual processes. ABB estimated that by 2025, more than 60,000 non-surgical medical robots are expected to be working in hospitals. RR -- Steve Crowe

www.therobotreport.com

June 2020

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

ACEINNA ships cost-effective, highprecision navigation system for robotics and autonomous vehicles Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

ACEINNA U.S. www.aceinna.com 2017 20+ Product, Technology & Services Innovation Product Introduction

Description: In March 2020, ACEINNA launched the OpenRTK330L, a high-performance, multiband RTK/GNSS receiver and triple-redundant inertial sensor designed for autonomous vehicles, Level 3 autonomous driving and driver-assistance systems, drones, mobile robots, and industrial/agricultural machinery. The OpenRTK330L is compatible with multiple satellite systems, including GPS, GALILEO, GLONASS, QZSS, and BeiDou.

Analysis: Commercial class mobile robots, drones, and other vehicles face conflicting mandates for autonomous navigation and mapping. It is critical that they locate themselves as precisely and reliably as possible, but the technology must not be cost-prohibitive. Solutions must be robust in the extreme, but the devices themselves must be as compact as possible.

The OpenRTK330L is the only positioning solution that can boast of a

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June 2020

triple-band RTK/GNSS receiver and a tripleredundant inertial in a single device.

With the OpenRTK330L receiver/sensor, ACEINNA has delivered a cost-effective (a $150 price point), highly accurate (3cm), and dependable positioning solution.

For developers creating mobile robots, drones and autonomous vehicles, the cost/ performance tradeoffs for guidance and navigation systems are now much less stark. RR - Dan Kara

www.designworldonline.com

DESIGN WORLD

PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Advanced Motion Controls adds 15 models of FlexPro high-performance servo drives Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Advanced Motion Controls Inc. U.S. www.a-m-c.com 1987 140+ Product, Technology & Services Innovation Product Introduction

Description: Camarillo, Calif.-based Advanced Motion Controls designs and manufactures compact servo drives for the robotics industry. In 2019, it added six models to its FlexPro product line, and it added nine more in the first quarter of 2020.

Advanced Motion Controls said its drives are designed for high performance, easy connectivity, and functionality in challenging environments, which is important for mobile robots.

The FlexPro line includes a variety of designs because they are used in numerous applications, om industrial automation and collaborative robot arms to autonomous vehicles and automated storage and retrieval systems.

Analysis: Advanced Motion Controls has developed drives that can be used in increasingly specialized robotics applications. They can tolerate vibration and high temperature, use a wide range of voltages for different types of batteries, and be placed nearly anywhere in a device.

THE ROBOT REPORT

The new FlexPro models enable robotics developers and vendors to select precisely the servo drives they need for power and endurance.

The company’s servo drives can be found in surgical robots, orderfulfillment systems, and unmanned military vehicles. RR -- Eugene Demaitre

www.therobotreport.com

June 2020

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Agility Robotics commercializes Digit humanoid robot Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Agility Robotics U.S. www.agilityrobotics.com 2015 11-50 Product, Technology & Services Innovation Product Introduction

Description: Agility Robotics in January 2020 launched the commercial version of Digit, a humanoid robot that costs in the low-mid six figures. Digit’s upper torso includes integrated sensing, computing, and two 4-DOF (degrees-of- eedom) arms that can carry up to 40 lb. Digit also has two 2-DOF feet, sealed joints for outdoor operation, a UN 38.3-certified battery for cargo air shipment, and an API so it can be used as a development platform. Digit navigates semi-autonomously, thanks to lidar and other sensors. Digit is designed for classic dull, dirty, and dangerous manual labor jobs, including basic tasks in warehouse logistics that can have high rates of dissatisfaction, injury, and turnover.

Analysis: Digit is the first humanoid with walking and manipulation capabilities to be sold commercially rather than just to academic institutions. While the utility of humanoid robots has and will still be questioned, perhaps Digit will start changing that tune.

Commercializing Digit is an important milestone for humanoid robots and Agility Robotics, which spun out of Oregon State University in 2015 to specifically

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June 2020

commercialize bipedal locomotion research.

Ford, which purchased the first two Digits, is exploring how the robot could be placed in self-driving delivery vans to carry packages from vans to customers’ front doors. This is what Ford is calling “last-50-feet delivery.”

The automaker is also focusing on how Digit can be used indoors for first-mile logistics. RR -- Steve Crowe

www.designworldonline.com

DESIGN WORLD

APPLICATIONS & MARKETS INNOVATION — Construction/Demolition, Other

AMP Robotics launches Cortex Dual-Robot System for recycling Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

AMP Robotics U.S. www.amprobotics.com 2015 52 Applications & Markets Innovation Construction/Demolition, Other

Description: Louisville, Colo.-based AMP Robotics launched its Cortex Dual-Robot System (DRS) in May 2019.

It is an expansion of its high-speed recycling robots guided by the Neuron platform, which uses computer vision and machine learning to recognize items of different shapes, as well as materials such as metal, paper, and plastic.

The AMP Cortex DRS uses two robots to pick and place materials for recycling around the clock at up to 160 pieces per minute -- twice as fast as human workers. The system can be easily added to existing recycling facilities, and its precision results in a purer stream of post-consumer materials and construction waste.

In September 2019, Single Stream Recyclers LLC (SSR) in Sarasota, Fla., added eight AMP systems to its existing six for sorting fiber in the largest deployment of its kind to date. SSR was able to increase its productivity while moving people to higher value-added roles.

Analysis: The U.S. recycling industry has faced serious difficulties in the past few years, with fewer countries accepting mixed waste for sorting, chronic staff shortages, and the need to keep workers safe. The AMP Cortex DRS allows recyclers to extract materials for better commodity prices and protect people om handling dangerous items.

THE ROBOT REPORT

The ultimate benefit of AMP’s Cortex system is that it reduces the amount of waste going into overstuffed landfills and directs more materials toward recycling and less resource consumption. This could help U.S. industry achieve the economies of scale for profit-driven environmental protection. RR -- Eugene Demaitre

www.therobotreport.com

June 2020

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Apex.AI adapts ROS 2 to autonomous vehicles with Apex.OS software framework Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Apex.AI Inc. U.S. www.apex.ai 2017 38 Product, Technology & Services Innovation Product Introduction

Description: Among the technical hurdles for developers of autonomous vehicles (AVs) is the need for standardized and reliable so ware to build upon. The open-source Robot Operating System (ROS) offers such a code base for robotics developers, and Palo Alto, Calif.based Apex.AI has worked to extend it to the AV so ware stack with Apex.OS. Apex.OS v1.0 is based on ROS 2 and uses more modern programming techniques than those used in electronic control units. This is necessary for the many simultaneous functions of AVs, including sensor fusion, machine learning, and controls.

Apex.AI is working with automakers and Open Robotics, the organization supporting open so ware and hardware, to incorporate the latest features that are relevant to self-driving cars.

Analysis: One of the benefits of an open-source code base is that anyone can contribute to it and help improve its security and reliability. The assurance that Apex.OS provdes can help advance the acceptance and adoption of autonomous vehicles.

The system is the first of its kind to be certified to ASIL-D, the highest level

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June 2020

of functional safety for road vehicles, according to the company.

By adapting ROS 2, which has already gone through an extensive development process for industrial automation, Apex.AI is helping the entire autonomous vehicle space. RR -- Eugene Demaitre

www.designworldonline.com

DESIGN WORLD

BUSINESS & MANAGEMENT INNOVATION — Market Engagement

ARM Institute relocates to new, stateof-the-art facility, further distinguishing Pittsburgh as a robotics powerhouse Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Advanced Robotics for Manufacturing (ARM) Institute U.S. www.arminstitute.org 2017 22 Business & Management Innovation Market Engagement

Description: In July 2019, the Pittsburgh-based ARM Institute (Advanced Robotics for Manufacturing) relocated its headquarters to Mill 19, a redeveloped facility that was part of the former Jones & Laughlin Steel Co. The site had shuttered completely in 1997. The new ARM Institute headquarters is co-located with Carnegie Mellon University’s Manufacturing Futures Initiative in a 90,000-sq.- ., state-ofthe-art facility that offers labs and office space optimized for robotics development.

Analysis: The ARM Institute is one of 14 Manufacturing U.S. Institutes in a national network of linked manufacturing institutions funded by the U.S. Department of Defense with the goal of accelerating advanced manufacturing. Each Manufacturing U.S. Institute has a unique technological concentration.

In the case of the ARM Institute, it is collaborative robotics, sensors, and other technologies for advanced manufacturing.

Constructing the Mill 19 building within the steel ame of one of the largest steel mills in Pittsburgh showcases ARM’s dedication to driving the future of manufacturing while honoring the past.

The sheer size and modern amenities at the Mill 19 facility are sure to spur robotics and automation innovation. Not only could it

THE ROBOT REPORT

ArmInstitute_RBR50_Vs2_ed.indd 69

www.therobotreport.com

benefit manufacturing, a well-funded vertical market sector, but it could also act as a catalyst of all manner of non-manufacturing robotics applications. The new headquarters also makes it easier for ARM to partner with other regional and national stakeholders.

The fact that the ARM Institute is co-located with Carnegie Mellon University’s Manufacturing Futures Initiative makes it easier for ARM’s robotics and workforce projects to take advantage of manufacturing research incorporating artificial intelligence and other digital technologies.

Finally, ARM’s new facility bolsters Pittsburgh’s regional robotics capabilities, and by extension, the global reputation of the Pittsburgh robotics cluster. RR - Dan Kara

June 2020

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6/10/20 8:17 AM

BUSINESS & MANAGEMENT INNOVATION — Social Good

AutoGuide Mobile Robots hires re-trained coal miners as robotics technicians Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

AutoGuide Mobile Robots U.S. www.agmobilerobots.com 2018 60+ Business & Management Innovation Social Good

Description: AutoGuide Mobile Robots, a Massachusetts-based developer of autonomous mobile robots, and its premier integrator, Heartland Automation, have hired 25 former coal miners to fill labor shortages. The displaced miners were retrained and graduated om the Haas eKentucky Advanced Manufacturing Institute (eKAMI) in Paintsville, Ky. Students train on state-of-the-art CNC equipment and are taught so skills for professional development. AutoGuide was acquired by Teradyne in October 2019 for potentially $165 million.

Analysis: eKAMI was started in 2017 by Kathy Walker, who spent many years in the coal business herself, including 15-plus as a member of the National Coal Council, a federal advisory committee that helps shape policies about matters relating to coal. Many coal miners are born into the business, and those living in Appalachia o en live below or straddle the poverty line. In 2008, regulatory pressure om President Obama forced many coal mines to close. The industry

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June 2020

coined this the “War on Coal.”

Robots are o en viewed as a threat to human jobs, but not in this case. This is a great example of how re-skilling helped AutoGuide fill labor shortages and positioned dislocated coal miners for future career success. It also provides a potential blueprint on how to re-skill more displaced coal miners and diversi the local economy by creating additional advanced manufacturing opportunities. RR -- Steve Crowe

www.designworldonline.com

DESIGN WORLD

APPLICATIONS & MARKETS INNOVATION — Healthcare/Rehabilitation

Blue Ocean Robotics builds UV-D disinfection robot Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Blue Ocean Robotics ApS Denmark www.blue-ocean-robotics.com 2013 95 Applications & Markets Innovation Healthcare/Rehabilitation

Description: Even before the COVID-19 pandemic, hospitals needed a way to disinfect rooms without exposing personnel or patients to harmful pathogens or radiation. The novel coronavirus crisis has rapidly escalated demand for disinfection robots worldwide, but only a few companies were ready to satis that demand.

Blue Ocean Robotics began as a robotics integrator and became a full-service robotics company, designing and developing service robots for the agriculture, construction, healthcare, and hospitality markets. As a “venture factory,” it has created divisions to commercialize its technologies. Its UVD Robots unit first sold the UV-Disinfection robot last year a er six years of development.

The UVD robot is an autonomous mobile robot that uses UV-C light to kill up to 99.999% of viruses and bacteria in a patient room in 15 minutes. A Taiwan hospital study conducted over four to six months found that the UVD robot can reduce the number of infections by more than 25%.

Analysis: In the U.S. alone, more than 1.7 million people develop hospital-related infections each year, and 75,000 die om them, according to the Centers for Disease Control. Blue Ocean Robotics has rapidly scaled up production and distribution of the UVD robot, providing it to more than 50 countries in 2020.

In addition to hospitals, the UVD robots can be used in other public spaces,

THE ROBOT REPORT

such as hotels, schools, and airports.

Since the novel coronavirus outbreak, Blue Ocean Robotics’ UVD robot has experienced a quadrupling of sales (and spawned a host of imitators). With thousands of robots expected to be in the field in the next few years, this disinfection robot will continue to be on the ont lines of the fight against pandemics. RR -- Eugene Demaitre

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BUSINESS & MANAGEMENT INNOVATION — Market Engagement

Bossa Nova Robotics expands Walmart deployment to 1,000 stores Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Bossa Nova Robotics U.S. www.bossanova.com 2005 185 Business & Management Innovation Market Engagement

Description: In January 2020, mobile retail robotics supplier Bossa Nova Robotics announced that the company will deploy its shelf-scanning inventory robot to 1,000 Walmart stores in the U.S., up om 350. The deployment should be completed by early fall 2020. Boss Nova initially partnered with Walmart in 2017 with a 50-robot evaluation program.

Analysis: Bossa Nova Robotics was founded in 2005, a spinout om Carnegie Mellon University’s Robotics Institute. The company initially focused on robotic toys. Bossa Nova pivoted to become a data service provider for the retail industry using highly sensored, autonomous mobile robots to detect out-of-stock items, identi mispriced and misplaced items, and more.

Bossa Nova faces competition om a number of other companies that employ robotics as autonomous mobile sensors. The 2017 partnership announcement with Walmart

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was rightly seen as a huge win for Bossa Nova.

At one stroke, it legitimized the company, along with its business model and value proposition.

But it is Bossa Nova’s follow-up expansion of Walmart deployments following initial assessment phase that is most critical.

Walmart is the world’s largest brick-andmortar retailer, with over 1,500 stores and 2 million employees worldwide. It is in the midst of a massive innovation program centered on robots, AI, and data. Bossa Nova Robotics is a key piece of that initiative. RR – Dan Kara

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Boston Dynamics commercializes Spot quadruped robot Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Boston Dynamics U.S. www.bostondynamics.com 1992 101-500 Product, Technology & Services Product Introduction

Description: Boston Dynamics’ Spot quadruped launched in September 2019 through the company’s Early Adopter Program. With mounting rails, payload ports, and an open-source so ware development kit, developers can create custom methods of controlling the robot, design payloads that expand the capabilities of the base robot platform, and integrate sensor information into data analysis tools.

Spot autonomously accomplishes industrial sensing and remote operation needs, while carrying payloads with endurance far beyond aerial drones. Early adopters are in a range of industries, om construction to energy utility, public safety, mining, and entertainment.

Analysis: Quadruped robots have historically been relegated to research labs. The high prices, combined with challenges in agility, control, power consumption and stability, o en make them less reliable and desirable than wheeled mobile robots. Boston Dynamics is hoping to change that and kick-start the commercial quadruped market with

THE ROBOT REPORT

the limited release of Spot. This is not only an important measuring stick for quadruped robots as a technology, but it is also a crucial test for Boston Dynamics’ goals of solving the hard problems in robotics. These efforts have led to major new functionality, as the company focuses on developing robots for realworld applications. RR -- Steve Crowe

www.therobotreport.com

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BUSINESS & MANAGEMENT INNOVATION — Leadership

Built Robotics partners with 400k strong International Union of Operating Engineers Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Built Robotics U.S. www.builtrobotics.com 2016 11-50 Business & Management Innovation Leadership

Description: Built Robotics, a San Francisco-based startup that transforms heavy equipment into autonomous robots with its AI guidance system, partnered with the International Union of Operating Engineers (IUOE). Founded in 1896, the IUOE represents 400,000-plus members, primarily construction workers who work as heavy equipment operators, mechanics, surveyors, and stationary engineers.

The multi-year partnership will train IUOE members to oversee and manage robotic equipment, as well as work alongside autonomous machines. Built Robotics will provide its guidance systems to the IUOE’s International Training & Education Center near Houston. IUOE members will be trained to install, operate, and repair robots in realistic job-site conditions.

Analysis: The construction industry has not been known to embrace cutting-edge technologies with open arms. By partnering with the IUOE, one of the largest and most historic construction institutions in North America, Built Robotics is getting its technology into the hands of more skilled operators. This will help construction workers familiarize themselves with and accept robotic technology, which is o en a barrier to adoption in many industries.

Built Robotics’ technology can help fill an impending labor shortage facing the construction industry. According to the nonprofit National

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Center for Construction Education and Research, many current heavy equipment operators are close to retirement age. The Bureau of Labor Statistics estimates such jobs will grow 10% between 2018 and 2028, twice the rate for all occupations.

Finally, this partnership is noteworthy, as other unions have not embraced automation. In 2017, for example, the International Brotherhood of Teamsters, a union representing truck drivers across North America, helped convince the U.S. Senate to exclude autonomous trucks om dra legislation on self-driving vehicles, which has been a major setback for the technology. RR -- Steve Crowe

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Cruise Origin autonomous vehicle challenges transportation paradigm Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Cruise LLC U.S. www.getcruise.com 2013 1,400 Product, Technology & Services Innovation Product Introduction

Description: Electric and self-driving cars are o en envisioned as more efficient replacements for conventional gasoline-powered, human-driven automobiles. Delivery and ride-sharing services are among the applications, but what if a vehicle was designed om the ground up for a different model of personal transportation?

Cruise, which General Motors Co. acquired in 2016, has been working on autonomous vehicles to improve safety, reduce the environmental impact of transportation, and mitigate urban traffic congestion. In January 2020, Cruise unveiled Origin, a new approach to transportation combining elements of rides on demand with an electrical and fully autonomous vehicle.

The Origin has a modular design with fewer moving parts for a longer lifespan. It is also intended to be comfortable for up to six passengers facing one another. The shuttlebus-like Origin has no steering wheel and was developed in cooperation with GM and Honda Motor Co.

Analysis: Cruise executives said they expect Origin to surpass human performance levels.

Other technology companies and automakers are pursuing self-driving vehicles, but none has so directly challenged the traditional model of individual ownership. GM said it is investing $2.2 billion in its Detroit-

THE ROBOT REPORT

Hamtramck plant in Michigan to manufacture Cruise Origin.

While it’s too soon to say which autonomous vehicles will be technologically viable or commercially successful, Cruise’s Origin is a bold step toward a new mode of transport. RR -- Eugene Demaitre

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BUSINESS & MANAGEMENT INNOVATION — Leadership

CSIRO’S Data61 opens a new robotics innovation center Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Commonwealth Scientific and Industrial Research Organisation (CSIRO) Australia www.csiro.au 1949 5,500 Business & Management Innovation Leadership

Description: In March 2019, Data61, a business unit within Australia’s Commonwealth Scientific and Industrial Research Organisation (CSIRO), opened a new purpose-built research center for robotics and autonomous systems – the Robotics Innovation Centre. The 48,000-sq.- . facility, which is located at CSIRO’s Queensland Centre of Advanced Technologies, features the biggest motion-capture system in the Southern Hemisphere, which used to validate data collected by robotics systems. It also boasts of a 13x5 m pool, which is used for testing aquatic robots, along with a number of unmanned ground vehicles, legged systems, aerial drones, and industrial robots. Data61 representatives indicated that the Robotics Innovation Centre is open for both research and industry use, along with collaborative projects.

Analysis: Australia has a well-deserved reputation as a robotics innovation leader, known for groundbreaking research and commercialization efforts. In particular, the country has expertise in “field robotics” systems for agriculture and mining, along with advanced manufacturing, machine

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learning, and various autonomous systems. The new CSIRO Robotics Innovation Centre solidifies Australia’s international robotics standing. More importantly, the center will directly support ongoing research and help speed robotics commercialization efforts. RR - Dan Kara

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APPLICATIONS & MARKETS INNOVATION — Healthcare/Rehabilitation

Diligent Robotics introduces Moxi mobile manipulator in hospitals Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Diligent Robotics Inc. U.S. www.diligentrobots.com 2017 31 Applications & Markets Innovation Healthcare/Rehabilitation

Description: Healthcare facilities were already understaffed before the COVID-19 pandemic, which has brought new attention to how robots can help improve care by eeing human staffers to attend to patients. A prime example is the Moxi mobile manipulator, which Diligent Robotics began testing in hospitals last year.

Healthcare industry analysts estimate there will be a shortage of 1.1 million registered nurses in the U.S. in 2022, and 9 million in 2030. Moxi is designed to retrieve medical supplies and integrate with hospital systems so that human staffers spend less time running around.

The robot uses machine learning for object recognition and grasping, as well as navigation so ware based on the Robot Operating System (ROS). Moxi also includes components om Fetch Robotics, Velodyne Lidar, Intel, Kinova, and Robotiq.

Moxi is available through a robotics-as-a-service (RaaS) model om Diligent Robotics, and the Austin, Texas-based company raised $10 million in Series A funding in March 2020.

Analysis: Rather than try to perfect a humanoid general-purpose robot or create a system for both patient interaction and materials handling, Diligent Robotics has built an autonomous service robot that can be deployed now to help nurses and other clinicians.

In addition, Moxi can help

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reduce the need for contact among personnel and patients, thereby reducing the risk of infection.

Mobile manipulation has taken a while to arrive in supply chain operations and e-commerce order fulfillment, but the urgency of hospital demand makes Moxi’s arrival especially timely. RR -- Eugene Demaitre

www.therobotreport.com

June 2020

77

APPLICATION & MARKET INNOVATION — Transportation

Energy Robotics and ExRobotics launch mobile robots for remote inspection of oil and gas sites Organization Names: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Energy Robotics and ExRobotics Germany / Netherlands www.energy-robotics.com / www. exrobotics.global 2018 (Energy Robotics), 2015 (ExoRobotics) 5 (ER) / 7 (EX) Application & Market Innovation Transportation

Description: In 2019, Germany-based Energy Robotics and Netherlands-based ExRobotics launched the ExR-1, the world’s first commercially available IECEx/ATEX certified (Ex certified), explosion-proof, mobile ground robotics system for remote inspection for oil and gas (O&G) operations. ExR-1 systems, which can operate in potentially explosive environments, are in daily operation on four continents serving multiple first customers.

Analysis: The O&G industry operates about 100,000 onshore and 9,000 offshore sites. The sector is under intense pressure to improve cost efficiencies, enhance safety, ensure environmental compliance, and increase the digitalization of operations at their sites. Continuous inspection can support these initiatives.

The remotely operated ExR-1, which unlike inspection drones is explosion-proof and robust enough

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to operate in adverse weather and environmental conditions, can provide continuous and detailed multi-sensorial inspection data of O&G facilities. This delivers a more accurate overview of the maintenance state of expensive industrial installations, as well as ensures compliance with environmental regulations, while eliminating any risks of operators being exposed to hazardous materials. RR - Dan Kara

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APPLICATION & MARKET INNOVATION — Mining/Quarrying

Exyn Technologies offers aerial mapping systems for surveying mines Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Exyn Technologies U.S. www.exyn.com 2014 About 50 Application & Market Innovation Mining / Quarrying

Description: In February 2019, Exyn Technologies announced the commercial availability of its Advanced Autonomous Aerial Robot (A3R). It is a fully autonomous aerial system for data collection in GPS-denied environments, including for mapping and inspection of underground mines. Exyn’s exynAI so ware stack allows robots to navigate autonomously and reliably without the need for prior information, persistent communication, or in astructure of any kind. They can generate detailed maps using 3D lidar and work together as a collaborative swarm. Last year, Exyn deployed its A3Rs as a service for customers in the U.S., Latin America, and Europe.

Analysis: For mining operations, underground cavities must be continually analyzed to determine the success of drill and blast exercises. These areas are o en over a kilometer underground, extremely dangerous, and constantly changing.

Current technology requires workers to be dangerously close to the edge of an open slope, takes over an hour to use, and can only gather data visible at

THE ROBOT REPORT

the base of the cavity. By flying pilotless robots that do not require GPS or consistent communications into these cavities, Exyn is able to produce information-rich 3D maps that can dramatically improve a mine’s dayto-day operations and safety. The maps also help mine operators better understand their own project needs to improve resource planning. RR - Dan Kara

www.therobotreport.com

June 2020

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

FAULHABER MICROMO releases compact BXT flat brushless DC motors Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

FAULHABER MICROMO LLC U.S. www.faulhaberusa.com 1961 81 Product, Technology & Services Innovation Product Introduction

Description: FAULHABER MICROMO recently became part of the FAULHABER Drive Systems division. Among the products that FAULHABER MICROMO has launched in the past year or so is the BTX flat brushless DC motor series.

The BXT’s compact design makes it suitable for medical devices and robotics, and FAULHABER can customize its electrical and mechanical interfaces for different industrial applications.

The external rotor BXT can provide continuous output of 100 W and up to 134 mNm of torque. The motors also come in a variety of gearhead, encoder, and diameter options, as well as with digital Hall sensors that are designed for up to 10,000 rpm. It can come with or without housing.

Analysis: FAULHABER is already known for its high-precision components for medical, manufacturing, telecommunications, aerospace, and robotics applications. With the BXT line, Clearwater, Fla.based FAULHABER MICROMO supplies a full range of

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miniature and micro motion systems.

The BXT series uses highperformance, rare-earth magnets to delivery high torque with a short drive, putting power where it is needed for robotics developers. RR -- Eugene Demaitre

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APPLICATION & MARKET INNOVATION — Product Introduction

Fetch Robotics WorkFlow Builder simplifies deployment of mobile robot fleets Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Fetch Robotics U.S. www.fetchrobotics.com 2014 51-200 Application & Market Innovation Product Introduction

Description: Fetch Robotics launched in March 2020 its Workflow Builder toolkit, which allows customers to design, implement, and redesign their own workflows for Fetch’s autonomous mobile robots (AMRs). Based on Blockly programming, Workflow Builder features a drag-and-drop interface that non-programmers can learn. WorkFlow Builder allows customers to deploy AMRs in days, doing all the work in-house without the need to rely on third-party integrators.

Although Workflow Builder is used for device, warehouse management system (WMS), and warehouse execution system (WES) integration, it is not dependent on the use of a WMS or WES. It can be deployed with WMS-related workflows such as picking and putaway, or workflows completely outside the WMS such as pack station replenishment, empty tote return, or recycling removal.

Analysis: Designing for ease of use is a growing mantra of the robotics industry. In fact, Fetch Robotics CEO Melonee Wise at RoboBusiness Europe 2017 called ease of use the next big challenge for robotics. Fetch’s WorkFlow Builder is certainly a major step in the right direction.

It is now easier than ever for Fetch’s customers to design, install, and maintain their fleets of AMRs. Many other types of robots still require the expertise of third-party integrators

THE ROBOT REPORT

for initial setup and reprogramming when workflows change. This work is costly, disruptive, and does not guarantee that automation workflows will meet ROI expectations.

WorkFlow Builder helps lower several barriers to adoption by simpli ing integration and re-programming efforts, lowering overall system cost, enabling system flexibility, and shortening the return on investment. RR -- Steve Crowe

www.therobotreport.com

June 2020

81

PRODUCT, TECHNOLOGY & SERVICES — Product Introduction

Formant puts data collection, analysis, and robot management in the cloud Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Formant Inc. U.S. www.formant.io 2017 18 Product, Technology & Services Product Introduction

Description: An emerging challenge for enterprise robotics users is analyzing the data gathered and generated by fleets of robots. Formant.io provides the analytics platform, which presents application data in a single Web-based user interface.

Formant’s cloud software enables organizations to monitor robot fleets in real time, look deeply into their operations, and take remote control of individual robots if needed.

The San Francisco-based company said its monitoring, analytics, and intuitive interface can help healthcare, maintenance, construction companies and more.

Analysis: As mobile robots and other hardware gradually commoditize, the value of automation lies in analyzing and acting upon business data. Formant has created a platform that is ready to handle increasingly complex tasks and robot configurations while focusing on delivering actionable information to end users.

Even as systems gain more autonomy,

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humans will still need to be “in the loop” for higher-level decisions, particularly those affecting mission-critical enterprise functions.

With automated analytics and annotated data, Formant’s platform allows humans to work with robots in real time while also having instant access to relevant historical data. RR -- Eugene Demaitre

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APPLICATIONS & MARKETS INNOVATION — Logistics

Gatik Level 4 autonomous vehicles tackling middle-mile logistics for retailers Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Gatik U.S. www.gatik.ai 2017 11-50 Applications & Markets Innovation Logistics

Description: Palo Alto, Calif.-based startup Gatik came out of stealth mode in July 2019 to address the pain point of middle-mile logistics for businesses. Middle-mile delivery is the most expensive part of the whole supply chain for businesses. With the rise of e-commerce and a short supply of drivers, businesses are struggling to meet the consumer expectations of an increasingly on-demand economy.

Gatik’s Level 4 autonomous vehicles, which include light trucks and vans, operate on fixed, repeatable routes about 15 times per day. The autonomous vehicles are restricted to the rightmost lane as o en as possible to eliminate technical challenges such as unprotected le turns.

However, if needed, its vehicles will operate in le lanes and are capable of making lane changes and unprotected le turns. The vehicles also avoid routes with fire stations, hospitals, and schools to avoid unpredictability.

Analysis: Gatik is implementing its solution with major retailers in North America, including Walmart, the world’s largest retailer. Gatik’s vehicles are responsible for shuttling groceries om a Walmart Supercenter to Neighborhood Stores in Bentonville, Ark. The company is helping retailers like Walmart reduce the high cost of middle-mile logistics, while improving safety, increasing efficiency, and reducing

THE ROBOT REPORT

congestion and emissions. Gatik claims it makes “millions” per year in revenue.

The partnership and approach to autonomy are unique in the autonomous vehicle industry. They are also proof that commercialization and scalability of autonomous vehicles could happen first in B2B short-haul logistics and that viable business models do not require SAE Level 5 full autonomy. RR -- Steve Crowe

www.therobotreport.com

June 2020

83

BUSINESS MANAGEMENT — Leadership

Geek+ expands globally, provides 10,000 mobile robots as a service Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Geekplus Technology Co. Beijing www.geekplus.com 2015 438 Business Management Leadership

Description: The global market for autonomous mobile robots (AMRs) is growing quickly, with many players and plenty of room for growth, thanks to accelerating e-commerce demand.

Geekplus Technology Co. marked several milestones in the past year, including deploying more than 10,000 AMRs worldwide, working with major brands, and opening new offices in San Diego and Dusseldorf, Germany.

Geek+ also launched its RoboShuttle system for multi-level, goods-to-person automation and opened a factory that uses its own robots to build more robots. The Beijing-based company offers its AMRs through a robotics-as-a-service (RaaS) model.

It raised $150 million in Series C1 funding last July.

According to Interact Analysis, Geek+ has become the No. 1 supplier of AMRs in the world, with 10% market share. Its customers include Decathlon, Dell, Nike, and Walmart.

Analysis: Geek+ said its mobile robots can replace traditional conveyor belts and provide scalable and flexible production. On Nov. 11, 2018, or “Singles Day” in China, Geek+ helped deliver 8.11 million orders within 72 hours at a rate nearly double that of manual 3PL (third-party logistics) warehouses.

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The company has carefully cultivated major customers and partners, applying its understanding of their capabilities to new applications. By using this know-how in its own production lines, Geek+ promises to scale to satis global demand for fast, accurate deliveries. RR -- Eugene Demaitre

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BUSINESS MANAGEMENT INNOVATION — Leadership

Harmonic Drive opens a new manufacturing and R&D facility Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Harmonic Drive LLC U.S. www.harmonicdrive.net 1960 154 Business Management Innovation Leadership

Description: Harmonic Drive, a leading producer of servo actuators, gearheads and gear components, opened a newly constructed, purpose-built headquarters and manufacturing facility in Beverly, Mass., in January 2020. Approximately two-thirds of the 97,000-sq.- . facility is dedicated to manufacturing. The space is also optimized for gear production and parts flow. This includes flooring specifically engineered for the heavy equipment and specialized machinery used to manufacture high-precision gears. The site also includes clean rooms, test labs, assembly rooms, a painting chamber, and more.

Analysis: The new Harmonic Drive facility more than doubles the square footage of the location it replaced.

Company representatives have stated that the new plant will allow it to increase its manufacturing capacity by several hundred percent, partially in anticipation of strong robotics sector growth. They also noted that the state-of-the-art

THE ROBOT REPORT

Harmonic%20Drive_RBR50_Vs2REV_ed.indd 85

site will allow Harmonic Drive to manufacture more efficiently, and thereby increase production capacity and lower overall costs. The state-ofthe-art facilities will also enable the company’s R&D engineering team to design, test, and deliver prototypes and products faster for both standard and custom-engineered systems. RR -- Dan Kara

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PRODUCT, TECHNOLOGY & SERVICES INNOVATIONS — Production Introduction

Intel announces low-cost, high-resolution RealSense LiDAR Camera L515 Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Intel U.S. www.intelrealsense.com 1968 110,000 Product, Technology & Services Innovation Production Introduction

Description: The Intel RealSense LiDAR Camera L515, which is optimized for indoor applications such as warehouse robotics, features a proprietary micro-electro-mechanical system (MEMS) for enhanced precision and resistance to shock, temperature fluctuations, and vibration. The L515 captures 9.2 million depth points per second in 640 x 480 resolution, with a 95% reflectivity range of 0.25 to 9 m. It also captures 23.6 million depth points per second in 1024 x 768 resolution, with a 95% reflectivity range of 0.25 to 6.5 m.

An included RGB camera with a rolling shutter, the OV2740 CMOS image sensor om OmniVision, provides up to 1920 x 1080 resolution at up to 30 fps. An inertial measurement unit with accelerometer and gyroscope is included, and processing is achieved via an Intel RealSense Vision ASIC.

Analysis: At just 61 x 26 mm in size and 100 g in weight, the L515 packs a power technological punch into a small form factor. Intel claims this is the world’s smallest, most powerefficient high-resolution lidar. It is also one of the most cost-efficient lidar sensors, starting at $349.

While Intel’s RealSense cameras

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are popular among robotics developers, the L515 marks its first product that incorporates solid-state lidar technology, which is a sensor without moving parts, into a depthsensing camera. But the combination of low cost and high resolution make it an ideal lidar option for indoor robotics applications. RR -- Steve Crowe

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BUSINESS & MANAGEMENT INNOVATION — Leadership

iRobot diversifies its manufacturing supply chain Company / Group Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

iRobot Corp.

U.S. www.irobot.com 1990 1,000+ Business & Management Innovation Leadership

Description: iRobot, the market leading producer of robotics vacuum cleaners and other consumer robotics products, announced in November 2019 that manufacturing operations in Malaysia had commenced. iRobot representatives indicated that the Malaysia manufacturing expansion was the result of the company’s strategic supply chain diversification initiative.

Analysis: Many U.S. manufacturers are actively diversi ing their supply chain and manufacturing locations as they seek alternatives outside of China to reduce exposure to continuing trade issues. For example, the 25% levies against Chinese imports raise the cost of manufactured goods, iRobot’s vacuums among them, which results in reduced unit sales.

In the announcement describing the Malaysia move, iRobot noted that project was completed om start to finish in less than a year and ahead of schedule, a huge undertaking and

THE ROBOT REPORT

accomplishment. iRobot also highlighted the assistance it had received om manufacturing solutions provider Jabil.

Jabil has been an iRobot partner since 2006, when it first began supplying parts for iRobot’s mobile robots for defense applications.

The corporate partnership was key to the iRobot expansion. In addition to providing manufacturing outsourcing competency, Jabil’s large size, global reach, and massive buying power ensures a vast, diversified supplier base. RR -- Dan Kara

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June 2020

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Production Introduction

KINOVA’s Gen3 family of robotic arms supports research efforts and spurs commercial development Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

KINOVA Canada www.kinovarobotics.com 2006 160+ Product, Technology & Services Production Introduction

Description: Following several years of research and development work, and in close collaboration with research centers worldwide, in January 2019, KINOVA announced the commercial launch of the KINOVA Gen3 robotic arm. It is a 7-DoF (degrees-of- eedom), lightweight (carbon-fiber) collaborative robotic arm specifically engineered for research and commercial labs. The Gen3 system boasts of embedded 2D (RBG) and 3D (Intel RealSense) vision, and an interface module offering a variety of options for connectivity and end effector development. In March 2020, the company extended the Gen3 line with the Gen3 Lite, an ultralight arm designed for light manipulation tasks.

Analysis: Academic and commercial R&D efforts are the wellspring of most robotics innovation, including early experimentation and development for commercial-class robotics systems. Collaborative robotics arms are commonly employed as research tools, but the suppliers of most cobots consider research to be a secondary or tertiary target market a er the manufacturing, logistics, and other commercial sectors.

Since its founding, KINOVA focused on supplying highly versatile, off-the-shelf robotics technologies for academic and commercial R&D -- initially, personal assistance systems.

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The company has been working with partners to provide robotics solutions for challenging, typically low-volume applications.

This approach has resulted in KINOVA arms acting as adaptable research tools for many commercial solutions, or as the platform on which a wide range of commercial systems and applications are built. Examples include bomb disposal and hazmat robots, surgical systems, field robotics technologies and more.

With the release of the Gen3 and Gen3 Lite systems, robotics innovation will be better supported in just this way. RR -- Dan Kara

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APPLICATIONS & MARKETS INNOVATION — Logistics

Locus Robotics expands partnership with DHL Supply Chain Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Locus Robotics Inc. U.S. www.locusrobotics.com 2014 51-200 Applications & Markets Innovation Logistics

Description: Locus Robotics and DHL Supply Chain expanded their partnership to include 10 new deployments of the LocusBots autonomous mobile robots (AMRs) across U.S. locations throughout the rest of 2020. With the agreement, DHL Supply Chain, part of the Deutsche Post DHL Group, will have 1,000 LocusBots supporting 12 DHL sites in North America. The two companies initially partnered in 2017 to pilot the LocusBots to support associates in piece-picking order fulfillment in warehouses.

The AMRs navigate autonomously within a warehouse to quickly locate and transport pick items to associates. The robots can support a range of picking strategies, helping to reduce time spent on routine or physically demanding tasks, reducing manual errors and increasing productivity for customers.

Analysis: Out of all of its customers, which include Boots, GEODIS, Port Logistics, Radial, Verst Logistics and many others, the DHL Supply Chain partnership has proven Locus’ approach to logistics robotics the most. DHL has piloted many of Locus’ competitors. In fact, the entrance to DHL’s Innovation Center in Chicago prominently displays the logos of the many logistics automation companies it has worked with over the years.

DHL Supply Chain announced in 2018 a multi-year plan to invest $300 million in

THE ROBOT REPORT

emerging technologies in its North American operations. Locus has capitalized on this opportunity.

DHL’s initial implementation of the LocusBots within the life sciences and retail sectors saw increases in fulfillment productivity of up to 80%. This new expansion is a direct result of proven customer success.

Earlier in 2020, Locus surpassed its 100 millionth pick with its LocusBots. And the pick happened at a DHL Supply Chain fulfillment facility in Hanover, Pa. RR -- Steve Crowe

www.therobotreport.com

June 2020

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BUSINESS MANAGEMENT INNOVATION — Business Models

MassRobotics expands robotics innovation center to nurture innovations in industrial automation, human-machine interaction Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

MassRobotics U.S. www.massrobotics.org 2017 7 Business Management Innovation Business Models

Description: In November 2019, MassRobotics, an independent, non-profit organization serving as an innovation hub for robotics and smart connected devices, formally opened a 25,000-sq.- . addition to the existing MassRobotics facility in Boston’s Seaport District. The expansion was funded by a $2.5 million grant om the state of Massachusetts, with equivalent funding coming om MassRobotics’ corporate partners.

Analysis: A er two years of concept planning and development, in early 2017, MassRobotics officially opened an initial 15,000-sq.- . robotics innovation center. Within the first six months, the facility attracted 18 startups om around the US, which grew to 34 companies by mid-2019.

The MassRobotics expansion nearly doubles the size of the original workspace. The most critical driver for the success of MassRobotics initiative is the organization’s business model, in which resident startups are provided with much more than space to work.

Under the MassRobotics program, tenant companies have access to state-of-the-art electronic and mechanical prototyping labs, including a variety of 3D printers, soldering stations, oscilloscopes, laser cutter, mini-CNC, and other machine tools.

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www.designworldonline.com

The expanded space also includes industrial automation labs equipped with conveyor belts, a variety of robotic arms and other manufacturing technologies.

In addition, the center has common robotics platforms, om collaborative robot arms to autonomous mobile robots and even humanoids, that residents can borrow and experiment with.

MassRobotics offers its tenants CAD and other design and development tools om vendors such as AutoDesk, SolidWorks, MathWorks, Amazon AWS and Google.

Finally, MassRobotics’ expert staff can provide personal Introductions to investors, corporate partners, potential customers, manufacturers, and technical and business talent. RR -- Dan Kara

DESIGN WORLD

BUSINESS MANAGEMENT INNOVATION — Market Engagement

maxon precision motors opens new manufacturing facility, expands capabilities Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

maxon precision motors U.S. www.maxongroup.com 1961 3,000+ Business Management Innovation Market Engagement

Description: In March 2019, maxon precision motors, a subsidiary of Switzerland based maxon motors, opened a new 59,000-sq.- . engineering and manufacturing facility in Fall River, Mass. The site also includes conference areas, design spaces, and offices. Company representatives indicated that maxon planned to add employees at the site.

Analysis: maxon motors has a well-earned reputation as a producer of high-quality, precision motors, gearheads, encoders, and controllers. They are used in a variety of commercial robotics systems, some of them the most recognizable in the world including NASA’s Mars rovers and Robonaut humanoid. maxon drive systems are also used in medical devices, industrial systems, tools, and other products.

North America, particularly the U.S., is maxon’s largest market. The previous maxon motors facility, also located in Massachusetts, provided sales, distribution, and assembly operations for maxon’s

THE ROBOT REPORT

North American customers.

With the new building, maxon will increase its North American capabilities to include not only manufacturing, but also design and engineering. The new building includes an electronics and machine shop, and prototyping and modeling space maxon also said that it intends to work with domestic suppliers for their engineering projects and that local customers will be able to work with maxon engineers developing new solutions, including dedicated, customerspecific products. RR -- Dan Kara

www.therobotreport.com

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Microsoft Windows 10 supports Robot Operating System Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Microso Corp.

U.S. www.microso .com 1975 150,000+ Product, Technology & Services Innovation Product Introduction

Description: At its 2019 Build Conference, Microso announced that Windows IoT Enterprise now supported Robot Operating System (ROS), the widely used open-source platform that provides robotics developers with a variety of powerful libraries and tools for developing and deploying robotics solutions. Prior to this, the ROS developer community had built kludgy workarounds for Windows. ROS had mainly been running on operating systems such as Linux and an experimental version of MacOS.

Analysis: The partnership between Microso and Open Robotics, the company behind ROS, is mutually beneficial. For Microso , ROS for Windows 10 is an opportunity to expose its Azure cloud platform, and associated products, to ROS developers around the world.

This will help Microso bring innovations in edge computing to robots.

ROS for Windows 10 also creates a more familiar, user- iendly development environment. For example, ABB recently released ROS nodes for Windows. ABB roboticists can bring up ROS and RobotStudio, the company’s simulation and offline programming so ware, on the same Windows machine to commission

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the robot and run simulations. This means the simulation tests are now more realistic because the virtual controller running on RobotStudio truly mimics the capabilities of the robot controller. It is also easier for business developers to work on one computer rather than switch among multiple machines.

There also was a time when Microso was anti-open source. In 2001, Microso ’s thenCEO Steve Ballmer said, “Linux is a cancer that attaches itself in an intellectual property sense to everything it touches.”

Many robots run on Linux, and Microsoft has had a change of heart over the years. RR -- Steve Crowe

www.designworldonline.com

DESIGN WORLD

APPLICATIONS & MARKETS INNOVATION — Manufacturing

New Scale Robotics introduces Q-Span Automated Small-Part Measurement Systems Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

New Scale Robotics U.S. www.newscalerobotics.com 2002 11-50 Applications & Markets Innovation Manufacturing

Description: New Scale Robotics in March 2020 introduced its Q-Span Automated Small-Part Measurement Systems for quality control (QC) teams in high-mix, small-batch manufacturing environments. Q-Span combines robotic pick-and-place with automated measurement of small parts. Q-Span can pick small parts weighing up to 3.5 oz. (70.8 g) and measuring up to 3.94 in. (10 cm). Measurement resolution is 0.0001 in. (0.0024 mm), with better than 0.0002 in.

(0.005 mm) repeatability and 0.0006 in. (0.015 mm) accuracy.

Each Q-Span workstation includes up to three New Scale Robotics gripper/calipers with part-specific metrology fingertips, modular trays for parts-in and parts-out, a measurement fixture and zero-reference fixture with gauge block, and a worktable. New Scale integrates a six-axis UR3e e-Series cobot arm om Universal Robots (purchased separately) into the workstation and creates the scripts for each customer’s first part.

Analysis: Q-Span helps accelerate robotics sector growth by introducing affordable automation to a new audience in manufacturing -- the QC department of high-mix, small-batch manufacturing companies. Until now, the use of cobots in these companies has been concentrated on materials handling and assembly. Customers will see improvements in measurement consistency and the ability to maintain or increase throughput without adding headcount.

THE ROBOT REPORT

Q-Span also helps accelerate cobot adoption by offering a complete, applicationspecific solution. The QC team does not need to have an automation specialist, learn about cobots, or identi the right combination of cobot, end-of-arm-tooling, and accessories.

Q-Span is also the first application kit for quality inspection to be certified by cobot leader Universal Robots and featured on the UR+ platform. RR -- Steve Crowe

www.therobotreport.com

June 2020

93

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APPLICATIONS & MARKETS INNOVATION — Transportation

Nuro upgrades R2 autonomous vehicle development platform, obtains dual exemptions for on-road testing Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Nuro AI U.S. www.nuro.ai 2016 200+ Applications & Markets Innovation Transportation

Description: In February 2020, Nuro AI became the first American autonomous vehicle developer to be given exemptions by the U.S. National Highway Traffic Safety Administration (NHTSA) for testing on public roads without the need to have controls for human operators.

In April, Nuro received a second permit, this time granted by the state of California, allowing the company to test its second-generation test platform, the Nuro R2, on certain public roads in sections of nine cities within Santa Clara and San Mateo counties.

Analysis: The NHTSA and California exemptions are a step in the right direction and an important milestone in the development of SAE Level 4 automation on the road.

The Nuro R2 itself is a significant upgrade on the earlier R1 vehicle, weighing nearly twice as much

THE ROBOT REPORT

at 1,150 kg to the R1’s 680 kg. It is designed for a payload of up to 190 Kg (418 lb.). The R2, which is described as an SAE Level 4 vehicle, began testing at the end of February, joining the fleet of Toyota Priuses that Nuro uses for autonomous vehicle testing. RR - Dan Kara

www.therobotreport.com

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PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

NVIDIA debuts the Jetson Xavier NX, a credit card-sized supercomputer for AI at the edge Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

NVIDIA U.S. www.nvidia.com 1993 13,200+ Product, Technology & Services Innovation Product Introduction

Description: In November 2019, NVIDIA launched the latest entry into the company’s Jetson portfolio of embedded processors, the Jetson Xavier NX, a powerful, low-power edge-computing platform for machine learning inferencing. With a form factor smaller than the size of a credit card, the Jetson Xavier NX delivers up to 21 terra operations per second (TOPS) for running artificial intelligence workloads. It consumes as little as 10 watts of power. The NX can also run multiple neural networks in parallel and process data om multiple sensors simultaneously.

Analysis: The Jetson Xavier NX, like all Jetson family members, is enabled and supported by NVIDIA’s programming model and solution stack. For example, all Jetson developers can use NVIDIA’s CUDA-X GPU acceleration libraries for data science and machine learning. The same holds for NVIDIA’s JetPack (including CUDA, cuDNN, and TensorRT) and DeepStream so ware development kits.

The Jetson family is also agnostic regarding machine learning, supporting the most widely used ameworks, such as TensorFlow, PyTorch,

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Caffe, and MXNet and their “lite” equivalents, as well as less-common libraries and tools.

For developers of commercial robots, drones, and other edge computing devices that demand high performance, but are constrained by power and size considerations, the Jetson Xavier NX checks all boxes and at a very affordable price ($399).

While it is ideally suited as an Internet of Things edge device, the NX is primarily engineered to support AI on the edge – really machine learning/deep learning on the edge. RR -- Dan Kara

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DESIGN WORLD

PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

OnRobot’s One System Solution provides a unified interface for end-of-arm tooling Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

OnRobot Denmark www.onrobot.com 2015 101-500 Product, Technology & Services Innovation Product Introduction

Description: OnRobot’s One-System Solution provides a unified interface for end-of-arm tooling (EOAT). It allows OnRobot’s cameras, grippers, and sensors to work with leading robot brands, including ABB, Doosan, FANUC, Hanwha, Kawasaki, KUKA, Nachi, Techman, Universal Robots, and Yaskawa.

All OnRobot products now have an integrated mechanical and communications interface based on the OnRobot Quick Changer. An additional Dual Quick Changer incorporates these same capabilities while allowing the use of two tools in one cycle, mixing and matching to suit application needs and maximizing robot utilization.

Analysis: OnRobot’s goal is to become the one-stop shop for collaborative EOAT. Its approach to doing so is transforming the market by moving the focus om the robot to the customer’s applications. OnRobot said its EOAT technologies reduce engineering time and get customers’ collaborative applications up and running almost immediately.

The One System Solution ees up manual labor om many “dull, dirty, and dangerous” tasks, allowing workers to put

THE ROBOT REPORT

their skills to better use with more valueadded tasks, according to the company.

With the One System Solution, all of OnRobot’s products are multipurpose solutions that can be attached, programmed, and changed in minutes, supporting faster production line changes.

The One System Solution is another example of OnRobot’s continued innovation and disruption of the EOAT market since it was founded in 2015. RR -- Steve Crowe

www.therobotreport.com

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APPLICATIONS & MARKETS INNOVATION — Forestry

Robotics Plus automates log scaling; increased productivity and reduced injuries result Organization: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Robotics Plus New Zealand www.roboticsplus.co.nz 2008 40+ Applications & Markets Innovation Forestry

Description: In June 2019, New Zealand-based Robotics Plus, an agricultural robotics and automation supplier, launched its Automatic Log Scaler (ALS), the world’s first automated logging truck scaler. The ALS uses a robotic arm to scan truck loads. Using machine learning techniques, the system quickly provides an accurate volumetric measurement of logs on trucks and trailers, along with generating an audit trail. By the end of 2019, the company had finished seven installations in several locations in New Zealand, with another six planned for 2020.

Analysis: The logging industry is under intense pressure to improve efficiency, productivity and safety. The critical forestry supply chain process of measuring log volumes on trucks is normally a manual operation that is slow and repetitive. It can also be dangerous -people are o en required to climb at risky heights over muddy and wet vehicles. These challenges are exacerbated by chronic labor shortages and other inefficiencies.

According to Robotics Plus, the ALS can process a logging truck between 3.5 to 4.5 minutes with an accuracy that exceeds manual methods. This compares favorably

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with the manual process, which takes an average of 18 minutes, and sometimes up to 40 minutes. Productivity benefits are amplified when fleet utilization is accounted for (trucks waiting to be measured).

The ALS solution demonstrates how robotics and automation can positively impact society by transforming traditional industries facing increasing labor shortages, higher costs, supply chain inefficiencies and growing demand. Automating dirty, dull, and dangerous manual tasks also creates opportunities for higher value roles and labor upskilling. RR -- Dan Kara

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DESIGN WORLD

Product, Technology & Services — Product Introduction

Sarcos Robotics commercializes Guardian XO full-body exoskeleton for industrial use Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Sarcos Robotics U.S. www.sarcos.com 2015 98 Product, Technology & Services Product Introduction

Description: While researchers have been developing wearable robotics for therapeutic uses for years, industrial exoskeletons have emerged only recently. Such technologies promise to relieve fatigue and augment human capabilities. Sarcos Robotics began delivering its Guardian XO last year and demonstrated the exoskeleton with partner Delta Air Lines at CES 2020.

Salt Lake City-based Sarcos has been developing its exoskeleton for more than 20 years with initial funding om the Defense Advanced Projects Agency (DARPA). The Guardian XO can help humans li 35 to 200 pounds and reduce the risk of injury. It is also designed to be worn for an entire shi and can run for up to eight hours on a single charge.

Sarcos said Guardian XO is the first full-body commercial exoskeleton in the U.S. It is designed to address labor shortages and occupational safety hazards in industries including aerospace, construction, defense, logistics, and manufacturing. The exoskeleton is currently in alpha testing, and the company expects to deliver it via a robotics-as-a-service (RaaS) model later this year.

Analysis: Labor shortages and worker safety have posed challenges for a variety of industries, but powered exosuits remained science fiction until Sarcos developed comfortable and compact systems. The Guardian XO bears its own weight and is designed to be adjustable according to the size of the wearer.

Sarcos has worked with its Exoskeleton Technical Advisory Group (X-TAG), which

THE ROBOT REPORT

includes executives om companies such as Bechtel, BMW, Caterpillar, and Delta to ensure that its exoskeletons meet their needs.

Among the benefits of Sarcos’ Guardian XO is that it could enable a wider and more diverse talent pool to engage in heavy li ing without risk of injury. The commercial exoskeleton is a milestone in technologies to assist human strength and endurance. RR -- Eugene Demaitre

www.therobotreport.com

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Product, Technology & Services — Product Introduction

SCHUNK EGL-C provides high gripping forces while complying with global safety standards Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

SCHUNK GmbH Germany www.schunk.com 1945 500+ Product, Technology & Services Product Introduction

Description: Introduced in March 2019, the EGL-C gripper surpasses the typical force-limited 140 N used by most collaborative grippers in accordance with safety standard ISO/TS 15066. It achieves high gripping forces up to 450 N, offers a long stroke of 42.5 mm per finger, and handles workpiece weights up to 2.25 kg. The gripper force is limited to <140 N while the fingers are in motion. Only when the gripper fingers are within 4 mm of gripping the workpiece can the force be increased up to 450N. The EGL-C combines six safety functions -- an integrated, safe path-measuring, a safe position detection of the gripper fingers, a safe switch-off, a safe brake control, a safe operating system architecture, and a safe movement and speed control.

Analysis: SCHUNK has time and again introduced innovative grippers for the global market, and the EGL-C is no exception. SCHUNK’s EGL-C is one of the world’s first longstroke grippers designed for humanrobot collaboration (HRC). The gripper

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helps open up HRC to applications that involve weights beyond small parts assembly. The EGL-C will prove beneficial for the automotive, automotive relatedsupply industry and other industrial applications. RR -- Steve Crowe

www.designworldonline.com

DESIGN WORLD

Product, Technology & Services — Product Introduction

Sense Photonics launches Osprey, a novel 3D flash lidar system for automotive applications Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Sense Photonics U.S. www.sensephotonics.com 2016 1000+ Product, Technology & Services Product Introduction

Description: Fast on the on the heels of its $26 million Series A round in June 2019, Sense Photonics in January 2020 formally launched Osprey, a “modular,” high-resolution 3D flash lidar system for automotive applications that provides for a 80 degree x 75 degree field of view and has a range of 15 m. The units consist of two components, a laser emitter, and a separate sensing unit (the 3D receiver) which simplifies installation and allows for positioning flexibility.

Analysis: Sense Photonics’ proprietary laser and sensing solution provides advantages over both standard lidar solutions and other 3D flash lidar providers. The company’s laser array and 3D receiver provides for an ultra-wide field of view, and the images themselves do not suffer from motion distortion. It is also possible to combine Osprey with 2D cameras to create a 2D textural image overlaid with 3D depth imagery.

Sense Photonics also produces its own

THE ROBOT REPORT

advanced laser emitters that overcome earlier drawbacks to flash lidar sensors – namely, high cost, along with limited range and resolution. These attributes map to Sense Photonics’ primary value proposition – namely, high-performance delivery of quality data at low cost – which is especially well suited to automotive safety systems such as collision avoidance and lane-departure warning systems, as well as with autonomous driving in general. RR -- Dan Kara

www.therobotreport.com

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Product, Technology & Services â&#x20AC;&#x201D; Product Introduction

Sevensense Roboticsâ&#x20AC;&#x2122; Alphasense Core visual sensing solution born out of necessity Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Sevensense Robotics Switzerland www.sevensense.ch 2018 30+ Product, Technology & Services Product Introduction

Description: In the fall of 2019, Sevensense Robotics, a spin-off om the Swiss Federal Institute of Technology, ETH Zurich, released Alphasense Core, an advanced multi-camera sensor designed specifically for robotics applications. The Alphasense Core consists of up to eight high-resolution cameras that can be flexibly mounted around a robot to ensure the best positioning on the system, depending on the target application. The cameras are all precisely mid- ame, synchronized together with a motion sensor to provide high quality, 360-degree spatial awareness, even in suboptimal lighting conditions.

Analysis: The Alphasense Core had its genesis at ETH Zurich, and was the product of more than a decade of research and development.

ETH researchers were dissatisfied with the sensing capabilities and reliability of the 2D lidars typically employed for sensing on mobile robots, as well as with vision-based navigation solutions that required complex

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and costly so ware and hardware.

Born out of necessity, Sevensense Roboticsâ&#x20AC;&#x2122; Alphasense Core provides robotics developers with a powerful, configurable multi-camera sensing solution. It also provides another sensing option when developing advanced robotics systems. RR -- Dan Kara

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DESIGN WORLD

Product, Technology & Services — Product Introduction

SICK launches extra-compact, 2D safety laser scanner Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

SICK Germany www.sick.com 1946 10,200 Product, Technology & Services Product Introduction

Description: In early 2020, SICK released its smallest 2D safety sensor to date - the SICK nanoScan3.

The nanoScan3, which measures just 101 x 101 x 80 mm, and has a field range of three meters with a scanning angle of 275-degrees. The device offers a choice of eight (Core version) or up to 128 (Pro version) configurable fields, including navigation data and contour-detection fields.

Analysis: SICK representatives describe the nanoScan3 as the world’s smallest safety laser scanner. Be that as it may, at only 80 mm in height (8 cm or 3.1 in.), the small size of the nanoScan3 allows the sensor to be easily sited into locations other than open, fixed in astructure.

In fact, the device is particularly well suited for integration into both fixed and mobile robotics systems,

THE ROBOT REPORT

according to the company.

The nanoScan3 is based on SICK’s proven safeHDDM (High Definition Distance Measurement) scanning and evaluation technology, which allows the sensors to operate under difficult conditions such as dust or variable lighting. This enables it to meet another requirement for use in robotics systems. RR -- Dan Kara

www.therobotreport.com

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BUSINESS & MANAGEMENT INNOVATION â&#x20AC;&#x201D; Market Engagement

Silicon Valley Robotics celebrates a decade of robotics cluster stewardship and success Orgaanization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Silicon Valley Robotics U.S.A. www.svrobo.org 2010 About 10, plus volunteers Business & Management Innovation Market Engagement

Description: This year, non-profit organization Silicon Valley Robotics (SVR), is celebrating a decade of successfully accelerating robotics outreach, innovation, and commercialization. SVR, in cooperation with its member companies and partner universities, organizes networking, startup, and investment events on a regular basis. The group also produces industry reports and hosts job fairs. In addition, SVR supports affiliates including international businessdevelopment groups, other robotics clusters, robotics media and event producers (such as Robotics Business Review), and others.

Analysis: Californiaâ&#x20AC;&#x2122;s Silicon Valley is the quintessential business cluster for so ware, hardware, and high-tech services innovation. The same holds true for robotics. The Santa Clara Valley contains a high concentration of universities and research institutions, autonomous systems startups, technology suppliers, investors, and other robotics ecosystem participants.

Although Silicon Valley is world-

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renowned for industry leadership, prior to the formation of Silicon Valley Robotics, the cluster was very loosely organized in comparison with the more formal robotics clusters found in Pittsburgh, Boston, and Odense, Denmark.

But a decade a er the founding of SVR, it has become an integrated, selfreinforcing web of robotics innovation, reciprocity, and promotion -- a true robotics cluster. RR -- Dan Kara

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DESIGN WORLD

PRODUCT, TECHNOLOGY & SERVICES — Product Introduction

Soft Robotics’ SuperPick addresses complexity, variability in the unstructured environment of reverse logistics Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

So Robotics Inc. U.S. www.so roboticsinc.com 2013 75 Product, Technology & Services Product Introduction

Description: The ability to quickly pick a wide range of objects has proven to be elusive for robots. This has led to the development of vision-guided systems and complex machine-learning algorithms to handle different shapes, materials, and orientations. So Robotics has reduced some of that complexity with its compliant grippers, which take inspiration om octopus tentacles and are based on the work of Harvard University researcher George Whitesides.

Bedford, Mass.-based So Robotics’ mGrip gripper kits enable companies to assemble the best configurations of so fingers for their robotics applications. These include pickinig and packaging in e-commerce order fulfillment, consumer goods, medical and pharmaceuticals, and food handling.

Reverse logistics and product returns are particularly challenging for retailers, with up to 30% of online orders sent back. So Robotics’ SuperPick system works with unstructured, heterogenous bins of products without requiring prior training of stock-keeping units (SKUs), and it integrates with existing warehouse management systems (WMS).

The SuperPick Polybag Picking System uses 3D vision in combination with so grippers to singulate and scan polybags, which traditional automation has had difficulty handling.

Analysis: So Robotics’ innovative combination of compliant grippers, computer vision, and suction cups directly addresses a pain point for many retailers. With approximately $90 billion in product returns om the 2019 holiday season, companies need to maximize

THE ROBOT REPORT

accuracy and throughput while minimizing waste and demands on scarce staffing.

The SuperPick Polybag Picking System continues So Robotics’ development of flexible solutions for both reverse logistics and order fulfillment. RR -- Eugene Demaitre

www.therobotreport.com

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105

PRODUCT, TECHNOLOGY & SERVICES INNOVATION — Product Introduction

Universal Robots launches 20 UR+ Application Kits to remove barriers to integration for UR cobots Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Universal Robots A/S Denmark www.universal-robots.com 2005 500+ Product, Technology & Services Product Introduction

Description: In March 2020, Universal Robots announced the release of 20 “UR+ Application Kits” for its UR family of collaborative robot arms. The kits fall into seven different classes, including Welding, Quality Inspection, Material Handling, Finishing, Machine Tending, Assembly, and Dispensing.

Analysis: Since 2008, when Universal Robots sold its first six-axis UR5 system, the Odense, Denmark-based company has claimed that the key value proposition of its articulated arms as their ease of setup, integration, programming, and use. As a result, customers could benefit om fast deployment, greater flexibility, and reduced operational costs.

However, many small and midsize manufacturers still found cobots to be too difficult to deploy and program, even for common tasks.

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Each UR+ Application Kit is designed to facilitate the automation of such manufacturing tasks. This benefits everyone in its collaborative robotics ecosystem, om full-stack integrators to small specialty firms and everyone in between, not to mention inhouse robotics engineers at cobot end users.

In addition, Universal Robots’ application-oriented solutions help the company with continuous product introductions, an expanding customer base, and new incremental revenue streams. RR -- Dan Kara

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DESIGN WORLD

PRODUCT, TECHNOLOGY & SERVICES INNOVATION â&#x20AC;&#x201D; Product Introduction

Vecna Roboticsâ&#x20AC;&#x2122; Pivotal provides interoperability, enabling robots from different companies to work together and add value Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Vecna Robotics Inc. U.S. www.vecnarobotics.com 2018 86 Product, Technology & Services Product Introduction

Description: As demand rapidly evolves, warehouses and distribution centers must keep up, but mobile robots alone are not enough to maintain and grow efficiency. Last year, Vecna Robotics introduced Pivotal, an AI-based â&#x20AC;&#x153;orchestration engineâ&#x20AC;? to help robots and human workers adapt workflows to shi ing demand.

Waltham, Mass.-based Vecna Robotics, which spun out of Vecna Technologies, provides an â&#x20AC;&#x153;autonomy stackâ&#x20AC;? of hardware, so ware, and support for safe and efficient materials handling.

Its offerings include automated pallet jacks, conveyors, and tuggers, as well as Pivotal.

The Pivotal AI analyzes an organizationâ&#x20AC;&#x2122;s operations and dynamically adjusts them in real time, coordinating and distributing tasks to both people and robots. It is designed to integrate with legacy automation, warehouse management systems, and manufacturing execution systems

Analysis: In the past few years, autonomous mobile robots have moved om trials to widescale deployments, and supply chain operations now need AI to effectively manage their fleets alongside other systems and staffers. Pivotal has helped one of the worldâ&#x20AC;&#x2122;s largest shipping companies double throughput and decrease non-value-added travel by 80%, according to Vecna.

Vecna Robotics has partnered with

THE ROBOT REPORT

GEODIS, Humatics, and UniCarriers Americas, and it raised $50 million in Series B funding in January. Daniel Theobald, CEO of Vecna Robotics, is also a co-founder of MassRobotics and has led the companyâ&#x20AC;&#x2122;s community and humanitarian initiatives. These include the development of the Ventiv automated manual resuscitator to address the novel coronavirus crisis. RR -- Eugene Demaitre

www.therobotreport.com

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PRODUCT, TECHNOLOGY & SERVICES — Product Introduction

Veo Robotics’ FreeMove turns any industrial robot arm into a collaborative robot Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Veo Robotics Inc. U.S. www.veobot.com 2016 50 Product, Technology & Services Product Introduction

Description: Collaborative robot arms are typically smaller, less precise, and slower than industrial automation, but what if workcells could perform at peak speeds until they recognize a human entering the area? Veo Robotics’ FreeMove system is designed to enable manufacturers to make industrial robots conform to international safety standards for speed and separation monitoring.

FreeMove uses custom 3D time-of-flight sensors and computer vision. It includes the FreeMove Engine for identi ing objects in a workcell. It also includes the FreeMove Studio proprietary so ware for self-service setup, configuration, and real-time visualization of FreeMove Engine data.

Waltham, Mass.-based Veo Robotics announced the availability of FreeMove last November.

It also released the FreeMove Application Development Kit so that customers could evaluate the system on non-safety-rated hardware.

Analysis: Most manufacturers are not yet at the fully automated, “lights-out” stage of operations, but Veo’s FreeMove can help them take advantage of the power, speed, and precision of industrial robots while also allowing for safer supervision by and interactions with human workers.

Veo Robotics has designed its systems with multiple redundant hardware elements and algorithms to expand the sphere of

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human-robot collaboration for flexible manufacturing. Note that robotics users should still conduct safety assessments for their systems, payloads, and workspaces.

By building its own sensors and software, Veo Robotics has started to change “collaborative” from a class of robots to a capability or characteristic, potentially transforming industrial automation. RR -- Eugene Demaitre

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DESIGN WORLD

BUSINESS & MANAGEMENT INNOVATION — Market Engagement

Waymo pulls ahead in the autonomous vehicle race Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Waymo U.S. www.waymo.com 2009 (formerly known as the Google Self-Driving Car Project) 1,500+ Business & Management Innovation Market Engagement

Description: Waymo has made many announcements since Jan. 1, 2019, the oldest date of eligibility for this year’s RBR50 list, including testing and mapping of new locations, new business applications such as delivery and trucking, selling its custom lidar to third-party customers, raising its first external funding round, and much more.

But the most significant announcement came late in 2019, when Waymo started to remove human safety drivers om some of its Chrysler Pacifica minivans taxiing members of its early rider program around the suburbs of Phoenix. Yes, the program is limited to a geofenced area that Waymo has been testing on since 2017, but it proves that autonomous vehicles are no longer a pipe dream. Fully driverless cars have arrived, albeit in a limited capacity.

Analysis: Waymo experiences more competition in the autonomous vehicle industry with each passing day. But its continued innovation, both om a technical and business standpoint, continue to separate the wholly owned Alphabet subsidiary om the pack.

In fact, Waymo has been the leader of the autonomous vehicle industry since it was founded in January 2009 as the Google SelfDriving Car Project.

THE ROBOT REPORT

But the flurry of activity over the past 18-plus months points to a shift from a technology project to a serious commercial business. Waymo’s expansion into new locations, business models, acquisitions and partnerships, combined with its first external funding round of up to $3 billion, indicate that the company is closer than ever to scaling its autonomous vehicle technology. RR -- Steve Crowe

www.therobotreport.com

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PRODUCT, TECHNOLOGY & SERVICES — Product Introduction

Waypoint Robotics releases MAV3K omnidirectional, heavy-duty mobile robot Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Waypoint Robotics Inc. U.S. www.waypointrobotics.com 2016 10 to 20 Product, Technology & Services Product Introduction

Description: Unlike many autonomous mobile robot (AMR) companies, Waypoint Robotics has designed and built its systems with factory and warehouse workers in mind. The Nashua, N.H.-based company last year added the MAV3K robot, which has a 3,000-lb. payload capacity, to its line of omnidirectional AMRs. As with Waypoint’s 600-lb.-capacity Vector AMR, MAV3K uses advanced obstacle detection and avoidance systems including an optional 360-degree, 3D, 90-meter lidar similar to those used in self-driving cars. The heavy-duty AMR also works with the Dispatcher fleet management so ware, which enables users to set it up in only 15 minutes. Waypoint’s systems are designed to be easily integrated with existing equipment and enterprise systems.

Despite its size, MAV3K can move safely around people, with dual safety-rated lidar sensors, a three-stage safety system, and continuous so ware upgrades. The Kingpin top module enables Vector or MAV3K to conduct multiple tasks, such as loading and unloading items while also towing carts.

Analysis: The design of Waypoint’s AMRs reflects its workforce-first approach to usability. MAV3K is engineered to be a ruggedized mobile robot with multiple redundancies for safety, as well as EnZone contactless charging, intuitive controls, and high capacity for automotive manufacturing, pallet

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moving, and other use cases.

By keeping its focus on workers on the floor, Waypoint Robotics has built an ecosystem of tools to help them deploy its robots as quickly and as smoothly as possible. This ees human workers for less stressful, more valueadded tasks.. RR -- Eugene Demaitre

www.designworldonline.com

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BUSINESS & MANAGEMENT INNOVATION — Market Engagement

WPI opens PracticePoint medical technologies innovation and commercialization facility Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Worcester Polytechnic Institute U.S. www.wpi.edu 1865 500+ Business & Management Innovation Market Engagement

Description: Following a two-year effort and a $5 million capital grant om Massachusetts Technology Collaborative (MTC), on Jan. 15, 2020, Worcester Polytechnic Institute (WPI) opened PracticePoint, a membershipbased, medical technologies research and development center. WPI pledged matching funds for the facility, and founding partners included MITRE, University of Massachusetts Medical School, and Boston Scientific.

The PracticePoint facility boasts of several different suites for home health, patient care, fully functional operating room, as well as MRI, neurotechnology, motion-capture, and 3D printing laboratories. It also includes an electronics fabrication workshop and a machine shop.

PracticePoint alliance members — such as public and private universities, research institutions and industry — have access to these collocated resources, and they can collaborate with one another and members of the WPI research community.

Analysis: The healthcare sector is struggling with skyrocketing costs, as well as the need to continuously improve the quality of services and results. Rapidly aging populations and a shortage of qualified workers, not to mention the COVID-19 pandemic, are also stressing healthcare systems.

Robotics technology can play a major role in addressing a wide range of pressing healthcare challenges. It can be a key means for providing better healthcare services while controlling costs. But despite the monumental

THE ROBOT REPORT

potential of such technologies and the obvious need, commercial development of healthcare robotic products has been relatively slow.

PracticePoint was specifically designed to accelerate development of commercially viable medical technologies, including robotics systems. This unique facility is more than the sum of its parts. One way to describe PracticePoint is as a one-stop, prototype-toproduct, innovation and commercialization ecosystem for medical – and robotics – technologies. RR -- Dan Kara

www.therobotreport.com

June 2020

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Yaskawa Motoman releases the HC20XP, the first food-grade collaborative robot Organization Name: Country: Website: Year Founded: Number of Employees: Innovation Class: Innovation Subclass:

Yaskawa Motoman U.S. www.motoman.com/en-us 1989 700+ Product, Technology & Services Innovation Product Introduction

Description: In March 2020, Yaskawa Motoman released the HC20XP, which it described as the robotics industry’s first fully collaborative robot with an IP67-rating. The single-armed, castaluminum, 6 DoF (degrees-of- eedom) HC20XP is engineered to operate continuously in damp or splash-prone environments. The robot’s easy-to-clean surface makes it suitable for use in sanitary environments. NSF H1 food-grade grease is included as standard, allowing the HC20XP to be used in settings where there is a possibility of incidental food contact.

Analysis: Food manufacturing has not yet benefited om robotics automation to the same degree of other manufacturing sectors such as automotive, electronics, and consumer durable goods. Yet food producers are under the same competitive pressures to reduce labor costs and increase throughput.

At this time, most robotics systems for food production are used for end-of-line picking, packaging (primary and secondary packaging) or palletizing operations, mostly using standard articulated and delta robots. These applications are typically less complex than the foodprocessing steps further up the line, where objects are unwrapped, inconsistent in size, and o en delicate, wet and slippery.

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Currently, much interest and a good deal of effort is focused on developing “upstream” applications for the robotic handling of raw or esh foodstuffs, such as inspection and processing, especially using vision-based systems.

Collaborative robots, which can operate in close approximation to human workers, are well suited to such tasks, but most cobots to date have not met the requirements for the hygienic handling of foodstuffs.

With Yaskawa Motoman’s introduction of HC20XP, collaborative robots can now be employed for these upstream food processing tasks. Other producers of collaborative robotics systems will follow suit, but Yaskawa Motoman got there first. RR -- Dan Kara

www.designworldonline.com

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Posital-Fraba Upgrade Your Motor Feedback with POSITAL ABSOLUTE Kit Encoders POSITAL ABSOLUTE Kit Encoders offer a great upgrade path for the traditional incremental kit encoders used for servomotors. Compact, rugged and cost effective, they provide accurate position feedback for precision motion control in robots, production machinery, autonomous vehicles and other motion and position control application. They can also be used to provide closed-loop feedback control for stepper motors. Rotational resolution is up to 17-bit (one part in 130,000) with a multi-turn range of

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Robotics

NEW Aksim-2 rotary absolute kit encoders offer outstanding performance – to 20-bits with no hysteresis Renishaw associate company RLS d.o.o Introduces an improved second generation of AKSim absolute rotary encoders widely used in many humanoid, medical and collaborative (Cobot) applications, where hysteresis, large through holes, low profile, reliability and repeatability are fundamental.

The additional benefits of AksIM-2 encoders are: • Full range of sizes • Onboard eccentricity calibration • Multiturn capability • Extended operating temperature and pressure ranges

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Big World of miniature brakes •• •• •

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Many industries have come to employ the compact cameras, sensors, batteries, processors, and communications technologies made ubiquitous by consumer products. Electromagnetic brakes complement such designs with miniature formats.

O

Brian Mather • Industrial product manager • Ogura Industrial Corp.

Oh, how times are changing. Zoom meetings are the norm. Children all over the world are experiencing cyberschooling. Robots are picking our produce. Doctors are performing surgery on patients while standing miles away.

Such developments are out of necessity, convenience, health, safety, and consumer demand. They’re also the result of advancements in manufacturing along with evermore-capable design and computing options.

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In fact, many new applications in the medical, robotics, aerospace, and automotive industries require compact mobile designs. These frequently employ small electric motors … and those motors sometimes need brakes or clutches. As we’ll explore, electromagnetic brakes are often the most suitable complement to such designs.

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Miniature electromagnetic brakes come in both round and square configurations … and can be dimensionally sized to meet the torque of the motor on which they are mounted. www.designworldonline.com

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Applications in medical devices In the medical industry, miniature electromagnetic motors and brakes work in curative tools and surgical equipment.

Consider how cameras and sensing equipment have advanced so dramatically that medical personnel can now see things inside the body in detail never before imagined … and can use precision controls to operate small devices inside patients to scope areas of concern. In a similar way, the latest surgical equipment operates with a surgeon driving motions through controls via robotic-assist functions. Such functionality provides better surgical outcomes with minimally invasive procedures, quicker recovery times, and lower total cost from start to finish. In some cases, doctors can even execute surgeries from another room or even another city.

For robotic and handheld batterypowered equipment in these applications, equipment must be extremely reliable with highest precision. Here, high-ratio gearboxes on the motor output help with precision positioning — to maintain the highest level of safety. Motors on motion axes in many such designs also need brakes for holding and emergency stops. The challenge is that brakes in these devices must be lightweight with low power requirements for ergonomics and longevity.

Uses in the robotics industry The robotics industry is diverse … we’ve just touched on medical robotics. There are other industrial-grade mobile robotics with

In aerospace applications, the low power requirements for electromagnetic brakes help minimize heat buildup.

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M o t i o n

C o n t r o l

Some electromagnetic spring-applied holding brakes from Ogura have diameters down to 10 mm.

some things in common: Motors and brakes in articulating robotic arms must be lightweight so that the fast-moving arms have less inertia — and a maximum amount of the joint torque capacity. Less inertia means less power required, quicker response, and more output.

For example, a brake with a 10-mm OD and 9-mm width weighing 7 g can disengage with overexcitation for a short period at 4 W — and stay disengaged with only 0.34 W. Any extra weight means more power loss on a mobile robot’s battery. Though batteries are longerlasting than ever before, it’s still a common design objective to have more uptime with less charge time and minimal operating cost.

In robotics, smaller and thinner brakes allow for greater system output. After all, a properly customized and optimized brake delivers the highest holding torque with lowest weight and lowest power demand possible — especially from electromagnetic variations having maximized magnetic flux strength. Properly specified brakes can also withstand millions of reliable cycles — preventing downtime that in a robotic application can cost significant money … and hinder other operations as well.

In fact, motor brakes in wheel drives are especially important for inclines, personnel safety, or product safety. The catch is that any servicing a mobile robot may require is often beyond any knowhow of inhouse personnel.

So these robots benefit from brakes that can operate over wide temperature ranges and even exposure to moisture. Here, brakes incorporating special materials and sealing

designs excel — especially brakes with bodies that do double duty as motor-housing endbells.

The special case of aerospace In aerospace applications, power and weight are most important. The primary design objective remains the same whether the brake installs on a fighter jet’s wingflap actuator or on a seat actuator in a private plane. These brakes must deliver the most torque output with smallest size, weight, and power. In this industry, there is a strict correlation between weight to power and total cost.

No wonder that in aerospace applications, it often makes sense to use customized brakes.

Brakes here must often survive a wide range of operating temperatures and other extreme conditions inducing highest coil resistance.

As we’ll explore in more detail, the low power requirements for an electromagnetic brake also help to minimize heat buildup.

Automotive applications The automotive industry is increasingly focused on producing electric and autonomous vehicles.

Such designs make copious use of electric motors and motor brakes. Case in point: Actuators in powered door systems need holding brakes with typical automotive specifications and quality.

Steering systems often need autonomous and manual steering capabilities employing small electric motors and brakes and clutches as well. In fact, a whole host of new functions on cars are now expected … functions often driven by electric-motor-based actuators for more convenience, safety, and service. So the

These are Ogura’s standard series of thin electromagnetic spring-applied brakes.

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convenience of powered sliding van doors that was introduced years ago is now seen in powered doors and powered pickup-truck tailgates and more. On autonomous cars such powered door functions aren’t extras but core to the vehicles’ usability.

Brakes in such applications must fit in exceptionally tight spaces and be of relatively lowest cost and high reliability — and capable of delivering precision torque.

Brakes made with advanced manufacturing techniques by experienced automotive suppliers excel here. This has led to the use of electromagnetic brake variations in the electrification of off-road vehicles and construction equipment — in their wheel drive systems and other subsystems.

Miniature brake details The brakes that go into all these applications are often electromagnetic spring-applied power-off brake variations … some as small

Ogura’s standard series of electromagnetic spring-applied brakes are indeed quite thin.

as 8 mm OD. Such brakes can reliably handle the torque load of the motors with which they dimensionally pair. Some models can be as thin as 9 mm — round or square in shape. Elements limiting just how thin brakes can be include the pressure plate, friction material, cover plate, airgap, coil, and coil body. Where justified by a need for controlled stops or higher torque density, permanent-magnet brake versions may be most appropriate.

Accommodating encoders: Small

motors are often fitted with encoders.

Where this is the case, accommodations can be made to mount both a brake and encoder. Typically, the brake body is designed to allow for the mounting of the encoder inside. This requires that the motor manufacturer or equipment OEM collaborate with the brake manufacturer.

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M o t i o n

C o n t r o l Customization: To optimize a brake’s

When power is applied, magnetic flux is created.

That in turn pulls the pressure plate toward the coil body — compressing the springs and freeing the friction disc to allow rotation.

torque capacity, airgaps on the miniature brakes are minimized. This is done through manufacturing techniques that differ from those used to make larger brakes. In addition, flux paths are maximized with special modeling software complemented by the component maker’s experience.

Further maximizing torque is friction material specially selected for the application at hand.

Note that most holding brakes use a friction material that provides higher torque than that of dynamic brakes. The latter employ friction materials having lower coefficients of friction (though more suitable for limiting frictional wear). Static holding brakes are typically designed to withstand some emergency stops as well.

A brake’s spring forces can also be optimized for the design to provide the highest possible torque.

Power density: Minimizing airgaps

on a brake serves a second purpose — to limit power requirements. Consider how overexcitation can disengage a springapplied power-off brake. This is quick short-duration burst of power followed by a lower power supply to maintain the disengaged status. It’s useful because it takes more power to disengage a brake than it does to keep it disengaged. To illustrate, a design can be made to disengage a brake

at 24 V but then power can be dropped to 7 V to maintain disengagement. Such operation also helps mitigate heat buildup in the coil body.

How is this functionality built into a customized brake? Well, it’s done through optimization of magnetic flux during the design stage. Recall from basic physics that magnetic flux naturally follows the path of least resistance. Within an electromagnetic brake, it takes stronger flux to jump the airgap when engaged. Also, the springs in spring-applied brakes need to compress as the pressure plate crosses the airgap. Once compressed, the pressure plate contacts the field coil … and the holding power is strong with power applied.

Cost: Considerations abound — although upfront component costs are the most obvious. Installation has a cost. Most miniature brakes are mounted with a press fit on the motor shaft. The torque is very low, so the mechanical fit is often sufficient to prevent slipping. Larger brakes still have D or double-D shaft fittings or setscrews for low vibration applications. Automotive applications tend to have a spline fit.

Weight can also be considered a cost factor for mobile applications, as these have an associated dollar cost per pound based on load and battery power required.

Other cost factors include a design’s expected life, maintenance requirements,

Airgaps are a critical feature of an electromagnetic springapplied brake. The airgap shown here is with the brake engaged and no power being applied.

This is an exploded view of a standard electromagnetic brake.

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These electromagnetic spring-applied holding brakes from Ogura’s MCNB series are suitable for compact medical, robotic, and aerospace applications.

and warranties. Most motor brakes should be rated for the life of the motor or application … but if the brake or motor is rated to be a service part, then servicing becomes part of the design’s cost. Of course, warranties include the price of a customer relationship, brand strength, time lost, warranty process, and potential product replacements.

Consider your brake supplier Given the world’s technology bursts and the necessity of getting designs to market quickly, there’s no time to get details wrong. Engineers want to design the best solution confident that it will perform

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as expected — and that their suppliers can deliver the design’s components in a reliable and consistent manner. If applications aren’t reviewed fully in the initial stage, there is a potential for major losses in time and money for failed testing and retesting.

Resource availability is also scarce at many equipment OEMs. By choosing an experienced and forward-thinking supplier, problems can be foreseen … and solutions discussed before testing processes even start. Weights and power requirements can be minimized, and assemblies optimized — along with product size and cost.

Brake suppliers can be more than parts

www.designworldonline.com

suppliers; they can be solutions providers.

But vet your brake supplier on their expertise and experience … and look for brake manufacturers that have high-volume repeatability in their manufacturing as well as experience in applications that are similar to yours. Also ask for their input at the earliest design stages: You may find the solution to a problem you didn’t yet know you had. DW Ogura Industrial Corp. ogura-clutch.com

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HeavyDuty encoders from Baumer HĂźbner are used in open pit mine applications. Here, their robust design and double-sided bearing setup ensures maintenance-free operation and a long service life even under severe loads and in adverse environments.

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Encoders

endure in tough applications A combination of mechanical and electrical resiliency along with design for impermeability makes for truly heavy-duty encoders.

Edited by Miles Budimir • Senior Editor

In critical motion applications, accurate feedback is essential to keeping the system operating smoothly and precisely. The feedback sensor, such as an encoder, has to be able to report accurately on the position and/or speed of the process or system. A bad or malfunctioning encoder produces bad data, and that’s not useful at all; especially in environments with extreme conditions like shock, vibration, extreme temperatures and humidity or the presence of washdown conditions. An encoder that isn’t hardened and able to withstand such conditions won’t last long and will fail quickly.

Enter heavy-duty encoders that are designed to withstand such conditions.

Baumer’s heavy-duty encoders One example of encoders that are designed to be rugged and robust, to endure harsh environmental conditions, comes from Baumer. The company’s POG 10 incremental HeavyDuty encoder and its sister model, the HOG 10 with hollow shaft, deliver reliable speed data in a host of applications and operate under the toughest conditions.

As a result, they help prevent failures saving downtime costs.

The POG 10 is designed for high reliability under challenging environmental conditions through a number of specific design features. Because of solid wall thicknesses and a warp-resistant design, the die-cast DESIGN WORLD

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housings are robust and highly resistant to vibration and shock. Bearings at both encoder shaft ends and a metallic incremental disk offer huge power reserves and durability through extreme resilience to axial and radial forces. For outdoor use, the anticorrosive properties of the CX category of HeavyDuty encoders to EN ISO 12944, achieved through an optimal choice of material and high-resistant coating, are also extremely important. These properties allow the encoders to be used even on or in the ocean, in the Arctic, in the tropics or in the desert.

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L i n e a r

M o t i o n Baumer HeavyDuty encoders feature bearings at both encoder shaft ends, making them more resilient to axial and radial forces.

The combination of labyrinth and shaft seals also protects the inner workings of the encoders from solid, moist and pastelike contamination. This sealing concept conforms to protection classes IP 66 and IP 67 within a broad temperature range of up to 95 Ë&#x161;C. Current-insulated bearings protect the ball bearings of the encoder from current flashovers. The result is an

almost indestructible full package that effectively prevents potential malfunctions and failures, even during tough continuous use.

The interference-immune scanning function with robust, optical circuits (Opto-ASIC) ensures reliable precision.

This guarantees optimum electromagnetic compatibility with a burst strength for highvoltage pulses of up to 4 kV. In addition, the Enhanced Monitoring System (EMS) continuously checks numerous encoder functions, swiftly detects connection and encoder errors and transmits the encoder status to the inverter or to the control via an error output. The encoders achieve the best possible SinCos signal quality through a LowHarmonics technology for outstanding control quality, low drive heat-up and high energy efficiency. The incremental square signal outputs also have short-circuit proof, powerful transistor drivers for peak currents of up to 300 mA. They ensure reliable signal quality even over long-distance transmissions of up to 350 m. Resistance to electromagnetic fields, vibration, shock, dust, hose water, salt spray and much more is ensured on test benches during production.

Encoders put to the test So how do these heavy-duty encoders hold up in some challenging environments? Here are a few examples that demonstrate how these encoders handle these challenges and the benefits they provide that keep these systems up and running.

One example comes from demanding conveyance tasks. Open pit excavators and spreaders are real giants among machinery.

Every day they do the hardest work under

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The sealing concept of Baumer HeavyDuty encoders ensures IP 66 and IP 67 protection over a wide temperature range up to +95 °C. The combination of labyrinth and shaft seals permanently protects the encoders against all types of contamination.

extreme conditions – dust, dirt, rain, heat.

There’s also a great strain imposed on the rotary encoders, which are responsible for speed control of conveyor belts.

Minera El Abra is an open pit copper mine, located northeast of the Chilean city of Calama. Mine output per day is more than 200,000 tons of copper ore for copper cathode production. Conveyor belts transporting the ore over many kilometers must deliver maximum performance.

For doing so, they are driven by powerful electric motors. This is where the HOG 10 HeavyDuty incremental encoders are a perfect fit for motor speed feedback in a such a demanding outdoor application.

They endure dust, dirt, vibration and other harmful impacts that are everyday conditions in open pit mines. 10,000 kilometers away, at the port of Rotterdam, another model POG 10 is on duty: In the largest port of Europe, more than 300 million tons of bulk cargo are handled every year, including more than 55 million tons of iron ore and coal. These intermediately stored goods are handled with bucket wheel excavators with a capacity of 5,000 tons per hour. Here, HeavyDuty encoders are at work because they withstand salty air, rain and frost without any problem.

In order to be characterized as being resilient and robust encoders, they must

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satisfy a number of criteria. For instance, precision is a focal point. Heavy-duty encoders must deliver the same precision signals as other encoders. Plant control systems use these signals for speed monitoring at drives or position feedback at machine parts. To controllers, this is the only way to “get informed” of any excess speed or the drive falling below a defined speed limit so they can intervene accordingly.

Even minor measuring errors can have drastic consequences that may result in system damage.

Besides precision, reliability is also important. For reliable performance in the harsh conditions present in open pit mines and port installations, the encoders must withstand hard shocks, vibration and other shaft impacts without losing their precision capabilities for a long period of time, often over many years.

Product exchange is expensive, not because of encoder pricing but because of installation in places difficult to access and system downtime for the time of exchange. Robust, thick-walled housings and a shock and vibration resistant interior are basic requirements.

Not only mechanical robustness but also electrical resilience is a must. For example, if electromechanical fields generated by live, unshielded cables are present close to the encoder, without appropriate shielding, the encoder electronics may be destroyed or at least be impaired to an extent resulting in measuring signals of bad quality. Shaft currents generated by voltage difference may burn the bearing lubrication and lead to bearing damage or destruction. So electrical isolation is indispensable for these encoders.

Tightness is another must. Whether moisture, dust or dirt, encoders must be well sealed. This is especially important at critical, neuralgic points such as shaft and electrical connections. Sealing includes corrosion protection by appropriate materials and coatings, against ingressing salt water and chemicals that would impair encoder functionality.

Another example involves Europe’s biggest roller coaster, the Helix at the Liseberg amusement park in Gothenburg. Here, POG 10 HeavyDuty incremental encoders monitor the speed of the carrriage’s drive as it approaches the start ramp. Liseberg in Gothenburg is Sweden’s largest amusement park, with the Helix roller 128

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The HOG10 / POG10 HeavyDuty series of incremental encoders ensure reliable operation under harsh conditions.

coaster being one of the star attractions.

With a 1,380-m track, Helix is the longest looping roller coaster in Europe and the second longest in the world. It hurls its riders at up to 90 kph through six loops and exposes them to up to five times their own bodyweight.

Before the start, the riders have to be brought to the start ramp at a height of 41 m. Controlled asynchronous drives with 315 kW of power are used to move the carriages into the start position.

The speed of this drive is recorded by the POG 10 HeavyDuty encoder which is exposed to the elements – heat from the sun, moisture from rain or wind currents.

With the roller coaster, it even makes a valuable contribution to the safety of human life – a malfunction in the drive of a carriage would at best be annoying for the riders, and at worst a life-threatening experience. These

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features – resilience and precision – make an important contribution to ensuring that the Gothenburg roller coaster riders are brought to the start ramp safely and at the correct speed. This is all the more important as a replacement can get costly – not because the encoder itself is expensive, but because it’s typically mounted in barely accessible locations, as is the case on a roller coaster. DW Baumer www.baumer.com

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o f

T h i n g s

Industry 4.0

and the Factory of the Future: Insights for new engineers Whether you’re an experienced engineer or a member of a new generation just launching your professional career, you can make full use of Industry 4.0 technology through a step-by-step approach.

Peter Fischbach Business Development New Technologies, Domain Expert i4.0 and IoT • Bosch Rexroth Corp.

Today’s manufacturing and automation industry segments are constantly leveraging new technologies and processes to become more agile, more responsive to fast-changing global markets and more innovative in their products and solutions.

There’s also another “new” element to consider in current manufacturing environments: a new generation of engineers, many of whom are entering the industrial workplaces with skills, backgrounds and experiences that are significantly different from previous cohorts of manufacturing engineers.

This newer generation is starting to work alongside existing automation engineering teams that may be grounded in production systems, plants and processes. In many cases, these legacy technologies are less digital, less connected and less “intelligent” than modern production systems and technologies being introduced. These new technologies, commonly referred to as Industry 4.0 or Factory of the Future systems, offer the potential to revolutionize global manufacturing operations — in fact, their rapid adoption is already having a significant impact in many industries.

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Whether they’re experienced engineers or part of a newer generation that just launched their professional careers, today’s manufacturing and automation engineers can make full use of i4.0 technology by targeting key productivity, throughput or quality issues and building a step-by-step approach to make smart, incremental investments to move forward on the path to the Factory of the Future.

Combining innovation with experience The current generation of engineers entering manufacturing operations have backgrounds and experiences that differ DESIGN WORLD

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in a number of ways from engineers with thirty, twenty, or even ten years on the job. Mechanical and process engineers fresh out of school grew up surrounded by and interacting with digital information technologies. They are used to having indepth data on hand, or easily searched and accessed, to make decisions.

They use more computer-aided design tools and three-dimensional simulations of systems, creating virtual prototypes of components or devices and testing them using those platforms before using a 3D printer to fabricate an actual prototype. Even if they studied electrical or mechanical engineering, they may have also www.designworldonline.com

Whether they’re experienced engineers or part of a newer generation that just launched their professional careers, today’s manufacturing and automation engineers can make full use of i4.0 technology by targeting key productivity, throughput or quality issues and building a step-by-step approach to make smart, incremental investments in the journey toward the Factory of the Future.

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o f

T h i n g s Before deciding what sensors to install and where, it’s important to start by applying lean principles in order to map the value stream and identify where time is wasted, or scrap is created. Lean principles can be used locate where initial investments in sensor and data-collecting technologies can have the greatest impact.

both veteran and new engineers can help companies implement i4.0 technologies more effectively as they seek to build the Factory of the Future. The older generation of engineers can contribute their experience and insights about how existing manufacturing systems perform, while the newer generation can contribute their skills at organizing and analyzing data and optimizing how digital technology like sensors, visualization systems and controls can be leveraged to maximum value. taken basic programming classes and have experience with commercial programming languages (as opposed to standard PLC programming methods using ladder logic), as well as designing and programming user interfaces.

They also tend to be more experienced with thinking about and designing systems that are networked and highly connected. That means they may assume that technology incorporates the ability to connect with other systems and share data horizontally and vertically, including the use of cloud-based applications and artificial intelligence-type systems.

In contrast, there are large segments of today’s manufacturing systems that are less networked and data-rich than the new generation of engineers might expect. The older engineering staffs in these operations draw more on their experience designing, building and running these systems, compensating for the comparative dearth of information. These more experienced engineers know their machines: how they sound, how products move through the equipment and where potential choke points, common areas of stress, and potential breakdowns are located.

Combining the skills and expertise of

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Starting the Factory of the Future journey Implementing the vision of the Factory of the Future requires a careful selection of targets for technology investment. In order to transform production systems — both existing equipment, as well as machines and production lines designed today or are still on the drawing board — data and connectivity both play a crucial role.

In the Factory of the Future, everything is connected, from the individual machine components with embedded sensors and intelligence up through machine-level and plant-level communications architectures to a cloud-based solution. Sophisticated software collects, transfers and processes data in ways to provide both production transparency and actionable answers to questions about production bottlenecks, inefficient workflows and equipment in need of preventive maintenance.

This is the level of data that many of the newer engineers will expect to have — but may not initially have access to.

Many manufacturing plants contain a mix of machines, from legacy equipment with little or no intelligent controls, sensors or communications capabilities to state-of-

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The new generation of engineers has developed skills for mining and analyzing data but configuring how that information is captured is just as important. A logical step to consider is embedding an intelligent “edge” or gateway that seamlessly collects the right data from the factory floor.

the-art systems fully equipped for Industry 4.0 operation. It may be necessary to develop a step-by-step strategy that starts small and is scalable — going after the most obvious issues and problems.

You may begin by asking, “Where is my value? Where can I gain the most in productivity?” Start by focusing on production bottlenecks and quality issues — for example, a production part that

consistently has quality issues and high scrap rates.

How do you get the information to address these quality issues? Improving connectivity between production units and upgrading sensors can help provide the data. Many plants today have island productions, where one machine produces one part. Then it goes to another machine for another production step and they are not connected — that is, the data about the production of the part in one machine doesn’t follow the part over to the next machine in any automated fashion.

To decide what sensors to install and where, you need to define what data you need in order to get at the root causes of quality issues. It’s important to start by applying lean principles to accomplish this goal, such as mapping the value stream and identifying where time is wasted or scrap is created. Lean manufacturing programs and processes are well established in many

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production environments and the older, more experienced engineers have long-standing, hands-on expertise applying lean to their plants.

It’s a perfect framework for collaborating with the new generation of engineers; lean principles can be used to point to where initial investments in sensor and data-collecting technologies can have the greatest impact.

By applying simple sensors and simple data storage for these targeted, high-level, highvolume areas, you begin collecting historic data and start visualizing it. It also provides the right framework for capturing and analyzing historic and trending production data for a more detailed and comprehensive approach to understanding how to improve operations.

With that insight, you have the information you need to apply continuous improvement process (CIP) tools that will gain value and correct your quality, cost or wasted time and effort issues. This approach can be applied to a range of production systems, not just the legacy ones with minimal sensors and connectivity. You can begin with sensors, but many machines also have smart motion drives and controls to deepen and enrich the data you’re capturing. For example, intelligent servo drives can capture feedback data on motion characteristics, such as torque and velocity.

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the load or resistance on a particular axis matches established parameters, or whether there are mechanical issues to be addressed.

Making smart use of connected data As manufacturers augment sensors, data collection and connectivity, machine by machine or production cell by production cell, there is the risk of “too much data, not enough insight.” One reason some companies resist investing in i4.0 technology is the fear that they will be overwhelmed by a mountain of data and not really know how to extract the right insights to improve their performance.

It’s a legitimate concern — and while the new generation of engineers has developed skills for mining and analyzing this volume of data, configuring how that information is captured and channeled is just as important. A logical step to consider is embedding an intelligent “edge” or gateway that collects the right data from the factory floor.

These gateways normalize the data streams to give you a coherent and actionable portrait of your production in real time. An IoT gateway, for example, makes real-time monitoring of process data, such as temperature, pressure,

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vibration, power consumption or other parameters, easier to set up without intervening in the automation logic. Data can be centralized at the plant level with local machine state monitoring systems and eventually scale up to using the gateway to connect all production locations through the cloud and using cloud-based analytical tools.

With these tools, it is possible to have much more data-driven solutions to help companies improve a number of critical productivity tools and strategic programs.

These include: • Predictive maintenance: having better insight about when and how to schedule machine service intervals and equipment upgrades to minimize downtime • Data analytics: making smarter use of production data and incorporating them into operational and strategic decision-making • Visualization and notification: feeding digital Kanban boards to visualize production data in real time and network with IT applications

for production planning and quality data management and communicating throughout plants to provide information as the basis for decisions and process improvements • OEE optimization: using data from across the enterprise to better quantify overall equipment effectiveness (OEE) and compare different production platforms to help guide investments in future equipment • Business intelligence: enterprise-wide strategic planning to address long-range investments in new production systems, plants, personnel and markets can be guided with solid historical data and better insight from cloud-based analytical tools Scalable pathways to the Factory of the Future It’s important to appreciate that the Factory of the Future is already being built.

Seasoned engineers and the new generation just joining today’s manufacturing companies both have important contributions to make. Together they can chart a scalable, step-by-step approach that

adds the layers of sensors, intelligence and connectivity to existing manufacturing platforms that can yield actionable insights to solve current issues. They can also collaborate with forward-looking OEMs and technology suppliers to determine the best way to incorporate i4.0 technology into the next generation of production platforms. DW Bosch Rexroth Corp. www.boschrexroth-us.com

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Bosch Rexroth’s IoT gateway makes real-time monitoring of process data, such as temperature, pressure, vibration, power consumption or other parameters, easy to set up without intervening in the automation logic. Data can be centralized at the plant level with local machine state monitoring systems and eventually scale up to using the gateway to connect all production locations through the cloud and utilizing cloudbased analytical tools.

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Look up in the

sky

it’s CAD software

A major CAD vendor is betting the modeling software’s future is in the cloud

Onshape set off ripples across the computer-aided design community five years ago when it announced its computer-aided design software would exist completely in the cloud. Last fall, PTC acquired Onshape.

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The purchase signals PTC’s conviction that engineering companies are ready to embrace CAD in the cloud. The SaaS model, while nascent in the CAD and PLM market, is rapidly becoming the industry’s best practice across most other software domains, said Jim Heppelman, PTC president and chief executive officer.

By bringing Onshape in-house, the software maker has placed itself ahead of the pack in what the engineering software maker sees as the inevitable industry transition to SaaS, Heppelmann said.

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“Today, we see small and medium-sized CAD customers in the high-growth part of the CAD market shifting their interest toward SaaS delivery models, and we expect interest from larger customers to grow over time,” he said.

In the future, CAD sellers may reach unique arrangements with resellers to bring CAD in the cloud to a wider user base, according to one potential reseller.

But PTC isn’t going all-in with the cloud. It will continue to offer its onpremise CAD software, Creo.

With CAD in the cloud, designs reside on the software provider’s secure server —rather than on individual workstations.

Because the software is accessed and managed online, engineers and designers can work on their models from any location and on any device. The SaaS refers to a provider’s capability to deliver everything needed to run CAD in the cloud—including the cloud infrastructure and the CAD software itself.

Though other CAD makers do offer some type of cloud capability, it’s generally the capability to check files into and out of an application on a cloud-based server; engineers don’t design directly with cloudbased software on other applications, said Jon Hirschtick, president of SaaS, DESIGN WORLD

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PTC. Onshape differs in that its software exists fully in the cloud and can be used by multiple users in real-time, he added.

(Hirschtick founded SolidWorks in 1993 and then went on to co-found Onshape with another former SolidWorks chief executive officer, John McEleny.)

The everyday cloud You’re already using cloud technology.

That’s almost certain. If you have an email account ending in gmail.com or yahoo. com, if you’ve checked a social media account from your desktop or mobile device, if you’ve streamed a movie via Netflix or Amazon or any other provider, you’re a cloud user. The email, social media, and streaming software exist on the software owner’s server (let’s say Google), as does your little piece of it—like your Gmail email address.

Though it’s been possible to run CAD as a SaaS for the past few years, CAD has always been slower than other large, graphic-intense and complex applications to pivot to new platforms, says Len Williams, content manager at designairspace, which gives engineering companies the capability to run any CAD system in the cloud.

“Last year’s acquisition is a very clear www.designworldonline.com

statement that vendors like PTC see cloud as a platform of the future for CAD and for all their other software,” Williams added, calling the acquisition a “Windows-level” move.

“CAD systems were originally based on UNIX running on silicon graphics workstations. Then Windows came along and people were laughing at the thought of using CAD on Windows,” he says. “Now most of the major CAD systems run only on Windows.”

Likewise, the way companies buy their CAD software has evolved, he said.

“We went from the old perpetual model, where you buy the software for a workstation, to today’s subscription-based model, where you rent the software,” Williams said. “The next step is when a CAD vendor is running it for you so don’t have to buy hardware or worry about upgrades.”

Large companies already run CAD in the cloud because of the benefits the delivery method offers, Williams added.

The difference is, those companies—the French automotive manufacturer PSA Peugeot Citroen is one example—have the funds to build their own, private clouds.

Designers, engineers, and suppliers at those companies can access CAD on the private cloud whatever their location: Tulle, France; Brussels, Detroit, or elsewhere.

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Working remotely and sharing with suppliers For the smaller guys, the cloud can bring the same benefits their larger counterparts already enjoy; mainly real-time working together and version management, Hirschtick said.

“Versioning” is built-in, which means file changes are tracked in a central database in real-time.

Because any engineer with permission can access the software from any device with internet connection, engineers in different places can work together on a design, such as a power supply, for example. There’s only one power supply file; Onshape doesn’t copy it. But with cloud, everyone in the world accesses real-time single source of truth database. We’re not passing around copies all over the place, he added.

“If multiple engineers happen to be working on that file at the same time, it’s not a problem. If one engineer rounded a corner and another one drilled a hole, both changes get captured,” Hirschtick said. “If we’re both rounding a corner at the same time, you would see my hand there in real-time—at the same table—and a box around the corner would indicate that another engineer is editing that right now.”

The bigger the team is, the quicker the product development process, as everyone—even suppliers— has visibility into the real-time database rather than a copy of something emailed a week ago.

When the workflows are quicker, engineers have more design time and are more willing to innovate to try new things, he added.

Most cloud service providers automatically update their programs. Thus, IT staff can focus on other tasks and engineers know they are working with the latest version of the applications.

Also, engineers aren’t bound to their workstations. The software exists at one central server while engineers work from many. They can be globally dispersed and can work from home or other locations outside the office.

Smaller companies that scale their workforce and supplier base up and down as projects change also stand to benefit from SaaS CAD software. When suppliers move away from a project, the company can easily suspend their CAD license and use of the CAD system, Williams said.

When the coronavirus began making headlines in early 2020, engineering companies running one Onshape customer with offices in three major Chinese cities particularly welcomed the remotework capability, Hirschtick said.

“Using Onshape analytics, they showed us where people were working before the virus situation

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in China,” Hirschtick said. As expected, employees worked at the offices in the three major cities.

“Then they showed a map of activity of first two weeks of virus quarantines and lockdowns in China,” he added. “This time there were 20 little circles in regions all over in China. They could see where their employees logged in remotely.

“It doesn’t matter if employees are caught at home with only an Android tablet, they can still do their work,” Hirschtick said. “Even with the phone they can even do some of their work.

There are cases where running CAD in the cloud just doesn’t make sense.

Some companies may use CAD only a small amount of time and will do better essentially renting a CAD program, perhaps through the cloud, Williams said.

With cloud-based systems, issues of total cost of ownership and return on investment are generally murky because companies want to see how cloud applications compare to traditional on-site infrastructure.

“But there are so many intangibles wrapped up in the cloud that it makes it hard to put calculations on it,” said Andrew Sroka, CEO at Fischer International Systems, which helps companies manage identities for on-premise and cloud-based applications. “It’s important to factor in expenses like utility costs and power requirements.”

If you can’t buy, rent With CAD in the cloud being not if, but when, designairspace has new ways to bring benefit to users and CAD makers; reselling vendor software in the cloud.

The company would offer customers workstations with major CAD vendor’s programs already installed. Designairspace can track use, which allows the vendors to charge based on time spent using the programs.

“It would be just like mobile phone plans back in the day, where you buy a plan based on minutes. We can do this with CAD in the cloud,” Williams says. “Let’s say you buy a plan with 500 minutes. If you need it for only one or two days a week, you can buy

it in a small, affordable plan that’s a small portion of what it would cost you to buy the software.

“Why limit CAD-in-the-cloud to large companies? In the olden days, only big companies could afford 3-D CAD systems.

We want small companies to have cloud benefits,” he added. “They would still need to buy their own licenses, but at least they can run it in the cloud like the big guys.”

The pricing model would benefit companies with project managers or suppliers who don’t design in CAD but log onto the program intermittently.

“These people use the software only a little bit at a time, so we can price it so it’s not so expensive for them,” Williams said.

“This is a whole new market for major vendors.”

Becoming a CAD-in-the-cloud reseller and offering online training in those CAD programs is the “next step” for designairspace, he added. With the business model, potential customers can also receive on-the-spot, specialized training if needed and can test the software to see if it’s right for their needs before buying a priced plan, he said.

Or, engineering companies might choose to run hybrid CAD, in which they host some CAD systems at workstations on-premise and buy CAD in the cloud subscriptions for intermittent users, Williams said.

“That way you can gradually move more and more users to the cloud. You can move one or two and see if it works and if it does move more to the cloud,” Williams said.

“The heavy users will never move to the cloud.”

That brings up another point.

Workstations that run CAD will always be with us, he added.

Companies that do work for the defense department or for the military must do their engineering work on company workstations. They cannot work remotely, Williams said.

For his part, Hirschtick is dreaming big.

He expects widespread cloud adoption for CAD as users begin to see the advantages.

“People think cloud tools don’t have the power or speed but that’s an old fable.

Cloud tools have more advantage and speed, it’s not a fair fight,” he said. “With desktop tools, you have one CPU sitting on the desktop. With the cloud, we’re able to use unlimited amounts of CPUs. I gave a demo and opened up ten models with thousands of thousands of parts on Macbook in Chrome on a web browser.

There’s no CAD workstation that could open them that fast, even the best desktop configuration.

“In a few years, people will be saying ‘how did you ever do CAD on a desktop.

How was it fast enough?’” Hirschtick says.

While the future remains cloudy, PTC is backing clearing skies for CAD in the cloud.

With a large CAD maker backing SaaS, expect to see a flurry of news and updates.

In other words, don’t delete your desktop program. DW PTC www.ptc.com Designairspace www.designairspace.com

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A supplement of Design World June 2020

A new approach to makes more materials available for additive manufacture 144

141 Designing medical devices for additive manufacturing

COVER_MPF 6-20_FINAL.indd 140

150 Combining additive and subtractive technologies for metal digital manufacturing

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A d d i t i v e

T e c h n o l o g y

Designing medical devices for additive manufacturing Additive manufacturing offers designers exceptional opportunities to accelerate prototyping, create custom devices, support just-in-time manufacturing (including producing parts on site at hospitals), and reduce or eliminate traditional production costs such as the development of mold tools. However, additive manufacturing is a relatively new and fast-evolving technology. The industry is racing to develop new specialized materials, printers, design software and other tools that can propel broader adoption of this process, with the goals of expanding the range of applications, boosting part volumes and streamlining production.

Production of medical devices, however, adds another layer of complexity to additive manufacturing, due to the many regulations and requirements that materials must meet to be used in these critical applications. They must be identified as safe, based on biocompatibility standards set forth in ISO 10993. Compliance with these standards is necessary to manage biological risk. Further, the U.S. Food and Drug Administration (FDA) recently issued official guidance on the use of additive manufacturing to produce medical devices. This report, “Technical Considerations for Additive Manufactured Medical Devices,” comprises two main sections:

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| Courtesy of 3D Systems

Printing equipment is increasingly open – allowing materials from diverse suppliers to be used on more additive manufacturing machines. The FDA is working with manufacturers, service bureaus and material suppliers on best practices. With strong support from all corners of the industry, healthcare device designers are gaining new resources that can expand additive manufacturing’s horizons and maximize its value.

design and manufacturing considerations and device testing considerations.

In view of these healthcare requirements, combined with ongoing changes in additive manufacturing technology, engineers need important resources to optimize medical device designs:

• Innovative new materials that meet the specific performance and aesthetic requirements of the application and the chosen printing method. Different

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Additive Technology

| Courtesy of Microsoft

material forms, such as filaments for fused filament fabrication (FFF), powders for selective laser sintering (SLS), and pellets for pellet extrusion, are required.

• Cutting-edge technologies and tools, particularly software systems, which help expedite the design process—including testing and prototyping.

• Regulatory expertise and quality system certifications, data and documentation to support FDA clearance under a 510(K) or premarket approval (PMA) pathway in the United States, assessment by Notified Bodies in the European Union, and the needs of other regulatory authorities worldwide.

Specialized materials for additive manufacturing Growing availability of advanced polymer materials in popular formats, including filaments and powders, gives designers the freedom to choose their preferred additive manufacturing method and ensures the end-use application delivers required properties and reliable performance.

Besides biocompatibility, material requirements for medical devices can include: • High temperature performance for sterilization • Chemical resistance to withstand harsh disinfectants • Impact strength for durable housings • Abrasion resistance for drill and cutting guides • Tensile strength for surgical tools

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• Rigidity for precision in small• •

diameter, minimally invasive instruments Fatigue performance for repeated loading in structural implants Radio-opacity or translucency for surgical imaging

Colorability is also often needed for device function identification and better usability.

High-performance healthcare materials for additive manufacturing include two chemistries with a long history of use. Polyetheretherketone (PEEK) delivers long-term performance under repeat loading, can be repeatedly steam sterilized due to its stability at temperatures up to 240°C (464°F), and offers exceptional chemical, wear and abrasion resistance. It is often reinforced with glass or carbon fiber for additional strength and stiffness. This combination of properties makes PEEK particularly suitable for metal replacement in surgical instrumentation.

Polyphenylsulfone (PPSU) offers bestin-class toughness and abuse resistance, which has led to its widespread use in surgical cases and trays. Chemical and hydrolysis resistance, and hightemperature capabilities are driving PPSU’s adoption for reusable surgical instruments that must be repeatedly steam sterilized. Early development work with fused filament technologies has shown a promisingly wide conversion

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processing window, which many attribute to PPSU’s amorphous chemistry. This polymer is translucent when additively manufactured.

Software systems for printing simulation Current design processes for an additively manufactured device may require multiple physical prototypes for testing and modification, adding time and effort.

Simulation software tools, on the other hand, allow engineers to test potential designs using different materials, identify issues and make changes digitally.

Further, integration with suppliers’ material data enables software systems to simulate and compare the printing process for a given design using different thermoplastics. For example, designers can predict mechanical performance and potential failures, and identify issues such as part warpage, anisotropic shrinkage, decohesion, residual stresses and process-induced microstructure.

They can use this information to optimize additive manufacturing parameters such as print direction and infill.

Material suppliers are working with software companies to print and test polymer samples and demonstration parts to predict thermo-mechanical performance and compare it to actual results. Such collaboration offers important advantages to the customer.

The benefits of using simulation software populated with material performance data start with faster time to market for a novel device. Designers can

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In some cases, processes that comply with current Good Manufacturing Practice (cGMP), the main regulatory standard for ensuring pharmaceutical

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Biological safety tests and reference standards More than 60% of global medical devices are still manufactured in North America. Device manufacturers should consider using material suppliers that are willing to support an FDA Master Access File for their additive manufacturing products. Material data provided by the supplier through a Master Access File can demonstrate successful testing for biocompatibility and include product formulation details to the regulator reviewing the FDA petition.

This confidential access by the agency can help reduce risk in the clearance process and accelerate time to market for additively manufactured medical products.n

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Regulatory and quality support for device clearance Device designers can benefit significantly from regulatory and quality assistance from their material suppliers.

Resources such as supplier support for an FDA Master Access File can help expedite the clearance process and strengthen the application. The following are key areas where suppliers can contribute to regulatory compliance and quality assurance.

• A robust quality management system (QMS) remains critical for medical raw materials converted for use in additive manufacturing.

The ISO 13485 standard sets out requirements for a QMS specific to the medical device industry Suppliers that adhere to this standard can demonstrate the stringency of their quality management processes.

• Validated processes are required in some supply chains for critical applications such as permanent implants. In additive manufacturing, where end products may not be able to be directly inspected or tested, regulators rely on process validation and need to understand how it is accomplished. The ability to explain validation methods can help manufacturers avoid a notice of non-compliance from the regulator.

quality, may be required. One example is a combination product—a device that delivers a drug or biologic. The FDA has issued a rule that the constituents of a combination product retain their regulatory status (as a drug or device, for example) after they are combined, and the cGMP requirements that apply to each of the constituent parts also apply to the combination product.

The biological safety of materials used in a medical device must be demonstrated under the ISO 109931 standard: Biological Evaluation of Medical Devices – Part 1: Evaluation and testing within a risk management process. Commonly required testing for the biological safety of limited body contact applications, such as wearables and instrumentation, includes cytotoxicity, sensitization, intracutaneous toxicity, acute systemic toxicity and subchronic toxicity.

Additionally, more-stringent testing such as genotoxicity, bone and muscle implant tests, hemolysis and complete characterization including exhaustive extractions and risk assessment, may be needed to ensure patient safety for long-term implants or devices that communicate with the body for a prolonged period.

in

avoid time-consuming trial and error by making design modifications digitally, based on results of the simulation.

In addition to identifying potential problems, they can spot opportunities to reduce infill for lighter weight parts and shorten printing times for improved productivity. Modifying a design on screen is fast, easy, less costly and potentially more accurate than creating and testing physical prototypes, and helps ensure the part is printed correctly the first time.

a

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A d d i t i v e

T e c h n o l o g y

A new approach

to powder bed fusion

makes more materials available for additive manufacture For a number of years, there have been two dominant ways to use powder bed fusion to additively produce metal parts. Now, there’s a third approach.

Will Richardson • CEO • Wayland Additive

Across many industry sectors, there is a continued drive to adopt metal additive manufacturing (AM) for production applications as an alternative to traditional fabrication processes. A key driver in this respect is the ability to produce geometrically complex and innovative products that are laborious, time consuming, restrictive, and cost prohibitive with conventional manufacturing processes.

New applications continue to emerge as manufacturers find ways to apply metal AM and harness its advantages. However, the rate of development is not as fast as many predicted even just a few years ago, because AM — particularly with metal materials — comes with a number of limitations of its own. Identifying applications that minimize these limitations is, unsurprisingly, not that easy.

At Wayland Additive, we have been working on the development of an entirely new powder bed fusion (PBF) process for metal AM that minimizes the existing limitations. When considering the two main PBF technologies, NeuBeam offers a third way.

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The end part — an impeller — directly off the NeuBeam system with no post-processing.

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Additive Technology In process view of the NeuBeam process, producing impeller part.

Metal AM processes Of the seven different process classifications for AM, there are three that are well established for metal.

Laser PBF is the oldest industrial metal AM process and uses precise, high-power lasers to melt powdered metals and alloys to form accurate, complex and fully functional metal parts.

• Powder bed fusion (PBF): using a high-power heat source — either a laser or an electron beam (eBeam) — to melt metal powders together, a layer at a time within a powder bed.

• Direct metal deposition (DMD): molten metal powder / wire is deposited onto an existing substrate in thin layers.

• Binder jetting: a powder bed process that uses a base metal powder material and a liquid binder material that is deposited a layer at a time to bind the powder.

This article is primarily focused on the most established metal AM processes for production applications — PBF. Laser vs eBeam for PBF PBF is arguably the most widely adopted AM process for structural production applications. This is partly down to process capabilities and partly due to the maturity of the technology. To date there has been a clear two-way choice with PBF, users either having the option to use laser-based PBF systems or eBeam PBF technology.

Both of these metal PBF processes have been around since the 1990’s.

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The most obvious difference between the two is the heat source used to melt the metal powder, indicated in the process names. Laser PBF typically uses a high powered 200-400 watt Yb-fiber optic laser (or series of lasers), while traditional EBM uses an eBeam in the region of 3–6 kW and a magnetic field to direct the beam. The very nature of the eBeam requires that the process occurs under vacuum, because any gas molecules in the chamber would adversely affect the beam, and the vacuum conditions also ensure safe operation. In contrast, the operating conditions for laser PBF platforms require inert gas, typically nitrogen or argon.

One trade-off between the two technologies comes down to precision versus speed. While laser PBF has traditionally held the advantage in terms of fidelity and surface finish (due to the precise nature of the laser(s)), eBeam PBF gains significant advantage in terms of speed and productivity as a result of the efficient way that electrons transmit energy to the powder bed, and throughthickness heating of the entire layer. In addition, eBeam can process multiple melt pools simultaneously, further contributing to increased productivity.

Specific benefits of laser PBF Laser PBF is the oldest industrial metal AM process and as stated uses precise, high-power lasers to melt powdered metals and alloys to form accurate, complex and fully functional metal parts. It is widely recognized as a stable process that can work with a relatively broad range of metal materials. The process handles very fine powders and therefore can achieve fine layer thicknesses (typically 20–40 µm, compared with 50–90 µm for EBM) and as a result produces parts with fine details and smooth surface finishes.

Specific benefits of eBeam PBF The eBeam PBF process is recognized as exhibiting favourable energy transfer physics and is characterised by superior metallurgy, with substantially fewer DESIGN WORLD

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issues concerning residual stress than laser PBF. This is because eBeam PBF operates at higher processing temperatures that minimize residual stresses and distortion, as well as failed builds due to cracking / mechanical failure. In addition, eBeam PBF permits good material properties, producing fully dense parts, and without contamination from highly oxidized particles seen in laser PBF [1] However ….

It is no secret in industry that existing Laser and eBeam PBF systems come with limitations, some of them prohibitive. To be clear (and fair) both have — rightly — proved valuable for certain industrial applications.

Although invariably this also necessitates compromise(s) to overcome their limitations, and sometimes, these compromises can negate the actual benefits of using AM in the first place.

With Laser PBF, the resulting internal residual stresses that the process generates requires extensive structural supports to prevent the parts distorting or cracking during the print process.

Sometimes these supports require as much material to manufacture as the parts themselves. Removing these supports post-build typically requires the use of wire EDM and machining operations. The parts typically also require stress-relieving in a furnace post-build – another operation, more cost, and another piece of equipment to maintain and run.

Laser PBF parts tend to be manufactured on support plates that are manufactured from a similar material to the printed part (Titanium parts are printed on Titanium plates etc). This is to ensure that the support material properly welds to the plate. As build volume size increases, the thickness of the plate also tends to increase, with very large parts requiring plates that may be several inches thick. For expensive materials such as Titanium this can be a considerable cost, especially if plates are lost to large distortion due to residual stresses. Notably, the eBeam PBF process can use thin plates made of cheaper materials [2], and thus does not require wire EDM to remove parts, and has many fewer supports.

Impeller part in prior to powder removal, illustrating the free-flowing powder, rather than the sintercake that is traditionally associated with the eBeam PBF AM process.

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With Laser PBF, the process also suffers from the production of highly-oxidized particles (“spatter”) being ejected from the melt pool [3]. Typically a cross-flow of Argon gas is used to carry away these highly-oxidized particles to a filter, but still a minority of these particles land in the powder bed and cause localized contamination, which can affect mechanical properties of the parts [4]. This cross-flowing gas contaminated with spatter is apparent as a plume of smoke emanating from the melt pool and carried in the downstream direction. When processing using multiple lasers, care has to be taken to ensure that one laser is not processing downstream of another as it can be obscured by the smoke. As the size of powder beds increases, it becomes increasingly difficult to maintain an even laminar flow of gas across the powder bed, and this tends to limit the feasible size of parts produced by laser PBF machines.

Similarly, the traditional EBM process faces its own challenges and constraints. First, users are often frustrated by the instability of the process.

This instability is caused by charge accumulation within the build chamber, which can result in powder scattering or a so-called “smoke event” that distorts the current layer of the build and therefore compromises the entire build. To avoid this, the process has to be operated in a specific way and has a steep learning curve. Particularly, it is critical to maintain the temperature of the powder bed between strict limits, which is required to cause the powder bed to sinter so that it isn’t disturbed by powder charging [5].

This unreliability means that eBeam PBF has typically been considered less favourable than laser-based PBF. The eBeam PBF process does however lead to downstream complexities that often negate the overall advantages of it. For example, the process entombs the parts in a sintered powder “cake,” which makes part removal and postprocessing very difficult, time-consuming and expensive. The challenge of removing unused powder from the parts also imposes geometry limitations on parts, for example with enclosed regions such as cooling channels on a turbine blade.

These compromises can limit the materials that can be used with eBeam PBF, as well as the geometrical forms that can be produced and ultimately the applications that it can be used for successfully. The powder recovery process for traditional EBM has long been a challenge as the June 2020

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Additive Technology break-up of the sintered powder is done with bead blasting in air, which presents an explosion risk when using fine, powdered reactive metals. Thus, coarser powders are used for safety reasons. Of course, there are benefits here, namely that the coarser powder is cheaper and builds thicker layers with faster build times. However, this comes with a tradeoff of rougher surface finish and lower fidelity. Typically, eBeam PBF is used with materials such as Ti 6-4, TiAl, CoCr or Inconel 718 simply because of the steep learning curve and complexity of process development.

A 3rd way — NeuBeam NeuBeam is a new PBF process that offers the best of both laser and eBeam PBF without the compromises, and opens up greater potential for more industrial applications. This new process is an eBeam PBF process that effectively neutralises the charge accumulation generated by the electron beam. This offers greater flexibility than laser PBF while overcoming the stability issues of eBeam PBF. In addition, the NeuBeam process enables metallurgical requirements to be tailored to application requirements. These process capabilities, along with the greatly improved ease of process development, also opens up the use of a much wider range of metal materials.

Despite a couple of commonalities between EBM and NeuBeam — namely that they are both PBF processes and they use an electron beam as the heat source to melt the metal powder — it is important to understand that EBM and NeuBeam are fundamentally different.

Unlike the traditional eBeam PBF process, the charging issues that make EBM unstable have been neutralized with NeuBeam using core physics principles developed in the semi-conductor industry. Moreover, NeuBeam is a hot-part process rather than a hot-bed process. The process efficiently creates parts that are free of residual stresses because the high temperatures are only applied to the part and not the bed, ensuring free-flowing powder post-build

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(no sinter cake) and stress free parts with reduced energy consumption.

Furthermore, the process overcomes many of the limitations for manufacturing large components – no residual thermal stresses, no gas crossflow, and a simpler powder removal process than existing eBeam systems.

The NeuBeam process can produce fully dense parts in a range of materials, many of which are not compatible with traditional eBeam or laser PBF processes such as refractory metals and highly reflective alloys. As a result, the NeuBeam process can demonstrate improved metallurgy without many of the compromises that existing metal AM processes necessitate.

NeuBeam also offers advantages with built-in real-time in-process monitoring, allowing for rapid material development or tuning of microstructures by adapting the solidification during manufacture.

With NeuBeam the process temperature is not constrained by sintering the powder bed, allowing the process temperature to be optimized to the material microstructure and/or the application.

These levels of in-process monitoring are achieved through a combination of advanced technologies, including structured light scanning, electron imaging and high speed infra-red cameras. Each of these different monitoring approaches are calibrated to the same reference points in the machine, with managed adjustments, to ensure optimum results and output.

Being a true thermal process, everything in the build chamber can be monitored, and it is possible to see the true temperature of the whole powder bed in-process as a build takes place. The thermal history of the material being processed can also be seen, as can the topography of the surface so that defects can be detected — and reported — as they occur. n Wayland Additive waylandadditive.com

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REFERENCES [1] C. L. A. Leung, S. Marussi, M. Towrie, R. C. Atwood, P. J. Withers, and P. D. Lee, “The effect of powder oxidation on defect formation in laser additive manufacturing,” Acta Mater., vol. 166, pp. 294–305, 2019.

[2] S. S. Al-Bermani, M. L. Blackmore, W. Zhang, and I. Todd, “The origin of microstructural diversity, texture, and mechanical properties in electron beam melted Ti-6Al-4V,” Metall. Mater. Trans. A Phys. Metall. Mater. Sci., vol. 41, no. 13, pp.

3422–3434, 2010.

[3] P. Bidare, I. Bitharas, R. M. Ward, M. M. Attallah, and A. J. Moore, “Fluid and particle dynamics in laser powder bed fusion,” Acta Mater., vol. 142, pp. 107–120, 2018.

[4] M. Velasco-Castro, E. Hernández-Nava, I. A. Figueroa, I. Todd, and R. Goodall, “The effect of oxygen pickup during selective laser melting on the microstructure and mechanical properties of Ti–6Al–4V lattices,” Heliyon, vol. 5, no. 12, Dec. 2019.

[5] Z. C. Cordero, H. M. Meyer, P. Nandwana, and R. R. Dehoff, “Powder bed charging during electron-beam additive manufacturing,” Acta Mater., vol. 124, pp.

437–445, 2017.

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Combining additive

and subtractive technologies for metal digital manufacturing Mark Cook • VP, Metals Products • 3D Systems & Dogan Basic • Product Manager • GF Machining Solutions

Bringing together additive manufacturing with precision machining enables manufacturers to seamlessly combine additive and subtractive technologies for more efficient production of complex metal parts within tight tolerance and reduced cost of operation. Here’s a look at one way to implement such a combination.

Working with an additive vendor’s innovation centers, such as the 3D Systems’ Customer Innovation Centers (CIC) or GF Machining Solutions’ AMotion Center, can help users on their journey with additive manufacturing. In printing, repeatable quality, process robustness and throughput are key to achieve a low TCO.

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A d d i t i v e

M

T e c h n o l o g y

Manufacturing is undergoing a transformation as companies introduce the power

of additive manufacturing (AM) into workflows built upon traditional technologies. Manufacturers that have earned a reputation as industry leaders have already embraced how additive manufacturing can complement their traditional workflows for competitive advantage. Weâ&#x20AC;&#x2122;ve seen evidence in the most recent Ernst &Young study (â&#x20AC;&#x153;3D Printing: Hype or Game Changer,â&#x20AC;? 2019) that confirms the adoption of additive is ramping, with nearly 75% of companies either already embracing the technology, or considering integrating it into their manufacturing workflow. As a result of using AM, manufacturers are able to achieve design freedom, increase agility, scale production, and improve overall total cost of operation (TCO).

The business case for metal additive manufacturing Metal AM is a design-driven manufacturing process that uses high-powered lasers to selectively weld powdered material where prescribed, and leave it to be evacuated where unwanted. Companies typically invest in metal additive manufacturing to take advantage of the benefits unlocked by the nearly unlimited design flexibility of a digital workflow.

Metal AM also enables the creation of parts that would be nearly impossible to produce in any other way, featuring custom exterior or interior geometries that lower weight (which translates to cost reduction in production, implementation, or both) or improve function (which can also have significant economic ramifications). Additionally, metal AM makes it possible to consolidate multiple parts into one single design and replace complex assemblies of components, which limits associated labor costs and contributes to enhanced structural integrity through the elimination of weak joining points.

Beyond the economic values already listed, metal additive manufacturing opens the door to more agile manufacturing, mass customization, and supply chain consolidation. Increasing productivity, reducing inventory, and accelerating time-tomarket become tangible and strategic opportunities with the

A zero-point System 3R referencing and clamping system enables optimal positioning of the build plate, facilitating a quick transition from the printer to post-processing steps. This reduces set-up times and provides enhanced flexibility by quickly transitioning the build plate from the additive process and sending it downstream, saving significant time and money.

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Additive Technology An all-in-one integrated AM software, such as 3Dxpert, handles all stages of the manufacturing process from design, print and structure optimization to build simulation and the programming of post-processing operations. In addition, such software can help predict build failures or damage to the printer before sending the model to print.

correct metal AM solution. While additive manufacturing’s benefits are numerous, the introduction of these technologies into existing business models and workflows can be challenging for those who are new to AM. Drawing on the know-how of experts can help companies plan for and execute a successful implementation.

Bringing together additive and subtractive technologies 3D Systems’ and GF Machining Solutions’ combined strengths to help more manufacturers take advantage of additive. Bringing together additive manufacturing with precision machining enables manufacturers to seamlessly combine additive and subtractive technologies for more efficient production of complex metal parts within tight tolerance, and reduced TCO. The companies developed an optimized workflow, from part design to post-processing, to help each manufacturer integrate and scale metal 3D printing solutions easily. These solutions require specific rules, different from those used in machining or injection molding.

The process begins with the customer’s application; designing the best solution to achieve their needs and address their challenges. Both companies offer service centers where customers can discuss a custom solution. The solution will involve metal AM workflow that uses steps to move from design to the final part. Here is a look at what those steps might encompass.

The first step, Design, requires all production steps to be defined.

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The second step, Prepare, involves preparing and optimizing a part for AM, as this has a direct impact on part quality, efficiency and cost. Users can use an all-in-one integrated AM software, such as 3Dxpert, to handle all stages of the manufacturing process from design, print and structure optimization to build simulation and the programming of post-processing operations. In addition, such software can help predict build failures or damage to the printer before sending the model to print, thereby facilitating the creation of successful prints and shortening time to market.

In printing, repeatable quality, process robustness and throughput are key to achieve a low TCO. For example, the DMP Flex 350 and DMP Factory 350 printers (from GF Machining Solutions’ and 3D Systems) use a vacuum chamber that guarantees a consistently low oxygen level of less than 25 ppm. A laminar argon flow, which, together with the low levels of oxygen, ensure consistent fatigue mechanical properties.

And a Removable Print Module (RPM) ensures minimum changeover times.

Quality analysis is key in serial part production, and many companies considering metal AM underestimate the cost and time factor currently required during inspection. Using tools such as DMP Monitoring and DMP Inspection helps users detect and analyze defects in the correct size and at the correct location with a high accuracy. This in turn helps users make informed decisions on part quality to reduce or eliminate certain quality inspection

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steps, thus improving efficiency.

The final step is post processing.

Almost all metal 3D printed parts require post processing to remove support structures, and drill or tap holes. Users need to keep in mind the specific properties of the 3D printed parts, especially when looking for solutions that integrate all technologies into the manufacturing process. There are tools that will facilitate clamping inside a milling machine. Several EDM options will separate the 3D printed part from the base plate at low operating cost.

This complete workflow, which combines additive and subtractive technologies, enables users to achieve high quality, repeatable parts at an optimized cost per part.

Transforming production for competitive advantage Metal AM has become an important technology for end-use production applications— especially for aerospace and healthcare. This is due in large part because of its benefits: unparalleled value in part cost reduction, increasing efficiency of designs, light weighting of parts, assembly consolidation, and the ability to design and produce unique parts that would not be possible with traditional manufacturing technologies. As adoption of metal AM increases, companies will transform how they create new, improved products while gaining efficiencies that place them ahead of their competitors. ■ 3D Systems www.3Dsystems.com GF Machining Solutions ww.gfms.com DESIGN WORLD

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Medical www.designworldonline.com

A Supplement to Design World - June 2020

How are alternative during ventilators helping the COVID-19 pandemic

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M e d i c a l

T i p s

How are alternative ventilators helping during the COVID-19 pandemic?

Amid the shortages of vital equipment during the pandemic, ventilators stand out — their presence a matter of life or death for people needing respiratory assistance.

Sean Whooley | Assistant Editor

COMMON INVASIVE VENTILATORS are in short supply. While numerous companies have stepped forward to scale up production of the expensive products (usually between $25,000 and $50,000), the need for equipment continues to grow.

“If a patient goes to a hospital, and all of the ventilators are taken up, the only other option the patient has is to have a nurse or, God forbid, a loved one, actually ventilate that patient by hand,” University of Minnesota Earl Bakken Medical Center lab supervisor Aaron Tucker recently told the DeviceTalks Weekly Podcast.

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This Ambu-bag-based ventilator from Georgia Tech, Cranfield University (UK) and Emory University is designed to help with the ventilator shortage during the COVID-19 pandemic. | Courtesy of Stephen Norris, Georgia Tech

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M e d i c a l

T i p s

DC DYNAMIC CONSTRUCTION Nitto Kohki’s manufacturing expertise has been leveraged for DC-motor driven vacuum pumps and air compressors

that consistently perform at the industry’s highest levels.

It’s all about how we build the product--- and how that translates into high reliability, impeccable quality, and long, consistent performance life (> 10,000 hrs.).

Tucker, in collaboration with the University of Minnesota’s Dr. Stephen Richardson and an interdisciplinary university team, developed the Coventor as an alternative to the common intensive care unit ventilator.

The device, touted as a design costing just $150, became the first of its kind to garner FDA emergency use authorization (EUA).

Boston Scientific is acting as the sole manufacturer of the device, which the company expects to sell at-cost at approximately $1,000 per unit.

A one-armed robot

The Minnesota researchers created what they call a “one-armed robot” to replace the person who would have to ventilate by hand, freeing up nurses and preventing loved ones from having to perform the task themselves. The device features a bag valve mask (commonly known as an Ambu-bag) and does not require pressurized oxygen or air supply, unlike commercially available ventilators.

The Coventor’s mechanical actuator was designed to stabilize and compress a commercially available ambulatory ventilation bag filled with oxygen or ambient air if oxygen is unavailable. That bag is connected to the patient’s endotracheal tube. It is possible to produce the device’s frame using metal stamping, 3D printing or by modifying consumer goods, according to the Coventor website.

“We are not trying to replace the highend ventilators,” Tucker said. “We’re in such a unique time right now that we didn’t think they could build those high-end ventilators fast enough… We wanted to give another option in the case of dire need.”

More ingenuity

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Tucker and the Minnesota team aren’t the only researchers putting together these kinds of machines. Georgia Tech Woodruff School of Mechanical Engineering associate professor Shannon Yee and a global group contributed to designing a device at Cranfield University in the United Kingdom before building and testing it at Georgia Tech, in collaboration with Emory University.

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The collaboration’s mechanicalassist product includes two Ambubags to offer the capability to ventilate two patients at once with individual controls for each patient’s volume. The device doesn’t rely on a microprocessor or sensors and instead uses a mechanical design with an eye on scaling more rapidly.

Yee told Medical Design & Outsourcing that he estimates that the bill of materials for just the parts comes in at less than $100, with the most expensive component being the motor and gearbox system at $63 when bought off the shelf.

Including labor, Yee said they’re looking at a couple hundred dollars as the cost to make each machine.

In the pilot assembly line, the team assembled seven devices in two hours, giving Yee confidence in the ability to scale production.

“I wouldn’t classify it as homebuilt,” Yee said. “What we specifically targeted in our design was recognizing that we’re going to be facing a logistics- and supply-chain problem. We wanted our design to be simple enough so that conventional manufacturing techniques … could be employed in order to mass-produce these makeshift ventilators.”

Like the Minnesota researchers’ device, this design is targeting the option to ventilate patients without replacing the common ICU machines.

Clinicians offered positive feedback on the device and the next steps include pursuing FDA EUA after licensing the product to a manufacturer.

manufacturers can focus on getting supplies out.

Tomes pointed out that that problems could arise with certain data not being reported to the FDA, and that word-of-mouth may not be enough to prevent the use of potentially problematic devices.

“With the relaxed rules, we’re not going to get that data,” Tomes told MDO. “It’s not a place where the FDA should be relaxing.”

However, if products like the Coventor prove safe and effective enough for FDA authorization, and more efforts like the product Yee’s team developed reach the market as well, the potential to plug a massive hole in the shortage of ventilators excites the former FDA employee.

“It’s amazing that they’re coming up with different ways to help these patients,” Tomes said. “To have a second option, even if it’s not as sophisticated … It’s fantastic that people all around the world are trying to help solve this problem.” M

High-quality devices contribute to patient safety and consistent coatings lead to predictable, reliable device performance for physicians and patients.

A University of Minnesota team developed the Coventor ventilator, the first device of its kind to win FDA emergency use authorization. | Courtesy of University of Minnesota

How will we know if they’re helping or hurting?

Device Events founder & CEO Madris Tomes, who previously worked in the FDA’s post-market surveillance division, raised concerns over the agency’s relaxed guidance on reporting problems with devices so DESIGN WORLD

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David Lindsay, a senior biomedical equipment technician and field service manager, works on an old ventilator in Jackson, Tenn. | Courtesy of Co-Vents

Could refurbished ventilators be a

secret weapon against COVID 19?

Old ventilators will get new life from a nationwide network of engineers and technicians.

Nancy Crotti Managing Editor

A pair of medtech industry veterans formed a not-for-profit corporation in April to obtain and repair used ventilators for patients fighting COVID-19.

Co-Vents has six FDA-approved and ISO-certified ventilator service centers lined up to do the work in New Jersey, Tennessee, California, Illinois and Georgia, according to co-founder Michael Raymer. The organization is seeking decommissioned Puritan Bennett, Philips/Respironics and CareFusion critical care ventilators to refurbish, Raymer told Medical Design & Outsourcing in an interview.

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D

ISO 9001 • ISO 13485

EAGLE STAINLESS Tube & Fabrication, Inc.

“Our goal is not to distribute directly to hospitals because we don’t want to encourage hoarding,” Raymer said.

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.

Co-Vents will buy or accept donations of old ventilators from hospitals, rental firms and brokers, Raymer said. If a ventilator is beyond repair, the shops will salvage the most expensive working parts and use them to repair other machines.

With the help of the White House Coronavirus Task Force, Co-Vents has obtained a $300,000 grant from a private foundation to start purchasing the machines so it can offer them at a fixed price to the national or state stockpiles once they’re repaired, according to Raymer. Proceeds from ventilator sales will go back into repairing and shipping others. Co-Vent will also pay for ventilator parts, labor and shipping, and aims for a turnaround time for just over a week. In the next two months, the organization aims to deliver 500 to 1,500 repaired or refurbished ventilators.

“Our goal is not to distribute directly to hospitals because we don’t want to encourage hoarding,” Raymer said.

The Co-Vents team knows its way around ventilators. Now a business consultant and chief strategy officer for investment and networking platform AngelMD, Raymer was general manager of clinical information systems for ventilator manufacturer Puritan Bennett from 1988 to 1998. He formed Co-Vents with his former boss at Puritan Bennett, Paul L. Woodring. Woodring spent 19 years at that company, serving as chief engineer, VP of engineering, VP and general manager. Woodring also worked for six years as president of Respironics’ hospital division.

William “Chip” Furniss has signed on as engineering manager for Co-Vents. A principal partner for product incubator and design consultancy Spectrum Biomedics, Furniss helped develop the first microprocessor ventilator at Puritan Bennett and went on to become a business unit manager there. Furniss later served as senior director of clinical research at Respironics and VP of surgical equipment R&D at Bausch + Lomb.

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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.

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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!

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6/9/20 9:42 AM

NEW GENERATION

You’ve never seen

a solenoid valve like this before.

TM

High Flow, Low Power, Low Leakage Across an Extensive Cycle Life The Lee Company is excited to announce a new generation of versatile and innovative 3-port solenoid valves. In a miniature 10mm package, the genvi™ solenoid valve platform features high flow capacity, low leakage and ultra-low power consumption. Designed using innovative manufacturing techniques, this new valve offers not only unmatched reliability, but also an economical price point suitable for molecular diagnostics, respiratory therapy, compression therapy, environmental analyzers, breath analysis and other applications where performance and reliability are paramount.

When designing portable or stationary instruments, OEMs are often challenged with meeting aggressive size, power, and weight limitations, all without sacrificing the remaining elements of system-level performance.

Each subcomponent is therefore pushed to offer improved performance within a smaller footprint.

Featuring high flow and low power consumption, genvi solenoid valves are the solution. An extremely tight leakage rating reduces compressor demand and further underscores the valve’s ability to provide consistent long-term operation across an extensive cycle life.

Custom valve solutions, supported by The Lee Company’s engineering experience in microfluidics, are also available to meet specific application requirements.

Innovation in Miniature ®

The Lee Company

2 Pettipaug Rd, Westbrook CT 06498-0424 8 6 0 - 3 9 9 - 6 2 8 1 | 1 - 8 0 0 - L E E - P L U G | w w w. t h e l e e c o . c o m W E S T B R O O K

Genvi_DesignWorld_DEC2019.indd The Lee Company 5-20.indd 160 1

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(Co-Vents is not alone in its mission to repair and redeploy old ventilators. According to a report by The Associated Press, fuel cell manufacturer Bloom Energy is doing the same, at the request of California Gov. Gavin Newsom.)

Raymer said he and Woodring came up with the idea for Co-Vents in late March when news started coming out about ventilator shortages and automakers like General Motors and Ford gearing up to manufacture the lifesaving machines.

They called the U.S. Department of Health and Human Services for help and found an Indianapolis firm that helped them incorporate the organization in 24 hours and file an expedited form for 501(c)3 tax-exempt status with the Internal Revenue Service. Co-Vents gained that status and accepted its first tranche of “retired” ventilators in midApril.

“We really did it because Paul and I had seen what was going on in New York and we called each other and said, ‘There are ways to get ventilators to patients instead of sharing ventilators or trying to convert a C-PAP device to a ventilator,’” Raymer said. “We think it’s a pretty remarkable story.”

Raymer wrote in an AngelMD blog post that starting with existing ventilators, whose designs that have already been approved by the FDA, is a lot more likely to ease a shortage than setting up new ventilator assembly lines in converted auto factories. One problem: Some ventilator designs have assembly steps that require clean rooms, perhaps time-consuming to set up in settings such as converted auto assembly lines.

“The Puritan Bennett 7200, for example, had two proportional valves that were fast-acting,” explained CoVents executive Dave Crawford. “One supplied oxygen from a high-pressure source, another supplied air. Those valves were assembled in a clean DESIGN WORLD

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room because they had to be clean.”

A point also favoring refurbishment rather than making new machines is that the testing protocols for refurbished ventilators are relatively straightforward, Crawford added. “After the refurbished machine has passed its initial tests, you run it at temperature for a few days and test it again. If it passes, it is good to go,” he said. “dThe FDA approves the process, but they don’t monitor every machine.”

Co-Vents CEO Woodring said he and his former colleagues could not stand by and watch patients suffer without access to ICU ventilators.

“Over the past three decades, we have designed, built, manufactured and sold the leading ventilators in the world,” he said. “We have assembled an all-star roster from those businesses to help fill this 90-day ventilator gap for our country while new ventilator production ramps up.” M

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A deployed stent in the Aortic Training Aid, used to replicate aneurysms, used to practice or familiarize residents and fellows with advanced endovascular skills. | from Steve Anderson/ Mayo Clinic

How glass tubing supports

Mayo Clinic innovation

At the Mayo Clinic Glass Shop, scientific glassblowing creates glass tubing and apparatuses for cardiac, transplantation and tissue perfusion research — and more recently, to help fight the COVID-19 pandemic.

Steve Anderson is one of only two scientific glassblowers in Minnesota. As a senior Danielle Kirsh Senior Editor

scientific glassblower at Mayo Clinic, he has developed glass aneurysm models, aortic stent placement training aids and liver perfusion systems. Recently, he received a request to make nebulizers to test the fit of N95 face masks in the fight against coronavirus. It was an apparatus he’s never made before.

“They can purchase the nebulizers made of plastic, but the people doing the testing prefer the glass models,” Anderson told Medical Design and Outsourcing. “They only have a few of the glass models, which are probably quite old, so they asked me to make up 20 more for them.”

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“They can purchase the nebulizers made of plastic, but the people doing the testing prefer the glass models,” Anderson told Medical Design and Outsourcing.

Scientific glassblowing is a form of glasswork that is used in organic chemistry, medical devices, pharmaceutical applications and research. Some of the earliest examples of scientific glassblowing include Galileo’s thermometer and Thomas Edison’s light bulb, according to the American Scientific Glassblowers Society. Today, scientific glassblowing offers highly specialized glass apparatuses for a number of applications, from training to nebulizers.

The Mayo Clinic Glass Shop goes back to the early 1900s and specializes in scientific glassblowing. It works in collaboration with clinical and research groups within the Division of Engineering at the Rochester, Minn.– based health provider. The shop has manufactured a number of glassblown apparatuses and models for research and training aids for physicians to practice endovascular skills and more.

The unique properties of glass offer benefits that medical researchers sometimes prefer over other materials like plastics.

“Glass is a real inert material, and it’s resistant to most acids,” Anderson said. “It has a low coefficient of expansion, so you can autoclave it.

You can adjust the temperature of an experiment rather quickly, and it won’t break. When you’re all done, you can wash it up and reused it again, sterilize it with the autoclave and put it back into service.”

For his new nebulizer project, Anderson is reverse-engineering one of the plastic nebulizers Mayo Clinic had. He starts with a 4- to 5-ft length of glass tubing and a 4 mm diameter tube to make the spray nozzle. The main body of the nebulizer is made from a 10 in. piece of 18 mm tubing

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Steve Anderson glassblowing at the bench with the Carlisle CC bench burner and hand torch. Lathe in the background. | from Steve Anderson/Mayo Clinic

with a 32 mm bulb that has a 5 ml reservoir on one end. Then, 4 mm OD tubing is used to fabricate a small injector that has a venturi-type effect to create a mist with a scent. If a person wearing a mask can smell the scent, the seal is no good.

“I seal the venturi tube into the bottom of the 5ml reservoir. So, when they give it a burst of air, it siphons up a small amount of water with some kind of scent in it. This creates a little mist that blows into a small hood area where the person is wearing a mask.

If they can smell the scent, the mask’s seal is no good,” Anderson said.

For medical devices, glassblowing offers high mechanical strength against pressure and impact. Most of the scientific glassblowing Anderson does consists of borosilicate glass,

www.designworldonline.com

which is more commonly known by the trade name Pyrex.

Glass for scientific glassblowing has working characteristics that are much stiffer than artistic glassblowing, according to Anderson. The soft glass in artistic glassblowing has a higher coefficient of expansion than the borosilicate used, so it stays soft and pliable longer.

“They make glass with many different properties, so you can actually seal glass to different metals and alloys for glass-to-metal sealing, which is good for working in vacuum systems,” he said.

Glass tubing is made using tools such as bench burners, hand torches and lathes. To make the tubing, Anderson puts a piece of glass on a lathe with a stopper connected to a

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swivel with a latex blowhose that allows the glassblower to blow through. Anderson heats up the glass as he turns it in the lathe. He can then bring in the tail stack of the tube as the glass melts or softens — thickening it or pulling it out thin. He can also shape tubes into different fixtures or fittings with joints on one side and a piece on the other.

“For high precision or larger pieces, I use a lathe. Smaller pieces I’ll make by hand, sitting at a bench with my torch,” Anderson said.

Anderson has also developed perfusion tissue baths with ECG capabilities at the Mayo Clinic Glass Shop. The perfusion tissue bath was created for cardiac researchers who requested a new design because the perfusion tissue baths they were using at the time were unable to simultaneously record multiple cardiac parameters without causing damage to the myocardium. The glass version allows for simultaneous automatic recording of the electrocardiographic, biochemical, hemodynamic and electrophysiological changes from a perfused heart in temperature- and oxygenation-controlled environments.

Anderson and engineers within Mayo Clinic’s Division of Engineering have also made a liver perfusion system for transplantation research. The glass design increased the average viability of the liver cells and the average yield of cells per gram of liver tissue. Human cells that have been isolated in the perfusion system have been used to study liver cell engraftment, vaccine testing, virus traits, studying the disease mechanism of the liver and for work on creating an artificial liver.

One of the most recent scientific glassblowing projects Anderson and his colleagues completed was a training aid for aortic stent placement. The model is a glass replica of the aorta with major arterial branches that can replicate aneurysmal disease of the aorta. Mayo Clinic fellows and residents are able to practice intricate procedures without being exposed to radiation or injuring a patient. M

NEWe!nt Kit

WHAT DO YOU THINK?

pm Develo able!

Avail

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

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MEDICAL MEDICAL DESIGN WORLD

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Eagle Stainless Tube & Fabrication Inc. Eagle Stainless Tube & Fabrication Inc. is the leading supplier of ultra high precision, cut-to-length, stainless steel tubing, nickel alloys, and alluminum for medical, electronic, semiconductor industrial, and aerospace applications.

ISO 13485 & ISO 9001 certifications have reinforced Eagle’s commitment to each and every customer to provide the ultimate in quality, service and reliability.

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Tubing - Hypodermic, Fractional, Metric and Pipe Bar Stock Custom Sizes and Shapes Custom Fabrication Precision Cut-to-length Laser Welding & Cutting CNC and more!

At Eagle we welcome the opportunity to share our expertise in developing product concepts and helping you solve your engineering problems.

Eagle Stainless Tube & Fabrication Inc. 10 Discovery Way Franklin, MA 02038 E-mail: info@eagletube.com www.eagletube.com Tel: 1-800-528-8650 Fax: 508-520-1954

Master Bond Inc. Toughened, Urethane Based Epoxy System Meets USP Class VI Specifications Master Bond EP30DPBFMed is a two part, flexibilized epoxy-urethane hybrid system that can be used for bonding, sealing, coating, and encapsulation. It is formulated for disposable and reusable medical devices, meeting USP Class VI requirements while also complying with RoHS3 in accordance with the EU directive 2015/863/EU. EP30DPBFMed is resistant to thermal cycling and sterilization, withstanding exposure to gamma radiation, e-beam, EtO, as well as other liquid sterilants.

Due to the addition of a urethane based flexibilizer, EP30DPBFMed offers both a higher abrasion resistance and a higher elongation when compared to a typical epoxy system. At room temperature, it has an elongation at break of 20 to 40%, and Shore D hardness of 30 to 50. It is useful in applications where low stress is important, due to its low modulus value. This compound is electrically insulative with a volume resistivity greater than 1014 ohm-cm. EP30DPBFMed is serviceable over a wide temperature range from cryogenic 4K to 250°F.

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

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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

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DESIGN WORLD

6/9/20 11:11 AM

MEDICAL

A New Generation of Versatility & Innovation Introducing genvi® control valves, a new generation of versatile and innovative 3-port solenoid valves, offering high flow rates and low power in a miniature, 10mm package. The genvi solenoid valve challenges the limitations of current fluidic technologies by allowing design engineers to use a miniature, low power solenoid valve without compromising system-level flow rate requirements.

The genvi solenoid valve was designed using innovative manufacturing techniques to offer not only unmatched reliability, but also application versatility at an economical price point. This solenoid valve platform is suitable for molecular diagnostics, respiratory therapy, compression therapy, environmental monitors, breath analyzers and other applications where performance and reliability are paramount. To learn more, visit www.theleeco.com/genvi.

The Lee Company 2 Pettipaug Road PO Box 424 Westbrook, CT 06498 www.theleeco.com Phone: 860-399-6281

It’s not a web page, it’s an industry information site So much happens between issues of R&D World that even another issue would not be enough to keep up. That’s why it makes sense to visit rdworldonline.com and stay on Twitter, Facebook and Linkedin.

It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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Product World Linear position potentiometers AutomationDirect automationdirect.com GEFRAN linear potentiometers and accessories are used to detect position and linear direction movement. A sliding contact moves along a linear resistive element acting as a variable resistor. The proportional change in resistance indicates the position and provides a distance measurement signal. A signal conditioner can be used with the potentiometers to

Ultra-lowtemperature FKM Greene Tweed gtweed.com The Fusion FKM 665, an ultra-low-temperature, and chemical-resistant elastomer, was specifically formulated to meet and exceed the requirements of Aerospace Material Specification (AMS) 7379 and AMS-P-83461. With a temperature range of -70° to 450°F (-57° to 232°C), Fusion 665 achieves low-temperature performance without compromising high-temperature performance.

Before Fusion 665, elastomer material composition resulted in trade-offs. Achieving optimal low-temp performance meant sacrificing high-temperature operating range, chemical compatibility, or dynamic sealing performance. Fusion 665 was developed to overcome existing limitations of comparable materials, such as NBR, FKM, or FVMQ (Fluorosilicone).

convert the signal to 0-10 V or 4-20 mA. Eight series of linear potentiometers are available. Configuration styles include slide housing, heavy-duty cylinder with rod eyes, rodless slide, spring-loaded with ball tip, ½-in. diameter cylinder with flange, rod eye or bracket mounting, and ¾-in. cylinder with

Compact global shutter 3.2MP sensor Teledyne e2v imaging.teledyne-e2v.com

rod eye mounting. Stroke lengths vary from 10 to 1000 mm depending on the series.

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The Emerald 3.2 Megapixel CMOS image sensor is specially designed to tackle the challenges of emerging applications such as security, drones, and embedded vision, as well as traditional machine vision.

With its 2.8 µm global shutter pixel, the new 3.2M sensor shares all of the characteristics of the Emerald sensor series: low-noise performance, compact format, easy integration, and a range of embedded features.

The sensor has been designed in an ultra-compact light package format with low power to address the challenge of optimizing SWaP-C (Size, Weight, Power, and Cost). The device also features a MIPI interface, that provides a direct connection to low-cost MIPI ISPs and a central optical center that helps to minimize camera size. Its small pixel enables the sensor to fit within compact and cost-effective S-mount optics. In addition, Emerald 3.2M is pin-to-pin and optically compatible with Emerald 2M and Emerald 5M, so that multiple resolutions are supported from one single design, saving cost.

www.designworldonline.com

DESIGN WORLD

6/9/20 8:58 AM

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

Brakes for automated guided vehicles Miki Pulley mikipulley-us.com Automated Guided Vehicles (AGVs) now require highly responsive braking and holding power while minimizing battery usage. BXR-LE brakes provide perfectly controlled braking using less power for the demands put on AGVs. Computer-controlled, wheel-based, and battery-powered, AGVs are load carriers that travel along the floor of a facility without an onboard operator or driver. The AGV must have emergency braking capability as well as have a default brake to hold position when not in motion. The BXR-LE brake is a power-off engaged brake that will hold the AGV in place when not in use. When the AGV must navigate the production floor, the brake is energized, which disengages the rotor disc and allows free rotation of the AGV drive wheels.

The BXR-LE brake uses 24 Vdc for a split second to overcome compression spring inertia to open the brake, then consumes only 7 Vdc by using the BEM power control module. This saves battery power and minimizes the number of battery recharging operations needed to keep the AGV in continuous operation.

Specifications: • Maximum RPM: 6000 • Static friction torque range: 0.044 to 2.36 ft.lb. (0.06 to 3.20 Nm) • Ambient operating temperature 14° – 104°F (-10° to 40°C)

Three-phase power analyzer Carlo Gavazzi GavazziOnline.com The WM15 Three-Phase Power Analyzer is a new addition to a range of energy meters and power analyzers, which are targeted to assist manufacturers and end-users in monitoring and managing escalating energy costs. The WM15 is a Class 1 (kWh) 3-phase power analyzer which can be used for single, two, and three-phase systems, as well as wild-leg systems. It can measure most relevant instantaneous electrical variables, energy consumption, and harmonic distortion.

The WM15 is a suitable alternative when traditional analog meters need to be replaced, providing final users with immediate visual indication of the current values using the three-bar graphs shown on the matrix LCD display.

Installation is easy and error-proof, and commissioning is fast, making the WM15 suitable for panel builders, OEMs, and installers. The economical WM15 is designed for use in a variety of markets and applications, including conventional energy, building, and industrial automation.

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Product World Easy programming software ABB new.abb.com Wizard easy programming is a graphical programming method designed to enable users to quickly create robot application programs for ABB’s single-arm YuMi collaborative robot, without the need for specialized training.

This easy programming software is built on the concept of Blockly, an open-source visual coding method that presents programming language or code as interlocking blocks. By using this simplified approach, Wizard allows users to program and use the Single-Arm YuMi robot without prior knowledge of any robot programming language. A user can simply drag and drop these functions on the FlexPendant, see the results immediately, and adjust the robot’s actions within seconds.

Combined with its lead through programming feature, Wizard easy programming makes using a single-arm YuMi robot smoother than ever.

The software features essential robot functions such as “move,” “pick,” and “vacuum,” covering a range of tasks that are usually executed by the robot. There are also functions for error handling, allowing novice programmers to handle errors such as collisions. By simplifying the typically complex programming associated with handling errors, Wizard easy programming can help any robot user develop highly effective robot programs.

SFF embedded computer Acromag acromag.com This rugged, small form factor (SFF) embedded computer system with modular I/O is design for signal processing, communication, and control functions. The ARCX1100 is optimized for size, weight, power, and cost (SWaP-C) with a COM Express Type 10 CPU and four slots for Acromag’s plug-in AcroPack I/O modules. Overall size with an integrated removable SSD bay is just 7.6 x 7.6 x 3.25-in. and 4.55 lbs.

Fanless, extended temperature operation from -40 to 71°C is supported with an Intel Atom E3950 (Apollo Lake) processor and four AcroPack I/O modules installed. Peripherals include two RJ45 gigabit Ethernet, two USB 3.0, two RS232, mini DisplayPort, and audio ports, plus M.2 and SATA data storage connectors. Four 68-pin VHDCI connectors securely route field I/O to the AcroPack modules without any loose internal cables to interface a mix of analog, digital, serial, FPGA, avionics, and other I/O signals.

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TUESDAYS Working remotely is going to get a little less remote.

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Each week, the organizers of DeviceTalks conferences will bring a lively, informative and enjoyable opportunity to catch up with medtech colleagues, gain insights on our evolving sector, and make new essential connections to help you move forward.

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Working with medtech leaders, our DeviceTalks team will bring together medtech professionals for a 90-minutes to discuss pressing issues of the day in these five critical areas in our industry.

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INNOVATION & FINANCE PROTOTYPE & PRODUCT DEVELOPMENT MANUFACTURING & SOURCING REGULATORY, REIMBURSEMENT & MARKET DEVELOPMENT NEW TOOLS AND TECHNOLOGY Each DeviceTalks Tuesday will kick off with a quick briefing from the Editors of MassDevice and Medical Design and Outsourcing. These presentations will give attendees insights on what trends will be moving medtech in the days to come.

Next, Tom Salemi, host of DeviceTalks Weekly, will interview medtech leaders and facilitate discussions or presentations tackling critical areas within medtech.

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Product World Cables for food and beverage processing applications Lutze lutze.com There is now a new line of food-safe control and motor cables for the food and beverage industry. LUTZE SILFLEX FBP cables are designed to meet both UL and FDA requirements solving the compliance challenge many food and beverage machine builders and processing companies are facing.

Equipment and machines for the food and beverage industry are required by the FDA to be sanitary, easy to clean, and safe for food contact. However, most industrial cables contain flame retardants and other harmful additives which do not meet food contact requirements. LUTZE SILFLEX FBP cables are an innovative patent-pending solution to this problem. The cable design achieves compliance with UL flame test requirements while meeting FDA food contact requirements outlined in 21 CFR.

Downloadable upgrade software Heidenhain heidenhain.us There is now new free downloadable upgrade software with new features for all users of current model ACU-RITE digital readouts to be more productive and efficient in their manufacturing.

ACU-RITE’s current family of DROs include models 100, 200, and 300. The new software version is titled “v1.4.0” and is available online on the ACU-RITE website / Software Updates. This new version includes several new enhancements.

Features: • Axes Q - The letter Q has been added to the axes’ names list specifically at the request of our customers using their DROs on Optical Comparators. Available in DRO 100/200/300.

• Zoom Timeout - A “Zoom Timeout” time delay has been added to the Dynamic Zoom & Highlight feature so that users can set the amount of time that the Zoom or character color change stays active when an axis stops moving. Of course, if the user starts moving another axis before the delay time is reached, the delay is ignored in about half of a second. Available in DRO 200/300.

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Drive series for infrastructure pump, fan, and compressor applications Siemens new.siemens.com The Sinamics G120X drive is a simple, seamless, and easy-to-use drive, designed for use in pump, fan, and compressor applications in industries such as water/wastewater, HVAC/R, irrigation/ agriculture, and in industrial environments. Sinamics G120X has a power range of 1–700 hp (0.75–630 kW) and can operate in a temperature range from -4 to +140° F (-20 to +60° C) with any standard motor, including synchronous reluctance motors (SRM). It has an integral DC choke which improves harmonics and EMC performance.

Sinamics G120X meets all the latest and upcoming UL, NEMA, and EN/IEC standards for 2019 and beyond and offers up to 100 kA short-circuit current rating (SCCR) ensuring enhanced product safety and energy efficiency.

Sinamics G120X easily integrates into existing applications and is configured for cost-optimization and resource-saving operation, which ultimately helps reduce total cost of ownership.

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

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

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Little vs Big Data

By Derek Thomas Vice President of Sales & Marketing Machine Automation Solutions at Emerson

This article is the second in a four-part series exploring three new but related concepts for deriving value om big data: little data, edge processing, and embedded connectivity. The first column provided an overview of all three topics, and this column will focus on little data and how it differs om big data.

As discussed in the first column, many companies are tempted to tackle the big data issue in one fell swoop with mega-scale projects to ambitiously gather all the data om various sources into a data lake. This first step alone presents an enormous challenge, but still provides no value as the data must be cleansed to remove anomalies. Only when these tasks are complete can analysis begin to create insights and improve outcomes.

Huge and complex big data projects cause many companies to fail or abandon efforts before results are attained. A better path for most manufacturers is to start small with a little data approach to greatly simpli and speed implementation, with positive results generated in days instead of the years typically required for a big data project.

The most successful little data projects arenâ&#x20AC;&#x2122;t driven om the top down but instead start at the plant, line or even machine level.

Personnel at these levels deal with and know the daily operational issues, but decisions around improvements are o en made based on single-point observations or â&#x20AC;&#x153;gut feelâ&#x20AC;? because the data being created by the machine goes to waste. Answers to these types of problems might reside in the data being collected and stored, but it is o en not presented in a meaningful context or is diluted by a larger data pool.

Therefore, the first step in any little data project is to identi known pains or problems causing operational issues, such as poor product quality and downtime. This step is o en skipped or over-generalized in IoT projects as companies and stakeholders rush to implement a technology or â&#x20AC;&#x153;the newest big thingâ&#x20AC;?. But without clear and up ont objectives, the chance of success is low, especially in companies just beginning their digital transformation journey.

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When one starts with small, everyday pains and problems, plant personnel can quickly prioritize and address each issue one at a time by first determining what data is locally available, then suggesting the addition of any required new sensing points. This helps drive early success to fuel organizational enthusiasm, as well as providing savings and increased revenue for funding subsequent little data projects. This is the power of the little data approach, now made more feasible by moving computing power to the edge.

For example, one end user was experiencing performance issuesâ&#x20AC;&#x201D; including excessive downtime, rate loss and poor qualityâ&#x20AC;&#x201D;with a new machine and couldnâ&#x20AC;&#x2122;t identi the root cause.

Existing data om the machine, along with data om new sensors connected to an edge controller, were used to monitor compressed air flow, motor vibration, actuator position and pressure and vacuum.

The data om these new sensors did not improve machine control and operation by itself, but it was instrumental in providing insight to the operator via a local operator interface, and to the OEM via secure transfer to the cloud. This provided both parties with near real-time access to the same data, enabling collaborative problem solving.

This improved visibility into a machineâ&#x20AC;&#x2122;s operation allowed the end user to use this additional data to initiate procedural and tuning changes to machine operation, thus increasing productivity and improving quality.

The OEM was able to provide early diagnosis of problems before they www.designworldonline.com

escalated, reducing downtime and maintenance expenses.

Another example of this concept in practice can be found within the Emersonâ&#x20AC;&#x2122;s machine automation solutions business, with headquarters and a worldclass manufacturing located in Charlottesville, VA. Plant personnel progressively and continuously look for improvement opportunities. The actions they undertake are not dependent on a corporate big data directive but are instead based on known needs for improving operations. This bottom up, little data approach ensures effectiveness because each proposed change is suggested by those closest to the problem, enabling rapid recognition followed by quick implementation of solutions.

Big data projects are highly complex, take years to complete, and require substantial investments. The technologies required to implement these projects o en become the area of focus, instead of the operational problems they were meant to solve.

Because results arenâ&#x20AC;&#x2122;t realized for such a long period of time, it at all, apathy o en sets in, discouraging efforts.

Little data projects are much simpler, take only days to complete, and require minimal investments.

Operational problems are the focus of these types of projects, with the second step selection of the correct hardware and so ware at the edge, which will be the focus of the next article in this series.

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Ad Index AllMotion ................................................. 4 Altech Corporation ...............................1 Altra Industrial Motion Corp. ................................21,22,23,24 Aurora Bearing Company ..............48 AutomationDirect .............................IFC Bansbach Easylift .............................45 Beckhoff Automation ......................33 Bison Gear and Engineering ..........41 Bodine Electric Company ................ 13 Bunting Magnetics ...........................48 Cadence ...............................................121 Carlyle Johnson ..................................16 CGI Inc. ..................................................29 Chieftek Precision ............................123 Clippard ................................................ BC Cornell Dubilier Electronics, Inc. ..... 9 Del-tron ................................................ 118 DeviceTalks ..........................................171 Digi-Key .................................................. 15 ebm-papst Inc. ......................................7 Encoder Products Company .........39

SALES

Fairlane Products ..............................35 FAULHABER MICROMO ................. IBC Interpower ............................................. 17 J.W. Winco, Inc. ...................................50 Keller America ....................................... 2 Maple Systems ................................ 128 maxon ....................................................26 Miki Pulley U.S. ................................. 134 MW Industries - Helical .................... 37 Nason ....................................................36 NB Corporation ..................................115 Novotechnik .......................................127 PHOENIX CONTACT USA, INC. ....... 11 SDP/SI ....................................................43 Smalley Steel Ring .......................... 133 Spartan Scientific ............................ 126 Tormach .............................................. 138 Trim-Lok .................................................19 TTI, Inc. ................................................. 119 Whittet-Higgins .................................. 27 Zero-Max, Inc. ....................................... 3

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