DESIGN WORLD JUNE 2022

www.designworldonline.com

June 2022

inside: CONNECTIVITY in MOTION:

Reflective wave phenomena in VFD applications p. 64

3D CAD: How to get everyone on the same page

p. 76

MEDICAL TIPS SUPPLEMENT:

Brighter laser-based future for materials

The Cloud is transforming MedTech p. 81

processing page 70

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At the recent NFPA Annual Conference, I was eager to hear Peter

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Ziehan, the famed geopolitical analyst, and his take on Russia’s invasion of Ukraine. Ziehan has been predicting this type of aggression om Putin for years, based on his country’s terrible societal demographics, which indicate a country slowly imploding.

But what I came away with om the talk instead was real surprise over what he had to say about China’s future. Ziehan spoke about the country’s “One child policy,” which was Mao’s creation in the late 20th Century. The concept was to push down what was looking to be a terri ing demographic structure that looked like it would eventually eat the country alive. (Similarly,

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the U.S. was a aid of a wave of young, hungry Chinese labor that would take all of our manufacturing jobs.) But today, seven years a er the policy was officially redacted, its consequences are fascinating and brutal.

According to Ziehan, data om January 2020 showed that the Chinese population was already the fastest aging society in human history.

DESIGN WORLD

DW.Insights.6-22_Vs2_PH.indd 5

“They were already past the point of even theoretical population replacement,” he said. “With this data, we know that China will cease to exist at some point in the century. And in the best-case scenario, there’ll be half as many Chinese in the year 2100 as there are now.”

What’s more, as the country has released more data om its 10-year census, it appears they over-counted their population by more than 100 million people. Ziehan said that means China will hit 50% of its current population level by 2050.

Ziehan also had plenty to say about Taiwan and the thought that China may invade this island nation that it sees as its birthright. But he didn’t paint a rosy picture there, either.

“Let’s say the Chinese can conquer Taiwan and it did. The U.S. doesn’t get involved. Japan doesn’t get involved … well then what? People like to point out the semiconductor FAT facilities.

Well, you don’t get so ware engineers who work for six figures to now work as slave labor in someone else’s plant,” he said. “The Chinese lack the technical expertise that built or operate those facilities themselves. Otherwise, they would already have them. We know that the Chinese have no problem building things. And all of the design work isn’t done in Taiwan. It’s done here.”

He also stressed that the Chinese Navy, while huge in terms of number of vessels, has limits. Ziehan said that less than 10% of its vessels can sail more than 1,000 miles om the coast — and that assumes “they’re going in a straight line at low speed and no one’s shooting at them.” They can’t get

to the Indian Ocean basin. And 80% of the oil China uses is imported and 80% of that comes om the Persian Gulf. So, in a hot war scenario, whether it’s the Americans, the Japanese, the Taiwanese, the Filipinos, the Vietnamese, or the Indians, Ziehan believes that someone will put a couple of boats in the Indian Ocean and cut the energy line.

“Three months later, all the trucks in China stop,” he explained.

“Three months a er that, the lights go out. And since agriculture is an industrialized sector, six months a er that, China has a famine that kills half its population. The Chinese know this.

That’s why they haven’t acted, even though they probably have had the military edge for 15 years.”

His last important point was about China’s Covid-19 vaccine, which he said is based on a dead virus in smallpox, a “top technology 50 years ago,” but not so much so today. The vaccine was reportedly only 55% effective in preventing death, and that was before the Alpha, Delta, and Omicron variants appeared.

Ziehan stressed that this is why the country doesn’t dare open back up — and why there’s such a huge crackdown on cities or regions even a er a small number of cases are discovered. Add this on to the country’s already shaky demographics, and the situation begins to look even more dire. We’re le to wonder: What will this mean for Chinese manufacturing and production in the coming months and years? It is going to be extremely fascinating to watch.

DW

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

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June 2022

5

6/6/22 1:59 PM

Teschler on Topic

Who’s reading your email?

There was a brouhaha recently on Twitter and Reddit regarding the Dutch telecom company KPN. Some of KPN’s central network equipment was made by the Chinese telecom equipment maker Huawei. An investigation found that Huawei had uncontrolled and unauthorized access to the core of the KPN mobile network, giving Huawei access to sensitive information including conversations and telephone numbers of Dutch political leaders and intelligence service officers.

The disclosures in the Netherlands are sobering. Jacob Helberg, who formerly led Google’s internal efforts to combat disinformation and foreign interference, sums up the concerns this way: “Political control is no longer determined merely by boots on the ground, it’s determined by wires in the ground. Imagine what might happen if a foreign adversary government knew the entire medical and personal history of every politician, every judge, and every journalist including all their sexual escapades, all their mental weaknesses, and all their corrupt dealings.”

But entities with nefarious intentions needn’t bother with building backdoors into telecomm equipment. They can program ordinary internet hardware to accomplish the same goals. This is the lesson learned from a stunt pulled by China Telecom (CT) in 2016 and 2017,

as described by researchers from the U.S. Naval War College and Blavatnik Interdisciplinary Cyber Research Center.

The caper involved what’s called the Border Gateway Protocol (BGP), basically a listing of the next—and closest—network system routers for a given internet packet. The BGP lets routing equipment send messages via the shortest possible route. Thus to hijack network traffic, bad actors can simply install a bogus BGP list that routes traffic through networks they own.

Researchers say that in 2010 CT used a BGP hijack to route 15% of all internet traffic for 18 minutes in what is believed to be both a large-scale experiment and a demonstration of Chinese capabilities in controlling internet flow.

BGP hijacking was facilitated by the fact that CT once had eight PoPs (point of presence) in the U.S. and two in Canada. A PoP consists of high-speed telecom gear that lets ISPs and their users connect to the internet. Researchers say CT used its PoPs to hijack domestic U.S. and cross-U.S. traffic and redirect it for about six months in 2016. In one case, CT hijacked routes from Canada to Korean government sites and routed traffic through China. Though the shortest and normal route goes from Canada to the U.S. to Korea, the hijacked route started at the CT PoP

in Toronto, then was forwarded inside the CT network to a CT PoP on the U.S. West Coast, from there to China, and finally to Korea. The same pattern repeated later for shorter durations.

Researchers also report that traffic from several U.S. locations to a bank headquarters in Italy was hijacked in 2016. The normal route would have been from Houston to the Washington D.C. area to Italy. Instead, it went from Houston to a CT PoP in Los Angeles and then to China. But the attackers seemed to have trouble routing traffic inside the Chinese network. Ultimately, the Chinese seemed to give up and the traffic never arrived.

And CT didn’t just divert domestic U.S. traffic. Researchers found that in 2017 traffic from Sweden and Norway to the Japanese network of a large American news organization was hijacked to China for about six weeks. The hijack started with a CT PoP in Maryland and was forwarded to a CT PoP in California, then went to China and Hong Kong before reaching Japan. “By no stretch could this period of disjointed routing have been accidental,” conclude the researchers.

Perhaps no surprise, the U.S. kicked Chinese PoPs out of the country last year. Meanwhile, these revelations are vindication of sorts for conspiracy theorists who think the government is trying to read their email: This might be true, just not for the government they had in mind. DW

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

6

June 2022 www.designworldonline.com

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Technology Forward

Additive Manufacturing Forward By the time you read this, you’ll know that President Biden launched a new bipartisan initiative to advance additive manufacturing, known as AM Forward. This initiative comes about a decade after President Obama launched America Makes. AM Forward will use the U.S. government and large multinational companies to support the small and mid-sized companies (SMEs) in their 3D printing/additive manufacturing efforts. This initiative will create a new Supply Chain Office, which will be established at the US Department of Commerce by the administration’s Bipartisan Innovation Act (if passed).

According to SmartTech Analysis, this effort will help grow the AM industry to $50 billion in revenues by 2030. Currently, this industry is valued at $10.6 billion.

The Covid pandemic has made various business markets aware of the issues in the global supply chain, and how additive manufacturing can help address those issues. By bringing production closer to the point of purchase, industry can avoid the revenue losses brought about by relying solely on outsourcing to supply product to customers.

The President’s initiative and supply chain issues are important shifts for the additive industry. But additive vendors are engaging in a shift of their strategy in working with customers.

The dominant additive business strategy has been to sell systems and machines to customers. With this strategy came the need to educate designers and others on how to use this technology.

But this previous strategy enabled vendors to keep various parts of its business proprietary, locking in

8

customers if they could. For the metal side of AM, it meant revenue streams of support as metal has different handling and processing needs than polymers.

Much of this older model will change, according to market forecaster IDTechEx. Instead of selling machines, a number of vendors will be selling 3D printed parts.

This shift differs a bit from those vendors that have developed service bureaus as part of their overall additive strategy — most of the major vendors in additive offer this capability. The traditional service bureaus tend to be technology agnostic whereas this new trend lets those participants focus on retaining their proprietary product line. They have the teams necessary to handle the needs of metal 3D printing, most particularly those areas users find too manually intensive — such as finishing.

As IDTechEx notes, service bureaus like Materialise and Protolabs generate hundreds of millions of dollars in revenue each year, indicating that the contract manufacturing sector of the 3D printing industry will continue to grow strongly.

This shift to in-house production adds a dimension for additive vendors. It helps them keep their proprietary printing technology inhouse, and demonstrate what their systems can do for customers.

June 2022 www.designworldonline.com

Tech.Forward.6-22_Vs2 MS.LL.indd 8

Vendors will continue to develop materials for their printers, some of which will be proprietary. But they will also deliver finished components, taking on the post-processing needs, such as debinding, sintering, milling, and so on, that some criticize the industry for not making more user friendly.

The vertical integration that has been occurring over the last decade is making it possible for additive vendors to provide a full suite of services to end-users — design, consultation, prototyping, and part manufacturing.

Some of the companies involved in this shift include 3DEO, with its metal binder jetting process that is similar to the Multi-Jet Fusion systems, and High-Speed sintering processes.

Another start-up to watch is Seurat Technologies with its Area Printing system of laser powder bed fusion.

In addition, there is a spin-out of Autodesk, Holo, that has developed a technology platform called PureForm.

PureForm is a vat photopolymerization printer that cures photopolymer resin loaded with metal powder, creating a green part. Holo debinds and sinters the part to remove the photopolymer in the final metal part. An interesting aspect of this technology is that it works for 3D printing pure copper.

And now, we have the potential for greater government support to grow and develop the additive industry. It does look as if Additive Manufacturing will continue to move forward. DW

Leslie Langnau llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

DESIGN WORLD

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Contents 6 • 2022

•

vol 17 no 6

•

designworldonline.com

76 64 _CONNECTIVITY IN MOTION Reflective wave phenomena in VFD applications

Medical www.designworldonline.com

Reflective wave phenomena or voltage spikes can damage motors and cables. Learn critical design considerations to reduce these risks.

A Supplement to Design World - June 2022

ft, so ps icro hili re , M J, P hca on lt az , J& ea plain Amoogle E H s ex G d G er an lead

70 _LINEAR MOTION Brighter future for laser-based materials processing

Leaders in medtech and cloud computing discuss payoffs and potential in device connectivity, product development and crossindustry partnerships.

New modular controllers offer flexible solutions for linking a laser to multi-axis positioning, making it easier for system integrators to design and build advanced systems for a new age of laser applications.

Page 82

Medical Tips cover 6-22_V1.indd 81

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81-93

76 _3D CAD How to get everyone on the same page

Making both CAD renderings and BOM information available to all systems on the factory floor and outside its doors cuts costs and raises productivity, whether the product is new or remanufactured.

2022

2022

2022

2022

2022

GOLD NATIONAL AWARD

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SILVER REGIONAL AWARD

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ON THE COVER

10

June 2022

CONTENTS 6-22_Vs3_MS.indd 10

Novel solutions are now available that take a modular approach to laser control, making it easier and faster for system integrators to design and build systems.

www.designworldonline.com

DESIGN WORLD

6/7/22 10:56 AM

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6 . 22 • content s departments

THIN ENOUGH?

04

Insights

06

Teschler on Topic

08

Technology Forward

14

Design For Industry

30

Design Notes

40

CAE Solutions

55

Coupling Notes

58

3DP AM

94

Product World

96

Ad Index

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June 2022

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6/6/22 11:09 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

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

VIDEO SERVICES

WEB DEV / DIGITAL OPERATIONS

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick Front End Developer Melissa Annand mannand@wtwhmedia.com Software Engineer David Bozentka dbozentka@wtwhmedia.com DIGITAL MARKETING

VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com @WTWH_Taylor Digital Marketing Coordinator Jill Bresnahan jbresnahan@wtwhmedia.com @WTWH_Jill Webinar Coordinator Halle Kirsh hkirsh@wtwhmedia.com Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com

EVENTS

Events Manager Jen Osborne jkolasky@wtwhmedia.com @wtwh_jen Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

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

Video Manager Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Garrett McCafferty gmccafferty@wtwhmedia.com PRODUCTION SERVICES

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com Customer Service Representative Tracy Powers tpowers@wtwhmedia.com Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com Customer Service Representative Renee Massey-Linston renee@wtwhmedia.com

Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Specialist Nicole Johnson njohnson@wtwhmedia.com Digital Design Manager Samantha King sking@wtwhmedia.com Marketing Graphic Designer Hannah Bragg hbragg@wtwhmedia.com Digital Production Specialist Elise Ondak eondak@wtwhmedia.com FINANCE

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

2011 - 2020

2013 - 2017, 2021 2014 - 2016

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Medical Design & OUTSOURCING DESIGN WORLD

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June 2022

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5/27/22 8:08 AM

Design for Industry Aeropsace

Robot-ready frameless servo motors The TBM2G series of ameless servo motors offer features that simpli the design of collaborative, surgical, aerospace and defense, and other robots while delivering performance in a lighter, more compact package.

Resulting om several years of research, testing, and customer feedback, these servo motors deliver torque in a compact electromagnetics package. These next-generation motors enable robots with lower joint weight, higher load-carrying capacity, improved energy efficiency, lower thermal rise, and faster, smoother movements.

Frameless torque motors typically deliver their best performance at low speeds but suffer at higher speeds. TBM2G motors remove this limitation through advanced windings and materials that deliver power, torque, and efficiency consistently across a wide speed range.

The motors also remove the sizing limitation that engineers o en face when using off-the-shelf strain wave gearing, also known in the robotics market as harmonic gearing. The motors are sized for a perfect fit with readily available strain wave systems, eliminating the need for extensive customizations that can increase engineering time and cost while potentially leading to supply and quality issues when robots enter full production.

The series is available in seven ame sizes with three stack lengths each — a total of 21 standard motors that can be integrated directly into robotic joints and similar embedded equipment. Typical applications are collaborative robots in the 3–15 kg range, powered at 48 Vdc and below. These motors perform at high speeds without exceeding the 80°C limit typically needed to safeguard humans working in proximity to cobots and to prevent degradation of grease and electronic components. And they’re available with thermal sensor options to meet the requirements of drives and control systems used in the cobot market. DW Kollmorgen | kollmorgen.com/TBM2G 14

June 2022

DFI_6-22_Vs7.LL MS.indd 14

www.designworldonline.com

DESIGN WORLD

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Design for Industry

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It is compatible with existing 369 connectors, and provides both space and weight savings compared to traditional circular connectors. Features include a simple push-in mounting and a positive button latching mechanism with an audible click.

The sealed panel mount connector is made of composite materials to meet lowsmoke, toxicity, and flammability requirements of the aerospace industry. The electrical interfaces are fully sealed and use a cork-in-bottle and triple-wire-seal technology to withstand high-moisture environments. The rectangular shape also allows for easy stacking of the connectors to achieve space savings in applications such as cabin and galley lighting, seat wiring and actuation, passenger service units, in-flight entertainment, electronic window shutters, and various other industrial uses.

The connectors easily mount to an LRU (line-replaceable unit) panel, bracket, chassis, or ame by using integrated panel latches to clip the connector into a rectangular cut out. This eliminates the need for additional fasteners or fixings, making removal, repair and maintenance fast and easy. In addition, the connectors have replaceable panel sealing gaskets allowing for IP67 level of protection om both moisture and dust.

The 369 series sealed panel mount connector features an operating temperature range of -55° C to +175° C, an IP67 rating, and a durability rating of 500 matings. It is easy to install and requires no tooling to remove or repair should the need arise. DW

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Design for Industry Medical

Adhesive offers 21 day extended wear As health care becomes more patient-centric and data and technology grows more sophisticated, medical device developers must make devices that integrate into users’ lives. Such devices help users comply with their health and wellness regimen while relevant data is collected.

Adhesives can be a key design choice. 3M’s latest medical adhesive, 3M Spunlace Extended Wear Adhesive Tape on Liner, 4576, was developed for extended wear devices requiring attachment to the skin for up to a 21-day wear time, ushering in the next generation of device design. Longer wear times, like 21 days, may support user compliance and health economic benefits.

“People deserve to live active lives without their condition — or a device meant to monitor it — getting in the way,” said Marcello Napol, vice president in 3M’s Medical Solutions Division. “Adhesives are more than a simple material. They have the potential to unlock longer wear times, slimmer device profiles, and more.”

3M Medical Tape 4576 is an acrylate-based adhesive for applications that require up to a 21-day wear time. It is flexible, conformable, and with its excellent adhesion to the skin, this new product suits devices that require continuous extended wear, both in and out of care facilities.

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As part of 3M’s extensive breadth of medical adhesives, 3M Medical Tape 4576 builds upon the company’s 55 years of experience sticking to skin and was made possible through a collaborative, global effort. DW

3M 3M.com/MedTech

www.designworldonline.com

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6/1/22 2:46 PM

Medical

Linear motor with built-in bearing A high force-to-size ratio is just one of the many features of the GVCM-051-089-02 Linear Voice Coil Actuator with Built-in Bearing. Applying up to 66.4 N (14.9 lb) of continuous force and 210 N (47.2 lb) of peak force, this linear voice coil actuator or moving coil actuator has high speed, high acceleration/deceleration, and zero backlash. It exhibits high accuracy, and high repeatability if a position sensor is used. This clean, quiet, efficient, low inertia, non-commutated linear actuator features high reliability and suits medical devices, work holding and clamping, assembly equipment, testing, sorting, laser machining and drilling, wafer handling, optical focusing, dynamic vibration absorption, scanners, laser beam steering, filtering, and antenna positioning.

This compact linear actuator is 50.8 mm (2.000-in.) in diameter and the total length of the actuator including the 82 mm (3.26-in.) sha extension is 190.5 mm (7.53-in.).

The diameter of the precision ground sha is 5.99 mm (0.2360-in.) with a M3X0.5 internal thread. The sha is supported by a long-life plain bushing and tolerates side loads to 4.4 N (1 lb). The housing and coil end have threaded mounting holes on a 25.4 mm (1.000-in.) bolt circle for easy integration into current and future applications. The linear voice coil actuator can also be ordered as a complete plugand-play servo controller electronics. DW Moticont www.moticont.com/linear-motor-with-bearing

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Design for Industry Pharma

High-precision microscope focusing stage for super resolution microscopy While microscopes have long been invaluable tools in biological research, a key drawback has been resolution limitations, making it impossible to use them as a tool to examine sub-cellular or sub-organelle details. Recent advances in fluorescence microscopy, a type of light microscopy in which one wavelength of light is absorbed and another omitted, allows super-resolution microscopy to observe living sub-cellular structures and activities.

The AI-VC-600-Z-SCB high-precision microscope offers this ability, and thus suits such applications as super resolution microscopy, atomic force microscopy, digital pathology, surface metrology, and industrial manufacturing and inspection applications.

It offers nanometer-level resolution and fast millisecond-range response.

When used in such applications, the stage provides closed loop precision and fast response to achieve sub-atomic resolution, critical in high resolution microscopy. The result is higher quality images at a faster rate of speed. With a 6 mm travel range and a 500g payload, the AI-VC-600-Z-SCB can achieve 4G 100% S-curve 20

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peak acceleration (which is equivalent to 2G trapezoidal acceleration) and 300 mm/sec with 5 nm resolution and can achieve 1 nm resolution by reducing the speed capability to 30 mm/sec.

The AI-VC-600-Z-SCB stage can be used to study DNA sequencing to stimulate the drive towards personalized medicine. The key to success in these types of applications is image capture at a high rate of speed with absolute focus on nanometer-level precision. The applications further require that the motion control solution must combine smoothness (meaning highest possible image resolution), flatness (controlling the z-axis meaning maintenance of focus), and straightness (reducing overlap between scanning “passes” and increasing throughput).” DW

ALIO Industries www.alioindustries.com

www.designworldonline.com

DESIGN WORLD

6/1/22 2:47 PM

POWER TRANSMISSION

RETAINING DEVICES &

Pharma

maintenance & assembly tools

XY tables for 2-axis

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

linear positioning

PRECISION NUTS & WASHERS

PI America www.pi-usa.us/en

ADAPTER SLEEVE ASSEMBLIES

Materials of: CARBON, ALLOY and HARDENED ALLOY STEELS

These high-resolution XY-tables can deliver the accuracy needed in pharmaceutical applications in biotechnology, microscopy, and other life science applications.

Air bearing XY tables deliver the highest accuracy and performance, and offer a long lifetime, since they do not contain mechanical elements that can wear. The A-322 PIglide Ultra version, for example, is based on an XY dual gantry design with liquid-cooled high-performance 3-phase linear motors and absolute linear encoder. This air bearing table can cover an XY linear motion travel range up to 500x1000 mm with resolution to 1 nanometer.

These 3-plate integrated XY-tables with mechanical bearings and direct-drive motors have a lower profile compared to other stacked XY-linear stages. While not as precise as an air bearing table, orthogonality of integrated 2-axis tables is typically an improvement over stacked XY-tables built om single-axis linear tables. For higher load and lower velocity applications, the integrated 2-axis stages are also available with ball-screw drives.

Two-axis nanopositioning tables with piezo drives and flexure guides are o en used in super-resolution microscopy, fiber-optic and semiconductor applications. Due to their high stiffness and low mass, piezoelectric XY-tables can provide high scanning equencies while delivering sub-nanometer precise motion. DW

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

Materials of: ALLUMINUM and CORROSION RESISTANT STEEL NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

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HI

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ET

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IG

GI

NS US

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

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

or a good distributor.

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June 2022

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

LVDT position sensors can be long-life replacements for failing

potentiometers

The chart shows how the output of a position sensor changes over time at a given point. A cycling, aging potentiometer will eventually experience wear between the wiper and the resistive element, degrading the quality of the electrical contact that creates noise and inconsistent results in the output signal. The inductive, ictionless operation of an LVDT give it superior repeatability for its entire service life. With no components that wear, the LVDT Position Sensor provides consistent output at a given position during decades of operation.

Pre-calibrated Linear Position Sensors serve as long-term replacements for potentiometers (pots) that become unreliable over time due to their contacting operation and effects om vibration and other environmental parameters.

As potentiometers rely on mechanical contact to provide position feedback, components wear out and are affected by heat, vibration, and humidity, making output progressively noisier and unreliable over time. Non-contacting and with no parts to wear out, these LVDT Position Sensors offer ictionless operation and do not dri or get noisy even over extended periods. The excellent repeatability, temperature resistance, and resolution of LVDTs suit applications that require measurement of very small movements such as TIR measurements, thermal expansion, and dimension quality.

Challenging operating conditions such as high shock and extreme temperatures also can limit a potentiometer’s performance and reliability. As a result, Mean Time Between Failure (MTBF) is typically lower for a potentiometer operating in a moisture- ee and low vibration environment, than an AC-operated LVDT Linear Position Sensor working in a

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demanding application. The high reliability of NewTek LVDT Position Sensors in high vibration and shock environments make them more suitable than pots for use in the position measurement of machine tools, drilling tools for oil and gas, high-temperature steam valves, and other components.

The design of today’s LVDT Position Sensors with a short sensor body length to sensor range, provides for an excellent stroke to length ratio that makes them suitable for longstroke applications traditionally reserved for pots.

These pre-calibrated LVDT position sensors are available in standard, miniature, hermetically sealed, high pressure, and high-temperature designs that serve as life-long replacements for failing potentiometers. Using the latest manufacturing techniques and high-tech electronics in engineering in high-performance LVDTs, all products are USA-manufactured, with most ready for quick delivery right off the shelf. DW

NewTek Sensor Solutions www.newteksensors.com/lvdt-sensors

www.designworldonline.com

DESIGN WORLD

6/6/22 12:01 PM

Power REVIEW THE POWER BRANDS IN POWER TRANSMISSION

Vol. 11 | No. 2 | 2022

www.AltraMotion.com

Follow Altra Motion on:

INSIDE THIS ISSUE:

Altra Launches Enhanced Virtual Trade Show Exhibit Booth AltraEX.com

Power Transmission Solutions for Food & Beverage Applications

Ameridrives American Made Products for American Mills

Twiflex USA Brake Calipers

Scan to download the interactive version of the Power Review

Altra Industrial_#1_6-22.indd 23

6/2/22 10:23 AM

Altra Launches Enhanced Virtual Trade Show Exhibit Booth The Latest Advancements in Power Transmission and Motion Control Solutions for Altra Motion are on Display at WWW.ALTRAEX.COM Altra has recently enhanced the scope and functionality of its virtual exhibit booth. The new interactive browser experience is the perfect resource for specifiers and end users. Visitors can easily navigate through the virtual exhibit to get a comprehensive overview of the capabilities of each leading brand while viewing imagery, videos, downloads and literature.

NEW INNOVATION SPOTLIGHT Every month, the Innovation Spotlight section will showcase a featured product from one of our brands that sets the industry apart.

This is a section you don’t want to miss to find out what products are chosen!

NEW VIRTUAL MARKET WEBSITES

NEW AUDITORIUM

Links to a series of interactive market-specific websites allow visitors to learn what Altra technologies are available for specific applications within an industry.

Upon entering the auditorium, visitors can register and access a wide range of Altra webinars.

FEATURED PRODUCT DISPLAYS Each product area/category contains multiple solutions with features and benefits, technical drawings, and catalog, brochure and application profile PDF downloads.

MEDIA TOWER

BRAND WEBSITES

Includes a link to Altra’s extensive video portal featuring product and application profile videos. A brand-segmented literature portal link is also included that allows visitors to view and download literature.

Quick links are provided for each individual Altra brand websites.

Altra Motio n

Altra Motion Virtual Exhibit Booth Guide AltraEX.com

A Global Footprint to Support Customers Around the World Altra Headquarters Altra Engineering & Service Altra Manufacturing

Centers

Facilities

The Brands of Altra

Motion

Couplings Ameridrives www.ameridrives.com Bibby Turboflex www.bibbyturboflex.com Guardian Couplings www.guardiancouplings.com Huco www.huco.com Lamiflex Couplings www.lamiflexcouplings.com Stromag www.stromag.com TB Wood’s www.tbwoods.com

Visit the Altra Virtual Trade Show at www.AltraEx.com

Altra Industrial_#2_6-22.indd 24

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

Linear Systems Thomson www.thomsonlinear.com

Geared Cam Limit Switches Stromag www.stromag.com Engineered Bearing Assemblies Kilian www.kilianbearings.com Electric Clutches & Brakes Matrix www.matrix-international.com Stromag www.stromag.com Warner Electric www.warnerelectric.com Belted Drives TB Wood’s www.tbwoods.com

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

Components

Boston Gear www.bostongear.com Delevan www.delevan.com

For more information, download P-8940-C from www.AltraLiterature.com Delroyd Worm Gear www.delroyd.com

Nuttall Gear www.nuttallgear.com

Engine Braking Systems

Jacobs Vehicle Systems www.jacobsvehiclesystems.com Precision Motors & Automation Kollmorgen www.kollmorgen.com Miniature Motors Portescap www.portescap.com Overrunning Clutches Formsprag Clutch www.formsprag.com Marland Clutch www.marland.com Stieber www.stieberclutch.com

6/2/22 10:23 AM

Power Transmission Solutions for Food & Beverage Applications The industry-leading global brands of Altra Motion provide precision engineered power transmission components to meet the most demanding washdown requirements for all types of food and beverage processing applications. Altra offers a full range of drivetrain solutions including geared motors, speed reducers, air motors, clutches & brakes, torque-limiting devices, couplings, bearings and shaft accessories.

Altra Motion utilizes advanced technologies, materials and coatings together with extensive application expertise and world-class engineering capability to provide custom-designed, efficient, cost-effective solutions to our customers. For this reason, many of the world’s leading food and beverage producers and OEMs choose Altra products for their power transmission needs.

Highly engineered Altra products provide exceptional performance in a wide range of applications including bakery & snacks, meat & poultry, fruits & vegetables, dairy, candy and bottling & capping.

Altra brands that support the food and beverage market include Bauer Gear Motor, Boston Gear, Formsprag Clutch, Huco, Kilian, Stieber, and Warner Electric.

Bauer Gear Motor Boston Gear Formsprag Clutch Huco Kilian Stieber

to A Global Footprint Around Support Customers the World

Warner Electric

on Altra Moti

Power Transmission Solutions for Food & Beverage Applications

Altra Headquarters Altra Engineering &

Service Centers

Altra Manufacturing

Facilities

The Brands of Altra Couplings Ameridrives www.ameridrives.com Bibby Turboflex www.bibbyturboflex.com Guardian Couplings www.guardiancouplings.com Huco www.huco.com Lamiflex Couplings www.lamiflexcouplings.com Stromag www.stromag.com TB Wood’s www.tbwoods.com Linear Systems

For more information, download P-8891-C from www.AltraLiterature.com

Thomson www.thomsonlinear.com

Motion Geared Cam Limit

Switches

Stromag www.stromag.com Engineered Bearing

Assemblies

Kilian www.kilianbearings.com Electric Clutches

& Brakes

Matrix m www.matrix-international.co Stromag www.stromag.com Warner Electric www.warnerelectric.com

Heavy Duty Clutches Twiflex www.twiflex.com

& Brakes

Stromag www.stromag.com Svendborg Brakes www.svendborg-brakes.com Wichita Clutch www.wichitaclutch.com Gearing & Specialty Bauer Gear Motor www.bauergears.com Boston Gear www.bostongear.com

Belted Drives TB Wood’s www.tbwoods.com

Components

Delevan www.delevan.com Delroyd Worm Gear www.delroyd.com Nuttall Gear www.nuttallgear.com

Systems Engine Braking Jacobs Vehicle Systems com www.jacobsvehiclesystems.

Precision Motors

& Automation

Kollmorgen www.kollmorgen.com Miniature Motors Portescap www.portescap.com Overrunning Clutches Formsprag Clutch www.formsprag.com Marland Clutch www.marland.com Stieber www.stieberclutch.com

Ameridrives American Made Products for American Mills Ameridrives Americardan U-Joints and Amerigear gear couplings and mill spindle shafts are designed and manufactured in the USA. Ameridrives is the only company that makes all its gear couplings, spindles and U-joints in the USA. Their dedicated teams in Erie, Pennsylvania and San Marcos, Texas utilize advanced testing, analysis and manufacturing processes to ensure that the quality products provide long-lasting performance in tough hot and cold mill applications.

AMERIDRIVES ADVANTAGES FOR US MILLS: • Unique, high-quality mill-proven solutions • Faster response and delivery compared to off-shore competitors • Expert mill application engineers available to provide analysis of repeated coupling/spindle/ U-joint problems on any mill machines • Visits to your facility (or ours) can be easily arranged

• Metric-sized solutions available to fit all OEM mills • Fast-turnaround repair and maintenance service for Ameridrives and competitive brand U-joints and products

Altra Motio n

American Mad e Products for American Mills Ameridrives Americarda n U-Joints and Amerigear gear couplings and mill spindle shafts are designed and manufactured in the USA American ingenuity and quality are built into all our products We provide real value to metal producing and processing mills in the US. Our experienced application engineers routinely develop solutions that reduce mill downtime and improve productivity.

Ameridrives is the only company that makes all its gear couplings, spindles and U-joints in the USA. Our dedicated teams in Erie, Pennsylvannia and San Marcos, Texas utilize advanced testing, analysis and manufacturing processes to ensure that our quality products provide long-lasting performance in tough hot and cold mill applications.

Ameridrives advantages • Unique, high-quality

for US mills:

mill-proven solutions

• Faster response and delivery compared to off-shore competitors • Expert mill application engineers available to provide analysis of repeated coupling/spindle/ U-joint problems on any mill machines • Visits to your facility (or ours) can be easily arranged • Metric-sized solutions available to fit all OEM mills • Fast-turnaround repair and maintenance service for Ameridrives and competitive brand U-joints and products www.ameridrives.com 1802 Pittsburgh Avenue Erie, PA 16502 - USA 814-480-5000 P-8890-AC

6/21

For more information, download P-8890-AC 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

Altra Industrial_#3_6-22.indd 25

6/2/22 10:24 AM

Sure-Flex Plus® & Dura-Flex® Elastomeric Couplings TB Wood’s Incorporated

Sure-Flex Plus EPDM and Neoprene sleeves are best-in-class for coupling performance and value. Here’s why: • High Torque Rating: 30% Increased Torque Rating Provides longer service life in demanding applications, reducing required maintenance and associated replacement cost.

• Longer Life: Lasts Over 3X Longer than the Competition Extensive testing shows our sleeves outlast the imitators. More uptime means less costly downtime.

• Better Value: Save Money Using a Smaller Coupling The increased rating of the Sure-Flex Plus sleeves lets the user choose a one-size-smaller coupling for over 50% of common applications. This lowers the cost of both initial purchase and future sleeve replacement.

• Interchangeable: Retrofits to Existing Flanges No need to replace the full coupling – The Sure-Flex Plus sleeve design is 100% compatible with the current industry standard that TB Wood’s created over 50 years ago.

Dura-Flex® • Outperforms the Competition: Testing shows Dura-Flex outlasts competitor couplings under both normal and tough environmental conditions.

• Longer Life: Superior element geometry and material provide better flexibility and longer life in challenging environments.

• Unique Design: Patented shoe design minimizes bond stress to ensure long life.

• Easy Installation: “Split-in-half” element design allows for replacement without moving hubs or equipment.

E

SUPP O RT

SERV IC

• Interchangeable: 100% part-for-part interchangeable with competitive designs.

y the Specif Dif ference od’s TB Wo H ST RE NGT

Altra Industrial_#4_6-22.indd 26

For more information call:

1.888.829.6637

or visit www.tbwoods.com 6/2/22 10:26 AM

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

Motion control systems for 1, 2,

3, and 4 axis of motion

The FIGARO series is an easy-to-use, plug-and-play, cost effective solution motion controller. The standard 1, 2, 3, and 4 axis FIGARO Motion Control Systems are available as compact, countertop enclosures or 19-in. rack mounts for Stepper Motors, DC Servo Motors with Quadrature Incremental Encoders, threephase Brushless DC Servo Motors with Quadrature Incremental Encoders and Hall Effect Sensors, or Voice Coil motors with linear encoders. Additionally, these controllers can be configured with any combination of drivers for Steppers, DC Servos, and BLDC Motors.

An external host such as a PC, micro-controller, or PLC sends commands to the Controller via a USB or RS-232 serial port, and the Controller processes and executes the commands. When commands are loaded into the controller’s memory, the controller is capable of running the commands without need of the host. The FIGARO series works with host installed programs such as: C/C++, Python, Visual Basic, LabVIEWTM, and MATLABTM. Also, the System can be operated using an analog joystick or a trackball. Options in-

DESIGN WORLD

DFI_6-22_Vs8.LL MS.indd 27

clude: HOME and LIMIT switches, TTL/CMOS Inputs and Outputs, Quadrature Encoder Feedback, and an Ethernet interface.

The controllers can provide up to 7 Amps per phase current, and up to 256 micro-steps per step resolution, for stepping motors om NEMA 8 to 42; for DC Servos and BLDC motors up to 40 Amps per phase, and + 18 VDC to 80 VDC power supply voltage.

Easy to install and use these Motion Control Systems are integrated solutions featuring ee so ware. The FIGARO Motion Control Systems operate on an input power of 115 or 230 VAC, 50-60 Hz, and can be ordered Plug-and-Play when ordering a single or multi-axis positioning stages. DW

Optimal Engineering Systems, Inc. (OES) www.oesincorp.com

www.designworldonline.com

June 2022

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

Encoders for small motors

These PressFit rotary encoders give small-motor manufacturers a better way for incorporating automated mounting for feedback devices.

The ExI 11xx encoder series has a compact design that allows fast and simple mounting by press-fitting into a motor housing while still allowing surrounding space for cables and seals. The encoders are made for integration into motors with a flange size as small as 40 mm x 40 mm or an axis height of only 20 mm.

The encoders can be secured in a motor housing through a ictional connection, using a specially designed tolerance sleeve. This system promises to support automation efforts by easing mounting requirements, leading to less mounting time being required. DW

WHAT DO YOU THINK?

HEIDENHAIN www.heidenhain.us

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

28

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DFI_6-22_Vs7.LL MS.indd 28

www.designworldonline.com

DESIGN WORLD

6/1/22 2:53 PM

All products available directly on

from

WHAT’S NEW RULAND

RULAND.COM

Ruland 1-21.indd 29

TOOL-LESS ADJUSTMENT COMPONENTS • Adjustable handles and knobs replace standard hardware and can be used to torque components without tools.

• Levers can be used with Ruland shaft collars for quick installation and adjustment.

Adjustable Handle

Star Knob

Shaft Collar with Lever

SLIT AND CONTROLFLEX COUPLINGS

Ruland Manufacturing is proud to support the FIRST Robotics Competition as a Gold Supplier of precision shaft collars & couplings.

• Slit couplings are available in short and long styles giving designers a variety of body sizes to choose from to fit application envelope and performance requirements.

• Controlflex is a highly flexible encoder coupling designed for applications with high speed, low torque, and wide differences in shaft sizes (up to a 4:1 small to large ratio).

• Slit couplings are available in bore sizes from 1.5mm to 12mm (1/8” to 1/2”) and controlflex couplings are available in sizes from 6mm to 40mm (1/4” to 1-1/2”).

Slit Coupling

Controlflex Coupling

MOUNTABLE SHAFT COLLARS • Available with OD flats and holes for direct mounting of the collar to other components.

• Proprietary manufacturing processes ensure superior fit, finish, and holding power.

MODULAR MOUNTING SYSTEMS • Assortment of components that allow users to build small assemblies for mounting sensors, conveyor rails, machine guards, and more.

• Optional pre-designed kits make it easier to select the right system for your application.

• Manufactured in a variety of sizes, styles, and materials.

QUICK CLAMPING COLLARS

UNIVERSAL JOINTS

• Hand operated: no tools required to install, remove, & adjust.

• Widest selection in the industry: over 3000 standard single and double universal joints to start your next design with.

• Available from Ruland in 2 weeks or less for the shortest lead times in the industry.

• Best suited for systems that require frequent adjustments.application.

• Yokes, pins, and blocks are precision machined, ground, and selectively heat treated for smooth operation at high operating angles.

www.ruland.com | sales@ruland.com 6/2/22 7:28 AM

Design Notes

Straight up: industrial cameras

help with spine and posture analysis Edited by Mike Santora • Managing Editor

Video gait analysis and leg axis measurement.

Back pain is one of the leading causes of sick leave in Germany — o en caused by lack of exercise, work stress, and obesity. Other causes include osteoporosis, chronic inflammatory diseases, or spinal deformities such as scoliosis. Innovative systems for 4D measurement of body statics can be used for precise diagnosis. DIERS International GmbH enables fast and high-resolution optical measurement of the back, spine, and pelvis with DIERS formetric 4D. A dynamic version and additional modules for determining the mobility of the cervical spine or gait analysis and leg axis measurement make the system a compact movement analysis laboratory.

Up to 5 camera units are integrated and equipped with uEye industrial cameras om IDS Imaging Development Systems GmbH.

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Design-Notes-6-22-Vs3.LL.indd 30

www.designworldonline.com

Application DIERS formetric surveying technology is physically based on the principle of triangulation. A light projector casts a grid of lines onto the patient’s back, which is recorded by a camera unit.

Computer so ware analyses the line curvatures and generates a three-dimensional image of the surface using photogrammetry (image measurement), similar to a virtual plaster cast.

The examination is quick, radiation- ee, and contactless.

DESIGN WORLD

6/1/22 3:04 PM

Additional components for a holistic movement analysis To carry out examinations in motion, the company also has a dynamic version of the DIERS formetric system in its range — DIERS 4D motion. The patient runs on a treadmill, using the latest projection and camera technology (60 images per second) and specially developed so ware; the complex interaction of the spine and pelvis are measured during walking and displayed in moving images. This enables an analysis of the vertebral body rotation and the creation of movement models of the spine.

Additional modules increase the range of applications up to a compact motion analysis laboratory. With optional camera modules DIERS leg axis posterior and lateral for video-based analysis of the leg axis geometry, for example, asymmetries in stance and in the movement sequence can be determined and documented. The system so ware detects reflective markers applied to the patient and calculates movement patterns (dynamic) and angles (static and dynamic). In the case of foot and posture corrections, the effects on the leg axes can thus be directly displayed and checked.

With the additional module “Cervical Spine,” the mobility of the cervical spine can also be recorded three-dimensionally.

PLANETARY BLDC and PMDC

GEARMOTORS

RATED SPEED 11 to 658 rpm

TORQUE 5 to 226 lb-in.

GEAR RATIOS 4:1 to 162:1

VOLTAGES 90/130, 24, 12 VDC

High Torque. Compact Design. Long Life.

Bodine planetary gearmotors deliver high continuous and peak torques.

These 60 mm gearmotors are available from stock and with many custom options. PMDC models rated up to IP-66. Low-voltage 12 & 24 VDC models are ideal for solar or battery powered applications.

Visit our website at: bodine-electric.com info@bodine-electric.com DESIGN WORLD

Design-Notes-6-22-Vs3.LL.indd 31

June 2022

•

773.478.3515 (USA)

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Design Notes The measurement data and Holistic movement asymmetries are displayed analysis at a graphically and can be running speed of up analyzed. The measurement to 30 km/h. process takes place using a special head hood. The DIERS formetric 4D system requires an additional camera system for the Cervical Spine Module.

With the integration of these and other measurement systems, it is fps. This makes the camera suitable for possible for the first time to view the classic industrial applications like surface complex biomechanical interaction in inspection but also for detailed image the human musculoskeletal system evaluation in medical technology. holistically. The spectrum of uses ranges The UI-3240CP-M-GL Rev.2 is a om medical diagnosis to training powerful industrial camera with the therapy and sports science. It detects e2v 1.3 megapixel CMOS sensor. This scoliosis, pelvic obliquity, and rotation, sensor is one of the most sensitive progress controls in osteoporosis and sensors in the IDS portfolio. Besides its arthrosis, and neurological examinations outstanding light sensitivity, the camera (e.g,. Romberg test), posture tests, is distinguished by several additional (Matthiass test, Flamingo test) and much functions — for example, the sensor more. Up to 5 uEye CP industrial cameras offers two global and rolling shutter om IDS are used per unit. variants that can be switched during operation, thus providing maximum Up to 5 uEye cameras per unit in use flexibility for changing requirements and The uEye CP stands for “Compact environmental conditions.

Power” and is suitable for all kinds of industrial applications with its high level Outlook of functionality with comprehensive The medical technology market is pixel pre-processing and its size of highly regulated, so changes and new only 29 x 29 x 29 mm. The internal 120 developments of products must be MB image memory for buffering image well-considered through elaborate sequences also qualifies it for multicertification and approval procedures. camera systems. The USB 3.0 cameras At the same time, price pressure is enable a data rate of 420 MByte/s, low increasing. Nevertheless, DIERS is CPU load, and easy integration. Users currently working on various new can choose om many modern CMOS developments — om insole production sensors om Sony, CMOSIS, e2v, and to research projects in the rehabilitation ON Semiconductor, with a range of and care sector. In addition to classic 2D resolutions. industrial cameras, 3D models are also The model UI-3040CP-M-GL Rev. conceivable, which inherently introduce 2 enables strong image quality even in the spatial component. DW low light or when shooting fast-moving subjects. The integrated IMX273 global IDS shutter CMOS sensor om Sony’s www.ids-imaging.us Pregius range scores particularly well for its image quality, high sensitivity, and wide dynamic range. With a resolution of 1.57 MPixel (1448 x 1086 px) at 3.45 µm pixels, it achieves an impressive 243

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Design Notes

Thirty-five non-Sulzer OH2 process pumps were upgraded using the OHX retrofit kit.

Retrofit solution improves pump reliability for refinery Edited by Mike Santora • Managing Editor

Established refineries and petrochemical plants have hundreds of process pumps, usually om myriad manufacturers, that may have been in operation for decades. Over the years, API 610 specifications, which govern their design, have evolved to improve both safety and reliability. Today, modern materials and design concepts om Sulzer can be used to improve the performance of existing pumps, as exemplified by a case in Mexico, where 35 process pumps were upgraded.

For time-served assets in refineries and petrochemical plants, extending service life can be a challenge and a replacement may appear to be the simplest option.

However, in some cases, this may require extended lead times and changes in the existing pipework or pump foundations. A much quicker solution is to upgrade key

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components of the pump, bringing it in line with current specifications while simpli ing the parts inventory at the same time.

Improvements for aging assets For example, a refinery in Mexico, which was commissioned in 1976, processed several thousands of barrels per day. But since the refinery was built, API standards have moved on considerably, now in its 11th edition.

Within the plant, process pumps are used DESIGN WORLD

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for transporting propane, liquefied petroleum gas (LPG), sour water, and gasoline.

Maintenance engineers had identified several pumps that were manufactured to 6th edition standards and would benefit om improved reliability. For example, one of the significant factors affecting seal performance is pump vibration, and since the 8th edition, the API 610 specification for stiffness of the impeller sha has increased, reducing vibration, and extending the mean time between failures (MTBF).

In addition, the design of the mechanical seals has also been enhanced, and, in this case, a double seal as per API 682 was implemented to further increase reliability and reduce fugitive emissions to comply with new environmental regulations. Thirty-five non-Sulzer OH2 process pumps had been identified for upgrade and Sulzer was selected to handle the issue.

Cost-effective retrofit solution Sulzer engineers developed the OHX pump retrofit kit to offer the latest API specifications to any brand of OH2 pump while delivering overall performance improvements without replacing the casing or making any changes to the connecting pipework. Only the affected

Redundancy in the processes enabled one pump to be repaired without affecting production.

parts can be upgraded, which is more cost-effective than replacing the whole pump.

A new case cover with API 682 seal chamber meets latest API 610 standards, including the double mechanical seal. In addition, the bearings are upgraded to a longer life component, extending the expected service life om 25’000 hours to 50’000 hours. This improvement also includes upgraded oil guards, which offer much better oil sealing compared to the components of the 1970s.

Sulzer’s onsite support was provided by the local service center.

The retrofit kit also introduces a cooling fan and an improved coupling and guard. The former helps to reduce bearing temperatures, extending their service life, while the latter meets the latest occupational safety and health administration (OSHA) requirements.

Improved performance Isabel Najera, Project Manager for Sulzer, explained, “The objective of this retrofit solution was to optimize long-term performance and reliability without impacting the existing in astructure. Pump upgrade projects such as the one for the refinery begin with essential information being gathered, including impeller diameter and volute measurements, which enable the case cover and other components to be manufactured without affecting the process pumps’ operation.”

Once all the parts are complete, they can be either installed on-site or at the local Sulzer service center, keeping downtime to an absolute minimum. In most cases, these process pumps are paired with a standby unit, enabling the application to continue while one is upgraded.

Following on om the retrofit program, the updated equipment at the refinery now has common parts with pumps on-site that have been installed more recently, allowing the spare parts inventory to be optimized. DW

Sulzer | www.sulzer.com DESIGN WORLD

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Design Notes Size changeover using a labeling machine in pharmaceutical manufacturing.

Pharma 4.0 with intelligent size changeover

Juergen Schuh — Head of the Changeover Solutions business unit at SIKO

“Size changeover” is not a term that immediately makes people stop and pay attention in the pharmaceutical industry. However, considering the challenges in pharmaceutical manufacturing, which are characterized by cost, competitive pressure, and strict regulations, intelligent size changeover means competitive advantages in terms of efficiency, product quality, and process reliability. With automated, networked solutions, pharmaceutical companies can take a decisive step towards Pharma 4.0.

In the pharmaceutical industry, “centerlining” is relevant, which means optimum machine settings must always be selected to prevent unnecessary deviations in the process. The aim is to network manufacturing, technology, maintenance, and electronic data acquisition in the best possible way. In addition, the growing variety

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of products and ever smaller batch sizes in pharmaceutical manufacturing demand a high degree of flexibility om the systems. This is where size changeover comes into play, which can be a decisive factor for system availability.

With optimized size changeover, reconfiguration times for product changes can be significantly reduced and process reliability increased. SIKO GmbH, DESIGN WORLD

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E Z I M I OPT N G I S E D R U O Y

a manufacturer of sensors and positioning systems, has introduced various options for size changeover, om purely mechanical position indicators to fully automated positioning drives.

In pharmaceutical manufacturing, size changeover occurs everywhere, especially in packaging processes, labeling, and product inspections. Whenever the dimensions on the machine must be changed for a new product, this involves size changeovers — whether manually via a crank or automatically via an actuator.

Always exercise caution when changing the machine settings, as errors can creep in and harm the product result.

Monitored or even automated size changeover minimizes the risk of incorrect settings and can make processes more flexible.

A distinction is made between manual, monitored, and automated size changeovers. Which type of format change is most suitable depends on the requirements: the more sizes need to be changed over, and the more demanding manufacturing is om a quality perspective — which is usually the case in the pharmaceutical sector — the more sensible it is to use monitored or automated positioning systems.

For manual size changeover, both mechanical and electronic position indicators are used, which indicate the actual value of the current position. They are suitable for basic machines with rather in equent adjustments. The common mechanical-digital SIKO position indicators are precise, easy to read, and configured for each application.

Electronic position indicators have an advantage over mechanical ones in that they are eely programmable and can therefore be used with greater flexibility. Parameters such as

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Design Notes

Size changeover using electronic position indicators in pharmaceutical manufacturing.

spindle pitch, decimal places, direction of rotation, mounting position, or use in angle mode can be conveniently configured.

Monitored size changeover is made possible by bus-compatible electronic position indicators with setpoint value specifications which are integrated into the machine control system. Actual and target values are exchanged and compared between the individual position indicators and the higher-level control unit with a formula management system in which all product variants are stored with their setpoint values as formulas. This enables increased process reliability, as the system is only restarted when all setpoint and actual values on the indicators match. Rejects or damage to system parts are thus avoided. The changeover of the axes is still carried out manually with this variant, whereas the monitoring of the correct settings is carried out electronically. The special feature of the electronic position indicators is the LED lights which clearly display the position status to the operator: Green lights for “position correct,” red lights signal “position not correct.”

Monitored size changeover can be helpful in pharmaceutical manufacturing, for example, in the case of systems for cartoning machines requiring

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Size changeover using SIKO position indicators on a Track & Trace system in pharmaceutical manufacturing.

equent adjustment. A relatively new development are “Track & Trace” systems, which require prescription drugs to be provided with a clear, traceable label. This involves several processes such as printing, reading, labeling, and weighing. The process reliability of these systems is increased with monitored size changeover.

If axes are changed over without any manual intervention, this is called automatic size changeover via compact positioning drives. The actuator, networked with the machine control www.designworldonline.com

system, moves directly to the required position. With automation, a further significant reduction in reconfiguration times is achieved.

An actuator is characterized by its highly integrated design, which combines all components in one device: the brushless DC motor (which is wear- ee), a low-backlash and powerful gearbox, a position encoder, and power and control electronics. The integration of the actuator into the machine controls and the communication with the controls is easily achievable.

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Depending on the application’s requirements, different power classes of actuators are required: om small actuators with low power requirements for fine adjustment in a folding box magazine to feeding systems for large cardboard boxes where entire machine aggregates must be moved with actuators with relatively high torques.

With this variant of size changeover, the controls only initiate a system restart when the process data exchange between the drive and the control has resulted in a match between the actual and setpoint values.

Another functionality of the compact actuator makes it possible to conclude operating status: the diagnostic capability. By collecting and monitoring various drive parameters like current consumption in the motor, temperature,

or voltage values at the control and load circuit, irregularities can be detected at an early stage.

In pharmaceutical manufacturing, smart size changeover involves several dimensions: there are the directly measurable effects such as reduction of set-up times, increased plant availability, increased efficiency, and increased process reliability. Also, intelligent solutions help carry out secondary processes within manufacturing as unobtrusively as possible. DW

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Automated machine reconfiguration with SIKO actuator.

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CAE Solutions

CFD so ware with high-order flow solver delivers up to 10X the accuracy of standard flow solvers The Cadence Fidelity CFD so ware claims to deliver more accuracy for multiphysics simulation. The so ware consists of a suite of computational fluid dynamics (CFD) solutions for multiple vertical markets, including automotive, turbomachinery, marine, aerospace, and others. Fidelity CFD introduces a nextgeneration flow solver with high-order numerics, scale-resolving simulations, and massive hardware acceleration, which together boost performance and accelerate turnaround time without sacrificing accuracy.

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Building upon the expertise and technology gained from the NUMECA and Pointwise acquisitions and organic computational software expertise, Fidelity CFD unites all of the compelling technologies a CFD engineer needs to simulate the performance of multiphysics systems in a streamlined workflow.

Included in Fidelity CFD are several specialized flow solvers for marine and turbomachinery applications, as well as general-purpose flow solvers for a range of flow types.

Engineers can address wind noise around road vehicles, expand the flight envelope of next-generation aircraft designs, optimize the power generated by wind and gas turbines, and cut fuel consumption of marine vessels, all while maintaining high accuracy and reducing turnaround time.

Fidelity CFD includes major technological innovations that are breaking through the limitations of traditional CFD solver technologies. Fidelity CFD software’s next-generation, high-order flow solver with its advanced simulations of fluid turbulence have demonstrated the ability to predict aerodynamic drag on an automobile up to 10X more accurately than a traditional CFD solver. In addition, the turnaround time for these accurate simulations can be reduced from weeks to a day or less.

Unique to Fidelity CFD is the combined meshing expertise from the former NUMECA and Pointwise teams. While geometry and meshing can consume up to 75% of a CFD engineer’s time, Fidelity CFD builds upon a long tradition of innovation and turnaround time reduction in these areas.

While integration of the meshing technologies continues, the software products continue to advance individually.

In particular, the release of Fidelity Pointwise Meshing accelerates the technique used for meshing the flow field around commercial and military aircraft and space launch vehicles by up to 3X. DW

Cadence www.cadence.com

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CAE Solutions

Update to Multiphysics Version 6.0

A screenshot from the Model Manager UI within the COMSOL Desktop that shows the different databases that have been set up to administrate and structure models, along with branching, version control, feature lists, and the folder system used to manage the simulation. The model tree of a selected model can be previewed without opening the model.

COMSOL offers a major update to the COMSOL Multiphysics so ware version 6.0.

The update builds out the Model Manager server with a web interface — an asset management system — to make it easier for users and nonusers to manage models, simulation apps, and supplementary and auxiliary files.

Through two decades of development, COMSOL Multiphysics evolved om a so ware that solved partial differential equations to one that defines the nature of multiphysics modeling: being able to build models with any combination of physics phenomena via the Model Builder. COMSOL completes the environment for managing modeling and simulation projects for product and process design through the recently introduced Model Manager and the Model Manager server with its accompanying asset management system.

Released in December 2021, the Model Manager lets users: • Search through models for particular parameter names and feature strings.

• Track model development through version control with model comparison and merging capabilities.

• Upload, link, and administrate supplementary and auxiliary files to a modeling and simulation or development project.

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The Model Manager has now been complemented by the Model Manager server’s asset management system, which is accessible through a web interface. In the asset management system, an asset can be considered as a container for links to model versions, attached supplementary and auxiliary files, and various custom metadata fields.

With the asset management system, users can itemize assets through model and app files, adding abstracts, setting permissions, and include thumbnail images of the model at hand.

The Model Manager server is a database system that can be managed om either the COMSOL Desktop or a web-based UI. A local installation of any DESIGN WORLD

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license type of COMSOL Multiphysics with the Model Manager and a local database is usually the initial step for a modeling engineer to acclimatize themselves to how this system can be best used within their organization.

From there, full deployment can occur by installing the Model Manager server on a central server. Local installations of COMSOL Multiphysics can connect to the central server with the Model Manager server.

Organizations may start by moving the tens and hundreds of COMSOL models they have developed over the years to their asset management systems as a communal model library. This practice will reduce the need to chase down the many engineers using the so ware for different purposes, as they will be able to find and search through those models as a centralized repository instead.

Internal or external customers may use the database system to keep track and use results om a project. They may also use simulation apps and provide feedback about their measurement and test data by uploading them and reports to the relevant asset. And, of course, contributors on the model development can also add their auxiliary data, such as CAD files and specifications, to the project. DW

A web interface of the Model Manager server asset management system that shows different assets and metadata (asset type, author, distribution, etc.)

COMSOL www.comsol.com

Clicking into an asset allows you to add files and metadata (abstract, thumbnail image, product requirements, etc.)

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CAE Solutions

Verisurf So ware debuts new 2023 release Verisurf 2023 continues to refine metrology workflows with added features designed to reduce time and improve the efficiency of automated quality inspection and reporting, scanning, reverse engineering, and tool building.

Verisurf so ware is built on a CAD platform involving Model-Based Definition (MBD). Verisurf 2023 takes this a step further with automatic conversion of 3D CAD annotations into MBD and intelligent Geometric Dimensioning & Tolerancing (GD&T). This new automatic feature will further reduce the time needed to set up inspection plans, reduce input errors, and increase process control. DW

Verisurf So ware, Inc. | www.verisurf.com

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 for the design engineering community.

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A D V E R T O R I A L

THE RISE OF LOW-COST AUTOMATION:

Trends and technologies you need to know about

Contents 46_Alexander Mühlens

Automation Is Surging So are low-cost solutions for ease of entry

47_Low Cost Automation and Robotics, An Overview 50_New Gantry Robot: Up to 60% more cost-effective, easier to use 52_Matt Mowry

What Are the Major Types of Industrial Robots?

Answers you need before you buy

Published in Design World June 2022 | Becky Chambers Hennessy

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L E T T E R

Automation Is Surging So are low-cost solutions for ease of entry

By Alexander Mühlens I think it’s safe to say that industrial automation is a highly dynamic

Alexander Mühlens, head of low-cost automation, has been with igus since 2010. He is responsible for the Automation Technology and Robotics business unit. His unit develops automation products — from robots to control technology and software. He also runs the robotics marketplace RBTX.com powered by igus, which specializes in lowcost robot solutions. In addition, Mühlens is a member of the Board of the VDMA Robotics + Automation Association.

field that’s fast advancing across all large-scale manufacturing facilities and supply chains. Today that growth is higher than ever due to a variety of technological developments and solutions — in everything from software and artificial intelligence to cloud computing and robotics.

Thanks to this growth, the cost of entry into automation is fast lowering for new, and small-to mid-sized companies. Here at igus we remain focused on providing component-level linear bearing parts for OEM projects. igus is a global leader in lightweight, corrosion-resistant parts that slide with no needed external or wet lubrication. That will not change.

Where igus is experiencing change is in rising demand among new and smaller companies looking to our company for low-cost automation solutions. They want the same access to automation combined with an influx of smaller, cost-effective, and maintenance-free power-transmission products such as our drylin®, which make it easier for these companies to cross the cost barrier.

They also want affordable and flexible solutions for increasing productivity, coping with labor shortages and enhancing workplace safety. At igus, our low-cost automation solutions help users meet these goals while accelerating return on investment. One flexible solution for reducing safety risks to operators is our Rebel® articulated arm robot, which features up to five degrees of freedom and allows humans to shift from rote tasks that can lead to fatigue and injury to other productive work.

Another example of a low-cost automation solution that is timely during pandemics, flu seasons and beyond: Touchless respiratory mask dispensers for work and other public spaces. Our designers came up with a simple automated dispenser using an igus delta robot with our Robot Control to drive a linear axis. Users can choose between a self-assembly modular kit or preassembly in a transport.

You’ll read more about this and other low-cost automation topics and solutions in our Feature and Profile articles. You’ll also see more in our FAQs 46 June 2022 www.designworldonline.com

igus_THE RISE OF LOW-COST AUTOMATION_ADVERTORIAL 6-22_Vs9.indd 46

piece by drytech® Product Manager Matt Mowry that highlights a few of our popular low-cost automation and robotics solutions. Please don’t hesitate to give Matt a call to learn more.

Your business needs and the partners you work with to address them will guide your decisions about how, and how much, to automate your facility. These are exciting times. It seems that only a few years ago we were lamenting the decline of the manufacturing sector. Now low-cost automation is rapidly turning much of that around due to its speed, precision and overall accessibility — namely, its low cost, ease of implementation and many pre-configured application options.

We are seeing how our increasingly skilled workforce, our people, are working with automation in unprecedented ways to increase morale, productivity and profitability. These indeed are exciting times. igus, a Design World 2021 Leadership in Engineering award recipient, is a global leader in the manufacture of engineered products made of high-performance plastics. These include plastic plain bearings, flexible cables, energy chains, connectors, robotic components, 3D-printed products and ball bearings.

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F E A T U R E

igus low-cost automation solutions feature faster ROI.

LOW-COST AUTOMATION AND ROBOTICS, AN OVERVIEW On the minds of most looking to purchase automated systems is how to justify the cost. The

good news is the cost of entry into automation has never been lower and easier than it is today. All you need is the right partners to help identify and customize the best low-cost automation solutions for increasing productivity and return on investment.

Despite the pandemic, changes in the economy and other pressures, automation is on the rise.

“Transformation for robotic automation is picking up speed across traditional and new industries,” says Milton Guerry, president of the International Federation of Robotics (IFR). According to the IFR’s 2021 World Robot Report, from 2015 to 2020 industrial robot density nearly doubled worldwide.

Robot density is a metric used by IFR to track the degree of automation adoption around the world.

One key to the increase: Low-cost automation that is significantly lowering the cost of entry — leveling the playing field — by making implementation and components simpler, smaller and affordable.

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F E A T U R E

Whether users are looking for off-theshelf or do-it-yourself solutions, today’s low-cost build-or-buy automation toolbox comes with many customized options.

These range from individual robotic components to finished products, engineered to “do more with less” while keeping automation system designs as lean as possible — without reinventing the wheel.

Low-cost automation applications are broad in scope and include pick and place; sorting; labeling measurement; inspection automation; and repetitive material handling.

Low-cost automation In defining “low-cost automation,” it’s helpful to start with automation itself.

The International Society of Automation (ISA) defines automation as “the creation and application of technology to monitor and control the production and delivery of products and services.

Automation crosses all functions within industry, from installation, integration, and maintenance to design, procurement, and management.”

Automation benefits virtually all of industry, including manufacturing, transportation, utilities, defense and facility operations, the ISA adds. It is integral to a broad spectrum of traditional industrial applications and advanced technologies. Automation often is used with robotics, particularly in the manufacturing and engineering space looking to eliminate downtime and human error, which in turn leads to fewer worker accidents and improved workplace safety. Automation also allows for workers to focus on other important tasks.

The phrase “low-cost automation” stands for increased productivity driven by simple and affordable automation in the form of robotics components.

Low-cost automation in production and processes is made possible in large part by the growing demand for low-cost, high-performance polymers used in plain bearings, flexible cables and robotic components.

Whether users are looking for off-theshelf or do-it-yourself solutions, today’s low-cost build-or-buy automation toolbox comes with many customized options. These range from individual robotic components to finished products, engineered to “do more with less” while keeping automation system designs as lean as possible —without reinventing the wheel. Low-cost automation also offers bundled hardware packages with pre-installed software for integrated workflows. Users increasingly are turning to one-stop shops for these solutions.

Robot systems and components For new businesses, small and medium-sized companies and others looking for a competitive advantage, low-cost-automation using robot systems and components has become a game-changer. The rapid growth

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of robotic production in fact relies on these components.

Depending on the scope of the application, whole processes or parts of them can be automated with the help of cost-efficient robotic solutions.

These include gantry robots; delta pick-and-place robots; robotic arms and parts; multi-axis robotics carriers; linear actuators; and 7th-axis robot slides for cobots; individual components for single or multiple applications; and control systems with intuitive software.

One of any robot’s limitations is the physical space in which it moves. The gantry robot, similar to a cartesian robot, is a mainstay of modern automation due to its low cost, high speed and precision, and ability to get big jobs done in small work envelopes.

This line of robots enables movement along linear paths within a 3D workspace. Gantries are comprised of two base X axes, a Y axis and an optional Z axis. In advanced models, ball bearings are replaced with self-lubricating plastic liners that slide rather than roll, ensuring a smooth and quiet run.

Gantries are beneficial to engineers looking to automate their warehouses, improve current systems or solve design challenges. Advanced gantries are ideal for applications with two sets of easily configurable parameters: Low speeds with high loads or high speeds with low loads. The gantry’s many applications include pick-and-place; packaging; palletizing; sorting; labelling; measurement; inspection automation; and material handling.

In one example, 14 container gantry cranes at the HHLA Container Terminal Altenwerder (CTA) were equipped with energy chains to supply the gantry trolleys with energy and signals.

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use of energy chains and highly flexible cables, is recognized worldwide.

Another popular robot line is the delta robot, or parallel kinematic robot, a simple solution for fast assembly tasks whose initial investment is far less than many units used in manufacturing industries. For this reason, they are ideal for a variety of users, including those new to automation. The lightweight three-arm delta is connected by a common joint above and below the arms to allow for high-speed pick-andplace applications in industries such as food, pharmaceutical and electronics.

They are based on three toothed-belt actuators, with self-lubricating sliding plastic liners, spherical bearings and other lightweight components that don’t require external lubricants or maintenance. They come in large and small sizes, both of which enable users to achieve high speed no matter the work area size. Stepper motors and encoders ensure quick handling by the delta robot.

In this pandemic era, one timely application for delta robots is in the design of contactless, low-cost automation face mask dispensers that make mask accessibility safer and easier. A delta robot is used with a robot control that helps drive a linear axis. Delta kinematics are optimal for fast dispensing of up

to 60 picks per minute. Users choose between a self-assembly modular kit or preassembly in a transport.

Whether you’re in the market for gantry, delta or other automation options such as articulated arm and SCARA robots, you’ll want to familiarize yourself with them before you buy.

(See “FAQ: What are the major types of industrial robots?” for more.)

Emerging technologies and the workforce With low-cost automation on the rise, there’s a strong case for robots like linear gantries and deltas empowered by lubricating products and other components. They address the pain points like cost, quality and throughput that keep users up at night. In process and production robots are proving their repeatability and flexibility, and performing at astounding speed — all while optimizing throughput and maximizing ROI. In manufacturing, the “Fourth Industrial Revolution (Industry 4.0)” has seen traditional processes being revolutionized by emerging technologies, including robotics, according to the Association for Advancing Automation (A3). “Manufacturers have realized that, when it comes to quality and efficiency, the best way to compete is to automate their factories with robots — whether they are programmed to carry out autonomous tasks or support manual processes.”

A3 adds that when it comes to manual labor, today’s users increasingly recognize that the benefits of low-cost automation cannot come at the expense of workforce stability and employee retention. The pandemic and other pressures have worsened the labor gap, but have increased automation and software systems and, with that, healthy profit margins. This allows for higher wages and benefits to employees.

In addition, gantry, delta and other robots handling repetitive tasks needn’t be seen as “robots in, humans out.”

According to A3 and other experts, people will upskill or reskill to handle other processes or work alongside collaborative robots.

As low-cost automation continues to mature it will increasingly attract and retain high-quality employees, including those who have gone through apprenticeships, and primary and secondary school programs. Because automation is not a cure-all, trained workers will remain critical to optimizing decisionmaking, productivity and profitability. igus provides a variety of low-cost automation robots and robotic components and other tools for all of users’ preconfigured, do-it-yourself and other needs. igus also believes users should be able to test before investing: We encourage you to test your application before you buy.

To learn more, visit www.igus.com/ automation or call an igus expert at 800-521-2747.

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A D V E R T O R I A L

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P R O F I L E

New Gantry Robot: Up to 60% more cost-effective, easier to use

The self-lubricating and maintenance-free drylin® XXL room linear robot from igus lifts up to 10 km and costs up to 60% less than comparable solutions.

igus is committed to helping new companies enter the world of automation through low-cost solutions. Toward that end, the company has expanded its range of low-cost automation solutions with the addition of the XXL Large DIY 3-axis linear gantry robot.

This newest member of the igus gantry — similar to cartesian — product line features an action radius of 2,000 x 2,000 x 1,500 mm, and it is ideal for palletizing applications of up to 10 kg. Another feature: The pricing for the robot and control system. It is structured to help new, small and mid-sized users enter the world of low-cost automation and robotics.

The system is easy to set up and program using the do-it-yourself principle — no help needed from a system integrator. And, the 3-axis linear gantry robot is maintenance-free.

Lowering the barrier to cost-effective automation The DIY kit allows companies to easily install a pick-and-place 3-axis linear gantry for tasks ranging from palletizing and sorting, to labelling and quality inspection. Palletizing robots created in collaboration with 50

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external service providers cost from $95,000 to $135,000.

The people at igus believe that’s a hefty price tag for many small companies. At igus, the use of high-performance plastics and lightweight materials such as aluminum results in a highquality, low-cost solution. Because the drylin® XXL Large DIY palletizing gantry robot comes at a fraction of the price of comparable systems, it is a low-risk investment that typically pays off in a few weeks.

Assembling the DIY kit without prior knowledge Users are introduced to the igus robot through its 3-axis linear gantry as a DIY kit. It consists of two-toothed belt axes and a toothed rack cantilever axis with stepper motors and an DESIGN WORLD

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action range of 2,000 x 2,000 x 1,500 mm. A maximum length of up to 6,000 x 6,000 x 1,500 mm are also possible.

In addition, the package includes a control system, cables and free igus Robot Control (iRC) software. The software includes a matrix function for palletizing exercises.

Users can assemble the components into a ready-to-use system in just a few hours — without prior knowledge or lengthy training. If additional components such as camera systems or grippers are needed, users can easily find them through the igus robotics marketplace.

Augmenting the work of employees A gantry robot can be used on conveyor belts that transport products from injection-molding machines. The robot picks parts with a maximum weight of 10 kilograms from the conveyor belt, transports them at a speed of up to 500mm/s, and positions them on a pallet with a repeatability of 0.8 millimeters.

This automation relieves employees of physically demanding and time-intensive palletizing work, freeing them up for more important tasks. Linear axes consist of corrosion-free aluminum, and the carriages move via plain bearings made of igus high-performance iglide plastics. The self-lubricating properties of igus bearings enable a low-friction, dry operation without external lubricants.

drylin® XYZ Gantries from igus®: • Workspace: Up to 6,000mm • Positioning accuracy: Approx. +/-0.8mm • Max load: 24.5N (5.5lbs) horizontally mounted • Max speed: 0.5m/s • Higher load and speed options available • Different motors and Ingress Protection Ratings available.

Enabling foolproof robot programming The iRC software from igus enables simple and intuitive robot programming and control, allowing for easy entry into automation. The free software allows users to program different robot kinematics.

For many companies without in-house IT specialists, programming robots can be fraught with challenges. That’s why igus developed iRC, a no-cost software application that visually resembles commonly used office software and allows intuitive programming of movements. What makes it special is the resulting low-code programming that can be used 1:1 on the robot.

The core of the software is a 3D digital twin of the 3-axis linear gantry, which can be used to define movements with just a few clicks. Prospective users can use the 3D model to check whether desired movements are feasible before making a purchase.

With the igus gantry configurator, you can customize the specifications, requirements and size of any type of gantry, whether it’s a XY actuator (single rail), XY gantry or XYZ gantry.

Contact igus to determine your requirements and which gantry is suitable for your application.

To learn more, visit www.igus.com/ gantry or call an igus expert at 800-521-2747.

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A D V E R T O R I A L

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F A Q s

What Are the Major Types of Industrial Robots?

Answers you need before you buy

By Matt Mowry | drytech® product manager When considering low-cost automation solutions, you’ll want to know the differences between the top industrial robots on the market. We’ll take a look at four of them included in the igus catalog: Gantry, delta, articulated arm and SCARA robots.

Their main differentiators are size, speed and workspace. The design of each type is customized for various applications such as handling, palletizing and packaging.

Matt Mowry, drytech® product

manager, started at igus in January of 2000 in outside technical sales.

In 2005, he became North American product manager for the drylin® Linear Bearings and Low-Cost Automation business unit at igus and spent four months at igus headquarters in Cologne, Germany. Mowry holds a bachelor’s degree in communications from Washington State University.

GANTRY

The gantry robot, similar to a cartesian robot, is a modular system that allows movement along linear paths within a 3D space. Gantries are configured with two base X axes, a supported Y axis that spans across the two X axes, and an optional cantilevered Z axis. It has a rectangular or cubic work envelope. It requires a mounting frame.

Advantages • Self-lubricating and maintenance-free • Resistant to dirt, dust and corrosion • Clean and quiet Applications • Food packaging • Material handling • Automotive assembly

igus drylin® gantry robots consist of two base X axes, a Y axis and an optional Z axis. Their self-lubricating liners are quieter than recirculating ball bearings.

DELTA

Also called parallel or spider robots, deltas consist of three arms and a single base. The base is mounted above the work area while the arms move at high speeds with the help of motors on each axis. Delta robots have a dome shaped work envelope. The delta’s payload capacity is lower than that of other robot types.

Advantages • Linear actuators with self-lubricating sliding plastic liners • No external lubricants needed • Exceptionally high speed

igus delta robots with drylin® linear actuators feature self-lubricating sliding plastic liners.

No external lubricants required, and switching out liners is easy.

Applications • Parts inspection • Material handling • Friction welding 52

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ARTICULATED ARM

Articulated robots, or robotic arms, are fixed to a base with a rotating joint. The arms can be designed with two to 10 or more axes, with each added axis enabling more motion. Their design is optimal for complex movements. They can pitch, roll and yaw, allowing for directional control. They feature a large work envelope.

igus robolink® articulated arm robots can be used individually and flexibly.

They feature a precision of 1mm and loads of up to 3kg in most industries.

Advantages • Precision movement • Adaptable to process changes • High speed Applications • Palletization • Pick-and-place and gripping • Arc welding

SCARA

Newer to the low-cost automation range is the selective compliance assembly robot arm, or selective compliance articulated robot arm. The SCARA robot features three axes — X, Y and Z — for rotating and lateral movements. They are suited for simple assembly and robotics tasks. They have a cylindrical-shaped work envelope.

At igus, they are fully integrated into our Robot Control software.

Advantages • Compact size • Adaptable axis configuration • High speed and accuracy

igus drylin® SCARA robots are fast and flexible. Typical applications include assembly and joining tasks.

In most cases, they are used for loads of up to 3 kg.

Applications • Higher speed with optional cleanroom specification • Material handling • Assembly and joining

Whether you’re interested in turnkey or fully assembled solutions, or looking to build your own customizable project, please call me or one of our other igus experts at 800-521-2747.

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Coupling Notes

Jaw couplings from Ruland in different sizes with spiders available in three durometers.

Jaw couplings in

surgical robot applications

Edited by Mike Santora • Managing Editor

Zero-backlash jaw couplings with a balanced design, creating reduced vibration and constant velocity, are critical in applications that require demanding starts and stops, such as those in industries like semiconductor, solar, medical, and packaging. The dampening ability of jaw couplings aids in reducing settling time and shock loads, making them a common option for precision positioning systems.

Jaw couplings have a three-piece assembly comprised of two aluminum hubs and an elastomeric element called the spider. The spider is made om complex polyurethane, which reduces impulse loads that might cause shock to the motor and other sensitive equipment. Available in three durometers, the spider in Ruland jaw couplings allows the user to tailor the jaw coupling’s torsional stiffness, misalignment, and dampening requirements to their application.

These jaw couplings have a curved profile that press fits onto the spider, ensuring zero-backlash operation. The curved jaw profile evenly distributes the forces to the center of the spider’s limbs, improving the effectiveness of DESIGN WORLD

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Coupling Notes the elastomer material. Raised contact points on the spider limbs help maintain proper spacing between the two hubs, allowing for electrical isolation and full angular misalignment capabilities.

The designer can mix and match clamp or set screw hubs with inch or metric, and keyed or keyless bores. Bore sizes range om 1/8 to 1-1/4-in. and 3 to 32 mm. Spiders are available in 85 shore A for the best dampening ability, 92 shore A for a balance of dampening and torsional stiffness, and 98 shore A for the greatest torque and torsional stiffness. This combination of hubs and spiders gives designers a high level of customizability.

These zero-backlash jaw couplings are manufactured om select North American bar stock in Ruland’s factory in

Marlborough, Massachusetts, under strict controls using proprietary processes.

Summary: • Balanced hub design to support higher RPM with reduced vibration • Wide range of clamp and set screw style hubs with inch, metric, keyed, or keyless bores • Spider dampens impulse loads while minimizing shock to sensitive equipment • RoHS3 and REACH compliant DW

Ruland ruland.com

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

EE Classroom on Silicon Carbide

Silicon Carbide (SiC) has made its mark in bringing faster, a smaller, and more reliable components than its fellow semiconductors to market. While SiC components have been around for a couple of decades, there is still a lot to learn and a lot to consider when choosing the most suitable WBG semiconductor for your device.

LET US HELP with tutorials, from looking at how WBG semis stack up in power conversion efficiency to an overview of SiC FETs and MOSFETs.

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More affordable 3D printed sand casting for foundries

T 58

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he ExOne S-Max Flex, om Desktop Metal, is a scalable, large-format binder jetting system that 3D prints sand tooling. Applications include sand casting complex metal designs for the aerospace, automotive, and energy industries.

This 3D printer comes to market at a time of strong demand for castings, along with challenges finding labor.

A er years of contraction, the U.S. metal casting industry is experiencing growth as a result of supply chain changes related to the COVID-19 pandemic. A recent survey released

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Never Bring an Unreliable Cord to a Supply-chain Fight Interpower® Mission-ready Cords!

Interpower manufactures dependable, mission-ready North American and International cords and cord sets.

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Our American-made cords are ready to use right out of the box—and downrange ready. Every Interpower cord and component undergoes hipot testing, continuity testing, ground testing, and multiple inspections after each manufacturing process.

• • • • by the American Foundry Society shows that 90% of responding North American foundries have a positive business outlook and anticipate making capital investments in the next 12 months, including of 3D printers.

The S-Max Flex combines ExOne’s sand printing expertise in process and materials with proprietary Desktop Metal SPJ technology. The S-Max was designed om the ground up leveraging SPJ technology with the idea of making premium sand 3D printing accessible to every foundry, so that more companies can take advantage of the benefits of AM 2.0, such as distributed, local production.

The S-Max Flex pairs an affordable industrial robot with an all-new end effector printhead design that deposits binder into a 1900 x 1000 x 1000 mm (74 x 39 x 39 in.) telescoping build box that grows as the parts are built layer by layer. Additional build box sizes are available up to 4700 x 1000 x 1000 mm (185 x 39 x 39-in.), with taller versions available up to 1000 x 2500 x 2400 mm (39 x 98 x 94-in.). The SPJ technology delivers a build rate up to 115 l/h.

The S-Max Flex prints standard silica sand with furan binders and delivers

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final parts with dimensional accuracy of +/- 0.5 mm. The system comes with several accessories and safety features that are configurable to fit many spaces.

Industries beyond metal casting are also set to take advantage of the S-Max Flex’s large form factor and ability to binder jet many powders.

Infiltrated sand tooling for plastic thermoforming, composite layup, and sacrificial tooling applications are printed today on S-Max machines, along with infiltrated sand consumer products, such as those offered by Sandhelden and Deeptime.

Desktop Metal’s Forust brand, which upcycles byproducts of the wood waste stream into consumer designs, will also leverage the new system to print large form factor wood parts at scale cost-effectively. Additional projects are underway printing reclaimed concrete and other materials.

ExOne was acquired by Desktop Metal in late 2021. DW

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Exploring 3D printing’s capabilities The Members’ Choice Award went to Jung Kyu Im’s and Daniel Goncalves’ entry titled “Metal 3D Printed Bathroom Faucet.” The custom design incorporates water channels within the organically shaped ‘stems’ that twist as they rise to connect with the ‘flower’ that discharges the flow of water. The faucet and the accompanying handles were manufactured in stainless steel using laser powder bed fusion technology from Renishaw.

O

ne of the highlights of any Additive Manufacturing Users Group (AMUG) conference is the annual Technical Competition. It offers members an opportunity to showcase their skills with additive technology, as well as their imagination. It gives attendees a chance to see what can be done with this technology as well.

The competition recognizes excellence in additive manufacturing applications and finishing techniques. This year, a panel of industry veterans selected Bill Braune of Dinsmore, Inc. and Nanci Hardwick of MELD Manufacturing as winners in the Advanced Finishing and Advanced Concepts categories. AMUG Members selected Jung Kyu Im and Daniel Goncalves of Custom Prototypes Inc. for the first-ever Member’s Choice Award.

AMUG Members cast votes to determine the winner of the Members’ Choice Award. Of the 32 entries, they selected Jung Kyu Im’s and Daniel Goncalves’ entry titled “Metal 3D Printed Bathroom Faucet.” The custom design, which had floral inspirations, incorporates water channels within the organically shaped ‘stems’ that twist as they rise to connect with the ‘flower’ that discharges the flow of water.

The faucet and the accompanying handles were manufactured in stainless steel using laser powder bed fusion technology om Renishaw. In their entry description, Im and Goncalves said, “The complex shape could only be produced with powder bed metal 3D printing.” They also commented, “We had to design the water channels in a way that would avoid internal supports.”

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Winning the Advanced Finishing category is a creation by Bill Braune, “Mars Attacks,” a large, highly detailed homage to the hit film by Tim Burton.

The Las Vegas sign has 111 individual pieces, ninety of which are individual light bulbs that go around the sign. To bring Mars Attacks to life, Braune and his team invest over 200 manhours and countless hours of build time on seven different AM platforms.

Nine judges scrutinized every detail of the competition entries to select the winners in Advanced Finishing and Advanced Concepts.

Bill Braune’s winning entry in the Advanced Finishing category was “Mars Attacks,” a large, highly detailed homage to the hit film by Tim Burton. Measuring 34 by 23-in., everything from the base to the Martians to the Las Vegas sign was 3D printed and brought to life through artistry and craftsmanship.

Braune said, “The Las Vegas sign has 111 individual pieces, ninety of which are individual light bulbs that go around the sign.” He continued, “We embarked on this journey to showcase everything we [Dinsmore Inc.] have to offer.” To bring Mars Attacks to life, Braune and his team invest over 200 manhours and countless hours of build time on seven different AM platforms.

Nanci Hardwick received first place in the Advanced Concepts category for “Metal 3-D Printing Raises the Bar for the Army’s Jointless Hull Program.”

The entry was a representation of what the U.S. Army plans to do with MELD Manufacturing’s technology, which was chosen to be a part of the world’s largest metal printer for the Jointless Hull Program.

The patented MELD method is a solid-state process that ‘stirs’ plastically deformed metal. The Army’s program plans to have a printer with a build envelope of 20 x 30 x 12-ft, which is big enough to manufacture a monolithic hull. Hardwick’s entry was a section of a hull made from aluminum and weighing over 200 lb.

Meyer shared the following comments from the panel of judges. “Fascinating,

novel AM technology that enables large-scale manufacturing.” “Maybe the most impressive new AM technology here.”

For Advanced Finishing, Mark Abshire took second place with his work titled “Adding a Colorful 3rd Dimension.” Third place was awarded to Brent Wright of LifeNabled for “Curiosity Revealing and Animating Gears.”

Andreas Vlahinos of Advanced Engineering Solutions received the second-place award for “Avionics Heat Exchanger” in the Advanced Concepts category. Third place went to Jason Jones of Hybrid Manufacturing Technologies for his entry “Using PBF to Enable DED in a CNC.” The Technical Competition judging panel was comprised of nine AMUG DINOs, a recognition of selfless service to AMUG, its members, and the additive manufacturing community. These judges were Ron Belknap, Rey Chu, Jeff DeGrange, Jason Dickman, Dave Flynn, Sheku Kamara, Bruce LeMaster, Bob Markley, and Robin Van Bragt. DW

Additive Manufacturing Users Group (AMUG) www.amug.com

Nanci Hardwick received first place in the Advanced Concepts category for “Metal 3-D Printing Raises the Bar for the Army’s Jointless Hull Program.” The entry was a representation of what the U.S. Army plans to do with MELD Manufacturing’s technology. The MELD method is a solid-state process that ‘stirs’ plastically deformed metal. The Army’s program plans to have a printer with a build envelope of 20 x 30 x 12-ft, big enough to manufacture a monolithic hull. Hardwick’s entry was a section of a hull made from aluminum and weighing over 200 lb.

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Repair STL and scan data at the push of a button

With a new function called “Marching Cube,” the latest version of CoreTechnologie’s 3D printing so ware 4D_Additive repairs and simplifies 3D scan data and STL files into closed volumes, within shortest space of time.

The feature allows any type of triangulated 3D model to be automatically corrected and prepared for 3D printing.

Modern 3D printing is based on accurate CAD data but today more and more o en on data generated with a 3D scanner. The quality of STL data is o en poor and not suitable for 3D printing or other subsequent processes. To ensure error- ee slicing and printing, it is necessary to repair errors on STL models and send

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With the innovative Marching Cube function, faulty STL models as well as scan data can be repaired and transformed into closed solids practically at the push of a button. closed solid models to the printer. In addition, scanned parts often have file sizes of several gigabytes due to the high number of very small triangles. Especially if several scanned files are to be printed in the same print job, the size of the data that must be sent to the machine can become a real problem.

The 4D_Additive 1.4 software has revolutionary functions to close the tessellated models into “watertight” solids and intelligently mesh reduction functions in order to reduce the number of triangles without losing accuracy.

These new features called “Marching Cube” and “Mesh Simplification” allow any type of triangulated, mostly STL data, to be automatically corrected and simplified at the touch of a button.

With the Marching Cube function, faulty STL models and scan data can be repaired and transformed into closed solids practically at the push of a button.

The new function saves the user an extremely time-consuming manual repair. The Marching Cube function combines a “voxelization” of the parts with their repair, whereby the size of the voxel, i.e., cube, and thus the fineness can be defined by the user. After the adaptive filling of the part volume with voxels, the so-called “voxelization,” a closed 3D mesh is generated. The 4D_Additive software thus repairs models with hundreds and thousands of triangulation defects fully automatically within a few seconds.

In addition, the user has access to various options for the intelligent DESIGN WORLD

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reduction of triangles. By defining a maximum angle between the triangles, the maximum chord deviation by percentage reduction or by defining the desired number of triangles, the file size and complexity of triangulated models can be reduced easily.

The use of the two new functions makes it possible to repair any type of scanned part without manual effort, thus creating printable solids with a reasonable file size and resolution from scans and faulty STL models in a very short time. In the future, this technology will enable simplification of the scanning and printing process in many areas. DW

CoreTechnologie www.coretechnologie.com/ products/4d-additive

www.designworldonline.com

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Reflective wave phenomena in VFD applications

Reflective wave phenomena or voltage spikes can damage motors and cables. Learn critical design considerations to reduce these risks.

Gordon Post • Regional Sales Manager • Helukabel

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Mechanical representation of RWP. When the wave reflects from the free end, the pulse reflects without inverting.

When the wave reflects from the fixed end, the pulse inverts as it reflects.

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W

hat is a reflective wave? A good example would be dropping a pebble into a glass of water and watching the ripples hit the edge of the glass and bounce back towards the center. Another way of understanding this phenomenon is tying a length of string to one fixed end, holding the line taught and inducing a small whiplash effect at the open end to see the wave hit the fixed end and then return 180 degrees out of phase as it travels back to you.

Reflective wave phenomena (RWP) in AC motors, when using a variable frequency drive (VFD), are also known as reflective waves or standing waves, which are basically voltage spikes that can damage the motor or cable. RWP has become more prevalent since the incorporation of insulated gate bipolar transistors (IGBT) into VFDs. Basically, a VFD will take a voltage (480 VAC 3-phase) and immediately convert it to a DC voltage (600 VDC), often referred to as bus voltage. Then IGBTs, which are controlled by the CPU on the VFD, will switch the DC output voltage on and off, at different levels and polarity. This makes an AC sine wave out of the DC voltage pulses, also known as pulse width modulation (PWM), so the power and frequency can be altered for AC motor variable speed and performance.

Not all motors are the same, so the specifications of both the motor and its applicable cable should be considered when deciding to use a VFD. Items to consider are: What is the difference between inverter duty, industrial duty, and a standard AC motor?

Why use VFD cable instead of standard cable?

How does RWP have an effect on your design choice?

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Always assume RWP is present First when using a VFD, it should be assumed that RWP is present. Standard duty (Class B, 80°C rise) and industrial duty (Class F, 105°C rise) will not perform as well as an inverter duty motor (Class H, heavy duty, 125°C rise) and it should be noted that the service factor (SF) of a motor is typically 1.15. This means for a short time the motor can perform 15% above its rating,

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VFD cables installed in wire basket trays before connecting to equipment controlled by a VFD motor.

the SF is reduced to 1.0 when used with a VFD. With the differences in motor winding temperature rating and the service factor being 1.0 with the use of a VFD, the sweet spot for sizing a motor is typically 20 to 25% above the required horsepower. Other factors that can cause RWP to have a negative effect on the selected motor are faster switching IGBTs, multiple motors connected to the same VFD, and installations above 3,300-ft where cooling is more difficult.

All three of the previously mentioned are contributors to RWP and all over

time will break down the motor winding insulation and eventually lead to system failure.

Standard cable need not apply For motor cabling from the VFD to the inverter duty motor you need VFD cable that can handle the harsh electrical environment for which standard cable is not designed. Similar to design considerations for an inverter duty motor, cabling between the VFD and motor are subjected to a significant amount of electrical noise in the form

of voltage spikes, reflected waves, charging currents, common-mode voltage, and RWP/electromagnetic interference (EMI). This leads to voltages that are up to two times the source voltage. In the case of a nonVFD cable, this could result in insulation breakdown and cable failure. Non-VFD cable also allows common-mode (or stray) voltage to find its way through the VFD motor and equipment grounds, which causes motor and equipment failure. VFD-rated cable significantly reduces the risk associated with these

Sine Wave Power Variable Frequency Power

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Power Conversion

Pictural representation of the basic functionality of a variable frequency drive.

Power Conversion

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issues. RWP and its degrading effects on motors, drives, and cables clearly illustrate the importance of designing in a VFD-rated cable.

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Pictural representation of reflective wave phenomena, as a small whiplash effect or wave at the open end hits the fixed end and then returns 180 degrees out of phase as it travels back.

Criteria to look for in VFD cables VFD-rated cables should focus on three main criteria in application: 1 Shielding for high and low frequency noise protection by using foil (100% coverage), plus tinned copper braid (85% coverage), or a triple shield using a conductive fleece with foil and a braid shield (80% coverage).

2 Ability to withstand voltage spikes and RWP. XLPE insulation has a much lower capacitance than cable that uses PVC for its insulation, thus allowing it to withstand voltage spikes better. VFD cables should also be rated for 1,000 VAC compared to the industry standard of 600 VAC. 3 High temperature rating. Using a thermoset insulation allows the cable to withstand higher temperatures that would typically degrade a thermoplastic insulation also caused by RWP and lead to system failure.

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Free End

Fixed End

In summary, you are only as good as the weakest link in the system both mechanically and electrically. For motion applications where a VFD is being used with high-performance IGBTs to create a PWM signal for variable speed control, design considerations need to be made for the motor and for the VFD-rated cables connecting the VFD to the inverter duty motor to reduce or eliminate the effects of reflective wave phenomena, which can cause costly down time. DW

Helukabel | helukabel.com

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

Why Use XLPEinsulated VFD Cables?

Because It’s the CODE! NFPA 79 Chapter 4, Article 4.4.2.8 “Electrical conductors and equipment supplied by power conversion equipment as part of adjustable speed drive systems and servo drive systems shall be listed flexible motor supply cable marked type RHH, RHW, RHW-2, XHH, XHHW, or XHHW-2” Helukabel’s Topflex & Topserv VFD product families are suited to power and monitor VFD performance in static and continuously flexing applications.

Source: NFPA.org

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5G TECHNOLOGY WORLD Delivers the Latest 5G Technology Trends

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

Get caught up on critical 5G information, check out the following articles on 5GTechnologyWorld.com: Massive MIMO performance testing: Emulate the channel Performing MIMO testing using real-world conditions is critical for successful 5G deployments. www.5gtechnologyworld.com/massive-mimoperformance-testing-emulate-the-channel

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

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

IEEE 1588 adds timing performance while reducing cost and risk GPS and GNSS have been the standards for network timing, but they have security issues. A Master clock and IEEE 1588 reduces the risk and lowers installation costs. www.5gtechnologyworld.com/ieee-1588-adds-timingperformance-while-reducing-cost-and-risk

For additional content, go to: www.5gtechnologyworld.com

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Brighter

Part 1 of 2:

future for laser-based materials processing New modular controllers offer flexible solutions for linking a laser to multi-axis positioning, making it easier for system integrators to design and build advanced systems for a new age of laser applications.

Dr. Cliff Jolliffe • Head of Automation Market Segment | Physik Instrumente (PI) GmbH

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Lasers have been used for welding and cutting applications in materials processing for years.

However, laser technology has frequently been considered a specialist area, requiring complex control systems for accurate positioning, as well as significant investment and expertise. Recently, the cost of lasers has decreased, opening them up to new applications; even the latest extremely fast ultrashort pulse lasers are now feasible options for machine builders who would typically have used less risky laser setups.

The commoditization of lasers means that system integrators must do more to gain and maintain an advantage, and that positioning and control – as integral parts of any laser system – are important elements of this. The newer technologies work in a slightly different way, so it makes sense that positioning and control also need to be different. The basic ability to fire the laser in the right place has become more challenging, and a simpler approach is even more important than ever, especially for those who are completely new to the technology.

Novel solutions are now available that take a uniquely modular approach to laser control, making it far easier and faster for system integrators to design and build systems in the first place, whether or not they have previous experience of lasers. The use of industrial control networks such as EtherCAT makes this modular solution even more flexible, as other items – such as sensors, or non-motion devices – can be easily incorporated.

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Laser pulse placement during a constant speed profile. | courtesy PI

An example of a non-uniform laser pulse delivery. | courtesy PI

Why choose laser processing?

There are many significant advantages to using lasers instead of traditional machining processes, not least is their capacity for much higher throughputs.

Lasers are not susceptible to the same wear and tear that can lead to breakdown disruption and costs in mechanical components, and are often efficient at processing materials that are otherwise notoriously difficult to deal with. The fine beams of lasers also give a level of detail and accuracy that is near impossible to create using other methods, which is ideal for applications such as those generating high aspect ratio holes or other features requiring similar high precision.

High intensity short pulse lasers, in particular, are incredibly precise. The low thermal energy deposition around the beam of these lasers means there is negligible damage to the surrounding areas. Lasers can even process below the surface of a material, depending on where the beam focuses, examples of which can be commonly found in microelectronics devices, such as lightemitting diodes and flexible displays.

Striking the right balance of speed, power and precision Whatever the application, fast shuttering and accurate firing of

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A non-linear path can lead to laser pulses bunching up around corners. | courtesy PI

laser pulses is essential to ensure consistent, high-quality processing.

Precise placement and energy control are crucial here and can be achieved by linking the automation and motion system directly to the laser output. It’s extremely important to be able to make sure that the laser is focused on the right place, for the right amount of time, and delivering the right level of power in order to prevent damage to the material or the production of inaccurate parts.

One option is to link laser power to pulse rate and modulation. If the power is fixed, then the motion system will need to run at a constant speed to ensure that the correct level is delivered across the surface. This suits some operations, such as raster scans where the laser is fired following motion in one direction, or during the constant velocity phase between acceleration and deceleration phases. However, cutting and welding applications may also need the laser pulses to overlap at a consistent ratio, even when the motion path speed is not constant, and laser pulses occur at a fixed frequency.

This could result in a non-uniform pulse delivery, where too much energy to a particular area could create HAZ (heat affected zones), and too little could cause weak regions or breaks in the cut or weld path. www.designworldonline.com

The problem of HAZ occurs even more frequently with multi-axis systems, simply because of the nonlinear path of corners or arcs. The best analogy is that of a sports car driving around a racing track – when it gets to a corner, it must slow down, otherwise it wouldn’t be able to follow the racing line and would probably run off the track; the same is true for an XY table. However, if the motion path slows down too much but the laser pulsing rate remains constant, too much power is delivered into the corners as the laser pulses bunch up.

Some G-code capable CNC machines have look-ahead capabilities to address this, allowing the motion controller to look for changes in speed that exceed predetermined limits.

Linking laser control to speed and position One of the simplest methods of controlling laser power is to link it to the velocity of the motion path. This can be simply achieved by linking an analog output in the controller to that of the vector speed of the motion path, and linking this to the laser power.

The analog output is connected to the power input connection on the laser, for example, a 0-10 Vdc range.

Typically, the motion controller will let users define a scaling factor so that DESIGN WORLD

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the maximum output is relative to the maximum power of the laser required for the process – a lower limit may also be set. It’s important to remember that if the motion is badly tuned, jerks may result in bad processing. Poor placement accuracy could also create a bad quality part. This is a simple but effective process, for example, in welding.

Another approach is to precisely control the laser by pulse placement along the motion path, regardless of the vector velocity. It’s also possible to combine these two methods to control scaling of the power output, which overcomes undesired features of the laser electronics or optic path.

There are several technologies available in the industry that can generate such accurate, high-speed, positionbased events linked to electronic outputs; for example, laser pulses.

Although subtly different from each other, they essentially do the same thing for motion in a single axis. Some are better suited to galvo-technology, others are more aimed at motorized positioners.

New developments such as modular controllers from Physik Instrumente’s ACS Motion Control, Position Event Generation (PEG) is emerging as a solution for linking a laser to multi-axis positioning.

Challenges of controlling multiple axes Paths that create three-dimensional trajectories can be created from three or more axes. Examples are simple dualvector tracking – generated from two axes and widely used for linear XY table contouring, including circles or arcs and straight lines – a linear theta combination for processing tubing, or any combination of linear and rotary stages, for example, producing helical motion for drilling.

Until recently, controlling the motion path for lasers across multiple axes has come with certain limitations relating to performance, speed, practicalities, and, not least, higher complexity and costs.

Many of the drives available for precision motion and laser processing have to be predefined, depending DESIGN WORLD

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Sine wave encoder subdivision (encoder multiplication). | courtesy PI

Because laser processing adds hardware requirements to a system, designers may need to replace the original drive with a larger, more complex one. | courtesy PI

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on the feedback device used on the stages or the table used in the motion system. Positional feedback means a device that is capable of reading the stage’s position, but also allows the controller to calculate the speed of such a device. Some motion stages do not use any feedback; they rely on the principle that the commanded motion request equals the actual response. Typically, feedback systems are either incremental or absolute – incremental encoders require a reference point or known position when the system starts up, often a homing switch. In comparison, an absolute encoder system has the positional data built into the feedback measurement scale. This positional data is available at startup and therefore removes the step of physically moving the system to a reference device.

There are two types of incremental encoders; square wave or sinusoidal (sin/cos wave). Square wave encoders provide the system with discrete digital steps of a fixed distance. For example, a square wave encoder on a rotary motor may output 1,000 steps per revolution; if the rotary motor was driving a 1-mm pitch screw, the system resolution would be 1 mm/1,000, i.e. a 1 µm resolution. A potential problem with a square wave encoder is when it has a high-count output to obtain resolution, and the system also requires high speed. The output frequency could potentially exceed the maximum frequency input of the controller’s feedback circuit, resulting in position loss.

Sine wave encoders are able to provide much higher resolution with higher stage speeds because the controller inputs the data at the fundamental frequency of the encoder, which is much lower than the square wave equivalent. The controller feedback circuit internally subdivides the sine wave into digital steps to produce the internal digital steps; this process is called multiplication.

In practice, a square wave encoder may start out as a sinusoidal encoder, and the key difference is where the digitization or multiplication takes place – at the feedback device in the case of a square wave or in the controller.

However, many laser firing controllers unfortunately cannot use sinusoidal feedback to produce an output that will trigger the laser – their electronics require digital square wave signals – and this may limit their usability to low-speed systems with high feedback resolutions or to high-speed systems with low feedback resolutions.

Multiple feedback in multi-axis systems Laser synchronizing technologies use encoder data for single axis path motion to trigger, for example, one-to-one firing so that there is a single laser pulse

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with every millimeter or micron moved.

When it comes to multi-axis, for example, pulsing in a circle, the same principle can be applied – data is taken from the individual encoders of each axis and fed into on-board electronics hardware, where the combined vector output is calculated. This has been the accepted norm for many years and, in theory, its accuracy comes from the fact that it is based on real-time positional information from the encoders. However, in reality, if the motion system is not adequate in performance, then this approach will produce poor results. For example, a constant speed circle on an XY table is made up of sinusoidal changes in velocity for each axis. A change in velocity means there must be an acceleration associated with the motion.

Acceleration is directly proportional to following error (the difference between the commanded path and the actual path). Therefore, the path will always deviate from what was commanded, and it is the user’s responsibility to ensure the error is below the threshold for the required accuracy. The path may be longer or shorter because of the deviation, which would mean the laser pulsing could be activated at incorrect positions.

Additionally, the electronic circuitry used for processing multiple feedback devices, and creating the output vector used for firing, can result in a significant delay (latency) to the output; the more encoders that are tracked, the more dramatically the speed of the output reduces, consequently the data input rate (tracking) of each feedback is reduced.

Firing hardware that requires encoder data obviously cannot be used to generate events for motors that have no feedback; for example, stepper motors.

Similarly, they’re not appropriate for serial communication-based absolute encoders. These encoders do not need to be homed when they start up, which can be a significant advantage with regard to safety and convenience for some advanced systems. Kinematic systems like hexapods are also DESIGN WORLD

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challenging – the encoder data is not directly linked to the position or motion in a parallel direction, or may be a combination of data from multiple axes that requires calculation, and so does not generate direct triggering for paths in Cartesian coordinates.

There are few automation controllers on the market that can handle this level of complexity to ensure that the motion system not only has the correct motion performance, but also the ability to read in and trigger out the encoders used for these applications. With this in mind, users should consider pulsing strategies that do not rely solely on direct feedback.

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Whichever method is chosen, the machine builder should always consider the motion performance of the mechanics and controller. Motion systems have other system issues, such as resonances, low bandwidth, under-powered motors, or mechanical inadequacies (accuracy, roll, pitch, yaw, flatness, straightness, and stacking areas) that need to be appropriately matched to the system requirements so that the work piece or the laser head is in the right place when firing occurs.

The drawbacks of repurposing drive systems Laser processing puts additional hardware requirements onto an automation system and the system designer needs to be aware of the input and output needs of connecting a laser to a controller. In theory, every time a system integrator designs a new system with advanced laser control abilities, they must take the input/output capability of the master controller or the master drive unit into consideration. This is frustrating because the focus shifts from the servo performance required to the laser connection functionality. Typically, the machine builder has to literally rebuild the entire control system to take account of these additional requirements.

This may involve replacing the first drive unit with a physically larger, much more complex, and more expensive drive that combines such capabilities.

This can have a significant impact on cost, including time for redesigning the system, additional hardware, stock of spare parts, and larger electrical cabinets. DW

Physik Instrumente (PI) GmbH www.pi-usa.us/en/ New developments such as Physik Instrumente’s ACS Laser Control Module (LCM) offers designers a different way to construct motion systems based on the EtherCAT industrial network. | courtesy PI www.designworldonline.com

Part 2 of the series (in the July issue of Design World) looks at the benefits of modular control for laser processing.

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How to get everyone

on the same page Making both CAD renderings and BOM information available to all systems on the factory floor and outside its doors cuts costs and raises productivity, whether the product is new or remanufactured.

Jean Thilmany • Senior Editor

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For many years, a three-dimensional product remained locked

inside the computer-aided design system, meaning only the engineers who had designed the model could access its associated data.

Sometimes that information was shared with a select few people in manufacturing to assure engineers the part could be manufactured as defined.

In today’s digital age, manufacturers saw no reason for that information to go to waste.

They knew that model data could be used in myriad ways to improve efficiencies and cut costs. It could drive the build of a digital twin, for example, that mirrors how the product is operating in the real world. It could be associated with bill of material information to predict how much raw material to procure and to manage logistics.

Beyond the factory floor, marketing departments could refer to the models to answer potential customer questions. And they would certainly be a boon to service and repair people who could consult them to learn more about a part and a product. www.designworldonline.com

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Vermeer makes heavyuse equipment like this mini skid steer. The company recently updated the way it engineers and manufacturers work together on new product development. | Vermeer

But freeing that information from the CAD system has come with two pretty significant drawbacks. The first is that CAD models must be essentially translated before they can be used by other software systems across the company. The second is the offer of data visualizations to any number of users. If they can see a rendering of the product, and can dive down into its individual parts, they can better understand how the product works and how to repair and maintain it.

And then there’s Industry 4.0, which moves to digitize the entire manufacturing plant. The move necessitates pushing product models — and the 3-D data they contain — across the extended enterprise to business systems like the enterprise resource management system.

“Access to 3-D models and product data across the extended enterprise has been a major barrier to collaboration for cross-functional teams for decades,” said Dan Murray, who founded Vertex. The company takes CAD information into the DESIGN WORLD

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cloud and turns it into a high-quality rendering that is tied to the BOM. The rendering software allows models and information to be quickly and easily shared with the ERP, the product lifecycle management, marketing, and many other business systems.

That data has use beyond the factory walls. Repair and service people, for example, would easily be able to reference a simulated model on their tablet.

That’s a big key for Vertex. The rendered CAD models — no matter how intricate — are available on tablets and even smartphones, Murray says.

He showed the example of an intricate airplane model that included CAD information for every part on the aircraft, no matter how small. The rendered results were almost instantly viewable on a smartphone. Data-heavy sets like these can take several minutes to load even on a powerful desktop computer.

To see the model pop up quickly and to manipulate it — zoom

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When a piston seizes, the entire engine goes down with it; when an engine valve seizes the part can be remade and the engine is brought back to life.

in on a part, move the drawing, and look up part information — in real time can actually be startling, just like the internet itself was in its early days.

For Industry 4.0, software like Vertex’s enables companies to integrate 3D visualization anywhere along the digital thread. Gartner research defines the digital thread — and by extension a product’s digital twin is “a virtual representation of a product, process, or system from inception, through production, to operation.”

The digital twin is made up of three main elements, said Mairi Kerin, a mechanical engineering professor at the University of Birmingham in England. It’s comprised of: a real product in real space a virtual product in virtual space the connections of data and information that tie the “products” together

• • •

For digital efforts to move forward within manufacturing, product data must be easily integrated across all the systems that will use it, said Sonal Naik, managing director of Deloitte Catalyst, a consultancy that helps startups by connecting their prototypes with a larger community, “As manufacturers continue on their digital transformation journey, the value of having data at the fingertips of all workers — whether it’s on a factory floor or in field service — is only growing,” Naik said. “When we turn that data from text into pictures and videos, it drives even more value.”

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A thread through the middle Though the digital thread ties every stage of a product by defining it in digital forms, the term mostly refers to products in their first go-round: from initial inception to creation.

What’s not as discussed is how digital transformation applies for what’s called “middle-of-life” or remanufacturing, use.

The capability to share CAD models across many types of software systems holds great potential to drive that sector forward, say industry watchers including TWI, a membership organization in Cambridge, England, that consults with remanufacturing companies, offering information on engineering, materials, and joining technologies.

Remanufacturers rebuild and recover previously sold, worn, or nonfunctional product that can be rebuilt and recovered. They do this in a number of ways, including by disassembling and cleaning the product, repairing it, or replacing worn or obsolete components, according to TWI. The remanufactured piece can be returned to a “like-new” or even a “better-than-new” condition. The process differs from recycling in that products retain their general form, even if it includes remade parts. With recycling, the product is broken down into component parts, which are then remade into something completely new, the consultancy said.

Those in the remanufacturing industry need straightforward access to a product’s digital twin: but that’s not always so easy for products that www.designworldonline.com

may have been produced a while ago or those where original manufacturers can’t provide a digital twin. After all, the digital factory is still in its infancy.

Many companies don’t maintain model information and visual files.

The problem is compounded by the fact that no ultimate, universal definition of the digital twin — not to mention associated standards — exists today, said a team of four researchers who write about the challenges of using a digital twin for remanufacturing in the May 2022 issue of the International Journal of Advanced Manufacturing Technology.

At every stage of the asset’s life, there is a need to update the virtual twin to match that of the real one,” wrote Kerin, lead author the manufacturing journal paper. “However, there is still a need to access data from previous key points in the asset’s life.”

To use primary digital records, including a digital twin, in middle-stage remanufacturing, the researchers propose a unified modeling language that can be applied to generic assets to be remanufactured.

For example, the original as-built CAD data the digital twin provides can help remanufacturers find a way to machine a vital part they need to remake a product.

The researchers propose what they call digital siblings, which provide information about a product at different states of creation and use. These include the data information used to make the part, of course, as well as digital data on how the part might appear in the future states and at what manufacturers call end-of-life, which is when a product can no longer be used or remade, Kerin said.

The sibling could help remanufacturers determine if a product is at the end of its life, or if it could be remade.

“That way, remanufacturers have visibility of the previous state, current state, and potential future states of the asset whether that be a component, product, system, or process,” she said.

In addition, remanufacturers can use the bill of material data tied to the sibling to ensure their product will meet DESIGN WORLD

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the definition of “remanufactured” by matching or surpassing the “as-new” performance the BOM depicts. If their parts lists match those of the original product, remanufacturers can be pretty sure they can say their products are “good as new.”

The generic asset model the researchers propose for digital siblings would use unified modeling language (UML), which is a standard way to draw software models, sketch out designs, or document existing designs and systems. To be useful for future digital sibling users, engineers will need to denote possible future processes the part might undergo.

This could be part of the UML model before the original build is released, Kerin said.

Of course, an engineer drawing an original part model can’t be expected to know how the product will be remade, but the possible future processes give insight into the recoverable parts of an asset, she said.

Engine makers, for instance, might prioritize digital siblings for valves over pistons.

“A piston seizure can cause a catastrophic failure and unrecoverable engine; however, a valve seizure is

likely to need only a cylinder head replacement making remanufacturing a more realistic proposition,” Kerin said.

Remanufacturers could also refer to a digital sibling to help plant the remanufacturing process, which today remains fairly manual and few decisions are automated. The CAD software used for original design does automate some processes. If an engineer changes the geometry within one part area, the software updates the measurements for other areas accordingly, she adds.

The digital tool could also be used to help simulate how a product functions before remanufacture and how it will perform after its remade.

“Simulate is significant when predicting life expectancy, failure modes, and processing outcomes for remanufacturing,” Kerin said.

No more sticky notes To see how model data can best be shared within a typical manufacturing process, take the example of Vermeer Corp., which makes industrial and agricultural equipment. The company recently implemented Vertex to help with design review and approval.

Design reviews across departments often required slide decks created

from CAD screenshots. Of course, they were not interactive.

The most complete review of design — called the milestone review — happens at the company after a physical prototype is built, said Ethan Roth, project engineers for Vermeer’s hose and harness routing team.

“After the technicians build the prototype, every relevant group in engineering and non-engineering visually reviews it in person,” said Roth. “There was no great way for those groups to provide notes and for engineering to aggregate them.”

Vermeer had come up with a manual solution; team members placed notes on the physical prototype with change suggestions. Of course, the notes resulted in rounds of follow-up emails and procedures and could result in late-stage, expensive design changes, Roth said.

The company has improved collaboration through its move to Vertex, which gives everyone access to full-scale model visualization, he said.

Milestone design reviews can now be done using virtual prototypes because the cloud-based software doesn’t use much computing power when compared to software housed on site. Team members can now leave feedback directly within the model rather than on sticky notes.

Also, the virtual reviews ensure that physical prototypes more closely follow design intent, saving time and cost, Roth says.

Vermeer, like many other manufacturers is taking steps into its digital future. And it’s finding that, by pushing CAD data out to many other departments, it can save significant time and money.

Murray, who owns Vertex, isn’t surprised.

Expect your technician to carry a tablet and to call up a full-scale CAD model of your dishwasher in the future. That can only make repairs easier and faster — and hopefully cheaper for the person who pays the repair bill. DW

Vertex makes the software that translates CAD data into useful visualization and information accessible on many systems, including tablets and smartphones.

Vertex software. | Vertex DESIGN WORLD

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Medical www.designworldonline.com

A Supplement to Design World - June 2022

ft, so ips o cr il Mi , Ph care , J h n zo , J& ealt lain a e p Amoogl E H s ex G nd G der a lea

Leaders in medtech and cloud computing discuss payoffs and potential in device connectivity, product development and crossindustry partnerships.

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Leaders in medtech and cloud computing discuss payoffs and potential in device connectivity, product development and crossindustry partnerships.

J I M HAMMERAN D MAN AGI N G EDI TOR

I

f knowledge is power, that power comes from a steady stream of information, and we know there’s no shortage of that in healthcare.

The challenge has long been how to capture that information, store it, analyze it and deploy it to improve medical product design, manufacturing and the health of patients.

Then came the cloud, and with it a host of acronyms: software as a service (SaaS), platform as a service (PaaS), infrastructure as a service (IaaS), and — following the same convention — software as a medical device (SaMD).

Over the past few months, Medical Design & Outsourcing connected with leaders in medtech and cloud computing, including the three largest providers of cloud computing services: Amazon, Microsoft and Google. They offered examples of success stories in the cloud, ways the cloud can lift medicine to new heights, and some advice for medtech insiders looking to harness the power of cloud computing.

The following excerpts have been edited for space and clarity. Go to medicaldesignandoutsourcing.com for longer interviews and more on cloud computing, artificial intelligence and machine learning.

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MDO: What are some surprising and inspirational examples of what cloud computing enables with regard to medical device design, manufacturing and capabilities/performance?

Google Cloud Global Lead for Medtech Strategy and Solutions Alissa Hsu Lynch

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Alissa Hsu Lynch, Google Cloud global lead for medtech strategy and solutions: Researchers at Emory University used Google Cloud to create an algorithm that uses 71 factors to predict the onset of sepsis in patients within four to six hours with 85% accuracy, improving the time to diagnosis.

[On another front], DeepMind’s AlphaFold machine learning system recently helped solve the protein structure problem, which has been a grand challenge in biology for 50 years. Research organizations can now leverage AlphaFold to better understand complex diseases and accelerate the development of new treatments, such as life-saving cures that disproportionately affect poorer parts of the world. >>

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THE CLOUD IS TRANSFORMING MEDTECH

Microsoft Global Chief Medical Officer and VP of Healthcare Dr. David Rhew

Amazon Web Services Chief Medical Officer and Director of Machine Learning Dr. Taha Kass-Hout

Dr. David Rhew, Microsoft global chief medical officer and VP of healthcare: Sensoria makes a boot for diabetics to track pressure and movement and a variety of things, allowing us to pull all that data into the cloud and apply advanced analytics and AI to potentially predict pressure ulcers. We can think of putting sensors of any type on any device you wear or implant in your body. From there, the question is what do you do with the data? And that’s where artificial intelligence and machine learning can come in.

Dr. Taha Kass-Hout, Amazon Web Services chief medical officer and director of machine learning: Ambra Health used AWS to expand its software as a service medical imaging data platform to five new countries in order to meet strict data security requirements. Butterfly Network is an innovator with Butterfly iQ, one of the first handheld whole-body ultrasound systems that uses AWS for making medical imaging universally accessible and affordable, providing a personalized experience for healthcare providers at drastically lower cost.

Roshy Francis, GE Healthcare life care solutions chief technology officer: The pandemic overwhelmed hospital systems, and patient complexity has increased with multiple comorbidities.

These dynamics require multi-specialty care teams to collaborate to make timely and accurate decisions in acute care settings. Clinical care teams can now virtually come together around a patient, with a complete picture of the patient from various systems, without having to be physically present at the bedside. We have deployed solutions on the cloud that help ensure care protocol compliance in the ICU and Labor & Delivery for timely interventions that lead to improved patient outcomes. We are now deploying solutions that allow complex procedures like anesthesia delivery to be monitored and guided by experienced anesthesiologists remotely.

MDO: What are some previously unthinkable advances that now seem increasingly likely to become reality?

Larry Jones, Johnson & Johnson group CIO and global vice president of medical devices: Can you simulate a surgery? Can you create a digital twin of a hospital? Can you create a more personalized experience for surgery or any point of care? … If there’s an accident on the roadway and there’s trauma, shouldn’t the ambulance be the first data collection? Leveraging the cloud, leveraging IoT (the Internet of Things) that by the time that patient gets to the hospital, the oncoming care team is already aware of everything about that patient, has the right equipment and makes sure that patient goes to the most appropriate hospital. … Healthcare should be a lot cheaper, and a lot of folks should have access to it. And I think technology can really, really help that. The art of the possible is extraordinary in a sector, quite frankly, that’s fraught with inefficiency. (continued on page 86)

Johnson & Johnson Group CIO and Global Vice President of Medical Devices Larry Jones

GE Healthcare Life Care Solutions Chief Technology Officer Roshy Francis 84

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THE CLOUD IS TRANSFORMING MEDTECH

Philips Virtual Care Solutions Business Category Leader Christine Storm

GE Healthcare SVP and Imaging Solutions GM Rekha Ranganathan

Christine Storm, Philips virtual care solutions business category leader: In healthcare, there are many data sources holding personal, operational and clinical data such as EMR, Laboratory, ECG, PACS or other data lakes. At the same time, many patients and caregivers are trying to access the information using applications or solutions along the care pathways but are struggling to access this data due to a very fragmented IT infrastructure. Digital platforms, such as Philips’ HealthSuite, provide the capabilities to unlock and integrate the data from various sources, and allow caregivers and patients to interact seamlessly with this data, and gain actionable insights from it.

Rhew (Microsoft): We know the duration of a surgery has a direct impact on surgical outcomes. We now can get more granular. And that’s what’s exciting because we’re starting to gather patient-specific information but can start also thinking about different devices and different procedures being done within, say, the surgical unit. We can then start pulling all that together and analyzing across the board, comparing hospitals to hospitals and providers to providers. There is so much variation in care, and a lot of times it’s unwarranted, and there

are often best practices that can be gleaned. If we can understand what the benchmarks are and strive toward those, we can lead to better quality improvements. And that can only be done when you have data that’s accessible at the granular level, roll it up into different areas, benchmark it and allow for AI to be applied on top of it to provide real-time guidance and support and improve patient outcomes.

Rekha Ranganathan, GE Healthcare SVP and imaging solutions GM: Interventionalists can collaborate with each other with videos streaming realtime from cath labs or operating theaters, especially for complex procedures, to bring the best patient care possible. With healthcare organizations moving toward value-based care models, collaboration is essential between doctors, departments, and even institutions. Medical providers can transfer data between each other through a cloud computing server, boosting cooperation, discussing dashboards and treatment options for increasing patient care and making it more personalized for better treatment.

D E S I G N I N G A L I F E - S AV I N G D E V I C E O N T H E C L O U D In its quest to build a better blood and vaccine cooler, Delta Development designed its Autonomous Portable Refrigeration Unit (APRU) over the cloud.

The APRU refrigerates fresh blood and vaccines with a battery that lasts for days on a single charge. The cooler constantly monitors temperature and can withstand outdoor elements and extreme temperatures.

Chief Technology Officer Robert Futch shared his team’s experience using cloud tools to design, manufacture and sell the device.

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“Cloud-based design had a bunch of benefits for my team. No. 1 on the list is that it didn’t slow down our development when everybody went to work from home at the beginning of the pandemic,” he said. “Onshape was a big part of this, but a few other tools like Greenlight, Dozuki, Github and good old Google Docs were also important.”

Other benefits included version control, the ability to quickly scale with remote contractors, faster software bug fixes and manufacturing procedure updates, faster

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collaborative reports leaving more time to design and build, and “super easy” customer support and phone call management.

Cloud collaboration ultimately made employees happier, Futch said.

“They have flexibility and also had more time to go back to school,” he said. “It is easier to keep track of productivity as well. There’s no tribal knowledge and less supervision required. Everyone is aware of what they have to do and where to find the right information.”

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MDO: What sort of big, futuristic dreams do these or other advances inspire?

Lynch (Google): With the exponential growth of data in healthcare, the future of medtech will be about connected care. And in the future of connected care, technology will be a gateway to healthcare. I think it’s important to say that while AI has the potential to expand access to better care, we need to find ways to ensure equity, access and improved outcomes for everyone. AI technologies should work for the common good. I truly believe that big data and AI can help transform healthcare from reactive care to predictive, personalized and proactive care. But it will take all of us working together across the ecosystem — medtech and Big Tech, governments, health plans, health systems, research institutions and other stakeholders — to make this vision a reality.

Peter Schulam, Johnson & Johnson MedTech office of digital innovation leader: There’s a lot of friction in healthcare, and we have to remove that friction.

We’re focused on being smarter, less invasive, more personalized, but our overarching thing is we need to decrease patient outcome variability and improve operational efficiency. When we look at outcomes, we think there’s two main contributors: caregiver skill and provider judgment. And I think we have the ability through our assets that we’re innovating around to actually have impact on that. And if we do that, then we really believe that patient outcome will be improved. The standard of care will be improved. I tell everyone the variability that we see — if we narrow that variability and shift that whole curve to the right — that’s a good vision.

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THE CLOUD IS TRANSFORMING MEDTECH

Kass-Hout (AWS): Equity in care. How are we able to take all this information to provide more equitable care? Healthcare is a $7.5 trillion business globally, yet more than 4 billion people don’t have access to care — forget about high-quality care, just access to care in general. I believe AI and technology have to be part of a solution to creating that more equitable access. The future of healthcare is so vibrant and dynamic right now. It’s so dependent on big data, on AI and on cloud computing. Promising innovations like precision medicine, conversational chatbots, intelligent scribes, and APIs for data and interoperability may make healthcare better and more efficient and more equitable in the future.

MDO: What does cloud computing mean for how medical device designers and engineers should be thinking?

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Schulam (Johnson & Johnson): When you’re looking at a medical device in the conventional manner, you spend a long time developing, you launch, and then you never iterate. Guess what? In the software world and the agile world, it’s exactly the opposite: a minimal viable product and multiple iterations. We have to create this hybrid innovation cycle.

Jones (Johnson & Johnson): It means designing connectivity in your solution.

Design with security in mind as part of the product offering. Be very proactive in what sensors you’re using, what are you designing, even to the point of what preventive maintenance looks like. Learning from Microsoft, as we’re designing products, don’t try to solve problems that’ve already been solved. There’s a lot of leverage across the board, and that’s why we’re we believe this audacious task is gonna take partnerships to do that. I remember when we had constraints on any product design.

Storage was expensive. Computing was expensive. Battery life was challenging.

Things like connectivity and speed, with 5G, 6G forthcoming with the cloud and being able to amass unlimited storage at a fraction of a cost, those constraints in your design aren’t as plentiful as they were in the past. I’m not a mechanical engineer, but I do believe that you’re now building without constraint.

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TUBING TALKS

Catheter delivery could enable better brain implants Synchron’s catheter delivery could make brain-computer interface technology simpler, safer and more accessible than the leading alternative: open-brain surgery.

O Jim Hammerand | Managing Editor |

fficials at Synchron, developer of the catheter-delivered Stentrode brain-computer interface (BCI) implant, believe they’re the only BCI company tapping into blood vessels to capture signals from the brain.

New York–based Synchron recently said four ALS patients with a Stentrode implant had no serious adverse events one year after their procedure. The implants allowed the paralyzed patients to control a computer for online shopping, banking and text communication without using their hands or voice for input.

“BCI has been on a bit of a journey,” Synchron Director of Neuroscience Peter Yoo told Medical Design & Outsourcing. “It’s been in the making for a few decades now, but it hasn’t quite translated into the real-life patient setting yet. It’s largely been an engineering problem because people need to pave the way of getting into the brain or getting inside the skull to record these high-fidelity signals.”

Synchron’s catheter approach Synchron uses catheters to feed the Stentrode device to a blood vessel on top of the brain, rather than the open-

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brain surgeries used by other neurotech developers like Elon Musk’s Neuralink. Once inside the vessel, Synchron’s mesh-like device expands to line the vessel wall so its 16 electrodes can capture and relay movement signals from the brain’s motor cortex to another device in the chest that translates the signals into laptop computer commands.

“The novel approach of the catheter delivery increases the number of physicians who can deliver our devices compared to a very specialized type of surgery, “ Yoo said. “The techniques that we use are standard angiography procedures and other neurointerventional techniques performed by stroke doctors. We’re hoping that it’ll help with the proliferation of the technology and access to the technology, that it can be cheaper and more available for the patients who are in need.”

The devices remained in place throughout the first year of the study, and the blood vessel remained open, Synchron said ahead of a presentation at April’s American Academy of Neurology conference. While Synchron is studying the safety profile of removing the device, the implant is designed to be permanent

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because the stent’s incorporation into the brain is helpful in a few areas, Yoo said. “[It] improves the isolation of the electrodes, so it doesn’t come in contact with the blood and other things that are conductive,” he said. “The electrodes inside the blood vessel secure the device in position and improve our ability to record the signal, so that increases stability and fidelity.”

Synchron Director of Neuroscience Peter Yoo

Synchron cofounder and CEO Dr. Thomas Oxley

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Breaking new ground Synchron said it is the only company with FDA approval to conduct clinical trials of a permanently implanted BCI. The company achieved the first human implantation in 2019, was granted breakthrough device designation by the FDA in 2020 and an investigational device exemption (IDE) in 2021.

“These results are a huge advancement for the field of BCI,” Synchron co-founder and CEO Dr. Thomas Oxley said in a news release. “We’ve shown that our endovascular BCI approach is safe, and allows patients to accomplish daily online tasks without invasive brain surgery. Years of research and technological development culminated in this moment, and as we continue to develop our technology, it has the potential to change the lives of millions of patients globally who suffer from paralysis and other debilitating neurological and brain-related diseases.”

Synchron’s team overcame several challenges along the way, Yoo said.

“Mounting electronics onto stents that are going to be permanently implanted didn’t exist prior to us,” he said. “We started off manually making them; now we’re printing them. All of those processes and methods had to be created from scratch, leaning on a lot of other manufacturing practices and know-how.”

Once they had the recording heads, the question was how to connect those sensors into the blood vessels and relay the signals out of the patient.

“The tortuosity of the blood vessels means that the device had to be flexible, yet firm enough so that you can push the device into the brain through those tortuosities,” Yoo said. “Getting those sweet spots right was definitely a challenge.”

The main challenge was a lack of chronic data concerning a permanent device inside a blood vessel, but they looked to a

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In December 2021, ALS patient Philip O’Keefe was the first person to post a message on social media directly through thought using an implantable brain computer interface, Synchron said.

Photo by Paul Burston/University of Melbourne

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HOW THE SYNCHRON STENTRODE BCI IMPLANT U S E S C AT H E T E R S A N D L E A D S TO TRANSMIT BRAIN SIGNALS

The Synchron Stentrode brain implant expands inside a blood vessel, placing its electrodes against the vessel wall to sense brain signals.

Image courtesy of Synchron

routine treatment for intracranial idiopathic hypertension, where intracranial pressure builds up.

“People have been putting a stent into the transverse sinus — which is the sinus that runs along back of the head sideways — permanently placing stents there with less than a 2% major complication rate,” Yoo said.

“But that’s the only chronic-stenting-inside-the-brain data that’s available. So we had to do a lot of work in the background, benchtop testing and some large-animal testing to make sure that leaving a permanent device with the lead inside the blood vessel doesn’t cause thrombosis or any other health risks.”

What’s next The company conducted the safety study with support from the U.S. Defense Advanced Research Projects Agency (DARPA), the Office of Naval Research, the National Health and Medical Research Council of Australia, the Australian Federal Government Foundation and the Motor Neurone Disease Research Institute of Australia.

The study will continue in the U.S. and Australia as it opens to more patients.

Meanwhile, Synchron will continue ongoing R&D in miniaturization and improved access to other blood vessels in the brain. Yoo described a future where Synchron’s technology might be able to diagnose conditions like epilepsy or perform deep brain stimulation without a craniotomy.

“Reaching those areas through the blood vessels and stimulating from within the [vessels] means that we don’t need to come in contact with the brain directly, which has its own set of advantages in terms of immune responses,” Yoo said. “It’s nice to just leave the brain alone and … speak to it from a distance.”

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Yoo explained how the catheter-delivered device makes its way to the brain and sends signals back. The following has been lightly edited for space and clarity.

“We do a direct internal jugular vein (IJV) puncture — we don’t do a cut-down — to access the blood vessel. For most individuals, there is a pathway through the IJV that goes off the sigmoid, which is this coily, roundy bit, into the transverse sinus and then into our target vessel, which is the superior sagittal sinus at the top of the brain. Once you’ve delivered the device through a series of catheters and unsheath all the catheters, you have the lead of the device sticking out from the IJV. From that point, we do a standard tunneling procedure —often done in the cardiac EP space for implantable pulse generators — to tunnel the lead under the skin into a small chest pocket and place the telemetry unit inside the chest pocket. Everything’s completely inside the body. That’s obviously very good for infection control.

"With our Some of the other devices device, we have transcutaneous connections, which means really made that it’s not fully implanted. careful designs With our device, we really made careful designs to make to make sure that the sure that the implantables are fully implanted and the data implantables transmission is wireless, are fully because we’re getting to the brain and we’re very implanted proactive about controlling and the data infection. Our current iteration of the device is transmission is transmitting raw data from wireless." the implantable through an RF link. Because it’s a custom communication protocol, it goes into a little intermediary box so we can sample the signal, and then that goes straight into a commercial laptop running our algorithms so we can translate the incoming signals into digital outputs so the patient can use generic, consumer-grade software and hardware at home.”

Read more from the interview at https://wtwh.me/bNy

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MEDICAL MEDICAL 92

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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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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: • • • •

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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.

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6/7/22 9:11 AM

MEDICAL

SDP/SI – One Single Source SDP/SI creates precision gears, superior mechanical components, and customized motion control solutions for medical device OEMs. With over 70 years of experience and proven performance SDP/SI provides the reliability that the medical industry requires. Partnering with companies that include Abbott Laboratories, Intuitive Surgical, Siemens Healthcare, Medtronic, and many more, we provide support from the early design stage through delivery.

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Send an RFQ online, discuss your project with our engineers, visit our facility. We look forward to working with you!

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Product World “Sliced” ASK couplings Miki Pulley mikipulley-us.com Stainless-steel ASK couplings have a “sliced” body structure making them an effective, low-cost, corrosionresistant solution that can accommodate many types of misalignments. The stainless-steel design makes them suitable for food and chemical applications. One-piece ASK coupling design is a preferable method for compensating for all types of system misalignment in a shaft-to-shaft connection.

The sliced design handles high rotation speeds in high-temperature ranges experienced in food and chemical systems. The ASK Coupling offers exceptional torsional stiffness and strength. The coupling is available in different materials that dampen conductive heat transfer from motor to output shaft. Also important, the coupling provides limited shaft misalignment to alleviate premature system bearing wear.

Basic ASK coupling specifications are: • Maximum RPM: 11,500 • Maximum allowable torque: 295 ft-lbs (400 Nm) • Bore size range: 0.118 – 2.17-in. (3.0 – 55 mm) • Backlash: Zero • Ambient operating temperature: -40 - 120 C (-40 - 248 F)

High-speed electric cylinder Moticont Moticont.com Moticont has added a high speed, high acceleration/deceleration, non-cogging, high resolution, high force-tosize Electric Cylinder to its product line of Linear Voice Coil Actuators. This new SDLM-051-095-01-01 Linear DC Actuator features high repeatability, 1.25-micron resolution, a continuous force of 33.9 N (7.6 lb), a peak force of 107.2 N (24.1 lb), and an integral thermistor to provide data to operate at peak efficiency for the highest possible thruput. This compact, patented SDLM Electric Cylinder or Linear Voice Coil Actuator is 50.8 mm (2.000-in.) in diameter, has a 25.4 mm (1.000-in.) stroke, and the housing length is 95.3 mm (3.75-in.) long. Each end of the housing has threaded mounting holes on a 25.4 mm (1.000-in.) bolt circle for universal mounting.

A linear encoder, mounted internally, provides feedback for high accuracy and repeatability when operating SDLM linear actuators as DC servo motors in a closed servo loop. The non-rotating shaft has internal threaded holes for direct, zero backlash connections to the load. Additionally, the shaft is supported at both ends by long-life linear bearings and can tolerate side loads up to 24.0 N (5.4 lb). These actuators have a HOME sensor and are suitable for medical, assembly, work holding and clamping, sorting, laser machining and drilling, packaging, sampling, scanning, laser beam steering, and filtering applications. A complete Plug-and-Play servo controller is also available.

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

Multi-level terminal blocks WAGO wago.com The range of WAGO’s TOPJOB S multi-level installation terminals has expanded with the addition of push-button and hybrid variants. This offering allows for fusing or blade-style disconnect, as well as direct ground connection to the DIN rail, all in one terminal block. These terminals share accessories with the rest of the TOPJOB S family, and conductor termination is fast and simple thanks to Push-in CAGE CLAMP. In addition to the choice between open-tool slot and push-button, these terminal blocks are also available as a hybrid solution of the two actuation types, allowing users to choose which is best for field wiring. Used to save space in industrial applications such as the process industry, this product provides various through terminal blocks in the same profile, giving assemblies a clean, seamless look.

piSAFE program Piab piab.com While maintaining vacuum performance through Piab’s patented COAX technology, the flexible design and ease of maintenance makes it a suitable choice for robotic applications and ergonomic handling devices where safety is key. Whether you want a centralized or decentralized vacuum gripping system, interfaces towards common (industrial standard) EOAT systems, or stand-alone mounting, the piSAFE program provides a high vacuum safety and high performing configuration. piSAFE program key benefits: • Vacuum safety non-return valve (check valve) which holds vacuum in sealed applications in case of a system or power failure.

• Available configurations suitable for both centralized and decentralized vacuum systems.

• Can replace more expensive mechanical or vacuum-tank safety arrangements in robotic tools and ergonomic equipment.

• Suitable in robotic applications requiring heightened safety.

• Suitable for ergonomic lifting devices/manipulators and cranes which must comply with lifting norms such as (DIN/SS) – EN 13155 and ASME Standard B30.20.

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Ad Index AllMotion ..................................................................4 Altech Corporation ..............................................Cover,1 Altra Industrial Motion Corp. ............................23,24,25,26 Automation24, Inc. ...............................................9 AutomationDirect .................................................IFC Bodine Electric Company ..................................31 CGI Inc. ....................................................................17 Clippard ....................................................................BC CMT ..........................................................................33 Del-tron ....................................................................73 Digi-Key Electronics .............................................11 ebm-papst ..............................................................7 FESTO .......................................................................67 Harwin ......................................................................16 igus ....................................... 45,46,47,48,49,50,51,52,53,54 Interpower ...............................................................39,59 Keystone Electronics Corp ...............................3 Miki Pulley U.S. ......................................................12 OKW Enclosures, Inc. ..........................................13 PBC Linear ..............................................................15 Permco .....................................................................IBC ROLEC Enclosures, Inc. ......................................63 Ruland Manufacturing ........................................29 Smalley Steel Ring ...............................................37 Smart Products .....................................................41 Trim-Lok ...................................................................19 Whittet-Higgins .....................................................21 Zero-Max, Inc. ........................................................2

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A Supplement to Design World - June 2022

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DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2022 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Leaders in medtech and cloud computing discuss payoffs and potential in device connectivity, product development and crossindustry partnerships.

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Eagle Stainless Tube ...................................................... 87 Nitto Kohki USA..................................................................88 Stock Drive Products/Sterling Instrument ..............90 The Lee Company ............................................................85

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