DESIGN WORLD MARCH 2017 by WTWH Media LLC

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INSIDE: LINEAR CONTROL: Difference between drum motors and gear motors for food conveying PAGE 56

MOTION CONTROL: How to select your next clutch & brake PAGE 66

ELECTRONICS Developing a mixed safety- critical IIoT robotic arm PAGE 76

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www.designworldonline.com March 2017

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I n s i g ht s

The creative power of big data Big Data, for all of its being touted across the manufacturing industry, remains somewhat of an esoteric topic. That’s understandable, as the concept of every bearing and every cylinder and every machine part having sensors seems far off or downright bizarre to some design engineers. Sure, sensors are becoming small and cheap and ubiquitous, but … well, who cares? Who needs all that data? And even if we had it, what on Earth would we do with it? While I’m on board that Big Data is coming—and that it will change a lot about how we see our world in the coming decade—I do confess that at times, it’s hard to see the applicability in some of what I see in today’s manufacturing operations. I was caught a little off guard by the way that the international food packaging manufacturer Tetra Pak is using Big Data right now during a recent visit to the company’s R&D center. They’ve found a fascinating way to use Big Data not just for themselves, but for their customers. Tetra Pak actively works to measure, benchmark, and improve its packaging machinery. Through the thousands of systems that it has installed globally, and the constellation of sensors that imbue each line, the company has been able to develop a baseline of how these systems operate in the real world. They have terabytes of data on how these processes are working, what the operators are doing, and how they’re reacting to different issues. But beyond simply using the data to improve the machinery it builds, this has given rise to a whole new business unit for the company, consisting of a service that includes helping customers understand where and how losses are happening on their production lines. When customers can’t produce any more product, they will generally go and buy more equipment. Now Tetra Pak can help them produce more with the equipment they already have, thanks to what Big Data tells them. Cynics might say the company’s shooting itself in the proverbial foot; that it should be trying to sell more hardware. But smart manufacturers know they need to focus on building long-term relationships with their customers—and helping with efficiency and productivity can go a long way toward cementing those ties. The other thing I’d point out to those cynics? Tetra Pak’s services business is now the company’s fastest growing segment. And that’s some Big Data that the corporate accounting department is surely smiling about. DW

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

On Twitter @ DW—Editor

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DESIGN WORLD

March 2017

3/1/17 10:42 AM

PICK YOUR

COLOR MPD m e m o ry p r o t e c t i o n d e v i c e s

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a n u fac t u r e r o f b at t e ry h o l d c o m p o n e nt s . W e b e l i e v e t h at d f i t e a s i ly i nto y o u r d e s i g ay s c r e at i n g i n n o vat i v e n e w

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

What are engineering technologists, and do we have enough of them? Those who’ve watched the engineering profession over the years might become suspicious when a prominent scientific organization studies employment in the field. The reason for this wariness arises out of previous proclamations from the National Science Foundation which has had a reputation for forecasting fake engineering shortages. One such occasion was in the 1980s. As explained by demographer Michael S. Teitelbaum, NSF claims of an imminent engineering shortage, which never materialized, were based upon simplistic demographic projections produced by a small NSF policy office. The projections, it turned out, had been criticized by the NSF’s own science and engineering workforce experts. So it is noteworthy that a new report, this time from the National Academy of Engineering, found no sign of an engineering shortage. The report covered engineering technologist (ET) jobs and engineering technicians. For those unware of the ET degree program, it typically resembles an ordinary engineering curriculum but with less higher level math and more application-oriented lab work. The fact that NAE found no shortage of

engineering technologists nor a shortage of engineering technicians is doubly interesting in that curriculums for technicians and ET grads are, in fact, inclined to have spot shortages because they tend to be more closely aligned to local industries than are engineering jobs. So they are more likely to be affected by the ups and downs of local economics. The rationale for NAE examining ET jobs wasn’t to go sniffing around for shortages. Instead, the Academy seemed interested in the area because it didn’t know much about jobs for ETs and technicians. In fact, few people, or engineering companies, seem to have a clue about ET degrees. There are only about 18,000 four-year degrees in engineering technology awarded in the U.S. annually, compared to about 94,000 four-year engineering degrees. NAE surveyed engineering employers and found that 30% of them had never heard of ET education. And a third of them didn’t know the difference between work done by engineers and work done by engineering technologists. Says Ron Latanision, NAE report co-chair and corporate vice president of Exponent Failure Analysis Associates, “We were surprised that companies were generally unaware that there are opportunities for people who have an inclination for handson work and implementation. ET students

I’ve seen are just as determined as the students I used to teach at M.I.T. Their career pathways are just as bright as for people with engineering degrees. And they are paid well.” When Latanision says ET grads are paid well, he means relative to the pay scale of technicians with two-year degrees. But the NAE report also noted that those graduating with engineering degrees typically earn more than ET grads. Sometimes the same schools graduating ETs also graduate engineers. All in all, there seems to be no difference in the cost of the two types of education. So given that engineers will probably earn more, you might wonder why anyone would go the ET route when it means a lower pay check. “You have to look beyond the cost of the degree,” says Latanision. “Some young people are just more satisfied with handson activities. There are salary differences in the beginning. But as people mature and grow, their skills become apparent to their employers and they advance.” Still, money talks. If salary levels are an indication, industry seems to think engineering technologists are important, but only to a point. The NAE wants to shine a light on this segment of the industrial workforce. “Technologist-level help is absolutely integral to our manufacturing base,” says Latanision. “The ET career path should be well known and something people aspire to.” DW

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

On Twitter @ DW—LeeTeschler

DESIGN WORLD

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March 2017

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Te c h n o lo gy Fo r wa rd

Grit in the future of IoT According to a 2015 McKinsey Global Institute report on American

All the gathered data are being stored and analyzed, with the goal of making old machinery and equipment work better and industry, the U.S. economy has only reached do old tasks and processes in new ways. One belief about the use of IoT is that about 18% of its digital potential. On the one “the cloud will amplify different forms of hand, that’s good news—there’s room to power—the power of machines, of individual people, of flows of ideas, and of humanity grow in the application of digital technology as a whole—to unprecedented levels,” said in many areas of the U.S. economy. Thomas L. Friedman in his book, Thank You for Being Late: An Optimist’s Guide to Thriving in the Age of Accelerations. On the other hand, we are already seeing digital technology take over many traditional jobs and tasks people used to do for income. Should it? Just how many tasks should be automated that people and employees can—and maybe should— do? Can society handle the implications of such a shift? We are already seeing blowback from the amount of automation in manufacturing. The concept of everything connected to the internet, and automating as much as possible has plenty of drawbacks. Two are privacy and security. What are the limits of data gathering? How risky is it really? Consider “ransomware,” which extorts companies for access to their stored information. What can be done to prevent others from misusing our information against us? Another example involves algorithms. YouTube recently used algorithms to automatically place ads in videos. Then those algorithms put some ads in front of ISIS videos. More than a few companies

were displeased with that placement. While the trend is to take anything and put sensors on it to gather data for the IoT, is that the right step? Do we, as engineers, even ask those questions anymore? What should the role of the engineer be in this digital age? One suggestion is the engineer should function as a systems architect of “complex technical, social, economic, and political systems capable of addressing the global challenges we now face,” says Friedman. Notes Friedman, some thinkers are saying we are now in an era of co-evolution. As technology evolves, it is forcing everything it connects with to change and evolve too— various business areas, medicine, and society in general. But can this evolution be better managed so as not to throw major portions of our society into unemployment? Bill Gates recently stated in a Fortune article that he thought companies should pay a tax for every robot they use to replace an employee. The tax money would go towards re-training displaced employees. (Although, as mentioned in the article, the effectiveness of job training programs is debatable.) Gates also suggested that it might be a good idea to slow down the rapid installation of technology. Not everyone is ready to be an entrepreneur. Not everyone is tech savvy. Not everyone is ready to “invent their next job.” Where does automation advance society’s growth, and where does it harm it? And what responsibility do engineers have in pointing this out? DW

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

On Twitter @ DW—3Dprinting 8

DESIGN WORLD

Leslie Column (Technology Forward) 3-17 Vs4.LL.indd 8

March 2017

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» Gre e n Engi neeri ng

Electrochemical micro transformation opens doors to design of lightweight metal surfaces n Paul J. Heney • Editorial Director

What design engineer hasn’t wished that s/he could simply modify the surface properties of the metal they’re using to better fit the application? What once seemed like something from the realm of alchemists may now be a reality. The newly developed Micro Arc Oxidation (MAO) technology allows for the multifunctional modification of lightweight metals such as aluminum, titanium or magnesium. Surfaces can be designed for their desired functions and the performance of lightweight metal components are significantly improved. This allows for new functional and decorative applications—including in mass produced products—with significant reductions in weight, material and costs while maintaining or even improving functionality. The Metaker MAO process modifies the outer layers of lightweight metals to form a strong, multifunctional atomic metal-ceramic bond. By adapting the process parameters, the material attributes (functionality) and their combination (multifunctionality) can be calibrated for specific applications. The procedure is an electrochemical nanotechnological surface treatment for light metals such as aluminum, titanium and magnesium. It uses billions of microplasma discharges (micro arcs) to transform a 2 to 200 μm thick layer of the surface microstructure of a workpiece to a sealed, multifunctional, atomically fused metal-ceramic bond. This metal-ceramic bond creates a complex, heterogeneous, multi-functional and gradient material mix whose composition, structure, substance and properties vary from the interior to the surface of the product and can

be adapted to specific applications. The ceramic substances used in the procedure are high-strength, high-pressure and hightemperature modifications of various oxides. By using the Micro Arc Oxidation Process, alloys of aluminum, magnesium, titanium and water resistant material combinations with these alloys can be custom modified. The production process of the desired component as well as its geometric complexity are both irrelevant. Full functionality can be achieved with aluminum alloys with a silicon content of less than 1012%. Alloys with a higher silicon content will face certain restrictions.

Material lightweighting for functionality could mean substituting aluminum instead of bronze for the thrust bearing of a large compressor.

www.designworldonline.com

Green Engineering_3-17_Vs1.indd 11

An example of a specific application. Cross section of a ca. 80 µm thick layer applied to the rounded edge (R=0.06 mm) of an aluminum workpiece (white in the image) with a variable microhardness of 894 HV (image below right) to 425 HV (image above right). The hard metalceramic bond strengthens and stiffens the thin aluminum component regardless of its geometric complexity. The image above left shows a SEM image of the surface topology.

March 2017

DESIGN WORLD

3/1/17 11:18 AM

» Gree n E n g i n e e ri n g

Double digit savings potential This procedure allows for a range of mechanical, chemical, electrical, optical, haptic, biological, ecological and technological properties of lightweight metals to be modified on an industrial scale. It transforms the surface into a constructional element, which potentially opens new possibilities for the industrial application of lightweight metals. For example, double digit improvement can be achieved in weight reduction, product and processing costs, lifespan, and efficiency. MAO surfaces have many potential uses for the implementation of lightweight metals in key industries. Applications include material substitution, functional integration, and hybrid lightweight design. In one instance, a manufacturer of high performance electric motors was able to replace a copper moving component with one made from aluminum.

DESIGN WORLD

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March 2017

The implementation of the lighter material resulted in a cost reduction of 92% and a weight reduction of 72%, while at the same time improving functionality and increasing the lifespan of the product.

Billions of microplasma discharges form complex metal-ceramic bonds The properties of the material can be controlled through changes to the various process parameters such as the electrolyte chemistry, electric current, voltage and discharge time. The surface and process properties offer truly unique features that provide unprecedented application potential as has been confirmed time and time again by researchers and industries. “The newly developed combination of water-resistant material components such as plastics, steel or glass with modified aluminum

components allows engineers to take new approaches in incremental and disruptive innovations,” said managing director Eugen Pfeifer. “If one were to choose for example a fiberglass reinforced plastic, the aluminum component can specifically modified prior to overmolding, to improve its resistance to corrosion and wear and to improve its surface structure for better bonding, and after overmolding modified again to further improve wear resistance.” The nearly limitless possibilities to combine and alter materials as well as the adjustable geometric complexity of Metaker material hybrids create a foundation for developing new technical systems and processes. DW Metaker | metaker.com Lightweighting Baden-Wuerttemberg | leichtbau-bw.de/en

www.designworldonline.com

3/1/17 11:19 AM

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Con tent s |

March 2017 • vol 12 no 3

designworldonline.com

F E AT U R E S

56 66

LINEAR MOTION Difference between drum motors and gear motors for food conveying A review of the strengths and weaknesses and potential improvements for both drive options.

Power supply design measurement tips from A to Z To design an efficient, reliable and compliant power supply, be sure to follow these testing and measurement guidelines.

3Dtechnology

enables conjoined twins to lead separate lives

How to select your next clutch & brake For dry running applications, evaluate your requirements thoroughly to choose the best solution to stop and hold rotary elements.

100

112

118

108 How to efficiently

Fast prototyping gets

move from 3D printing

products to market faster

to injection molding

COVER_MPF 3-17_FINAL.indd 107

MOTION CONTROL

3/2/17 2:15 PM

106-120 INTERCONNECT A deep dive into M12 connectors Learn what the different coding on M12 connectors means and see a round-up of a variety of new designs available in the marketplace.

ELECTRONICS Developing a mixed safety-critical IIoT robotic arm Robots that can man-handle car bodies incorporate several safe guards to protect workers. New software architectures have evolved to make these systems reliable and easy to manage.

INDUSTRIAL ETHERNET

ON THE COVER Photo: istockphoto

Ethernet from the ground up Here’s how to properly connect Ethernet hardware and related devices, and then manage the network for optimal IoT performance.

DESIGN WORLD

CONTENTS MARCH 2017_first page_Vs4.LL.indd 14

March 2017

A | S |B |P|E

American Society of Business Publication Editors

2016 Regional

2016 National

2016 Regional

Fostering B2B editorial excellence

ON THE COVER Ethernet connection options for better IoT performance. Image courtesy istockphoto.com

A supplement of Design World • March 2017

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D E PA R T M E N T S

4 Insights 6 Teschler on Topic 8 Technology Forward 11 Green Engineering 18 Design For Industry 30 Design Notes 40 CAE Solutions 44 Internet of Things

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18 16

Contents MARCH 2017_second page_Vs1.indd 16

DESIGN WORLD

March 2017

3/1/17 11:24 AM

Follow the whole team on twitter @DesignWorld EDITORIAL

GRAPHICS

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

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Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler

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Camera records 1,000 frames per second Certain features are needed in cameras in modern CMOS-based cameras, but Vision used in aerospace applications. These features should prevent motion artifacts with propellers, motors and other rotating objects and ensure timing precision throughout the entirety of each frame. The Phantom Flex4K-GS is a high-speed camera with a 35 mm, 9.4-megapixel sensor and global shutter, which fits the needs of this industry. The Flex4K-GS, developed on top of the established Flex4K platform, uses a custom sensor capable of recording 1,000 frames per second (fps) at 4K resolution, while its global shutter ensures that every pixel is exposed to light at the exact same moment in time. The camera has isolated electronics and a thermal design to operate in a temperature range of -20°C to 50°C, all the while maintaining a stable image. “There have always been trade-offs between speed, sensitivity and resolution

DFI 3-17_Vs5.LL.indd 18

DESIGN WORLD

March 2017

Research is changing the game with the new Flex4K-GS,” says Product Manager Toni Lucatorto. “The camera brings pixel resolution to the forefront, allowing for incredibly fine detail and improved visibility of phenomena and measurements.” The Flex4K-GS is available with either 64 GB or 128 GB of RAM and works with CineMag IV nonvolatile memory magazines for fast data transfer. One of its more unique features is the ability to save either uncompressed raw or compressed video in the Apple ProRes 422 HQ video format. When working with ProRes, a 2TB CineMag-IV will hold several hours’ worth of footage. The Flex4K-GS is also fully compatible with Phantom PCC software and can be synchronized and used in combination with other Phantom camera models. DW Vision Research | phantomhighspeed.com

www.designworldonline.com

3/1/17 1:28 PM

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

Analyze motion performance easily record any gears, motors, machinery, mechanical or robotic equipment that is moving too quickly to process with the naked eye. By using slow motion replay, you can see what you have been missing with normal speed video and analyze the performance of your equipment to improve design. With recording speeds of over 630 frames per second at HD 1080p resolution, over 3200 fps at VGA resolution and more than 29,000 fps at smaller resolutions, the IL5 lets you see what you have been missing with normal speed video. It saves images to an SSD or SD card while recording highspeed bursts of hundreds or even thousands of images at a time.

Built for flexibility and ease of use, the IL5 camera can be controlled over Gigabit Ethernet with Fastec FasMotion software on a PC/Mac or with the built-in web interface with a web browser on a PC, Mac, tablet, or smartphone. Using the (LR) FasCorder Mode, operate the camera as a regular camcorder to record and pause as needed and follow the action, stop recording and review what you have, and then append additional footage at will, even after a power cycle. The IL5’s Long-Record (LR) option can record at high speed for many minutes at high resolutions, to many hours at reduced resolutions. On-board SSDs are available in sizes from 256GB to 2TB. DW

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March 2017

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3/6/17 10:45 AM

Design for Industry | f o o d a n d b e v e r a g e

Fittings and tubings for beverage systems Push-to-connect fittings and tubing are for potable water and beverage systems, including applications such as brewing, coffee/drink dispensing, soup and liquid food production. HydroMode push-to-connect fittings are for use with polyethylene and other flexible tubing; all fittings are made of NSF approved materials with NSF-51 and NSF-61 certifications. Rated for up to 145 psi at 70°C (158°F), the body and collet of the fittings are made from acetal, while the O-rings are made of synthetic rubber; optional retaining clips prevent accidental tube removal. The flexible and lightweight PE tubing is available in sizes ranging from 5/32 in. to ½ in. and in seven colors: black, blue, natural, red, yellow, green, and white. HydroMode reinforced PVC hose incorporates a polyester spiraled yarn which allows use in high-pressure applications. The Shore A 73-rated hose provides good chemical resistance and is flexible and lightweight. It is Phthalate free and NSF 61 certified. HydroMode lead-free brass fittings are hose barbs with male NPT threads for use in potable water and beverage applications. Additional NITRA brass fittings have also been added. Machined from quality brass bar stock, they work well with air, water, oil, oxygen, nitrogen and argon. With a maximum pressure of 800 psi, fittings are available in most popular styles and sizes; the fittings all have NPT threaded connections. DW AutomationDirect | Automationdirect.com

#electricRULES Motion control that’s stronger, faster and smarter than pneumatics Make your next machine everything you imagine it can be. Optimize cost, performance and flexibility with our electric linear motion actuators. USDA and 3A approved design

• Hygienic design for increased food safety • Configurable strokes to fit your design • Clean, leak-free performance • Fast delivery

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

www.tolomatic.com

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Power Review

Altra Industrial Motion Vol. 6 | No. 1 | 2017

The Power Brands in Power Transmission

Featured in this Edition... Altra Introduces NEW Brand Websites, eCatalogs and Product Selection Tools Warner Linear Launches New H-Track Electric Linear Actuator System Altra Introduces Stromag Altra Certified Rebuild Services – Marland, Formsprag, & Ameridrives Stieber RDBR-E Torque Limiting Backstops Bauer HiflexDRIVE in Stainless Steel Design TB Wood’s Enhanced Belt Drive Selector Altra Webinar Series

NEW Brand Websites, eCatalogs and Product Selection Tools Find Altra Industrial Motion on:

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

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The Power Of Experience

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Clutch Stromag Svendborg Brakes

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

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

Scan to download the interactive version of the Power Review

3/2/17 9:36 AM

Altra Introduces NEW Brand Websites, eCatalogs and Product Selection Tools From each brand homepage, you can explore all of our resources and visit our key market portals to find solutions for your specific needs. Get Connected Each brand’s Newsroom makes it quick and easy to stay up-to-date with the latest brand news including new literature releases and trade show schedules. Selection Programs & eCatalogs Use the available Selection Programs to choose the correct product for your application. Additionally, the eCatalog offers product selections and comparisons to meet your specific needs. Responsive Design Responsive design ensures the new brand sites, eCatalogs and product selection programs display properly across all devices.

Warner Linear Launches New H-Track Electric Linear Actuator System Designed for use in extreme applications requiring high load capacity in a small footprint. The H-Track provides the performance of hydraulics without the expansive space requirements nor the prohibitive cost of full-sized hydraulic systems. The H-Track is a robust electric actuator solution with a force up to 4800lbs (21350N) and travel speeds near 4 inches (100mm) per second. The H-Track family feature the smallest mounting envelope in their class with a patented valve and reservoir design that provides significant space savings compared to competitive models. Features Include: • Flexible bore and rod combinations allow for multiple mounting configurations • Fluid reservoir is vented and isolated from the atmosphere with a flexible lid • Solid rods allow for increased resistance to buckling allowing actuator and pump operation in any orientation without entraining or • Actuator mounting length is shorter than any other electromechanical cavitation actuator on the market • Minimum mounting clearance of 4.8 inches • Immune to vibrational drifting and hydraulically self-locks • Optional meter out circuits on one or both sides of the actuator ensures load run-away situations will not occur

For more information, download P-7994-WL from www. AltraLiterature.com

Altra Welcomes Stromag Founded in 1932, Stromag has grown to become a globally recognized leader in the development and manufacture of innovative power transmission components for industrial drivetrain applications. Stromag engineers utilize the latest design technologies and materials to provide creative, energy-efficient solutions that meet their customer’s most challenging requirements. Stromag’s extensive product range includes flexible couplings, disc brakes, limit switches, an array of hydraulically, pneumatically, and electrically actuated brakes, and a complete line of electric, hydraulic and pneumatic clutches. Stromag engineered solutions improve drivetrain performance in a variety of key markets including energy, off-highway, metals, marine, transportation, printing, textiles, and material handling on applications such as wind turbines, conveyor systems, rolling mills, agriculture and construction machinery, municipal vehicles, forklifts, cranes, presses, deck winches, diesel engines, gensets and stage machinery. Stromag Product Clutches & Brakes Limit Switches & Caliper Brakes Couplings

Facility New Hartford, CT Wichita Falls, TX Michigan City, IN

Phone Number 1-860-238-4783 1-940-723-3441 1-219-874-5248

For more information, visit www.Stromag.com

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Altra Certified Rebuild Services – Marland, Formsprag, & Ameridrives Marland: Your old, worn Marland clutches can be refurbished for substantially less than the cost of a new replacement clutch. Our economical rebuild service applies to all Marland Clutch BCMA, CECON and CEBMAG models. The local Marland Rebuild Service team will perform the following to restore your clutch to likenew condition: Inspect and replace seals, energizing springs, alloy steel rollers, aluminum cages, bearings and fasteners as required, inspect and precision grind the outer race and cam if required, assemble and test to meet Marland original design and performance specifications, paint and prepare for shipment. For more details on our cost saving certified Marland Rebuild Program, call 1-888-216-3515. Formsprag: Send Formsprag your old clutches to make them like new again. The difference is not just cosmetic. Consider these advantages: Price – A guaranteed savings of at least 30% or more versus new product, Speed – Clutches are received, inspected and rebuilt in the shortest possible time frame, Warranty – 1 year on labor and materials, same as new clutches, and Emergency Breakdown Program – All products that are air freighted into the Warren plant are processed immediately and, in most cases, are able to be rebuilt within a 24-hour period. For more information download Application Guide P-1465-FC from www.AltraLiterature.com. n Altra Industrial Motio

I N T R O D U C I N G

Ameridrives Rebuild Service

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

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

your old, worn couplings for Ameridrives Rebuild Service can refurbish replacement coupling. The economical ® substantially less than the cost of a new , Ameridrives couplings including Ameridisc rebuild service applies to all ® high speed couplings used primarily Ameriflex® and Amerigear high performance, applications in the power generation, on turbomachinery, compressor and pump brands are accepted on a case-byoil & gas and marine industries. Other coupling case basis. Ameridrives has the team, facilities, As a leading global coupling manufacturer, experience to rebuild and replace and nearly 100 years of inspection and repair are completed to meet the exacting all coupling components as required. Repairs standards of the original coupling.

components. • Removal and repair of surface defects on a lathe and glass bead blasting as appropriate while maintaining original coupling integrity. • Precision dimensional and Total Indicator Run-out (TIR) measurement • Rebalancing to original API 671 certification if applicable. This recertification requires the return of the entire coupling structure.

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

in the shortest possible time frame. Couplings are received, inspected and rebuilt down schedule. We will work to accommodate your shut call (814) 480-5095 or visit For details on our cost-saving program www.Ameridrives.com. www.ameridrives.com 1802 Pittsburgh Avenue Erie, PA 16502 - USA 814-480-5000 Fax: 814-453-5891

P-7948-AC

10/15

Printed in USA

Stieber RDBR-E Torque Limiting Backstops

Bauer HiflexDRIVE in Stainless Steel Design

Torque Limiting/Load Sharing Low-Speed Backstop Releasable Under Load • Releasable under load • Load sharing over several backstops • The Stieber RDBR-E limiting/ load sharing backstops limit the stresses and protect your conveyor belt system • At present, the RDBR-E torque capacity reaches a maximum of 350,000 Nm, although this will be extended up to 700,000 Nm in the future For more information download P-7820-SC from www.AltraLiterature.com

Stainless Steel drives are carefully designed for applications where regular washdowns are required to maintain a clean environment. The stainless steel design eliminates hygiene risks due to mechanical impacts or long operation in areas with intensive cleaning. The motor, just like the aseptic range, is designed so that a fan and cooling ribs are not required, thereby allowing for a completely smooth outer casing with a non-drive end which is sealed. This eliminates any dirt traps on the motor casing and also prevents re-infection of the local environment caused by air movement from a cooling fan. For more information download P-8083-BGM from www.AltraLiterature.com

Altra Indus trial Motion

RDBR-E Torque Limiting/Load Sharing Low Speed Backstop Releasable Under Load

High Torque Density Greater Reliable Functiona lity ...through innovative

design

• Highest torque capacity for releasable external backstops in the market • Load sharing over several backstops • The Stieber RDBR-E limiting / load sharing low speed backstop can really limit the stresses and protect your conveyor belt system

TB Wood’s Enhanced Belt Drive Selector TB Wood’s has recently introduced more enhancements to their popular online Belted Drive Selection Program. The improved online program now checks the arm/web strength of a sheave/sprocket along with the bushing torque rating for suitability of the application. The enhanced web-based tool works on PC, tablet or Mac platforms. Users can display Relative, Discount and Quote pricing. Favorite belted solutions can be more easily marked, shared and recalled.

Altra Webinar Series The Altra Webinar Series is open to the public and are held on the first Wednesday of each month at 10 AM (CST). They will also be posted to the websites for access. For more information, please contact altra-webinar@altramotion.com. Webinar Schedule (Upcoming webinars are highlighted) Title

Date

Load Holding Brakes Solutions | Small to Moderate Sizes

10/19/16

Load Holding Brakes Solutions | High Capacity Systems

11/2/16

TB Wood’s comprehensive Selector Program includes Classic, Narrow, Light-Duty and Premium V-Belt drives and Synchronous Plus, QT PowerChain® II Carbon and Timing Synchronous Belts.

Factors to Consider in Coupling Selection

12/7/16

Proper Torque Arm Use

1/4/17

Factors to Consider When Selecting a Clutch, Brake, or Clutch/Brake

2/1/17

Warner Linear New Product Launch – Introduction to H-Track

3/1/17

For more information, visit BeltDriveSelector.TBWoods.com

High Capacity Gearboxes, Overrunning Clutches & High Performance Couplings: To Rebuild or Replace

4/5/17

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Warner Linear H-Track Electric Linear Actuator System More Power in Less Space The H-Track provides the performance of hydraulics without the expansive space requirements nor the prohibitive cost of full-sized hydraulic systems. The H-Track is a robust electric actuator solution with a force up to 4800lbs (21350N) and travel speeds near 4 inches (100mm) per second. The H-Track family feature the smallest mounting envelope in their class with a patented valve and reservoir design that provides significant space savings compared to competitive models.

Features Include:

Scan to watch! Warner Linear H-Track Electric Actuator Video

• Flexible bore and rod combinations allow for multiple mounting configurations • Solid rods allow for increased resistance to buckling • Actuator mounting length is shorter than any other electromechanical actuator on the market • Immune to vibrational drifting and hydraulically self-locks • Optional meter out circuits on one or both sides of the actuator ensures load run-away situations will not occur • Fluid reservoir is vented and isolated from the atmosphere with a flexible lid allowing actuator and pump operation in any orientation without entraining or cavitation • Minimum mounting clearance of 4.8 inches

For more information on the H-Track Linear Actuator, visit www.WarnerLinear.com Altra Industrial_#4_3-17.indd 24

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food and beverage

Change seals on pumps fast Connecting a rotating piston lobe to a hollow shaft has been improved with the ETP-EXPAND, a patented bushing device that is fast and easy to install and adjust. The ETP-EXPAND was developed to simplify exchanging seals in pumps when fluid viscosity is changed. This bushing connects to a hollow shaft, locking the impeller/lobe wheel of the pump motor into position using just one actuation screw. Considerable space-savings are gained by mounting within the hollow pump shaft. The patented precision bushing is just for pump applications. Its design configuration accurately expands OD of the ETP EXPAND when a single actuation screw is tightened. Since the expansion is caused by self-contained hydraulic pressure, the resulting force is perfectly even along all surfaces. Most important, the bushing aligns precisely without axial movement as it is tightened. The positioning is very accurate and takes just seconds. Another key feature is that its robust design allows it to be actuated thousands of times with repeatable accuracy and without any axial movement. An Allen wrench is all that is required to mount and lock it into position. ETP-EXPAND has sealed, clean lines that resist debris collection and clean easily without special maintenance. It is customizable. DW

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

Zero-Max | Zero-max.com

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

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March 2017

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5 POWER TRANSMISSION

Design for Industry | o f f - h i g h w a y

RETAINING DEVICES & maintenance & assembly tools

High-performance controllers for real-time hydraulic control

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

The IQAN-MC4x family of master controllers are for hydraulic systems in vehicles and machinery using a 12/24 Vdc power supply. Three different versions handle a range of system requirements. The IQAN-MC41 is for economical task-oriented control; the MC42 for mid-size applications and I/O distribution; and the MC43 provides large centralized control. All the units share the same pinout and software for easy upgrading or scaling of applications. They permit up to 50 inputs (analog, timers, digital) and 36 outputs (PWM and digital). The MC4 family also supports CAM, Parkerâ&#x20AC;&#x2122;s proprietary circuit regulator that ensures consistent and precise control of proportional mobile valves. There are five CAN and Ethernet ports for in-vehicle networks and diagnostics. And in addition to common voltage, digital and frequency inputs, the MC4x family also includes 0-35 V and 4-20 mA inputs, giving OEMs greater freedom in selecting sensors for specific tasks. The MC4x architecture includes a powerful, lockstep CPU and hardware redundancy for high real-time performance and cycle times as fast as 1 msec. SIL2-rated versions for functional safety implementation will be introduced later this year. The MC4x devices have up to 1.5 MB application memory and 2 MB log memory for complete machine control and future expansion, if needed. The MC4x family is compatible with existing IQAN applications, and its IQANdesign software platform is used for programming, simulation, testing and maintenance. This helps ensure fast OEM development and better up-time in the field. The hardware is built for rugged, high-vibration mobile environments and uses reliable Molex MX123 connectors. The enclosure is rated IP 66/69K and sealed for outdoor use. Finally, the IQAN-MC4x controllers measure only 6.1 Ă&#x2014; 6.5 in. (155 Ă&#x2014; 166 mm) for ready installation in tight spaces. DW

PRECISION NUTS & WASHERS

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

ADAPTER SLEEVE ASSEMBLIES

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

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

Parker Hannifin | parker.com/iqan

-H

NS US

WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly. Visit our websiteâ&#x20AC;&#x201C;whittet-higgins.comâ&#x20AC;&#x201C;to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor. 33 Higginson Avenue, Central Falls, Rhode Island 02863 Telephone: (401) 728-0700 â&#x20AC;˘ FAX: (401) 728-0703 E-mail: info@whittet-higgins.com Web: www.whittet-higgins.com March 2017

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ADVANCED CONNECTORS MEDICAL APPLICATIONS

Rapid prototyping & production turnaround

MEDICAL MEASUREMENT AND TESTING

PUSH-PULL AND BREAK-AWAY

MILITARY AND SECURITY

MODULAR CONNECTORS

INDUSTRIAL

ENERGY

EMOBILITY

CONTACT TECHNOLOGY

TECHNOLOGIES THAT SAVE LIVES ODU connector solutions fulfill the most demanding requirements for medical applications including: monitoring devices, heart-lung machines, surgical hand tools, ablation systems, mobile ECG measurements, magnetic resonance imaging (MRI), and mobile and modular operating systems.

High mating cycles

High-speed data technology

Autoclavable

Disposable housings available

High reliability

Cable assembly integrated solutions

Shielded

Custom solutions

Sealed up to IP 68 Find out more at: odu-usa.com

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D e s i g n f o r I n d u s t r y | medical

YOU DESIGN

Compact drives with large air gap One component that delivers quiet power for medical designs is the linear motor. Sometimes referred to as electric cylinders, these linear motors are compact drives with a 1.0 in. (25.4 mm) stroke are just 1.00 in. (25.4 mm) in diameter and 3.75 in. (95.3 mm) long. These direct drive linear motors feature resolutions of 5 µm (0.000197 in.) and 1.25 µm (0.000049 in.) The integral, linear optical quadrature encoder is directly connected to the shaft for accuracy. Each motor features a continuous force rating of 20.1oz. (5.82 N) and a peak force of 66.3 oz (18.4 N). This motor is designed with a larger air gap of 0.059 in (1.5 mm), which allows the motor to be used for: vibration, noise cancelation, photonics, gimbals, antenna positioning, medical devices, semiconductor handling, SMT machines, assembly, wafer handling, optical focusing, dynamic vibration absorption, scanners and laser beam steering and filtering where excessive side play or tilt is required. The non-commutating SDLM-025-095-01-05 (5 µm resolution) and the SDLM-025-095-01-01 (1.25 µm resolution) Direct Drive Linear Motors have quiet long life plain linear bearings, a non-rotating shaft, pre-drilled and tapped mounting holes, and threaded (internal) ends of the shaft for easy integration into new and existing applications. These low cost direct drive motors are coupled directly to the load providing high acceleration and speed with zero cogging and no backlash as with other drive systems such as ball screws, gear, and rack and pinion drives. DW Moticont | moticont.com

WE BUILD Rapid Prototyping Custom OEM Manufacturing Cleanroom Manufacturing Automation and Assembly Supply Chain Management

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cadenceinc.com | 800.252.3371 www.designworldonline.com

DFI 3-17_Vs5.LL.indd 29

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

ave ber, de of rub a m o s h rt a lt A ified p quired, ally spec bility is re ra u d tradition n e h e for r steel w alternativ w e n a plastic, o g n sion consideri ear, abra w h ig h many are , ing nes. demand lyuretha t o s p o t s m a e c h : t ations ct applic and impa

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Cast polyurethane parts for high-impact, high-wear applications When a Dutch ship builder required a new slipway liner that could handle a speedboat exiting and entering its offshore patrol vessel through a rear bay, the company selected a custom polyurethane from Argonics, a producer of wear-resistant urethane products. The Dutch shipbuilder’s new urethane slipway liner was to replace a nylon plastic liner, which tended to damage speedboats because it was too hard, according to Lars Muller, owner of Muller-Beltex, a Netherland-based parts distributor, who was involved with the project. 30

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» De sign Note s

“The liner had to resist impact, abrasion, seawater, and UV exposure yet allow the speedboat to slide in and out of the bay without damaging the speedboat or the patrol vessel,” said Muller. To maximize durability and cushion the impact of the speedboat entering and exiting the offshore patrol vessel’s rear bay, Argonics engineers collaborated with the Dutch shipbuilder and Muller-Beltex to engineer a urethane slipway liner comprised of two layers of material each with a different durometer, a measure of hardness.

“With urethane, you can combine strength, resilience, and lifetime durability.”

Lars Muller,

owner of Muller-Beltex.

about the slipway liner.” Cast polyurethanes, broadly referred to as urethanes, are tough, elastic materials that combine many of the performance characteristics of high-tech plastics, metals and ceramics along with the resiliency and flexibility of rubber parts. Unlike its closest counterpart, rubber, which is prepared as sheets or loaves before being molded in a high pressure press, urethanes can be poured as a liquid mixture into less expensive, low pressure molds. Using this technique, complex mold cavities can be filled without high-pressure molds and presses. This technique provides many advantages, not the least of which are lower tooling and production costs than both rubber and plastic molding, and lower material cost than metals and ceramics. There are many formulations – some proprietary – that can be used to manipulate a range of variables such as hardness, resilience, spring rate, and chemical resistance. For this reason, design engineers interested in a possible switch to polyurethane from plastics, steel, ceramic or rubber parts are often best served by seeking out the assistance and guidance of experts in urethane formulation. DW

“The urethane’s harder top layer has more resistance against cutting and tearing, while the bottom layer is softer to better withstand the impact of the powerboats,” said Muller. The specific urethane formulation helped create strongly bonded layers that would not separate. “We recently beveled the slipway liner’s edges to ensure that no seawater or sand could get behind it. We also hardened the urethane at the bolt holes to better hold the screws and attachments where they fit the liner. To ease installation in the field, we added countersunk areas in the liner to match the exact positions of the part’s countersunk boreholes.” “With urethane, you can combine strength, resilience, and lifetime durability,” added Muller. “The end user is very enthusiastic www.designworldonline.com

Design Notes 3-17_Vs3.LL.indd 31

Argonics | argonics.com

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March 2017

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3/1/17 2:23 PM

» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

The right switch for the right job Finding appropriately priced components for Smoke detect ors have to operate in high -sulfur and high-CO2 enviro nments, requiring specia l consideration. Switch placemen t also matters as a sw itch exposed to elements will require more robust metals su ch as stainless steel with a pin toggle, nickel or tin-plated fram es to survive.

a design is a balancing act. It’s easy to err on the side of “cheap,” especially when it comes to switches. When switches are thought of last in a design, opportunities for better function can be missed. Answers to a few questions, though, will help guide switch selection:

• Does the application use batteries? Batteries have several areas that create complications for a device’s switch. For instance, a low-voltage, low-current battery is best suited for gold plating over silver, which can have an impact on a product’s costs. Typically, battery-operated devices also have limited space, influencing the type of switch that is used.

Per

Meet FDA and 3A Requirements

for m a nce

• Tolerates the Most Demanding Washdown Environments • Corrosion Resistant Materials • High Temperature, up to +400°F • Sanitary Design

316 Stainless Steel Simplicity® Bearing 316 Stainless steel shaft

Design Notes 3-17_Vs3.LL.indd 32

Read: Linear Motion Solutions for Washdown Applications, http://bit.ly/pbc-washdown

3/1/17 2:23 PM

» D esi gn Notes

• Is it a plug-in device? Plug-ins use direct voltage, which erodes plating quicker. They are typically best suited for front-panel power switches. Toggle and rockers switches are best suited for applications that require more than 110-volts to operate. •

Environment: What elements will this device be exposed to? Smoke detectors have to operate in high-sulfur and high-CO2 environments, which require special consideration. Special environments may require customized switches, which can add to a project’s costs. Switch placement also matters as a switch exposed to elements will require more robust metals, such as stainless steel with a pin toggle, nickel or tin-plated frames to survive. In severe conditions, it often makes sense to select lower-cost materials that are less apt to corrode.

Tactile switch es are underappreciated as an excellent selection for en gineers that need a relativel y inexpensive, high-performan ce switch within a tight sp ace constraint.

• What is the life expectancy for this device? Does the user expect this to last for 40 years? It’s important to select switches, batteries and devices with synchronized lifecycles so there is a consistent level of quality. Typically, rugged applications must be sealed to protect them from dust, water, fuels and other corrosive liquids that might affect a device’s performance. Some switches – such as basic toggles – are more rugged than others but there are also applications that must be used by workers wearing gloves, which would be better suited for a tactile switch.

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Bluegrass Bourbon &

» De sign Note s

Brakes

Common switch knowledge for common applications

DIP switches ha ve been around a long time and are also a highly versatile and in expensive optio n that are especial ly useful in lighting applicat ions. They offer low-profile, stan dard-profile, coded rotary, SI P and jumper options to engi neers.

In addition, here are some general lessons about switches and applications.

Yes, Brakes

For 45 years, Mach III has produced made-to-order friction brakes, clutches and torque limiters that meet the exact requirements of our client’s applications. • 2,000+ models • Torque to 60,000 in-lbs. • Quick & reliable lead times • Expert engineering assistance

Get to know another fine product from Kentucky.

•

Choose the correct plating (gold or silver) for the current and voltage the switch will be subjected to in the application. Choosing incorrect plating can cause switches to fail prematurely. Silver terminals can tarnish in corrosive and high humidity environments and require more than a logic level circuit to burn through the tarnish to provide reliable switching. Gold cannot handle power and will fail or weld shut if above logic level currents and voltages (0.4 Vac @ 20-28 Vdc max).

•

Tactile switches are under-appreciated as an excellent selection for engineers that need a relatively inexpensive, high performance switch within a tight space constraint. They come in a range of miniature, ultra-miniature and micro- miniature varieties for printed circuit board mounting and can provide good tactile feeling, low profiles and actuator and sealing options to suit any design. They can also be used to control downstream logic to serve as effective on/off switches or momentary switches that can perform on/off functions. Some of the best applications for tactile switches include computer screens, television sets, stereo equipment, room occupancy sensors, programmable light timers and even automobiles.

• DIP switches have been around a long time and are also a highly versatile and inexpensive option that are especially useful in lighting applications. They offer low-profile, standard-profile, coded rotary, SIP and jumper options to engineers. There has been an increase in rotary DIPs to create blink, flash and strobe settings for LED signage, high bay occupancy sensors and LED street lighting. Inline DIPs are commonly used as address switches, which help two devices communicate – ie. a garage remote control and the garage door opener – but they are also being used in wireless lighting applications. In this application, the DIP switch pairs the external wi-fi lights to the base station so they turn on and off. Choosing the right switch for the right application can be the difference between delivering a great project to market on time or a product life-cycle process nightmare. DW C&K Components | ckswitches.com

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Edited by: Mike Santora • Associate Editor

e hood” A look “under th shows of the iBOT AGV design the space-saving ntrols of the onboard co architecture.

PC-Based AGVs plot a path to greater flexibility Approximately three years ago, America in Motion (AIM), a North

Carolina-based builder of AGV systems, was approached by a leading home improvement retailer to help expand their distribution facilities with an AGV system tailored for its new storage and shipping centers. AIM also sought out a PC-based control system from Beckhoff. The newest iteration of AGVs at AIM is the iBOT series, which uses both Kalman filters and odometry for navigation, as well as the Dijkstra algorithm, a mathematical process for finding the shortest path between two points. Instead of using a proprietary, AGV-specific control system, AIM uses standard PC-based control technology to equip these vehicles with modern path-planning functions, similar to the navigation apps used on smartphones. These AGVs implement all the typical functions of a forklift, such as forward motion, steering and mast control.

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The future of AGV controls guided by PC-based PLC system For much of AGV history, a dedicated, hard-coded system running some sort of path-planning algorithm provided the motion control of the robotic system. Hard-wired controls and general system complexity made programming and commissioning these vehicles a time and labor-intensive process. “You can view an AGV just like any piece of equipment, as each consists of 3 different component categories: mechanics, electrical wiring, and electronic controls with software,” says Tommy Hessler, CEO at AIM. “Most end users have the experience to address any mechanical or electrical issues on an AGV, but when it comes to the controls and the software, they often have no choice but to rely on a single source vendor for support.” This makes an AGV system a less attractive option for many users, as their operation will be dependent on a single vendor. Hessler continues: “With the iBOT series, we now have an AGV based on a PLC system from Beckhoff that breaks down that barrier. Suddenly, an AGV can be supported just like a traditional PLC system with standard parts, enabling easy replacement of components.” AIM implemented a PC-based control system in their iBOT series, in this case CP6606-0001-0020 Panel PCs running TwinCAT software. These systems enable AIM to program PLC functions in software while integrating other features into the Windows system. A step up from the previous version using a separate control panel and Embedded PC, the new system features an integrated Panel PC, which provides the processing power in the iBOT systems. The device features a 1 GHz ARM Cortex-A8 CPU, Windows Embedded

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Compact 7 operating system, 1 GB of RAM, fanless operation and no rotating components. The Panel PC is integrated directly on the AGV, handling the iBOT system HMI display and reducing control component count. In addition, four stationary display panels, in this case 19-in. Stainless Steel, IP 65-rated CP7703 Panel PCs, are mounted at various locations around the home improvement retailer’s distribution facility. Each device displays the positions and traffic statistics of the eight AGVs and tracks performance, loads per hour, and any errors or performance inadequacies. Traditional onboard navigational systems use laser sensors and an algorithm to determine X, Y and T (angle) of the vehicle in relation to obstacles in a warehouse. Through

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the TwinCAT automation platform running on the Embedded PC, this navigation can be accomplished in software and carried out in real-time through the EtherCAT industrial Ethernet system. TwinCAT 2 provides the programming environment and runtime for the automation system, enabling PLC functions in software and adding a measure of accessibility to the system. TwinCAT TCP/ IP server provides a layer of communication between the AGVs and the end users’ corporate networks and facilitates communication between the controller and the onboard third party navigational system components. The processes handled by the controller are time critical, as the navigation system needs to know where the vehicle is at all times to avoid potential crashes and damaged

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These cloud-based design tools enable faster creation and refinement of sheet metal parts with simultaneous generation of editable, synchronized flat, folded and tabular views. “This has been one of the most highly anticipated enhancements requested by our customers,” says Scott Harris, Onshape’s VP of Product Definition and User Experience. “We’re proud to be delivering new tools that you can’t find anywhere else in the CAD industry. Our team has completely rethought and re-engineered the way sheet metal parts are designed and prepared for manufacturing.” Sheet metal professionals can speed up their design process in the following ways: Simultaneous Sheet Metal Views: Unlike traditional desktop-installed CAD systems that force users to work in only one mode (flat, folded or tabular) at a time, Onshape shows all representations in one 40

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simultaneous view. When designers edit one view, the other two are synchronized automatically using Onshape’s full-cloud database architecture. Seeing the flat and folded views side-by-side lets users visualize errors and interferences immediately, consider alternatives and ultimately, reduce scrap and wasted time. Editing Sheet Metal From a Bend Table View: The manufacturer can quickly change the parameters of a model in a bend table view – such as the radius or order of individual bends – while preserving the original design intent and seeing the impact immediately on the flat and folded views.

switching around rips and bends.” “This is going to prevent a lot of headaches between designers and manufacturers, because almost all sheet metal work is done collaboratively. We created the system to allow designers to build in design intent and allow fabricators to adjust the model based on specific tooling, without violating the design intent,” he says. The new precision sheet metal features, now concluding early visibility testing, will be made available to all Onshape users in a nearterm release. DW Onshape | onshape.com

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3DEXPERIENCE Lab to include collaboration with MIT’s Center for Bits and Atoms The 3DEXPERIENCE Lab in North America will open in May 2017 at Dassault Systèmes’ U.S. headquarters near Boston. Startups, entrepreneurs, students, makers, and individuals from industrial innovation departments or research laboratories based anywhere in North America, whose projects address city, life, lifestyle, the internet of things, Fab Labs or ideation themes, will have access to Dassault Systèmes’ cloud-based 3DEXPERIENCE platform, technical skills, mentoring and worldwide ecosystem, as part of one- or two-year programs to accelerate their product development. The 3DEXPERIENCE Lab will also house a new digital fabrication space designed and set up in collaboration with Massachusetts Institute of Technology’s Center for Bits and Atoms. In this Fab Lab, innovators can use state-of-the art computercontrolled tools and processes to create product prototypes or refine their product ideas. This Fab Lab will also serve as a laboratory for future hardware-software interfaces. It will be integrating design and fabrication tools into end-to-end real-time systems. “North America has been a wellspring for some of the most impactful startup and entrepreneurial technological innovations of our time. By expanding the 3DEXPERIENCE Lab to North America, we hope to continue this tradition of invention by offering entrepreneurs, makers and startups unique resources to work on disruptive innovations, leverage collective intelligence and create an impact on society,” said Bruno Latchague, Senior Executive Vice President, Global Field Operations (Americas), Dassault Systèmes. “SOLIDWORKS World 2017, whose community embodies the spirit of innovation, is the ideal venue for sharing the launch of this exciting new endeavor as it also complements our ‘SOLIDWORKS for Entrepreneurs program.’ It offers mentoring and greater access to the entire scope of the 3DEXPERIENCE platform for startups using SOLIDWORKS applications to digitally create smart products.” First launched in Europe in November 2015, the 3DEXPERIENCE Lab shapes a new framework of open innovation to foster entrepreneurship and strengthen society’s future of creation. It enables innovators to optimize and validate products and processes using the same virtual collaborative applications and expertise that have transformed how today’s products are designed, manufactured and supported. It has since yielded successful projects in multiple industries that advance a collective effort to harmonize product, nature and life. These include large-scale additive construction using robots, 3D printing of personalized organs for simulation of surgery, open source drones having capabilities of both a helicopter and an airplane, and upstream innovation by sketching in immersive virtual reality. DW

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Machines today produce parts in networked, pre-programmed production runs: pieces are turned, milled and measured in a set order. But what happens when a machine fails or a customer changes its order? Production has to be re-configured, which is time-consuming and expensive. What if there was a better way? Instead of a central control program issuing commands, the workflow would develop flexibly, each part deciding for itself the best route through production. Sound like a pipe dream? To the contrary--developers at the Fraunhofer Institute for Production Technology (IPT) in Aachen are working on such a system. It is called “Service-Oriented Architecture for Adaptive and Networked Production” and functions similar to an automobile navigation system that uses current data to determine the best route in real time. Each part carries information regarding the next production stage; which machine will be called into operation is purposely left undecided. Only when a production stage is pending does the system select a machine from those that are readily available. Each part bears a QR-Code identifying it as a unique entity.

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The software remembers what was done to each part at each production stage, for example, “Hole is drilled with machine parameter A and tool X.” A digital twin emerges from this history, displaying at any time where its physical counterpart is in the production process. Digital twins are especially valuable to manufacturers of a variety of goods because updating or changing a production run does not require a system overhaul. The “Smart Manufacturing Network” manages the digital twin, always analyzing and reusing its process data to improve process robustness and product quality. “Networking machines with parts will enable companies to produce one-off products in the future – production runs of one,” says Michael Kulik, project leader at Fraunhofer working on the software development. A unique aspect of the system is the menu, which configures a production sequence. Using drag-and-drop, a user selects individual steps

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from a list of all services and arranges them in the desired order like building blocks. If a machine fails, a part is simply rerouted to another available machine. “Many machines in a production line can perform a variety of tasks,” explains Kulik. “For example, a sophisticated 5-axis milling machine can also do the job of a simpler 3-axis milling machine. In the future, the Smart Manufacturing Network’s serviceoriented software can flexibly decide to do the job on an idle 5-axis machine.” Also important for flexible production: Machines from various manufacturers must easily integrate into the Smart Manufacturing Network. IPT is working on this with partners

from science and industry in Fraunhofer’s “Networked, Adaptive Production” performance center. “The plugand-play that we know from everyday technology does not yet exist in industry,” says Dr. Thomas Bobek, coordinator of the Fraunhofer performance center. “Our goal is to make plug-and-produce possible.” DW

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Easy connection to the IoT gateway

This IoT Gateway makes it easy to connect to the Internet of Things (IoT) without intervening in the automation logic. The precisely coordinated combination of control hardware and software for implementing IT applications collects sensor and process data, transmits it to MES, cloud applications or local machine state monitoring systems and enables process data analysis. The IoT Gateway’s modular software concept is based on Linux, Java apps and open interfaces. Configuration and handling is web-based, free from programming and performed logically in three simple steps. No software is needed to set up the system; everything is configurable through web interfaces. Furthermore, users don’t have to learn a programming language to use the system, making it easy to get started. And, scalable, embedded control hardware complements three system apps that make data recording, processing and forwarding easy. Dashboard App – The Central Hub The Dashboard App provides web-based interfaces for administration, configuration, parameterization and visualization of process data. Users receive a detailed overview of the collected data, and the Devices App enables local monitoring of process data with a standard browser without special software. Devices App – Flexible Peripheral Connections The Devices App establishes connections with peripherals such as sensors, and signal values are converted into process data (known as endpoints). Connection options for this app are analog voltage and current signals, digital voltage signals, OPC UA, Open Core Interface for Controls, Siemens S7, RFID and Bluetooth LE. 46

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Processing App – Fast Data Transfer The Processing App converts process data into information using logical and mathematical operations. The app then forwards that information to higher-level systems such as the Bosch Software Innovations Production Performance Management platform, the Bosch Sensor Cloud, the Bosch Energy Platform, Bosch Rexroth’s ODiN, as well as other MES systems and databases. DW Bosch Rexroth | boschrexroth.com/en/iot-gateway

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..................................... ........................... ................... .............. ......... ...... ... . High speed connectivity for high performance computing systems The SWE540 6U OpenVPX 40 Gigabit Ethernet switch provides high speed Ethernet connectivity for high performance computing solutions such as the SBC627 single board computer and the DSP282A digital signal processor. This switch helps deliver performance upgrades for the manufacturer’s pre-integrated mission ready systems. These solutions target high performance embedded computing (HPEC) applications requiring the transfer of large amounts of data with the lowest possible latency such as radar, surveillance, situational awareness and imaging. The rugged SWE540 is powerful and flexible, representing a 6U OpenVPX 40GigE switch currently available that supports full Layer 2/3 features including hardware Layer 3 forwarding at fabric speed rates. Layer 3 switching and routing is a critical requirement for advanced security and complex networks. It provides dynamic routing over standard routing protocols, enabling a flexible range of network/ fabric configurations and applications. Patent-pending cooling technology limits system thermal load while still enabling the switch to run at peak performance. The switch supports multiple OpenVPX profiles and uses the latest high performance switch silicon technology to support 40 Gigabit Ethernet performance across 20 ports. The switch features OpenWare switch management software, allowing it to be customized for specific customer requirements. OpenWare supports a range of network protocols and MIBs (management information bases) with capabilities for multicast, Quality of Service, VLANs, and differentiated services.

The OpenWare management interface may be accessed via serial console, SNMP, Telnet, SSH or web interface. The combination of the SWE540’s hardware and the OpenWare switch management software delivers comprehensive security capabilities. Designed for deployment in security-sensitive mission critical applications, SWE540 features include denial of service attack prevention, user password mechanisms with multiple levels of security and military level authorization schemes including 802.1X and sanitization to allow the overwrite of non-volatile storage if a system is compromised. Survivability is also enhanced by ECC protection on the management processor memory, which offers higher reliability in harsh environments. The SWE540 is available in both air-cooled and conduction-cooled versions, and can optionally support four QSFP+ and two 1000BaseT ports on the front panel. Rear transition modules are available to enable access to 40 Gigabit and one Gigabit ports off the backplane. DW Abaco Systems | abaco.com

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president of innovation, Schneider Electric Process Automation. “Business variables are changing quickly—sometimes by the minute—that by the time companies receive updates from whatever enterprise resource planning systems they use, the information is no longer relevant to the business decisions they need to make or should have made.” Because current cost accounting systems only measure the financial performance of the industrial operation at the overall plant level, it is difficult for companies to truly understand the financial impact—positive and negative—operational changes have on business performance. To address that need, Profit Advisor allows plant personnel to see and understand the ROI and business value their actions, activities and assets are contributing to the business in real time. It empowers the workforce to make better business decisions with a variety of data analytics, which can be displayed in various formats, to help drive operational profitability improvements, safely. Profit Advisor layers real-time accounting models onto the Seeq Workbench to become a scalable, repeatable and easy-to-implement solution for multiple segments, enabling customers to both measure and control their profitability. And because it can be integrated with Schneider Electric’s simulation and modeling software in a digital twin environment, users are further enabled to forecast profitability under different conditions or if changes to the operation are made. Overall, the software provides: 1. Historical Data Review: Profit Advisor can evaluate the historical performance of the plant to assess its operational profitability, helping plant personnel analyze and understand how the operation performed during different conditions. It enables the workforce to identify performanceimproving initiatives. And since it can be tied to individual pieces of equipment, it can provide that information down to even the smallest asset in the operation. 2. Real Time Performance Indication: Profit Advisor can indicate current performance and inform plant personnel when their operating decisions are making the business more profitable. Actual ROI and return on improvements will be visible, enabling plant personnel to concentrate and refine their efforts to the actions that provide the greatest financial returns. It also enables plant personnel to determine which parts of operation are constraining operational profitability and accurately estimate the business value their decisions might actually create. 3. Profit Planning: Profit Advisor empowers process engineers to predict the profitability of the changes they are proposing, which will substantially minimize project risk and help to eliminate waste. DW Schneider Electric | Schneider-electric.com March 2017

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»»

» Co u p li n g N o tes

The upside to downsizing elastomeric couplings Edited by: Mike Santora • Associate Editor

Located in the greater Houston area, GPM Pump and Seal is a provider of pumps, pump parts, mechanical seals and complete pump systems for oil and gas, petro-chemical, mining, water, wastewater treatment and other applications. They also specialize in pump and mechanical seal repair for all major OEMs. A size 7 TB Woods Sure-Flex Plus coupling was installed instead of a larger size 8 coupling on a small Group Summit/GPM ANSI pump unit. By using the smaller coupling, the overall package length was reduced allowing for a smaller baseplate footprint.

Elastomeric couplings are the industry standard for GPM’s market. Elastomeric couplings can accommodate the moderate misalignment that inevitably occurs in real-world applications due to pipe strain, thermal loads, settling baseplates and other causes. GPM started specifying TB Wood’s Sure-Flex couplings several years ago. “Engineers often have issues with burs and shaft bores on some of the lower-quality couplings,” said Jon Boultinghouse, Sales & Operations Manager at GPM.

A size 7 coupling was installed instead of a larger size 8 coupling on this small Group 1 Summit/GPM ANSI pump unit. By using the smaller coupling, the overall package length was reduced allowing for a smaller baseplate footprint.

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» Co u p li n g N o tes

The Sure-Flex Plus coupling’s new elastomeric sleeves performed better and were more durable due to improvements in proprietary EPDM and Neoprene materials. “We met with the GPM team to discuss the real-world benefits of EPDM and Neoprene sleeve materials. Our improved rubber compounds offered a 30% increase in torque ratings when compared to previous sleeves,” said John Smihal, Product Manager – Elastomeric Couplings at TB Wood’s.

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»» For GPM, the coupling line provided torsional flexibility, while the 4-way flexing action absorbed all types of shock, vibration, misalignment and end float. The couplings have 7° to 21° torsional wind-up (depending on sleeve material), and torque ratings up to 8,20 kNm (72,480 in.lbs.). The units also require no lubrication and no maintenance. “We use couplings on almost all of our pump applications. Picking the right size is important,” said Boultinghouse. “A balancing act is required to size the coupling large enough, with enough service factor to work effectively, but also not too large as to incur unneccessary cost, like larger guards, skids or baseplates.” GPM chose to use the couplings on all the non-closecoupled pump units they build. The most significant impact of the new couplings was on their ANSI pump packages. The ability to drop-down a coupling size helps them compete on large projects. The Sure-Flex Plus also helped with GPM’s smaller Group 1 ANSI pump packages. Those configurations typically have a short pump shaft along with clearance issues associated with some types of labyrinth bearing seals. “These conditions make it difficult to remove the coupling’s center sleeve element while performing a motor bump test. This is especially challenging when a larger horsepower motor is used, that requires a larger coupling,” Boultinghouse explained. “Dropping down to a smaller size coupling is a huge benefit, especially for maintenance operators.” Sure-Flex Plus sleeves are interchangeable with existing flanges, supplying true “drop-in” performance. With a 30% torque rating increase, the enhanced EPDM and Neoprene sleeves not only lets coupling users replace their couplings with a one-size-smaller Sure-Flex Plus coupling. DW

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Difference

between drum motors and gear motors for food conveying Traditional conveyor setups in food-processing and packaging industries use external gear motors as the belt-drive mechanism. But drum motors are increasingly common as an alternative conveyor drive. Here we review the strengths and weaknesses and potential improvements for both drive options.

By Davide Barbanti â&#x20AC;˘ Associate Professor Dr. Giampaolo Betta â&#x20AC;˘ Contract Professor in Food Science and Technology University of Parma

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Part of designing factory areas and applications — especially those in the food industry — is to pick belt drives for conveyors. Leading technologies make use of electric motors but differ in how much they maintain hygienic standards, ease installation, boost efficiency, and minimize noise and heat. As we’ll see, drum motors are a viable technology with distinct benefits in food applications.

Hygiene regulation and conveyors for discrete motion One industrial class of belt conveyors is for bulk material handling to transport materials such as grain, salt, coal, ore, and sand. The other for general material handling (as to move boxes in a warehouse) is what we cover here. Belt conveyors are the most common conveyor type. Usually two or more pulleys (as drums or rollers) hold taut an endless belt loop carrying medium that travels about them. One powered pulley advances the belt and items riding on it; the powered pulley is the drive pulley while the unpowered pulley is the idler. Belt conveyors abound in food processing to transport raw foods, food ingredients, final products, byproducts, food waste, containers, and packed food products. Here, private organizations including the European Hygienic Engineering and Design Group (EHEDG) have developed guidelines and certification procedures on hygienic design. In the European Union, regulations covering hygiene requirements for food equipment include regulation (EC) 852/2004, Directive 2006/42/EC, and others that dictate materials allowed to contact food. The European Committee for Standardization (CEN) and the International Organization for Standardization (ISO) also have harmonized standards EN 1672-2 and ISO 14159 that detail hygiene requirements to be met to comply with the European regulation. Compliance with these criteria (along with features to ensure worker safety) are prerequisites for all equipment that runs in the food industry. But other

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Criteria

Gear motor

Drum motor

Food conveyor Gear motor

Washdown conveyor

Drum motor

Gear motor

Drum motor

Install and maintenance

+++

Hygiene

Space

+++

Energy

Overheating

Noise Specific hygiene criteria

Non-food conveyor

Soil accumulation Accessibility

Non-food conveyor

+++

Cross-contamination Lubricant contamination

++ ++

Cleanability

Foreign bodies

Cleanability in-place

+++

Drainability

+++ ++

Food contact

Gear motors and drum motors differ on six measures including hygiene. Note the comparison of both drive technologies for each food-plant conveyor application. Orange squares correspond to conditions where gear motors excel. Green squares correspond to conditions where the drum motor shows better applicability or benefits. One (+) indicates slight advantage and (+++) indicates significant advantage.

factors come into play when choosing the right equipment, including maintenance and installation considerations; noise; space for installation; energy efficiency; and the potential for an overheating driving system. The conveyor’s effect on food safety and quality depend on the material handled by the conveyor and: • The area of the food factory where the conveyor runs • Any zoning and segregation in the food factory So the belt-conveyor design and installation must comply with all regulations for equipment for use in the food facility.

Two drive technologies for belt conveyors Gear motors include the motor and gear box. Torque transmits to the drive roller (or drum or pulley) through a shaft in a way that depends on the installation. In the first of four common setups, the gear motor is on one side of the belt conveyor. The hollow shaft of the gear motor directly connects to the roller shaft and the gear motor is only supported by the roller 58

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shaft bearings. Here, a torque arm fixes the motor to the conveyor framework to avoid rotation. In the second of four possible setups, the gear motor is on one side of the belt conveyor and a dedicated framework (shoulder) supports it where it’s fixed. A torque joint can facilitate dismantling and maintenance, and an enclosure is usually needed to ensure worker safety. In the third of four common setups, the gear motor is under the belt and connects to the roller shaft by a drive chain or belt. In the last of four setups, the gear motor is not visible because it’s protected by an enclosure. In some cases, the enclosure also supports the framework and the shaft installs as a cantilever. When the drive motor is on one side of the belt conveyor, it can be vertical with the gearbox under the motor; vertical with the motor under the gearbox; or horizontal.

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Details on the equipment used for conveyor-drive comparisons

1 Left is a gear motor and right is a drum motor. Both are used in food-related conveying applications.

In contrast with these gear-motor setups, drum motors usually install at one end of the belt conveyor. That said, when a setup needs small rollers at both ends of the belt conveyor, a drum motor can go under the belt. Drum motors usually install horizontally, but inclined installations are possible. One caveat: More lubricant may be needed inside the drum and closed greased bearings are recommended to ensure lubrication in this position. Now let’s look at three examples to see where each drive excels. Gear motors and drum motors both have advantages and disadvantages depending on the application. Considering belt conveyors in the food industry, we review three different scenarios to see how the drives compare. 1. The first setup is where the belt conveyor runs in a non-food area of a food-packaging facility. 2. The second setup is where a belt conveyor runs in a food area of a facility and will be cleaned with dry or manual means. 3. The third setup is where a belt conveyor runs in a food area of a food-processing facility and will get regular washdowns. The most important requirement for food equipment is hygiene, but complete evaluation considers several other criteria.

Installation and maintenance Ease of equipment installation influences system setup and operator safety and

ergonomics. Generic evaluation of both drum-motor and gear-motor technologies (including weight and dimensions) shows key differences. Heavier and more unwieldy conveyor drives make installation more difficult. Full analysis also considers the drive’s number of components to guarantee proper functioning, as that impacts the time needed to fit the motor to the conveyor frame. Maintenance is paramount in the food industry to maintain good functioning and efficiency of the plants — and to ensure safety and quality of the food product. Analysis of operations to maintain both drive technologies (especially where replacement is part of realistic analysis) shows that operations to replace components or the whole piece of equipment influence overall drive suitability.

Drive hygiene in our three example settings With current regulations, hygiene requirements are prerequisites given in a general way ... but real hygiene requirements vary with the application. The first conveyor scenario (in the non-food area of a food factory) includes end-of-line areas. So usually equipment here is kept dry and not washed or cleaned at a microbiological scale. But in many plants (including some open plant processes) end-ofwww.designworldonline.com

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First conveyor scenario: Non-food area The first design for testing represents several applications in the food industry where food product is not exposed to the surrounding environment. This is where food is protected by a sealed packaging or when the product is fully processed inside closed equipment. That said, adequate zoning principles should be put in place to reduce the risk of crosscontamination from non-food to food areas of any facility. Our test-setup equipment compared an RGM Ruhrgetriebe SN 5 FR gear motor and an Interroll Drum Motor 80i. Second conveyor scenario: Food area The second design for testing represents applications where food product is exposed to the surrounding environment and the equipment is intended to be dry cleaned or manually cleaned. In this case study, equipment must not be washed and pressure cleaning is not allowed. Eventual partial dismantling is normally used to improve accessibility and cleanability of specific components. Our test-setup equipment compared a Nord Drivesystems 93172.1 A – 80 LH/4HMTF gear motor and an Interroll Drum Motor 113i with hygienic seals. Third conveyor scenario: Washdown food area The third design for testing represents applications in which a microbiologically sensitive food is exposed to the surrounding environment and the equipment is intended to be washed with chemical water solution and pressure, foam, or gel cleaning. Here, equipment should be as cleanable as possible in place and must resist washing conditions. Dismantling for cleaning is reduced to a minimum. Our test-setup equipment compared a Bauer AsepticDrive DA08LB4-TF gear motor and an Interroll Drum Motor 80D drum motor. These pieces of equipment are state-of-the-art equipment and have comparable applicability to the scenario at hand — as well as comparable output torque, power, and belt speed.

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This is an example of an application where food directly contacts the conveyor — so necessitates regular washdown.

line equipment is in the same factory area where products are processed and packed, so exposed to the surrounding environment ... and zoning strategies aren’t implemented well enough to adequately protect food. That’s why end-ofline equipment can be a source of crosscontamination of the product. Reducing cross-contamination risk

needs end-of line equipment to at least: • Avoid accumulation of soil as it’s a source of cross contamination and pest attraction. • Be sufficiently accessible to allow proper manual cleaning. • Minimize interaction with the food area. What’s more, equipment design should prevent soiling food containers with lubricants. This isn’t usually a safety issue because food containers are already sealed — but it’s undesirable for consumers to touch a food container greased with lubricant and possibly contaminate other products during grocery shopping or meal preparation at home. So for conveyors going into non-food areas of a food-packaging facility, relevant factors include soil accumulation; accessibility for inspection and manual cleaning; other possible means of cross-contamination; and lubricant leakage and container contamination. With regards to the second scenario (the area of a food factory to be cleaned with dry or manual means) the EU machinery directive (2006/42/CE) demands that equipment here be of suitable materials; be easy cleanable and drainable; avoid accumulation of soil; and avoid contamination with lubricants. Moreover, equipment in food areas can be

a source of physical hazard if it introduces foreign bodies into product ... so equipment in food areas must avoid such risk. This requirement (not explicitly listed by European law) is in the U.S. Code of Federal Regulation (21 CFR Part 110). So comparisons of gear motors versus drum motors must account for likelihood of soil accumulation; accessibility for inspection and manual cleaning; its threat as a possible source of foreign bodies; and suitability for food contact. Measurements of surface roughness (a Mitutoyo Surftest SJ-201 surface roughness tester is used) and of radii of internal angle are also done to check compliance with the “c” requirement. For the third scenario (conveyors in food areas of a food factory intended to be washed) in addition to the criteria listed above, there are requirements for easy cleanability (with design features such as dismountable joints with elastomeric gaskets, for example) as advised by international rules including EHEDG Guidelines, European Harmonised Standards, 3-A Sanitary Standards, and NSF standards. So drum-to-gear motor comparisons for these situations account for cleanability per EHEDG guidelines — including measures of drainability; lubricant leakage and product contamination; possible source of foreign bodies; and suitability for food contact. Measurements of surface roughness (a Mitutoyo Surftest SJ-201

Three most common installations for gear motors powering conveyors

Common installation with gear motor under the conveyor

Common installation of gear motor

Cantilever installation with gear motor inside protective enclosure

Here are three common arrangements for gear motors on a conveyor. 60

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surface roughness tester is used) and of radii of internal angle are also done to check compliance with the “a” requirement. Note: One manufacturer addresses oil leaks as a potential disadvantage of the drum motor with a USDAapproved drum motor incorporating a leak-escape feature in its shaft.

Space for installation and energy consumption As we’ll outline, complete drum-motor-to-gear-motor comparisons account for space needed for installation and overall energy consumption. Our investigations explored consumption on conveyors approximating average setups for our three food-plant scenarios. Results we present in charts in this feature are based on setups in which a belt conveyor accepted driving from a gear motor or drum motor. Then a torque motor connected to the idler pulley and used a brake to reliably simulate a load on the belts. We measured active power and RMS current at various brake-torque values.

Conveyors that see direct food contact need regular washdown. Drum motors offer better hygiene than common gear motors in such cases.

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Assessing drive risk of overheating and noisiness Overheating can be a failure mode for both gear motors and drum motors. To avoid that risk, gear motors often include a fan for cooling ... but the fan is normally a hygiene issue, so many gear motors for the food industry have no fan. On the other hand, drum motors are closed systems and generated heat only dissipates by the drum surface. Preventing motor failures here requires that the winding temperature stay below a safety limit, so motors usually run with a safety system that cuts current if there’s a threat of overheating. Our drum-motor-versusgear-motor investigations estimate winding temperature through calculation, knowing the relation between the stator resistance and its temperature. Average winding temperature comes from comparing winding resistance at the temperature to be determined with resistance at a known temperature: T = RT /R1 (234.5 + T1) – 234.5

Where T is winding temperature, RT is the winding resistance at the temperature T, T1 is ambient temperature, and R1 is winding resistance at temperature T1. Challenge tests simulate all three conveyor scenarios under continuous functioning at two different belt speeds and high output torque. Then we compared sound-power measurements per Standard ISO 9614-2 (Determination of sound-power levels of noise sources using sound intensity — Part 2: Measurement by scanning) to investigate noise emitted by drum motors and gear motors in our three scenarios. This sound-intensity measurement doesn’t measure sound-pressure level but intensity level instead. That can be used to calculate sound power level W:

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Where In is the intensity over an nth surface and Sn is the area of the nth measurement surface. In this software-based analysis, a reference box is defined around the motor using a wire mesh and used for all tests. Then we measured power emitted from each motor by scanning all surfaces of the box with an intensity probe. Because we measured overall sound power, the results consider the March 2017

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overall sound power, the results consider the whole system. So for drum-motor setups, this accounts for the sound of the drum motor and belt — which constitute the whole drive. In contrast, this measurement in the gear-motor setups includes the effect of the joint torque, bearings, and roller. The difference between the measurements means they don’t give an absolute measurement of noise emitted by the motor itself ... so the results have only comparative meaning.

Drum motors outperform on hygiene and more Specific equipment choices can influence comparative performance, but here are some take-home points based on results from our investigations. Drum-motor drives offer benefits to keep designs hygienic which (in the case of the food-processing industry) is the most relevant of the six criteria we outline here. Their compact design helps them outperform gear motors in a few ways. Risk of soil accumulation and cross-contamination is significantly lower for drum motors than for common gear motors. Plus in washdown areas, installed drum motors have better cleanability.

Interroll designed a version of its drum motor (model 113i) specifically for the U.S. market, adhering to the meat, poultry and dairy processing guidelines set forth by the USDA.

That’s because all the subcomponents are embedded inside the roller and there’s no protective enclosure. This trims considerable cleaning time and cost for operators. The only weakness of drum motors from the hygienic point of view is the potential risk of contamination by lubricant. Even though synthetic foodgrade oil is used, this can be a critical point and further effort in validation should be done to ensure adequate reliability of the dynamic radial shaft seals. Note: The equipment we used to get our results are suitable for the three conveyor scenarios we explored. But unfortunately, gear motors with specifications like the one we used for the non-food scenario often

get put in food and even washdown areas. Such choices are usually made to cut costs, but they’re bad choices that can cause hygiene problems. As results show, drum motors offer other advantages for installation, making them the only possible choice in some layouts. Fewer components means drummotor installation is simpler and faster than that for gear motors. Lighter drives in food and washdown settings also helps installers and operators with better ergonomics and lower risk of injury. Onsite maintenance operations become more impractical as the piece of equipment becomes more specialized ... and food and washdown areas generally

Two most common installations for drum motors powering conveyors

These are two common arrangements for gear motors driving a conveyor.

Common installation of drum motor

Installation of drum motor under conveyor belt

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Oil leaks are potential disadvantage of drum motors. To address this concern, Interroll’s USDA-approved drum motor contains a leak-escape feature in the shaft.

need very specialized pieces of equipment. So in these cases, there’s no significant difference between using gear motors and drum motors. Regarding other evaluating criteria (energy consumption, noise and overheating) our study used experimental trials on specific commercial drum motors and gear motors. Results are strongly influenced by specific equipment choices. Here there are only slight or insignificant differences between drum motors and gear motors for conveyors involving food and requiring washdown. This article summarizes key findings from an independent study by University of Parma researchers. Download the full white paper at the Interroll “downloads” page online. DW Interroll | interroll.us WHAT DO YOU THINK?

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How to

select your next clutch & brake For dry running applications, you need to thoroughly evaluate your requirements to choose the best solution to stop and hold rotary elements

Michael E. Gamache • President • Carlyle Johnson Machine Co.

Clutches and brakes are used for two distinct purposes—a clutch is used to connect two moving elements, while a brake is used to stop or hold a rotating element. A clutch can operate in several configurations, including shaftto-shaft coupling and pulley designs. In a shaft-to-shaft coupling configuration, the clutch will bring the clutch output shaft speed up to the input clutch speed. The input and output shafts are both located upon a common center of rotation. In a pulley configuration, the clutch will bring the output (such as a pulley or sprocket) speed up to that of the clutch input speed. In this case, the two centers of rotation of the input and output are not along a common center line of rotation. A brake is only available in one configuration, but is offered with many mounting styles and options—this lets you attach the fixed brake housing to the non-rotating (stationary) part of the system.

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When applied dynamically, a clutch engages with a relative difference between the clutch input and output speed. Because dynamic clutches, such as the EMA unit (left) and smaller AHA unit (right), have a speed differential that is greater than zero, the engineer must determine the clutch’s required dynamic torque to select the proper size unit.

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MAXITORQ AHA25 pneumatic (hydraulic) clutches and brakes are rated from 15 lb-ft. dynamic to 60 lb-ft. of static torque, and torque can be regulated by adjusting systems pressures. These units are designed with a stationary cylinder assembly that is mounted on deep-groove ball bearings to accommodate thrust loads.

Dynamic vs. static torque Torque is a measurement of the torsional force and the distance required/available, from the origin, to achieve that force when a component either rotates or is prevented from rotating. Torque measurements are typically offered in pounds per foot, pounds per inch or Newtons per meter. There are two types of torque relevant to clutch and brake operation; static torque and dynamic torque. In dynamic braking, the brake is used to control the motion of the moving element

by absorbing the change in kinetic energy. In dynamic clutching, the clutch is used to bring a stationary output element up to the speed of the rotating input element by absorbing the change in kinetic energy of the nonrotating elements. Static clutch and brake usage is simply dependent upon the torsional load. To achieve static torque operations in a clutch, it must be engaged prior to rotating the input such that it acts as a solid coupling between the input and output elements. To achieve static braking, the brake simply holds the The materials in the MAXITORQ EMA500 electromagnetic clutch allow it to operate in both wet and dry applications, while minimizing weight.

output element stationary. In static usage, both the clutch and brake are not absorbing any kinetic energy. Static torque is the so-called holding torque that exists when there is no relative speed difference between the input and output shaft in a clutch, and when the shaft is stationary (not rotating) in a brake. The static torqueâ&#x20AC;&#x2122;s breakaway level must be reached before relative motion will occur between clutch shafts, or before the brake shaft can begin to rotate. Once the relative motion occurs in the brake shaft, or between the input and output in the clutch shafts, the unitâ&#x20AC;&#x2122;s torque capability reduces to a lower value. This value is dependent on the relative speed difference and is referred to as dynamic torque. Dynamic torque is typically less than static torque. It will vary with the relative speed difference between the clutch input and output, and the speed difference between the operating speed and the final stop speed (0 rpm) in a brake. This phenomenon is a result of the change in the coefficient of friction within the friction surfaces of the brake or clutch and will vary with the type of friction material used. Since the coefficient of friction will change during the clutch starting and brake stopping, an average coefficient of friction is typically used. The dynamic coefficient of friction is half the static coefficient of friction. The dynamic torque is therefore half the static torque rating. This is usually associated with an operating speed of 1800 rpm. Transmitting torque Torque in a clutch or brake can be transferred by two different methods, each with advantages depending on the

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When evaluating which clutch or brake to select, it is important to consider installation and performance criteria as well as unit capabilities. Shown here, both the clutch and brake models of the MAXITORQ EMA800 can be adapted for high-speed applications, andpage.pdf feature three holes 2:19:57 in the unitâ&#x20AC;&#x2122;s World P04 half 1 balancing 1/16/2017 PM body for dynamical balancing.

application. Torque can be transmitted through a jaw tooth friction element or a friction pad (disc). In general, jaw torque transmission is limited to engagement speed differentials of 100 rpm or less between the input and the output. The number of jaw teeth in the unit also limits the number of available rotary engagement positions. Due to their design, a jaw clutch or jaw brake can transmit more torque in a smaller space compared to friction disc clutch or brake, and tooth forms can be modified to generate specific results. Usually, friction pads or discs have no speed limitations for engagement speeds and can engage in an infinite radial position. The number of discs can also be changed to obtain higher or lower torques with the same actuation. Torque transmission methods can be combined to offer unique features and multiple functions beyond that of the individual clutch or brake components combined. For example, combining a bi-directional clutch and a spring-set friction disc clutch would result in a design that offers torque limiting, braking, back driving and stopping.

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Selection concerns The selection of a clutch or brake for a dynamic application requires the review of three characteristics: 1 What is the capability of the main driver in the system? This involves a review of the prime mover or driver (such as the motor input).

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2 What is the time required to bring the clutch output speed up to the clutch input speed—or for a brake, what is the time required to bring the shaft speed and torsional load to 0 rpm? The designer must determine whether the application has time limitations, and must compare the time requirements to clutch and brake capabilities.

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3 What is the number of cycles the clutch or brake will be subjected to? It is necessary to evaluate heat dissipation capabilities of the clutch or brake to ensure they are sufficient for the specified use. If the cycle rates are greater than five, equally spaced over an hour time frame, then this factor should be considered. Evaluating the system mover/driver The first characteristic of a dynamic clutching or braking application to evaluate is the prime mover or driver of the system (the motor input). The motor will drive the load, and once the motor is specified, the clutch or brake can be sized based upon the motor.

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In a dynamic clutching or braking application, the required torque can be calculated using the horsepower rating of the prime mover and the operational speed of the clutch or brake. The calculation is as follows:

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Torque (dynamic) = (5250 * HP/rpm) * SF

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• Torque (dynamic) is measured in lb-ft. • rpm is the relative speed difference between the clutch input and the clutch output, or the rotational shaft speed of the brake that must be stopped in revolutions per minute. • HP is the motor’s rating in Horsepower (HP). • SF is the adjustment for the type of driving member (motor) that is used. The SF adjustment is meant to adjust the torque capability of the clutch or brake for the type of driving member (motor) that is used. This factor March 2017

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Engaged statically, spring-set brakes can be wellsuited to holding applications, as they offer reliable positioning and prevent movement by disengaging when at stop. Most units are remotely controlled but available with a manual release, as shown here on this CJM FEA model, which features a puller cable type mechanism.

will adjust for the typical torsional load produced in the operational cycle of the motor. For example, the power stroke in a diesel motor will produce large torque spikes throughout the compression and exhaust cycles as each piston moves. These torsional loads will be directly driven through the clutch or brake. On the other hand, the torsional loading from a dc motor will be almost constant. The general SF numbers used for each motor type are as follows:

Note: The clutch or brake supplier can provide data for the inertia of

the rotational components of the brake or clutch. These values must be included in the calculated inertia load of your system. If the total inertia load is determined to be 50 lb-ft^2, the operating speed is 72 rpm and the dynamic torque rating of the clutch or brake is 730 lb-ft, then the time required to accelerate or stop the inertia load is calculated as follows:

Dc motor = 1 Gas motor = 1.5-2 Diesel motor = 2-3 This SF number can be reduced if a flexible, torsional or torsional absorption coupling is used after the motor and prior to the clutch input. The coupling will greatly reduce the torque spikes from the motor. Example:

A 10-hp dc motor runs at 1800 rpm and drives a conveyor through a 25 to 1 gearbox. The operator would like to disengage the conveyor from the motor to clear a jam without stopping the motor or the gearbox output, simply by turning a clutch on and off. To determine the clutch torque rating needed, one must calculate: T = (5250 * 10)/72 =729.17 lb-ft. (SF = 1) Note: The clutch is located after the gearbox and the shaft speed

after the gearbox is 1800/25 or 72 rpm. The time to stop the load (in the case of a brake) or to bring the load up to full speed (in the case of a clutch) is a function of the inertial load that the clutch or brake must start or stop. The time can be calculated as follows: t (sec) = (WK^2)(N)/(308 * Torque) t = Time (sec) (WK^2) = Inertia (lb-ft^2) of the clutch or brake and system (load) T = Dynamic torque rating of the clutch or brake (lb-ft) N= (rpm) Operating speed, the speed the clutch must accelerate the load up to, or the speed the brake must stop the load from

T = (50) * (72)/(308 * 730)= 0.016 sec Note: The calculated time to stop the load, or bring the load up to

full speed from 0 rpm, does not include the time required for the clutch or brake to react to the actuation method. For example, in an electromagnetic clutch or brake the coil must charge and produce an electromagnetic field to activate the armature and create torque through the friction disc(s). This loss of time can range from 10 to 500 milliseconds, depending upon the size of the clutch or brake. The total time—from the time the clutch or brake is switched on, to the time for the clutch to accelerate the load or for the brake to stop the load—must include the inherent engagement time of the actuation method. The dynamic torque rating of the clutch or brake can be increased by selecting a larger size unit, which reduces the total engagement time, if desired. It should be noted that the dynamic torque will also increase, as will the shear forces placed on the mounting components between the rotating and nonrotating members. The torsional force applied to the nonrotating members, such as keys and set screws, should be considered. The cycle rate is defined as the number of times the clutch or brake will be turned on per minute. This is the amount of energy the clutch must absorb from a stop or start, and the amount of energy the clutch or brake can dissipate before the next start or stop cycle. Energy is dissipated in the form of heat, and each clutch or brake has a defined heat load capability that can be obtained from the manufacturer. Data provided typically represents an average cycle rate, and if multiple cycles are performed periodically, then the cycle rates must

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be adjusted to account for a peak at some point in the total cycle. For example, the heat generated from 10 cycles per hour (equally spaced during the hour) will differ greatly from that of 10 cycles per hour if the 10 cycles are performed in the first 5 minutes of operation and no additional cycles occur until the end of the hour. It should also be noted that heat dissipation will vary significantly depending upon the ambient temperatures and the environmental conditions the clutch and brake are subject to. The formula to determine the heat loading is: E = BTU/min = 1.7 (Wk^2) (rpm/100)^2(Engagements per minute)/780

Wk^2: Inertia (lb-ft^2) of the system including the clutch non-rotating component rpm: Operating speed, the speed the clutch must accelerate the load up to, or the speed the brake must stop the load from. Example:

A clutch input is running at 1800 rpm and the inertia load to be accelerated from zero to 1800 rpm is 2.5 lb-ft2. The application will require the clutch to engage and disengage 10 times per minute. The calculation for the heat load that must be dissipated is: E = (1.7 * 2.5 * (1800/100)^2 * 10)/780 = 17.65 BTU/min. The clutch selected must be capable of dissipating at a minimum of 17.65 BTU/min. Clutch and brake actuation Clutches and brakes can be actuated with several different methods: mechanical, electromagnetic, and hydraulic/pneumatic. Mechanical actuation is typically performed with a handle that uses a mechanical advantage through a lever system for easy engagement and disengagement. The mechanical advantage squeezes friction discs (one or multiple) together to transmit torque. When the handle is moved to another position, the clutch or brake condition (engaged or disengaged) changes. Mechanical systems can be offered with an internal locking mechanism so that, once the clutch is engaged or disengaged, it will remain in that condition without the need for a constant external force.

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Mechanical clutches and brakes are robust, with no bearings to fail. The units are not affected by power failures from changes in power supplies, changes in pneumatic or hydraulic pressures, or from power outages. Mechanical clutches and brakes are also somewhat speed tolerant. Units are easily available with single position configurations, or with automatic overload release in case of a jam or over-torque condition. However, mechanical clutches and brakes will not automatically disengage with loss of power. These units require periodic manual adjustment to account for wear on the friction discs over useage. Electromagnetic actuation is performed by a magnetic coil and an associated magnetic flux path incorporated within the clutch or brake. The magnetic field created is typically used to move an armature and squeeze friction surfaces of the discs (one or several) together or to move the armature from contact with the friction discs when in a spring-applied design. Electromagnetic clutches and brakes can be supplied with either an energy-applied system or with a spring-applied/energydeactivated system, which provides flexibility to the design. This will also cause the clutch or brake to turn on or off when power is lost. Electromagnetic clutches and brakes have a long service life if used correctly. These units are somewhat speed tolerant, and can be modified to increase speed tolerance. These clutches and brakes are available with self-adjustment features to compensate for wear on the friction discs. An electromagnetic clutch requires bearings to support the stationary coil field. These bearings will be subject to loading due to the use of a radial flux path and, although loads are usually extremely light, this can be a concern for the engineer. Additionally, the time required to engage an electromagnetic clutch or brake can be greater than the engagement time of other actuation types due to the time required to build up the coilâ&#x20AC;&#x2122;s magnetic field. The hydraulic/pneumatic actuation of a clutch or brake is accomplished by pushing a piston to squeeze one or several friction discs together to transmit torque. This transfers torque from the input shaft to the output shaft. Hydraulic/pneumatic clutches and brakes offer fast response times based upon the actuation pressure and the clutch piston mass. Their design produces consistent engagement times based upon the control pressure variations. In a hydraulic or pneumatic application, the full force produced by the piston must be transmitted through a bearingâ&#x20AC;&#x201D;this allows the clutch body to rotate while the housing remains stationary. These bearings must be properly selected to ensure a reasonable service life. Additionally, due to the use of bearings and the high loads experienced by the clutch, operating speeds are limited. The hydraulic/pneumatic brake does not require a bearing. DW

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Developing a mixed safety-critical IIoT robotic arm Robots that can man-handle car bodies incorporate several safe guards to protect workers. New software architectures have evolved to make these systems reliable Image: istockphoto.com

and easy to manage. Muhammad Shafique Mentor Graphics â&#x20AC;˘ Embedded Systems Div.

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Electronics

The industrial automation industry is rapidly making use of today’s heterogeneous multicore system-onchip (SoC) architectures. These multicore environments help reduce operational and maintenance costs by combining functions once handled by separate processors and putting them on a single, multi-functional SoC (system on a chip). However, a problem can arise when combining functions on an SoC this way: Each function can have requirements – in the form of safety certifications, real-time response, rich UI/ HMI, and network connectivity functions to name a few – that compete for scarce resources. But there are various ways discrete functions can be isolated on a single piece of silicon using technologies such as hypervisors, ARM TrustZone, or a multicore framework. To understand these approaches, it can be helpful to study an example. So consider the case of a mixed safety-critical application comprised of an automated robotic arm used in an IIoT (industrial internet of things) factory setting. Traditional embedded control systems were designed with a single processor and one function in mind. Today, it is more often the case that embedded systems incorporate multiple discrete processors. The industrial robotic arm serves as an example. In addition to the mechanical arm itself, it includes an electronic control unit and HMI (human machine interface) display. The HMI enables manual operation or movement by programing a sequence of moves (script) that can take place without human intervention. The robotic arm controller handles the HMI and process control and also implements safety inputs/interlocks. These interlocks can be used to shut down the arm in an emergency and are programmed to take inputs from various types of sensors, for example, proximity switches, pressure sensors, and safety beam. The IIoT connection means the robot connects with an external network. So an additional processor might be incorporated to perform network communications and handle the firewall and various other associated activities.

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E le ctro n i c s

Figure 1: The block diagram of embedded virtualization technology using a hypervisor.

It’s important to note that each robot arm function has different processing needs. Consequently, it requires a different type of processor. Let’s identify and/or explain those needs: HMI/Operator Console: The processor •should be a high-end application processor

with rich graphics support such as an ARM Cortex-A with GPUs. Process Controller: This is a relatively •high-end processor with use-case specific

features. For example, it could be a DSP if the primary function involves processing large amount of data as in image processing. This can be an ARM Cortex-A, Cortex-R, or a DSP core. Safety Controller: Requires a relatively •low-end processor as its sole purpose is

to execute safety interlocks. This could be an ARM Cortex-R or Cortex-M. Software running on this processor typically needs to go through safety certifications such as IEC 61508.

•

Network Controller: The processor may have some additional network communication capabilities, for example, radio or communication interfaces to talk with other IoT nodes. This can be an ARM Cortex-A or Cortex-M device.

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Figure 2: The block diagram of the multicore framework created by Mentor Graphics.

This is a fairly simplistic view of an industrial robot. The design will require multiprocessor PCBs or multiple PCBs, defining a communication architecture between the processors, and integration testing at both the hardware and software levels. Multicore in embedded In past few years, multicore SoCs have proliferated. However, multicore in the embedded space is not entirely about computational performance. There are some obvious cases where embedded systems can

use more computational power e.g., network throughput or rich graphics. But in most situations, embedded systems are designed to excel at other factors such as reliability, responsiveness, real-time behavior, safety, security, power consumption, low cost, and low maintenance. So one might say the chief driving factor for multicore in embedded is a convergence of functions. Here convergence means combining different forms/components of technology into a single entity. In the robot example, there would be significant cost

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Ele c tronic s savings available if a single multicore processor could handle the four functions outlined above. Another benefit of convergence is that of a simple software architecture where various functions can talk to each other using inter-processor communication (IPC) mechanisms. This is far less complicated than implementing complex communication protocols between discrete processors. A single multicore processor also needs less power than multiple discreet processors and less supporting circuitry. Moreover, individual cores can be turned off when not needed. The key challenge in multicore convergence is to maintain the individuality of each discrete function. For example, when looking at the robotic arm scenario, the processor serving as the safety controller does not require much computational power. The most important requirement is to reliably read data from safety sensors and drive related actuators when needed. The code executing safety functions is typically subject to compliance requirements (IEC 61508 for industrial or ISO 26262 for automotive). On the other hand, the HMI/operator console requires a more computationally capable environment supporting a rich graphics framework or multimedia capabilities with no safety requirements.

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If we want to use one multicore processor to implement both the safety controller and HMI/operator console functions, we need a strong compartmentalization, or a partitioning mechanism that can create different execution contexts; one high priority context for the safety controller and another context for HMI (which is less critical). It’s important to make sure that non-critical code running the HMI never interferes or blocks any of the functions of the safety controller. Various technology options can enable this compartmentalization. Embedded Hypervisor: A hypervisor is a software component that

creates an abstraction on top of hardware and allows multiple guests operating systems to run simultaneously side-by-side. Virtualization technology or the use of hypervisors has been a convergence enabler for the desktop and server domains for quite some time. Virtualization extensions are available on multicore SoCs so this is certainly an option to consider. 80

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E le ctro n i c s

Figure 3: The block diagram of embedded virtualization technology using a hypervisor and ARM’s TrustZone technology demonstrating compartmentalization.

Multicore Framework: Processing cores

“The robotic arm controller handles the HMI and process control and also implements safety inputs/interlocks.”

running in an asymmetric multi-processing (AMP) configuration can be assigned individual functions. Multicore frameworks assist with life cycle management and help facilitate communication between various participating cores, which can be useful. ARM TrustZone: TrustZone is a hardwarebased feature where software running in a normal world is blocked from accessing secure world resources directly. ARM processors with TrustZone can run a secure operating system (secure world) and a normal operating system (normal

world) simultaneously from a single core or from multiple cores, thus enabling a form of compartmentalization. These components can make a design look a bit complex and overwhelming. But the good news is there are embedded software vendors who can help. Multicore SoCs from semiconductor vendors and embedded software platforms from companies such as Mentor Graphics provide convergence-enabling software technology components that are pre-tested, hardened, certified, and available with long term support and maintenance options. Typically, these platforms are also packaged with required tooling to get all of this working. To illustrate embedded multicore enablement and convergence using an embedded software platform, let’s continue with an example of the automated robotic arm. While the robotic arm moves, humans should be kept away to prevent hazardous

Figure 4: This robot application leverages ARM TrustZone hardware extensions to realize a mixed-critical environment on a single SoC where real-time safety functions are isolated from the HMI context. In this environment, safety functions are certifiable to the IEC61508 SIL3 level.

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situations. Consequently, industrial robots often use safety beam interlocks where a laser beam cordons off the entrance to the robot work area. Anyone entering the area obstructs the safety beam, stopping the robotic arm and latching it into a safe position. Additionally, the system generates an alarm on the HMI/operator console so the operator can take a corrective action. In this scenario, the three main components are the mechanical robotic arm operation (process), the HMI/ operator console, and the safety beam. The traditional approach to architecting this system would use one discrete processor to drive the HMI/operator console, one processor to control the robotic arm, and one processor to implement the safety domain. However, let’s follow a multicore approach. To begin, we select the NXP i.MX6 homogeneous quad-core processor to implement this system. In this design each of the TrustZone separated partitions run an independent instance of the Nucleus real-time operating system (RTOS). Nucleus uses ARM TrustZone technology and the OpenAMP-based multicore framework to do life cycle management and enable communication between secure and normal world. The secure world Nucleus application is responsible for both running the safety beam and rendering safe graphics on HMI/ operator console. This is called the safety domain and is represented by the red dotted line and shaded box in the nearby figure. So whenever the secure world Nucleus detects a safety beam obstruction it sends a command to the robot to stop moving and enters an alarm state. Realtime status of safety beam and alarm state is animated on the HMI/operator console. The normal world Nucleus application is used for the user interface to drive the robot and control its movement. This application also provides information on robot movement. An interesting point to note is that both secure and normal world Nucleus

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E le ctro n i c s

Multicore and Embedded defined Multicore: A microprocessor with two or more homogeneous or heterogeneous cores. Homogeneous Multicore: A multicore processor where all the cores are of same architecture e.g., ARM processor with two Cortex-A cores. Heterogeneous Multicore: A multicore processor where cores differ in underlying architecture e.g., ARM processor with mix of Cortex-A and Cortex-M cores. Multicore Framework: A software framework/package that helps to use and manage multiple available homogeneous or heterogeneous cores on a multicore processor. OpenAMP is one specification to implement such a framework that is promoted by the Multicore Association (MCA). Hypervisor: A lightweight high-priority execution context that helps to create and execute one or more virtual machines. ARM TrustZone: ARM TrustZone is set of hardware security extensions added to ARMv6 processors and greater e.g., ARM Cortex-A9 and Cortex-A15 cores. FPGA: Field Programmable Gate Arrays (FPGAs) are semiconductor devices based around a matrix of configurable logic blocks connected via programmable interconnects. FPGAs can be reprogrammed to desired application or functionality requirements after manufacturing. Mixed Safety-critical: Embedded software architecture that combines software components requiring safety certification (safety controller) and software components that do not need safety certification (operator UI/multimedia). Lifecycle Management: Managing the entire lifecycle of software running on a core including firmware upload, start (boot), stop (shutdown), and clean up.

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applications write to a single display unit (HMI/ operator console). This implementation uses layered graphics architecture with safe graphics overlaying on top of non-safe graphics. As the ARM TrustZone secure world has higher priority than the normal world, the safety functions are always available even if the non-safe or normal world is down or corrupted. So in effect, we have a single i.MX6 SoC fulfilling rich graphics, real-time control, and safety functions simultaneously without compromising any of these discrete functions (such as acting as safety controller and HMI/ operator console). There are numerous multicore homogeneous and heterogeneous SoCs available today that can converge and combine embedded software functions. The converged software architecture brings significant benefits and cost savings. Technology components such as hypervisors, multicore frameworks, and ARM TrustZone help maintain individuality of discrete functions being combined and provide the required isolation. To reduce time-to-market and simplify maintenance, it is also worthwhile to look at pre-baked multicore embedded software platforms from trusted software venders to complement todayâ&#x20AC;&#x2122;s more sophisticated SoCs. DW References Mentor Graphics, Embedded Systems Div. mentor.com/embedded-software/

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I n d u s t r i a l

E t h e r n e t

Ethernet from the ground up Here’s how to properly connect Ethernet hardware and related devices, and then manage the network for optimal IoT performance.

By Jonathan Griffith • Product Manager AutomationDirect FUEL Team – Industrial Communications & Power Supplies

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Due in large part to the popularity of the Internet of Things (IoT) and its partner, the industrial IoT (IIoT), the number of industrial Ethernet applications has never been greater. When connecting information across the plant floor, industrial protocols such as Modbus TCP/IP, EtherNet/IP, Profinet, EtherCAT, Powerlink and others use Ethernet as the underlying network. The IIoT starts with edge-connected sensors and instruments, which are often inputs to controllers and HMIs connected to the internet via Ethernet. Controllers and HMIs are often connected to each other using Ethernet, which is also the network of choice for connections from these components to higher level computing platforms such as ERP systems. Ethernet’s network framework and protocols are characterized by the Open System Interconnection (OSI) model, often depicted as a 7-layer Ethernet framework. The two lowest layers are related to hardware. Layer 1 is called the physical layer and includes electrical and physical specifications along with the cables and connectors. Layer 2 is called the data link layer. This layer includes MAC addresses and provides the connections among hosts such as PLCs and HMIs on the factory floor. Layer 2 connections are typically made through unmanaged or managed switches. The upper layers 3 through 7 are mostly software related including layer 3, the network layer that connects different networks through advanced managed switches and routers. We will discuss the physical and data link layers 1 and 2 of Ethernet, and show how to use them to physically connect components in an industrial Ethernet installation. Ethernet connectors and jacks Ethernet physical connections start with the connectors and jacks. The typical Ethernet connector, used most frequently in the office or home, is the RJ45 connector and jack. This 8-pin connector connects the 8-conductors in a CAT cable (8P8C) to a jack. When terminating a CAT cable to these connectors, users should follow the current TIA/EIA-568-B standard. RJ45 connectors can be used in industrial environments with careful cable routing, strain relief and connector shielding. If water, humidity, shock or vibration are a concern—an M12 connector is often an option for applications such as an electrical cabinet bulkhead connection or directly mounted on a machine. Depending on the Ethernet speed, a 4-pin or 8-pin M12 connector should be used. For speeds up

Ethernet patch cables used in industrial applications should include an overall metal foil shield to reduce EMI, intermittent control system problems and possible data loss in transmission.

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I nd ust r ia l E t h e r n e t to 100Base-T, a 4-pin, D-coded M12 connector is used to terminate the two twisted-wire pairs within a cable. One twisted-pair sends data and the other receives data. D-coding is the industry standard for use with an M12, 4-pin connector in Ethernet applications. If Gigabit 1000Base-T Ethernet is required, all four wire pairs are used for communication, requiring an 8-pin M12 connector. An 8-pin M12 connector with X-coding should be used as it is the Gigabit Ethernet connector standard for 1000Base-T. For comparison, fieldbus networks typically use 8-pin M12 connectors with B-coding.

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Ethernet cables To begin, users should specify cable that will handle gigabit Ethernet speeds. Gigabit (1000 Mbps) speeds require Category 5e cable (CAT5e), which should be sufficient to support most any industrial application for the foreseeable future. CAT6 cabling will handle 10 gigabit Ethernet. However, if that high level of speed is required in an industrial Ethernet application, there will be many more restrictive demands on the network design, which wonâ&#x20AC;&#x2122;t be covered in this article. Patch cables, made with stranded copper, are available in varying lengths up to 50-ft. If longer Ethernet cable runs are needed, CAT cable with solid copper conductors is typically purchased in bulk along with RJ45 connectors, and the cables are assembled by the user to the required length. If CAT cable is run in a ceiling, plenum-rated cable is usually required. Many of the connections made in industrial applications use patch cables. Because electrical noise is common in these industrial environments, shielded patch cables with connector shielding should be specified to avoid data loss in transmission and other intermittent problems. Patch cables with an overall metal foil shield covering the wire pairs will reduce electromagnetic interference (EMI) and help eliminate these issues. It is also good design practice to specify different patch cord colors for different applications (Figure 1). For example, blue patch cords for information-only networks, red patch cords for critical control applications, and orange for central office connections. While color guidelines are not required, good labeling practices should be followed at a minimum to assist with network troubleshooting and upgrades. With any CAT5e or CAT6 Ethernet connection, the maximum cable length is 100 meters. If copper is desired for runs over 100 meters, an Ethernet extender or unmanaged switch can be inserted to restore signal quality for another 100 meters. For applications exceeding this distance, fiber optic cable is often used. With fiber optics, the electrical signal in CAT cables is converted to light through

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I nd ustrial E t h e r n e t a managed or unmanaged switch or a media converter, which greatly extends transmission distance. Fiber optic cables have the added advantage of being immune to EMI and noise, even over great distances. Fiber optic cables support either multi-mode or single-mode transmission. Multi-mode cables support distances from 500 m up to 4 Km. Single-mode cables support distances from 10 to 120 Km. Due to their greater range, single-mode cables are typically more expensive than multi-mode. Fiber optic connectors come in three standard varieties: ST, SC or LC. All three connector types are used with both types of fiber optic cables (multi-mode and single-mode). LC connectors are most commonly used in small form pluggable (SFP) transceiver modules. These SFP modules plug into an unmanaged or managed switch to provide long distance communication links when needed, from 500 to 120 Km. ST connectors are most often used for applications from 500 m up to 30 Km, while SC connectors are used from 2 to 30 Km. Ethernet switches Switches are key components of industrial Ethernet networks because they play a big part in monitoring, managing, optimizing and securing communications. It is important to specify an industrial-grade managed or unmanaged switch rather than a commercial- or consumer-grade switch. Industrial-grade switches include a rugged metal housing for electromagnetic protection, and come with a variety of mounting options. A switch capable of handling an extreme industrial temperature range from -40 to 165Â°F or more should be specified. Industrial environments include noisy and sometimes unreliable power that can cause problems with commercial grade switches. Ethernet switches, such as a Stride industrial Ethernet switch from AutomationDirect, include hardware with redundant dual power inputs that include surge and spike protection. The dual inputs reduce downtime if primary power is lost by automatically switching over to the secondary power input. A typical industrial switch has 5 to 16 RJ45 Ethernet ports. As noted, these CAT cable connections limit the segment distance to 100 meters. To extend the communication range, a switch with built-in fiber optic ports can be used. A typical fiber optic switch includes both RJ45 and fiber optic ports. Fiber optic is most often used for the network backbone, while the RJ45 copper ports are used as drops to local Ethernet-enabled devices. Some Ethernet switches have ports that accept optional transceivers to add fiber optic connectivity to the switch. Examples include the Stride small formMarch 2017

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I nd ust r ia l E t h e r n e t factor pluggable (SFP) transceivers, also called mini-GBIC, with LC fiber connectors, which are hot-swappable. Several models of these SFP transceivers are available, with transmission distances ranging from 550m to 120 Km. Traffic filtering, troubleshooting and cybersecurity An unmanaged switch connects several devices and provides basic filtering of the data. It can automatically determine and remember where each Ethernet device is located by its MAC address, and can route messages only through the appropriate port to minimize network loading. Unmanaged switches can also enhance the speed of a 10 Mbps Ethernet device by increasing the transmission rate to 100 Mbps as it passes through the switch to other devices. No user setup is required on unmanaged switches, but users must be careful to watch for loops in their network as a loop can shut down an unmanaged network. Once five or more unmanaged switches are on a network, a managed switch should be considered. Managed switches provide enhanced traffic filtering and troubleshooting tools as compared to unmanaged switches. Multicast filtering (IGMP snooping) is a managed switch feature allowing the switch to learn which multicast data packets should be sent to devices on its ports, freeing up bandwidth. Setting traffic priority (QoS/Cos) is another managed switch function to give specific types of data a higher priority. VLANs allow two networks to be isolated from each other logically even though they may physically coexist. Troubleshooting functions in a managed switch include network statistics, port mirroring and others. Statistics show switch input and output data levels and can help classify and optimize network performance. Port mirroring and Ethernet sniffer software such as Wireshark allow viewing of send and receive data, which is the most effective way to debug network issues. Network cybersecurity is a concern for all industrial plants and there must be several layers of security. A managed switch serves as one of the first layers. Some managed switches include security features, such as port control to disable ports and limit unauthorized access. Port security MAC entries should also be considered to only allow certain devices to transmit across 90

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Managed Ethernet switches are used to create this redundant ring network connecting a variety of PLCs and HMIs.

the switch. IPsec or some other security protocol should be used to encrypt data going to or from the switch. Other security settings can control remote use by disabling access and requiring use of a password to access the switch. When installing an Ethernet network, the connectors, cables and switches must all physically connect properly to create a reliable network. This goes beyond the physical layer to the data link and network layer, where unmanaged and advanced managed switches reside. With the connections made, careful configuration of security is required. Understanding these Ethernet basics can make for a better performing and more secure control system on the factory floor. DW

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T e

Power supply design

measurement tips from

A to Z

To design an efficient, reliable and compliant power supply, be sure to follow these testing and measurement guidelines.

Power supplies are the lifeline behind all electronics and electronic devices – Varun Merchant • Tektronix

and the pressure is on to make them smaller and more efficient year after year. Achieving higher efficiencies and higher power densities while also meeting time to market demands, addressing regulatory requirements and keeping costs under control literally puts the power supply designer in the hot seat. Here, we outline the power supply design process and run through the test requirements at each step along the way. Component manufacturers usually provide designers with detailed datasheets containing the necessary operating characteristics for a good power supply design. In many

Testing an on-board power supply with multiple outputs, requires a DC power supply with multiple isolated channels, such as the Keithley Model 2280S-60-3 shown here. www.designworldonline.com

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T e s t

M e a s u r e m e n t

Power software, such as DPOPWR running on a Tektronix MSO5000B oscilloscope as shown here, automatically performs switching and conduction losses.

cases, component selection could be made on datasheet parameters alone. But increasingly rigid requirements on new designs often require designers to characterize components beyond the standard datasheet parameters. When working with critical power components such as MOSFETs, IGBTs and diodes, select an optimized key parameter. The optimized key parameter could be an on-state, off-state or an AC characteristic. Next, test components across all temperature ranges—well beyond the ideal conditions stated in the data sheet. Finally, test the passive and active components for real world conditions. The next stage in the design cycle is prototyping. It isn’t news that prototypes are prone to failure. Numerous things can go wrong with board routing, solder joints, component placement and hidden parasitics, so proceed with caution. Before powering on, always use a digital multimeter to check for shorts across all the input and output stages. Once that is completed, isolate the lowvoltage analog and digital circuit into as many sub-circuits as possible and power up the prototype board one subcircuit at a time.

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T e s t

"Because efficiency is usually the primary design goal, it’s crucial to minimize any losses that might have been introduced during the design process. Be aware that switching and conduction losses through power switches and magnetics are major contributors to the overall loss of a system, especially for modern highefficiency designs. " Next, isolate the on-board power supply and test the output with and without a load. After that is complete, check if the output voltage and ripple are what is expected. Lastly, use a precision DC power supply to power on individual lowvoltage sub circuits. Don’t just rely on the onboard power supply. If the on-board power supply has multiple outputs, we suggest using a DC power source with multiple isolated channels. For an on-the-spot reality check, use a DC power supply that shows both the programmed settings and the actual measured outputs simultaneously which will help to quickly determine if the DC stages are drawing too much current.

High-voltage AC circuit power-on Now that all of the low-voltage DC circuits are checked out, it’s time to power-on the highvoltage circuits. This is the stage where the prototype will see high voltage for the first time. It’s always a good idea to isolate high-voltage stages from low-voltage stages during the first power-on. We suggest using an AC power source with current limiting. It’s crucial to always start from the lowest AC voltage for the design to help reduce major blowouts, which can occur from bad soldering, poor assembly or PCB design mistakes.

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M e a s u r e m e n t

Assuming no major catastrophe has occurred, measure the AC input voltage and current with appropriately rated differential and current probes. Use a scope or a power analyzer on the AC input with logging enabled before powering on the device for the first time to capture the inrush currents and transients. If the high-voltage power stage checks out, enable the low-voltage control circuit, which will provide a complete picture.

Control circuit debugging Now let’s move on to digital and analog control circuit debugging. This is the stage where the control logic is checked —probably the most important, not to mention, complex part of the design. At this stage, test for proper compensation, voltage, timing and frequency responses. First, verify proper switching frequency, pulse width and duty cycle at different loads. To do this properly, measure the modulation signal at the switching device driver during power-on. Next, check the loop frequency by injecting a frequency sweep signal through a wideband injection transformer in the control loop. Lastly, use a frequency response analyzer to measure the gain and phase of the circuit. After the high-voltage circuits, low-voltage circuits and control logic have been verified, it’s time to check the switching characteristics of the power stage. Start by testing the switching characteristics at no load, nominal load and full load. Always double-check that the turnon, turn-off, duty-cycle and dead-times of all switches (MOSFETS, IGBTs, etc.) are as expected. Also, check the Vgs signals for noise and bumps. This is important because any unintended glitches on this terminal can lead to turn-on and shoot-through. Depending on the topology, also check the dead-time for sync rectifiers or H-bridges. This process will help ensure that there’s no possibility of shoot-through. To guarantee that everything is as expected, verify the timing relationships among gate drivers and other related signals. Because efficiency is usually the primary design goal, it’s crucial to minimize any losses that might have been introduced during the design process. Be aware that switching and conduction losses through power switches and magnetics are major contributors to the overall

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T e s t

M e a s u r e m e n t

A mixed domain oscilloscope such as the Tektronix MDO4000C speeds EMI troubleshooting by showing synchronized time and spectrum traces. loss of a system, especially for modern highefficiency designs. To be safe, we recommend against simply calculating switching and conduction losses based on a datasheet as this can not only be misleading, but also wildly off-base. The reason is that datasheets don’t provide a comprehensive loss profile accounting for operating conditions and circuit parasitics. Make sure to also check the rectifier, switches (MOSFETs, IGBTs, etc.) and magnetics for losses when the circuit is active and loaded. More often than not, magnetics are custom-designed and, just like switching devices, they’re important to test during operation. This process will help to ensure that the magnetics are properly characterized. To measure switching loss on an oscilloscope, multiply voltage by current and take the mean of the resulting power waveform during turn-on or turn-off. The use of power analysis software makes this process easier and more repeatable.

Specification check Now it’s time to determine whether your design meets certain key specifications, such as line and load regulation, ripple, noise, short-circuit protection, transient response and efficiency. For load regulation, it’s best to use a high-precision DMM directly on the input and www.designworldonline.com

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output terminals of the power supply. Then sweep the load from minimum to maximum while keeping the input voltage constant during the test. This is important to ensure consistent results. Be sure to log any changes in output voltage versus load to determine load regulation. Next, move on to line regulation, which can be tested with a similar setup. Output voltage is measured across a constant load, while input AC voltage sweeps from minimum to maximum. This test is especially critical for universal input power supplies. Now check for noise and ripple at full load using a scope that’s optimized for high-resolution measurements or a high-precision graphical sampling multimeter. Although the scope will provide higher bandwidth, the multimeter will give better accuracy. It’s also helpful to log efficiency using a power analyzer while sweeping the input voltage and output load through all the operating conditions. Now that the prototype is up and running, it’s time to see if the design will comply with local power line standards. Most AC-DC power supplies are designed to operate from an AC wall socket. The AC-DC power supplies are also subject to stringent power consumption and power quality standards, such as IEC 62301 standby power and IEC 61000-3-2 current harmonics standards. March 2017

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T e s t

"When measuring low and distorted standby power, be sure to doublecheck the connections as incorrect wiring can lead to significant errors. Make sure to always connect the voltmeter channel on the source side of the current shunt so as not to measure the current through the voltmeter impedance. " Compliance with these standards should be tested early in the design cycle to avoid future headaches. Also, make sure that the power analyzer used for testing current harmonics complies with the IEC 61000-4-7 standard for measurement techniques. When measuring low and distorted standby power, be sure to double-check the connections as incorrect wiring can lead to significant errors. Make sure to always connect the voltmeter channel on the source side of the current shunt so as not to measure the current through the voltmeter impedance.

M e a s u r e m e n t

Fortunately, EMI testing is simple and fast using the latest measurement tools that are more affordable and more capable than in the past. Use a USB-based spectrum analyzer and a pre-defined EMI compliance mask to perform the necessary tests to catch those pesky EMI problems before going to the test house later in the program. To quickly localize sources of EMI, try using a mixed domain oscilloscope (MDO) with a built-in spectrum analyzer and near-field probes. An oscilloscope and a schematic will be able to measure the spectral peaks and deduce root causes. Once the first prototype is thoroughly tested, it’s time to shift into overdrive and go for the next revision. As a sanity check, thoroughly repeat the testing steps. Once everything checks out, it’s time to check reliability. Test the power supply for all input configurations, which is especially important for universal-input power supplies. Next, sweep the load from no load to full load to test the power supply for all conceivable operating conditions. Finally, run a lifetime test using environmental chambers, which check the real-life performance of the design. Following the measurement step design process outlined here will put you well on your way to delivering a highly efficient, reliable and compliant power supply. DW

Tektronix | tek.com

WHAT DO YOU THINK?

EMI and RFI testing Far too often EMI and RFI testing is overlooked in the early design stages due to difficulty and expense. However, this stage should never be ignored as doing so could lead to unpleasant surprises and delays as deadlines loom. Make it a habit to test for EMC issues early in the design cycle. This will help to avoid unnecessary board turns and missed deadlines. www.designworldonline.com

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deep dive into

M12 connectors Learn what the different coding on M12 connectors means and see a round-up of new designs available in the marketplace. Edited by Mary C. Gannon | Senior Editor

M12 connectors are circular connectors with a 12-mm locking thread used for sensors, actuators, Fieldbus and industrial Ethernet, primarily in factory automation applications. They are especially suited to harsh environments where washdown and Image courtesy of Turck USA

corrosion may occur, as they usually come with IP65, IP68 and IP69K ratings.

100

They are available with 3, 4, 5, 8 and 12 pins. While higher pin counts are not planned, other locking styles such as bayonet and push-pull are continuously under development. The M12 family can be found in many applications such as factory automation, measurement and control, communications, food and beverage, transportation, agriculture, robotics and alternative energy. A chief advantage to using M12 connectors DESIGN WORLD

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I n t e r c o n n e c t

The most common types of coding include: • A -coded for sensors, dc power and 1 Gbit Ethernet for Profibus • B-coded C-coded for ac power • D-coded for 100 Mbit Ethernet • X-coded for 10 Gbit Ethernet • S-coded for ac power (will eventually replace C-coded power parts) • T-coded for dc power (will eventually replace A-coded power parts) • A-, B-, D-, and X-coded are most prevalent. This is because the A-, B- and D-coded connectors have been around for a long time and are some of the original M12 connectors. X-coded connectors are becoming more popular for high-speed industrial Ethernet and will eventually replace the A- and D-coded parts for Ethernet applications. A new code, K-coded, is under development for ac power, while a L-coded design will be released soon for Profinet dc power.

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comes in time spent installing wiring systems and maintaining them. This reduces setup time and the need to use electricians or qualified technicians. When it comes to specific applications, users must select the right pin count. For sensors and power applications, 3 and 4 pins are required. Profinet and Ethernet use 4 and 8 pin counts. And Fieldbus, CANbus and DeviceNet primarily use 4 and 5 pin counts. Finally, specify 12 pins for signal requirements. Several styles of coding exist in M12 connectors. This coding prevents incorrect mating on products. In addition, shielding is available in most coded M12 connectors. For example, X-coded connectors are specifically shielded by the design of their coding. March 2017

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2 M12 connectors for intelligent sensing and control applications M12 connectors for industrial I/O and sensing applications support various protocols via A, B and D code options built into the male/female mating connectors, including Fieldbus applications such as Profibus and EtherNetIP. Designed for advanced sensor and actuator applications, several designs are field installable, simplifying on-site installation into automation and control systems; robotics; safety devices; sensors for bar coding, bottling, labeling, packaging, and other intelligent conveying systems; specialty semiconductor equipment; and more. Offered in straight and right angle versions, the IP67/IP68-rated male and female connectors are available with coupling nuts in brass or stainless steel to ensure connectivity in rugged and high-vibration environments. Pin configuration and termination varies from 3, 4, 5 and 8 pins with screw-in termination, and 12 pins with solder termination. They are available with metal and plastic unshielded connectors for cables with OD ranging from 4 to 7.5 mm and rated for voltage up to 250 V, a current rating up to 4 A, and an operating temperature of –25° to 85°C. Chogori Technology Co., Ltd | chogori-tech.com

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Brad M12 Power F-Coded cordsets and receptacles offer current carrying capacity of up to 16.0 A per pin with a blind-mate key design. Developed to meet the growing power requirements of motors, solenoid-operated valves, actuation equipment and 24 Vdc auxiliary power systems in automation control systems, they are also well suited for LED lighting and commercial vehicle applications. The F-Coding mating interface prevents accidental usage with other M12 connectors being used for input, output, signal or industrial network connections. Blind-mate key design also significantly reduces the chance of mis-mating, especially in restricted access locations where visibility is limited. To eliminate the chance of electrical shock, connector pins are recessed in a contact carrier. An enhanced receptacle design more efficiently dissipates heat generated by the higher current-carrying capability while maintaining its compact size. The four-pin M12 connectors accommodate wire sizes up to 14 AWG/2.5 mm2 and are rated for 300 Vac/dc operation with a dielectric withstanding voltage of 1,600 V. Operating temperature range is –20° to 90ºC and an IP67 seal interface makes them ideal for use in harsh and wet industrial environments. The connectors are dust proof and can be temporarily submerged in up to 1 m (3 ft 3.37 in.) of water. Molex | molex.com

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P 4 Space-saving M12 panel feed with PushPull locking mechanism The new space-saving M12 Slim Design

PFT female panel feeds with D and X coding make it easier to connect Fast Ethernet and 10 GBit Ethernet when it comes to confined spaces and compact devices. The M12 PFT Slim Design is compatible with both HARTING M12 PushPull connectors and the standard M12 with the familiar screw fitting. This compatibility gives users the option to continue using existing connections, but also upgrade to new M12 connectors with PushPull locking at the same time — all without having to change the device connection again. The panel feed is exclusively available with a crimp connection that’s easy to assemble in the field, is protected to IP65/67 standard and is suitable for harsh ambient temperatures ranging from -40° to 85°C. The new 360° shield concept provides good protection against EMC interference and the X-coded version delivers the latest transmission rates up to 10 Gbit. HARTING Americas | harting-usa.com

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A supplement of Design World â&#x20AC;˘ March 2017

3Dtechnology

enables conjoined twins to lead separate lives

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How to efficiently

Fast prototyping gets

move from 3D printing

products to market faster

to injection molding

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How to efficiently

move from 3D printing to injection molding

Designers in medical device and health industries can benefit from integrating 3D printing, machining, and injection molding from prototyping to production and even during the post-launch phase of products.

Todd Nelson Proto Labs Inc.

Using industrial 3D printing for rapid prototyping of parts for new medical devices and other products can mean design risk reduction for developers. Rapid prototyping streamlines product development, provides iterations of multiple designs simultaneously, and reduces time to market by quickly validating designs.

On the production side, parts for products ranging from instruments

used in surgery to glucose monitors will frequently be produced using injection molding and CNC machining, depending on the parts. Additionally, med tech developers often face demand volatility and supply chain disruptions, so leveraging on-demand production from a manufacturer can be especially beneficial in reducing a companyâ&#x20AC;&#x2122;s inventory costs and risks, eliminating the need for forecasting, and avoiding, in many cases, minimum order quantities.

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A d d i t i v e

Therefore, engineers and product designers in medical device and health industries can benefit from integrating 3D printing, machining, and injection molding throughout the process, from prototyping to production and even during the post-launch phase of products.

For prototyping, low-volume production A design process that plays to the strengths of 3D printing, machining, and low-volume injection molding can dramatically reduce development time to quickly bring a project from the idea stage to FDA 510(k) premarket submission, and on to verification and validation. 3D printing works well with complex designs and multipart assemblies, and supports customization of medical devices such as prostheses, dental implants, and body parts, including tracheal implants and ribs, legs, joints, and hands. It provides for accurate testing, including tests that digital analysis may miss, making it valuable for early evaluation of new medical parts. Stereolithography (SL), a frequently used additive technology, works for concept modeling and prototypes of thermoplastic-like parts. The SL process can create components that represent production parts with great detail and are useful for testing. Parts made with SL can be used for lenses, monitors, housings, and

microfluidics, such as micropumps, microvalves, and other applications and products that are produced on a submillimeter scale. SL parts can also be used for marketing purposes, to show users in a clinic or hospital how a part will look or work. (Exposure to humidity and ultraviolet light, though, can change the properties and appearance of finished SL parts). Selective laser sintering (SLS), another 3D printing process, uses thermoplastic nylons to produce accurate, tough parts including durable medical prototypes. SLS parts also can be used in production of difficult-tomold components that reduce weight, cut the number of parts in an assembly, and shrink assembly time, while also, in some cases, increasing part performance. Another additive technology—direct metal laser sintering (DMLS)—can produce metal implants, specialized surgical instruments, and components with features, internal geometries or enclosed channels that would be impossible to produce with traditional casting or machining.

www.makepartsfast.com

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M a n u f a c t u r i n g

March 2017

» 3D printing delivers

repeatability and precision in small quantities, but it is not yet conducive for production runs of thousands or millions of components. That’s where injection molding can offer advantages.

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Additive Manufacturing

Âť Rapid machining has a long history of working well for prototyping, small quantities of end-use parts, and high volume production. Whether one uses CNC milling or turning processes, material properties with machined parts are representative of injectionmolded parts.

Beyond these processes, other 3D printing applications include methods such as fused deposition modeling (FDM) and polyjet technology.

After gaining FDA approvals using low-volume injection molding, moving to traditional high-volume molding with better per-part pricing may make sense. Making a successful transition from 3D printing to injection molding means designing a component with moldability in mind early on. That involves implementing design elements that improve part moldability like draft and uniform wall thickness. In addition to mechanical and physical properties, considerations in choosing a material include its resistance to heat, electricity, flammability, and ultraviolet light. Soft, tough, inexpensive materials such as polypropylene and polyethylene are examples of commodity resins while engineering resins range from inexpensive, impact-resistant ABS to very strong, expensive LCP and tough, moderate-cost polycarbonate. Additionally, injection-molded parts of liquid silicone rubber (LSR) are well-suited for medical products because of LSRâ&#x20AC;&#x2122;s thermal, chemical, and electrical resistance. LSR parts are also biocompatible, so they work well for products that have skin contact.

CNC machining

Design considerations

Rapid machining works well for prototyping and for small quantities of end-use parts. Whether using CNC milling or turning processes, material properties with machined parts are representative of injection-molded parts. Plus, high temperature-resistant plastics such as PEEK and PEI (Ultem) work well for sterilization, so parts made of these plastics are regularly used in the medical industry.

Taking the following design considerations into account can improve the moldability of your parts:

Design for moldability early on While 3D printing provides repeatability and precision in small quantities, it is not yet conducive for production runs of thousands or millions of components. Medical device companies designing a product or device to take to market on that scale often require injection-molded components. 110

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Wall thickness: Maintaining consistent wall thickness is perhaps the most important design requirement for ensuring good injection-molded parts. Controlling this aspect helps manage the partâ&#x20AC;&#x2122;s appearance, weight, and strength. Walls that are too thick result in parts with areas that sink, warp, or have internal voids from pockets of air. Coring out parts to eliminate thick walls can help avoid these unsightly distortions. Draft: Adding draft or slope to vertical walls of a part can make it easier to eject from the mold. A rule of thumb is to apply 1 degree of draft per inch of depth in the mold cavity.

3/2/17 11:31 AM

Additive Manufacturing

Stereolithography is one of several additive technologies for concept modeling and prototyping of thermoplastic-like parts. This process can create components that represent production parts with great detail and are useful for testing.

ill M at: C g CNrtin a St

Radii: Using radii or rounded corners can improve the flow of plastic into the mold as well as the part’s integrity. Sharp corners raise the stress on your part and hinder resin flow. Ribbing, gussets, and ramps: Including ribs and supporting gussets can increase the strength of structural parts and help eliminate warp, sink, and voids. Ribs should be 40 to 60% of the thickness of the adjacent wall. Ramps rather than sharp steps can reduce stress in shifts between thicker and thinner wall portions.

Bosses: Designing a thinner wall on a boss or mounting feature that will receive a screw will eliminate sink and voids.

0 5 9

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Finally, incorporating design for manufacturability into your product development process—even before you begin any actual manufacturing—will help facilitate an eventual move into injection molding. Ultimately, what’s really being addressed here is strategic management of your manufacturing supply chain. By integrating all of these methods —3D printing, CNC machining, and injection molding—into your overall development process, you may find clear benefits. Rapid prototyping will reduce your design risk and accelerate your products to market. And on-demand production will reduce demand volatility for those products. n MPF

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M a n u f a c t u r i n g

3Dtechnology

enables conjoined twins to lead separate lives

3D visualization and 3D printing help team of surgeons quickly and successfully separate conjoined twins.

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There’s a 50 million to one chance that triplets will include conjoined twins. There’s a 6% chance that twins of any kind will be joined near the hips.

The surgical team at Driscoll Children’s

Hospital in Corpus Christi, Texas, faced a case of twins conjoined at the hips. Fortunately, the team was able to tap into the expertise of 3D Systems Healthcare, which has created 3D visualizations and 3D-printed surgical models for more than 30 operations involving conjoined twins.

Wide-ranging team of specialists Ximena and Scarlett Hernandez-Torres were born fused from the navel downward with separate lower limbs. The other triplet, Catalina, had a normal birth. The twins shared a colon and half of their uterus on each side. The babies’ kidneys went to the opposite baby’s bladder, so surgeons would have to reroute them to go to the correct organ. Pediatric surgeon Dr. Haroon Patel headed up a team of medical specialists in pediatric surgery, urology, plastic surgery and orthopedics who would take on the case of the Hernandez-Torres twins.

Thanks to the 3D printed models, the surgical team streamlined the operation. “We had allotted 20 hours for the operation and the entire procedure lasted around 12 hours,” says Dr. Hopkins. “I have no doubt that the visualization and models saved us at least several hours of critical operating time.”

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Dr. Haroon Patel holds the physical anatomical model of the conjoined twins, printed with a 3D Systems ProX 800 SLA system.

Dr. Kevin Hopkins, working with his partner, Dr. Vanessa Dimas, was responsible for the extensive plastic surgery required before and after the twins’ surgery. Hopkins also took an expanded role in the case based on his working knowledge of what 3D Systems could offer. Since 2000, Dr. Hopkins had worked with the 3D Systems healthcare team on more than 70 cases, most involving maxillofacial surgery, with a few involving conjoined twins.

Meeting special challenges Planning for the surgery took place over several months, as doctors had to study the shared anatomy to understand how to best separate the infants and then reorient vital organs, skin, bones, muscle and tissue to ensure each girl’s survival following the operation. Once the surgeons had a plan, they passed along CT scan data and information to the 3D Systems healthcare team. 3D Systems took the CT scans of the twins and set about translating them into a 3D digital environment, enhancing the relevant parts of the anatomy, simulating the surgical procedures,

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Additive Manufacturing

and translating the digital models into the physical world in the form of 3D-printed anatomical models.The entire 3D Systems work took two to three weeks. In the case of the HernandezTorres twins, there were some special challenges. “Every case of conjoined twins is unique and there is always significantly abnormal anatomy in these cases,” says Joe Fullerton, Team Lead for Medical Imaging and Modeling at 3D Systems. “In this case, some of the organs were difficult to identify because they were in unexpected locations or shared between the twins.”

The ‘wow’ moment and beyond Once the 3D models and surgical simulation were prepared, a web

meeting was scheduled with all the surgeons involved in the planning and operation. It was revelatory, according to Dr. Hopkins. “There was a ‘wow’ moment when 3D Systems showed the cuts, separated the shared pelvis, and brought the individual pelvises back together,” he says. “The reaction was ‘holy cow, we can do this’! We also saw that Scarlett had one of her kidneys displaced much lower in her pelvis than originally thought, which only became readily apparent when we saw the 3D model.” Shortly after the web meeting, the surgeons received the 3D-printed physical models from 3D Systems, which enabled a greater level of planning and practice. “The physical models were fantastic,” says Dr. Hopkins.

“Unlike a two-dimensional x-ray or 3D visualization, you could hold these models in your hands. They were a great way to show team members exactly where the organs were located, where the cuts would be, and how to position the patient.” The two physical models were produced using a 3D Systems ProX 800 stereolithography (SL) printer. The ProX 800 prints parts that match or exceed the accuracy and resolution of injection-molded parts. The ProX 800 delivers speeds up to four times faster than competitive systems and can accommodate a range of printing materials. Translucent plastic material was used in one of the anatomical models to accurately depict the skeleton with major vasculature and organs involved

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in the separation procedures highlighted in color. The other model was printed in a white plastic material to depict the surface of the skin. “We chose that particular material because it is opaque, which is beneficial for incision planning because it clearly shows the contours of the skin,” says Fullerton. Both models could be cleaned, sterilized and taken into the operating room for live reference during the surgery.

March 2017

The 3D visualization and physical models saved a great amount of time, according to Dr. Hopkins. “We had allotted 20 hours for the operation and the entire procedure lasted around 12 hours,” he says. “I have no doubt that the visualization and models saved us at least several hours of critical operating time.” The operation was deemed a success, with the advance planning cited as a major factor.

3/3/17 9:38 AM

Additive Manufacturing

“If I had to use a cliché, it was like an orchestra,” said Dr. Patel in a statement following the surgery. “Everything just came together seamlessly.”

Changing the odds Following the operation, the twins spent a couple of weeks in intensive care, where they had a relatively routine recovery. They were released in May 2016, around their first birthday. Dr. Patel and Dr. Hopkins continue to check on their progress as they undergo physical therapy. “They are improving all the time,” says Dr. Hopkins. “We expect that both of them will be able to walk and lead a normal life.” Ximena and Scarlett might have come into the world facing incredible odds, but thanks to the work of extraordinary surgeons, medical specialists, hospital staff and 3D technologists, the odds have made a near-miraculous turn in their favor. n MPF

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M a n u f a c t u r i n g

and

Fast prototyping

gets products to market faster

At the Center for Advanced Design (CAD), a product development firm in Minnesota, a team of design engineers specializes in creating complex surface geometry for the plastics industry. The agile team of six handles everything from industrial design concepts and digital sketching to assisting clients with implementation by building production tooling. Their ability to advance projects quickly keeps them busy. “We’ve carved a niche for ourselves designing plastic components for customers in the power sports industry,” Jesse Hahne, partner at CAD, said. “Many of the larger companies we work for are very talented, but they move slower. When deadlines loom, they look to us to get their complex projects back on track.” Smarter prototyping Developing a customer need into a product requires an ability to verify concepts, validate designs and test function fast, a process made more efficient with CAD’s in-house Stratasys F370 3D Printer. “Time is our only product, so it’s all about saving time to get to the next project,” said Hahne. “3D printing prototypes give us the ability to fail fast. We can produce multiple design iterations quickly or change a product design overnight to meet a customer’s deadline. The parts are accurate and the process is dependable.”

Edited by: Leslie Langnau • Managing Editor

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CAD also designed a new mount to hold a GoPro camera on the visor of the helmet. “Typically riders use a suction cup or tape to attach a camera to their helmet, but they don’t want to stick adhesive to a really expensive paint job. So we built a mount right onto the visor of our helmet,” Hahne said. “We 3D printed and tested it three times to determine the optimal position for filming.”

Custom tooling for custom designs

The Stratasys F370 with GrabCAD Print software streamlines the team’s shared workflow and makes CAD even more responsive to fast-moving projects. “The Stratasys F370 prints quite a bit faster and we’re able to process projects quickly,” said Hahne. “We save time with GrabCAD Print and that’s a real cost savings to us.” The team not only benefits from the speed and ease of use, but the ability to use materials that create high-quality parts. “Now we can run ASA and we absolutely love it,” Hahne said. “With ASA we can run 5-slice and print higher-resolution parts, which gives that ‘wow’ factor with our customers. 3D printing intricate housings in 5-slice was almost like an injection molded part when we were done.”

Continuous design improvement The all-in-one capabilities of the Stratasys F370 help CAD continuously improve product designs, like their popular motocross helmet. Feedback on a previous version prompted CAD to make design changes more in line with what riders want – a helmet that can accommodate a neck brace and a camera. “We came up with an interchange system for the helmet to fit a neck brace better,” said Hahne. “We were able to print and test two different concepts before committing to tooling.”

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popular motocross

Not only does 3D printing enable quick product development, the team at CAD 3D prints assembly fixtures for clients that are specific to the new products they design. “Building fixtures out of wood or aluminum using CNC machining was a time-consuming process,” Hahne said. “With the new Stratasys F370, we can 3D print huge fixtures that we weren’t able to print before, or we’d have to glue together. Now we can print 70-90% of what we do without dovetailing.” Features of the Stratasys F370 like its minimal setup, fast-draft mode and auto-calibration ensure less time troubleshooting and more time for the team to tackle the next complex design. n MPF

helmet.”

Stratasys Ltd. | stratasys.com

“The all-in-one capabilities of the Stratasys F370 help CAD continuously improve product designs, like their

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3/2/17 11:26 AM

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Prod uc t World Three-phase ac motors AutomationDirect automationdirect.com The IronHorse line of general purpose three-phase motors now includes the MTRP-series 56HC-frame premium efficiency motors available from 1 to 3 hp. The rolled steel motors are available in 1800 and 3600 RPM models and feature 4:1 constant torque and 10:1 variable torque speed ranges, TEFC frames, cast aluminum end bells and removable mounting bases. MTRP-series motors meet RoHS and Low Voltage Directives, and are CSA and EU approved; available accessories include bases, junction boxes, fans, and fan shrouds.

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Self-clinching steel locknuts PennEngineering pemnet.com PEM Type SL self-clinching steel locknuts integrate a TRI-DENT locking feature to hold mating screws tight over time by providing sufficient torsional resistance to withstand vibration, thermal cycling, and other disruptive forces that could loosen the screws in service. These

Rexroth boschrexroth-us.com/XM This family of programmable logic controllers, XM 12/21/22, integrates the modular IndraControl S20 I/O series into the controller. When combined with the Sercos automation bus, speed and flexibility are added to make one functionally complete and scalable control system. The IndraControl XM platform is easily configured and has real-time data processing capabilities.

prevailing torque locknuts, which meet 3 cycle locking performance to effectively “self-lock” the threads of mating screws, further will allow for the screws to be removed and re-attached repeatedly as needed without compromising the locking threads.

Closed-loop motion control Koco Motion US kocomotionus.com ServoTrack technology provides both dynamic closed loop control for motion control systems, and Torque or Force Control, an integral part of ServoTrack technology. Specifications: • USB Programming Interface • Input Voltage 12 – 48 Vdc • RMS Current 4 Amps • Six (6) Programmable I/O • One (1) Analog Input • Auxiliary Encoder Input • Din Rail Mount • Distributed Motion Control via Serial Communications

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3-Phase monitoring relay with NFC configuration Carlo Gavazzi GavazziOnline.com WE Series Linear Guideway Wide Series Ball Type.

This 3-phase voltage and frequency monitoring relay provides flexibility in compact dimensions and has a range of features in a 22.5mm product width. It provides protection against phase reversal, phase loss and if the phase asymmetry, voltage or frequency measurements are not within the userconfigured settings and/or thresholds.

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4-Channel digital relay output module WAGO wago.us

MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

The 4-Channel Digital Relay Output Module has a compact 12 mm housing, and 750-515 reduces the cost per channel while maximizing space in the control cabinet. The 4-Channel Digital Relay Output module can be used universally with any WAGO PLC or coupler. Further benefits include: • Potential free-- use with multiple voltage potentials (250 vac/30 Vdc) • 2 A per electrically-isolated channel when all four are employed

HG / EG / RG Series Linear Guideways Ball and Roller Type.

• 5 A when used as single channel for high current applications • Onboard indication for ease of trouble shooting

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Prod uc t World Compact captive stepper linear actuators Koco Motion US kocomotionus.com These hybrid linear stepper actuators are available in sizes Nema 8 (21 mm), 11 (28 mm), 14 (35 mm), 17 (43 mm) and 23 (57 mm), and include an anti-rotation feature on the output shaft. These compact stepper linear actuators are available in a range of screw leads (linear travel per motor rev), allowing for higher speed or high resolution. In addition, an integrated Driver/Controller option is available.

Micro clutches Miki Pulley mikipulley-us.com These CYT Clutches are designed for compact precision applications and may be easily mounted to a driven shaft. The CYT Clutches connect and release power by being located between the input shaft and the load. The CTY stator is a bearing mounted type of clutch. CYT Clutches operate well in temperatures from +14°F to +104°F (-10°C to +40°C). They have a speed range up to 3600 RPM.

Coil platform for hazardous locations LISK gwlisk.com MH Coil platform is certified as an appliance, separate from the

Bore sizes range from 6 to 10 mm, with clutch torques ranging from 0.3 to 0.74 ft. lb. (0.4 Nm – 1.0 Nm). The CYT Clutch uses corrosion resistant materials, and is RoHS compliant.

solenoid valve, for more flexibility, global certifications, and more potential solenoid valve choices. The platform was developed specifically for use in areas where combustible gases and dusts may be be present, such as oil and gas drilling, power generation, turbine process control, and specialty actuators. It’s designed for high vibration environments and carries multiple global certifications (with additional certifications available for specialty markets). Manifold designers are specifically requesting the MH Coil because it can be directly mounted to the manifold surface, removing the load from the valve’s core tube – increasing resistance to shock and vibration.

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

Clutch/brakes in piggyback design Force Control Industries forcecontrol.com LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

Posidyne clutch brakes now come in piggyback designs. Special pads cast into the main housings mount an adjustable motor base, letting the motor sit atop the clutch brake. Other components include a gear belt drive from the motor to the input shaft and an enclosed belt drive guard. This design is suitable for applications where an inline arrangement is not possible.

The Posidyne clutch brake can be actuated by air or hydraulic

KA Type Linear Actuator / SAR Ballscrew or belt driven, exible design.

pressure for use in a plant or outside remote applications. The hydraulic actuation package includes a hydraulic pump, solenoid valve, regulators, and a filter. A heat exchanger can be added for additional cooling.

Generation C deep groove ball bearings KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

Schaeffler schaeffler.us FAG Generation C deep groove ball bearings are being upgraded with two new sealing concepts. Less grease loss and better protection against

KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

contamination extend the grease operating life and, thus, the bearing’s operating life. The Z-type dust shield with its labyrinth seal helps to reduce the egress of grease by 20%, and prevents contamination by 30% in comparison with the previous design.

AC Servo Motors.

The ELS lip seal (optional) provides maximum sealing action at low friction and is suitable

for alternating axial loads, such as in wheel bearings in motorcycles. The improved sealing action, without any additional friction loss, is from a lip shape that is perfectly matched to the ring recess. The recesses that have been shifted to the interior of the bearing significantly improve the bearing’s robustness during handling, for example during mounting. Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

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Ad I n dex

SALES

AIGNEP USA ..................................... .37,75 Altra Industrial Motion ....... 21,22,23,24 All Motion ................................................4 Anderson Metals ................................105 Aurora Bearing Company .................. 38 AutomationDirect ................................13 AVX ........................................................37 BellowsTech, LLC ..............................104 Bishop-Wisecarver ..............................62 Bison Gear & Engineering Corp. ........IBC Bodine Electric Company ...................83 C-Flex Bearing Company.....................54 Cadence Inc. ........................................29 Canfield Industries ..............................75 Central Semiconductor Corp ..............81 CGI .........................................................41 Chieftek Precision USA .............95,97,99 Cicoil .................................................... 49 Del-tron Precision, Inc. .......................71 Design-2-Part .....................................121 DieQua ..........................................50,103 Digi-Key Electronics ............................15 Dorner Mfg. Corp. .................................74 Eagle Stainless Tube ..................... .18,19 Eaton Hydraulics ................................ 92 Epson America, Inc. ............................ 48 EZAutomation ........................................1 Fabco-Air ...............................................85 Fotofab ................................................. 90 Galil Motion Control, Inc. .....................72 Harmonic Drive ....................................79 Helical Products Company ..................7 HIWIN Corporation ..............123,125,127 IDEC .......................................................69 IGUS .......................................................16 Imagineering ..........................................3 ITT Enidine Inc. ....................................12

A supplement of Design

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World • March 2017

3Dtechnology

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108 How to efficiently move from 3D printing

Fast prototyping gets products to market faster

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IXYS .......................................................45 J.W. Winco, Inc. ................................... 38 Keller America Inc. .............................. 89 Key Bellevilles Inc. ..............................54 Keystone Electronics Corp. ............... 39 LinMot .................................................. 70 Mach III Clutch Inc. ............................. 34 Master Bond .........................................51 maxon precision motors ................... 96 Memory Protection Devices, Inc. .........5 METCASE ..............................................17 Miki Pulley US ......................................25 Motion Industries / Eaton ...................35 ODU-USA .............................................. 28 OKW USA ...............................................31 OPTO 22 ............................................... 26 PBC Linear ......................................32,33 PHD Inc. ................................................63 PI (Physik Instrumente) LP .............. 80 Prince Manufacturing Corp. ............... 94 Proto Labs ..............................................9 Quantum Devices Inc. .........................51 Rollon Corporation .............................. 53 Rotor Clip ..............................................65 Servometer®.......................................104 SEW-EURODRIVE ..................................BC SIKO Products .....................................101 Smalley Steel Ring Company .............10 Solenoid Solutions, Inc. ..................... 42 ThermOmegaTech ................................55 THK America, Inc. (TOS) .....................IFC Tolomatic, Inc ...................................... 20 Tompkins Industries .......................... 98 TRIM-LOK, Inc........................................61 Turck .....................................................91 US Tsubaki ...........................................102 Visumatics Industrial Products .........43 Whittet-Higgins ....................................27 Zero-Max, Inc. .........................................2

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CS Hyde Company ............... 116 Proto Labs ............................ 106 Renishaw .............................. 115 solidThinking ....................... 117 Tormach ................................ 111

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DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2017 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. Subscriber Services: To order a subscription or change your address, please email: designworld@halldata.com, or visit our web site at www.designworldonline.com DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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