Design World March 2018 by WTWH Media LLC

www.designworldonline.com

March 2018

inside: Motion Control: Thermal time constants and

PMAC servo motor overloads

p. 78

Linear Motion: The differences in X, Y, Z,

linear motion systems

p. 86

Working with

Test & Measurement How to use an oscilloscope

p. 108

single cables

for servomotors page 102

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For years, economists like Alan Beaulieu of the Institute for Trend Research have been telling manufacturing audiences (like the NFPA) that Mexico represents one of the biggest opportunities over the next 15-20 years. The country is ripe for growth and is located in a stable part of the world. There are key manufacturing clusters there already, such as in the automotive industry. And wages look to be steadier that countries like China, which economists worry will continue to fluctuate. Mexico’s coming out party may likely happen next month, as the nation becomes the first-ever Spanish speaking country to be honored as official Partner Country of the Hannover Messe, the world’s largest industrial trade show. At last month’s Hannover press preview, S. E. Rogelio Granguillhome, Ambassador of the United Mexican States, Berlin, spoke to the assembled journalists in English, and explained that his country now has a $1.3 trillion GDP, ranking as the 2nd largest economy in Latin America. “In 2017, our economic growth was 2.2% and the prognosis for 2018 is 2.4%,” he said. “These numbers are considerably higher than Latin America’s growth average. Last year, inflation showed a moderate rate of 6.4% and unemployment was below 4%.” During the current administration of President Peña Nieto, the country has received $163 billion in investment, generating more than 3 million jobs in different economic sectors. Granguillhome said that this is the result of a successful transition of Mexico into an economy with a global network. I was surprised to learn the volume of Mexico’s trade with Germany: $22 billion in 2017. That’s more than its combined trade with the U.K., France and Italy, the EU’s second, third and fourth largest economies. Mexico has also been investing in reforming everything from energy to education. “Thanks to the energy reform in Mexico, $80 billion in investment is being committed by private investors, both foreign and domestic,” said Granguillhome. “The financial reform has allowed that credit to the private sector has increased from 27% to 35% of GDP between 2012 and July 2017. Likewise, our education reform has set a new education model focused on the student.” The days of us thinking of Mexico as a low-cost manufacturing market are over, and the sooner that our leaders realize that our southern neighbor is a competitive industrial hub starting to blossom, the better. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

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Teschler on Topic Too busy?

It may be because of fake work. Back in the dark ages when I was a young engineer, a colleague told me an interesting story. He’d just finished a lengthy project developing a complicated piece of test gear. He happened to visit another division of his company and was shocked to find they’d developed a similar piece of gear – completely unaware they were essentially duplicating what he’d already done. Even worse, the solution they’d come up with was markedly less capable than what my colleague had created. Their whole program had been wasteful and unnecessary. It happened simply because no one had bothered to look at what was transpiring outside a few corridors of an engineering department. I am sure the engineers on the project my colleague discovered would have said that they had worked extremely hard and had put in long hours laboring on that irrelevant piece of test gear. Their efforts are an example of what Gaylan Nielson and Brent

Peterson would call fake work. The two management consultants have encountered situations similar to what my colleague experienced many times. They saw the same patterns so frequently that they wrote a book outlining their observations (Fake Work: Why People Are Working Harder Than Ever But Accomplishing Less, and How to Fix the Problem). A lot of the hazards the two consultants point out will probably sound familiar even to engineers with only a few years of experience. For example, the two warn of managers who claim all tasks are equally important. When all work is treated as equal, fake work is the inevitable outcome, they say. You know you’re in trouble, they explain, when you ask supervisors to help prioritize and they just add tasks to your lists. Or when you ask for priorities, your supervisor gives you the wrong answer because he/she doesn’t actually know which tasks are important. When these things happen, you are probably not going to like the end result. Had the two consultants been aware of the situation with my colleague’s test equipment, they probably would have said the root cause was a group

of managers who were isolationists, egocentric, and who may have been obsessive organizers. The two advise that when employees find themselves reporting to people like this, they should figure out how to avoid falling into the fake-work traps managers set. Nielson and Peterson say a lack of communication is generally a big cause of situations where people follow the wrong schedule, focus on the wrong project, or give a task the wrong amount of effort. The primary cause: Many companies have developed strategies that their workers never hear about. Then all the work that went into strategizing in the first place is fake work because no marching orders resulting from this arduous, complex, and sometimes costly effort get into the hands of employees. And in the case of my colleague, lack of communication also gets the blame when a whole engineering department doesn’t bother to ask whether the project they’re about to embark on in has even been done outside of the 50-ft² area where their desks sit. DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW—LeeTeschler

March 2018 www.designworldonline.com

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Technology Forward International companies get serious about cybersecurity It’s past time the developers of digital technology took cybersecurity problems seriously enough to mount efforts to solve this challenge.

According to the ENISA Threat

Landscape Report, cybersecurity attacks caused damage totaling more than $691 billion worldwide in 2016 alone. For some European countries, the damage was equivalent to 1.6% of their gross domestic product. And in a digital world, the threats to cybersecurity are growing: According to Gartner, 8.4 billion networked devices were in use in 2017 – a 31% increase over 2016. By 2020, the figure is expected to reach 20.4 billion.

A recent report from the Munich Security Conference says that Siemens and eight industry partners signed the first joint charter for greater cybersecurity. Of course, this won’t be enough, but it is a start. Initiated by Siemens, the Charter of Trust calls for binding rules and standards to build trust in cybersecurity and advance digitalization. In addition, the companies Airbus, Allianz, Daimler Group, IBM, NXP, SGS and Deutsche Telekom signed the Charter. Other interested parties included the Canadian foreign minister and G7 representative Chrystia Freeland. Since data have become the new coin of the industrial realm, the only way to maintain the value of data is through protection. “Confidence that the security of data and networked systems is guaranteed is a key element of the digital transformation,” said Siemens President and CEO Joe Kaeser. “That’s why we have to make the digital world more secure and more trustworthy. It’s high time we acted – not just individually but jointly with strong partners who are leaders in their markets. We hope more partners will join us to further strengthen our initiative.”

The Charter discusses 10 action areas in cybersecurity where governments and businesses must both become active. The Charter calls for the highest levels of government and business to be responsable for cybersecurity, instituting a dedicated ministry in governments and a chief information security officer at companies. It also calls for companies to establish mandatory, independent third-party certification for critical infrastructure, especially where dangerous situations can arise, such as with autonomous vehicles or robots that will interact directly with humans during production processes. Designers and engineers can expect that security and data protection functions will have to be preconfigured as a part of technologies. Plus, cybersecurity regulations are to be incorporated into free trade agreements. The question is, will such protections be enough? What else must be done to protect the new coin? DW

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

March 2018 www.designworldonline.com

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Green Engineering Paul J. Heney

• VP, Editorial Director

New fans save energy,

reduce carbon footprint Ziehl-Abegg, a manufacturer of efficient fans and motors, recently replaced the fans that cool the BritNed converter station near Rotterdam in the Netherlands. BritNed is the operator of the high-voltage direct-current (HDVC) subsea power cable connecting the country with the United Kingdom. The new fans help BritNed lower energy consumption and reduce its carbon footprint. BritNed (a joint venture between British National Grid and Dutch TenneT) is responsible for the transport of electricity between the Netherlands to the United Kingdom. The subsea power cable connects the Isle of Grain in Kent with the Maasvlakte in the area of Rotterdam, a distance of 256 kilometers, and has a capacity of 1,000 MW. In order to convert the high-voltage direct-current (HDvc) to the widely used alternating current (ac), converter stations are located at each end of the power cable. These heavy-duty converter stations, of approximately 5 hectares each, are permanently working and produce a significant amount of heat. Reliable cooling is a continuous requirement, but cooling fans running without interruption consume a lot of energy. With the product series ZAplus, Ziehl-Abegg was able to offer several improvements to the existing system. The newly placed cooling fans have Electronically Commutated (EC) motors, which are proven to be highly energy efficient and environmentally friendly. The practical design of the fan allows easy maintenance and improves uptime guarantee. The use of EC-Technology will result in a significant reduction of the energy use and the bionic profile of the blades—inspired by owls—minimizes The new ZAplus fan system uses very noise pollution to the surrounding area. Altogether, the new fans will help BritNed to lower its energy consumption less energy, similar to a full dishwasher or by 450.000 kWh per year and reduces its carbon footprint by 51 washing machine cycle. tons per year. Improved efficiency is not the only benefit that the ZAplus | courtesy of Ziehl-Abegg / Arie Mastenbroek. fans bring to the energy operator. To improve uptime, the fans are equipped with a special service ring which enables easy access for maintenance and repair. The whole cooling unit no longer needs to be turned off for maintenance, so expensive outages will be reduced. Before the replacement, cleaning took two weeks—now it takes one day. The replacement of the 40 fans took place in two batches during planned outages. What’s more, the old cooling fans will actually be recycled. DW

March 2018 www.designworldonline.com

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Contents 3 • 2018

•

vol 13 no 3

•

designworldonline.com

A supplement of Design World March 2018

let software do the

78 _MOTION CONTROL

96 _ELECTRONICS

Thermal time constants and PMAC servo motor overloads

IoT could owe further advances to Power-over-Ethernet cabling

When high intermittent power density is required, using classic RMS calculations and speed-torque performance curves as the sole selection methods may be problematic. That’s because such approaches might cause motor or drive undersizing.

86 _LINEAR MOTION Difference between XY tables and Cartesian and gantry designs

There are many ways to build linear systems for motion in the X, Y, and Z directions — also known as Cartesian coordinates. .

90 _SENSORS Beyond standard sensors

Some less common sensor types can provide a solution to presence or motion sensing needs.

for additive manufacturing

| Courtesy of Kollmorgen

62 Additive manufacturing salaries—experience pays off

COVER_MPF 3-18_Vs1.indd 61

2/28/18 8:36 AM

102 _INTERNET OF THINGS Turning Two into One

Single-cable solutions for servomotors are becoming increasingly popular as they require less connection technology, which leads to quicker installation and overall cost savings.

108 _TEST & MEASUREMENT How to use an oscilloscope: the basics

Oscilloscopes, those stalwarts of electronic design, can be mystifying if you’ve never used one. Getting a good grasp of the basics, like signals and probes, can go a long way toward demystifying their operation.

ON THE COVER IMA Klessman relies on single-cable technology, which combines power and feedback into one cable for the servomotors running its woodworking machinery. | Courtesy of HELUKABEL USA

A | S | B | P|E

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72 3D printing and surgical simulation tackle tough medical challenges

61-77

Updated PoE specs let significant amounts of power flow down networking cables, so much that Ethernet wiring now can double as a power delivery system.

Fostering B2B editorial excellence

70 How HP slashes design cycle time

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DESIGN WORLD

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• contents

departments 04 Insights 06 Teschler on Topic 08 Technology Forward 10 Green Engineering 16 Design For Industry 30 Design Notes 40 Internet of Things

50 CAE Solutions 56 Coupling Notes 114 Product World 120 Ad Index

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CONTENTS 3-18_second page_Vs1.indd 14

March 2018

DESIGN WORLD

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DESIGN WORLD

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DESIGN & PRODUCTION SERVICES

EDITORIAL

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

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics

Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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Medical Design & OUTSOURCING DESIGN WORLD

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March 2018

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Design for Industry Machine tool

Precision and flexibility key features of

cross-roller bearing ball screw linear stages

W When recirculating ball bearings

won’t deliver the needed position stability for a machine tool design, an option is these ball screw linear stages. The ATX series linear positioning stages combine the performance capabilities of a high-precision crossed-roller-bearing positioner with the convenience and simplicity of a ball-screw drive mechanism. Featuring anti-creep crossed-roller bearings and a precision-ground, fine-pitch ball-screw, the ATX series delivers good geometric performance and minimal angular error motion. With up to 250 mm of nominal travel, these linear stages have minimum incremental step size and in-position stability compared to the use of recirculating ball bearings. ATX stages offer an integral center-mounted linear encoder for direct position measurement at the stage’s moving carriage. The typical effects of backlash commonly associated with screw drives are nearly eliminated when using the linear encoder as a position feedback device. Options are available with either incremental (1 Vpp and digital TTL) or absolute output signals. The ATX series is designed with a variety of standard features and options for easier integration into a larger subsystem or machine, or to serve as a stand-alone positioning axis. The units mount to both metric and English optical tables and feature a versatile customer mounting interface on the moving carriage to which other positioning stages or equipment can be mounted. Brushless, slotless servomotors, with or without a holding brake, as well as stepper motors are available. The ATX series can be equipped with an

March 2018 www.designworldonline.com

DFI 3-18_Vs.3.LL.indd 16

optional motor foldback kit to reduce the overall length of the stage. Vacuum- and cleanroomcompatible variants are also offered. Temperature changes and thermal effects are often detrimental sources of error in precision machines, and screw drives are particularly susceptible. All ATX-series stages are available with Aerotech’s ThermoComp feature, an integrated temperature compensation solution that delivers accurate and dependable positioning performance in the presence of thermal disturbances. It protects the stage from the effects of variable-temperature environments and friction-induced self-heating, ultimately providing stability to the user’s process even in extreme industrial environments. DW

Aerotech | www.aerotech.com DESIGN WORLD

2/28/18 11:35 AM

Packaging

20 m, long range laser sensor

In packaging operations, different sensors play vital roles in detecting targets and materials. This family of long distance high resolution photoelectric measuring sensors offers easy configuration and setup. Configuration is done using integrated pushbuttons for teachable set-points.Â Using time-of-flight measurement technology, the sensor is reliable with and tolerant of difficult to target surfaces and materials. The long distance photoelectric measuring sensor (BOD 37M) family meets the demand for precise optical measurement with a sensing range up to 20 meters and a resolution of 1 mm. The universal version has an integrated display that displays the distance in millimeters. The standard version is available in either voltage or current analog output while the universal version has both analog outputs, RS485 and two configurable discrete outputs. DW

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March 2018

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Design for Industry Robotics

Robots double the production of medical devices

Medical device manufacturer Tegra Medical faced profit erosion as costs

went up and customers demanded price cuts. Deploying three collaborative robot arms from Universal Robots to tend the machines manufacturing medical instruments doubled throughput, freed up 11 full time positions and enabled the

Tegra employees can work next to the UR robots without fencing due to the robot’s built-in safety system that causes the robot to stop operating if it could collide with a person.

manufacturer to keep up with customer demand while keeping costs down.

The novel robot cell is working at Tegra Medical’s main production facility In

Franklin, Massachusetts, operating next to employees and producing components for a Meniscal repair device. The robot arm performing the machine tending is a UR10 from Universal Robots. With a reach of 51 in., it picks up blanks from three different hoppers, feeds two of them into two grinders while the third product goes into a lathe where an internal cutting tool creates a bevel edge on the end of a Meniscal repair device. Before Tegra built the UR10 robotic cell, they started out with two smaller cells each tended by a UR5 robot arm, UR10’s “little brother,” featuring the same 4 mils repeatability but with a reach of 33.5 in. The UR5 picks up the blank from the feeder and then moves it between the lathe, the grinder and the conveyor in a cycle that now takes only 10 seconds compared with the 22 seconds it took with manual labor.

March 2018 www.designworldonline.com

DFI 3-18_Vs.3.LL.indd 18

DESIGN WORLD

2/28/18 11:36 AM

The UR robots are classified as collaborative due to a builtin safety system that makes the robot arm automatically stop operating if it encounters objects or people in its route. As an extra safety precaution, Tegra installed safety mats. Once an employee steps onto the mat and into the cell, the robot stops automatically. The robot continues its operation when the operator steps off the mat and hits a prompt. The types of activities Tegra wanted to automate first were the high volume, repetitive motion type processes.

After having gained experience with two smaller robotic cells each with a UR5 robot arm, Tegra decided to take on a more complex application having a UR10 robot handle three parts numbers simultaneously in the same machining cycle. The UR10 picks up blanks from three different hoppers, feeding two of them into two grinders while the third product goes into a lathe where an internal chamfering operation component creates a needle bevel grind on the end of the suture cutter.

DESIGN WORLD

DFI 3-18_Vs.3.LL.indd 19

March 2018

3/1/18 12:46 PM

Design for Industry

Robotics

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Tube bending

Tegra Medical produces components and assemblies for leading edge surgical and interventional companies.

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“Being in the medical industry, we were up against process change controls. We can’t be changing our process without notifying our customers and going through validation activity. But by simply replacing the operator with the robot, we essentially didn’t change the process. We just changed the handling of components in-between the processes. That was a huge win for us,” says Blenkhorn. The robot implementation doubled throughput and freed 11 full time positions. Tegra has repurposed the operators into other processes and operations to keep up with company growth. The modular design of the robot cell offers several benefits. Spare parts are held at the distributor’s facility or at a local UR office where they can be delivered overnight if need be. The larger reach of the UR10 gives Tegra the ability to run multiple machines, having more part numbers manufactured in a given cell. DW

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March 2018

www.designworldonline.com

DESIGN WORLD

2/28/18 11:39 AM

Aerospace/military

3D printing cuts

production tool costs by 40% for aerospace service provider

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Laser machining

3D printed camera case prototype for the Airbus A380, produced on Stratasys’ Fortus 450mc Production 3D Printer in ULTEM 9085 material.

perfection in stainless Eagle has the skills and the technology required to produce all of your custom exotic metal parts. Let us help !

3D printed tool used to install wiring in Airbus A380 camera case, produced using Stratasys’ Fortus 450mc Production 3D Printer.

Faced with lengthy lead-times and costly design iterations, Latécoère, which services aerospace giants including Airbus, Bombardier and Dassault, is using its Stratasys Fortus 450mc Production 3D Printer for both rapid prototyping and production tooling. According to Simon Rieu, Composite and Additive Manufacturing Manager at Latécoère’s R&D and Innovation Center, the adoption of this technology has been transformational for both design and manufacturing. “Additive manufacturing has integrated seamlessly into our design and production process; we’ve seen improved lead-times, reduced costs and enhanced operational efficiency,” he says. “As the requirements of the aerospace industry become more demanding, we’re also mindful of the need to maintain our competitive edge, and Stratasys additive manufacturing enables us to meet that objective.” Traditionally, the company uses CNC machining for rapid prototyping, but this presented limitations. “We recently produced a 3D printed prototype to verify the fit and function of a part for the interior lining of an aircraft door,” explains Rieu. “Previously, this would have been made from sheet metal – an often-time-consuming process. With our Fortus 450mc 3D Printer, we

DESIGN WORLD

DFI 3-18_Vs.3.LL.indd 21

www.designworldonline.com

March 2018

Eagle Stainless

Tube & Fabrication, Inc. Franklin, Massachusetts

Phone (800) 528-8650

www.eagletube.com 21

2/28/18 11:39 AM

Design for Industry Aerospace/military

TL Design

produced a fully functional prototype in two days, reducing our lead times by 95%. Crucially this has accelerated our design validation process before committing to costly and timeconsuming tooling.” Latécoère recently 3D printed a prototype camera case for the Airbus A380 aircraft for design validation with the camera’s internal parts housed inside. Prior to Stratasys FDM 3D additive manufacturing, the team would have had to directly manufacture an aluminum camera case for testing, with any design iterations proving costly. Using ULTEM 9085 material, the 3D printed prototype is also 50% lighter than its metal counterpart. The company is also using its Fortus 450mc 3D Printer for the on-demand manufacture of8:28 custom Worls ad copy.pdf 1 1/25/18 AM

production tools. This has reduced time and cost, and enhanced operator efficiency. “Using metal sheet manufacturing, creating a tool can take up to six weeks. Now we can 3D print a tool in just two days and 50% lighter using ULTEM 9085 material,” says Rieu. “With our 3D printer, we can also optimize the geometry of the tool to perfectly fit the part – making the operator’s job easier. Not only has this accelerated our production process dramatically, but I also estimate that we’ve reduced our tool production costs by 40%.” Latécoère’s long-term strategy is to 3D print final production parts for next generation airplanes from the likes of Airbus, Boeing, and other leading aircraft manufacturers. Indeed, the company has already begun exploring the potential to use its Fortus 450mc to produce final

interior aircraft parts with certification in mind. Using Stratasys’ tough, lightweight and FST compliant ULTEM 9085 material, the team has 3D printed various air duct housing components, which has seen significant weight reductions and time savings compared to traditional production methods. DW

Stratasys | www.stratasys.com

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2/28/18 11:40 AM

Power Review

Altra Industrial Motion Vol. 7 | No. 1 | 2018

The Power Brands in Power Transmission

Featured in this Edition... NEW Market Brochures!

Power Transmission Solutions for the Oil & Gas Market Power Transmission Solutions for Vertical Lift Systems

Find Altra Industrial Motion on:

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

Altra Industrial_#1_3-18.indd 23

The Power Of Experience

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Stromag Svendborg Brakes

TB Woodâ&#x20AC;&#x2122;s Twiflex Warner Electric Warner Linear Wichita Clutch

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

Scan to download the interactive version of the Power Review

2/26/18 2:46 PM

Altra Provides Advanced Power Transmission Solutions for the Oil and Gas Industry A new literature piece, P-8453-C, is now available that highlights advanced power transmission solutions for the Oil & Gas market. Oil and gas market OEMs and end users will find this brochure helpful as Altra provides premier power transmission products that feature extraordinary performance and reliability for long life and outstanding value. Aligned with various applications, this brochure provides specifics on the applications where the products are used as well as the benefits that they will bring. Areas that are highlighted in this brochure are: Offshore E&P, Onshore E&P, Vessels, Vehicles, Compressors and Refineries. Altra provides product solutions that will fit the needs of many applications. Specific products that are used within these types of environments include: Vessels • Winches • OSV, PSV & AHTS Vessels • Propulsion Shafts • FPSO & FLNG Ships • Knuckle Boom Cranes • Diving Support Vessels • Escalators

Onshore E&P • Drawworks • Pump Jacks • Mud Pumps

Offshore E&P • Cranes • Drawworks • Top Drives • Winches

Other Oil & Gas applications where Altra products are used include: Truck-Mounted Hydraulic Fracturing Pumps, Logging/Wireline Trucks, Refineries and Gas Compressors.

For more information about power transmission solutions for oil and gas applications from Altra Industrial Motion including case studies, literature, and service manuals, visit www.AltraOilandGas.com. ONSHORE E&P

www.AltraOilandGas.com

Pump Jacks

Pump Jacks Warner Electric CMS clutches reduce excessive wear by allowing operators to restart pump jack engines without the load after maintenance is completed. Warner SF Series bell housing clutches allow pump jack PTOs to be engaged and disengaged remotely saving time and money.

Warner Electric CMS clutches reduce excessive wear by allowing operators to restart pump jack engines without the load after maintenance is completed. Warner SF Series bell housing clutches allow pump jack PTOs to be engaged and disengaged remotely saving time and money.

Reliable TB Wood’s V-Belt sheaves and belts are commonly found hard at work on pump jacks worldwide. Nuttall custom parallel shaft gearboxes are also utilized on pump jack drivetrains. Guardian Couplings Cast Engine Housings; Couplings Nuttall Gear Custom Parallel Shaft Gearboxes Stromag Couplings TB Wood’s V-Belt Sheaves; Premium V-Belts; Sure-Grip® Bushings Warner Electric CMS Clutch; SF Series Bell Housing Clutch

Drawworks Heavy-duty, reliable Wichita Clutch products are preferred by many major drawworks OEMs. Units are designed to handle the extreme heat typically generated during an e-stop. They provide operational efficiency with less weight, a compact footprint and reduced noise and vibration. Industrial Clutch HC Clutches and Stromag eddy current brakes are also utilized on drawworks applications. Svendborg caliper brakes, and Wichita LI-SSB and AirMakks plate brakes are popular solutions for AC-drawworks emergency stopping, standard parking, and controlled load transfer modes. Nuttall gearboxes are widely utilized on AC drawworks. Couplings from Ameridrives, Stromag, TB Wood’s and Guardian can also be found on all types of drawworks worldwide. Svendborg, Stromag and Wichita Clutch products feature anti-corrosion protection and as an option, can meet API-7K and API-7k SR2 specifications.

Reliable TB Wood’s V-Belt sheaves and belts are commonly found hard at work on pump jacks worldwide. Nuttall custom parallel shaft gearboxes are also utilized on pump jack drivetrains.

Mud Pumps •

Ameridrives Amerigear Gear Couplings Guardian Couplings JF K45 Series Brake Disc Couplings; Shaft Couplings

•

Industrial Clutch HC Clutch Marland Clutch HBG Series Clutches Nuttall Gear Custom Parallel Shaft Gearboxes Stromag Caliper Brakes; Eddy Current Brakes; Brake Discs Svendborg Brakes Hydraulic Disc Brakes; HPUs

Various belted drive solutions including Offset Series MTO sheaves, bushings and belts, as well as couplings from TB Wood’s and Ameridrives are widely used on mud pump drivetrains. Wichita PTOs and SV clutches, along with Stromag limit switches and couplings are also incorporated. Boston Gear Series 2000 helical bevel gear drives and Bauer BG Series geared motors allow for fast and easy installation on mud pump agitators that are used to maintain uniform fluid/solid consistency. Ameridrives Amerigear Gear Couplings

TB Wood’s Form-Flex® Couplings

Bauer Gear Motor BG Series Geared Motors

Wichita Clutch Kopper Kool Spring Set Clutches & Brakes; wcbAM Brakes; LI-SSB Low Inertia Brakes; AirMakks SSB Brakes

Boston Gear Series CCC Centric Centrifugal Overload Clutches; Series 2000 Helical Bevel Gear Drives; 800 Series Reducers;

Guardian Couplings Cast Engine Housings; Couplings

Guardian Couplings Shaft and Flywheel Couplings

Nuttall Gear Custom Parallel Shaft Gearboxes

Marland Clutch CECON Clutches Nuttall Gear Open Gearing Stromag Couplings; Limit Switches TB Wood’s MTO and V-Belt Sheaves; Premium V-Belts; Sure-Grip® Bushings; Dura-Flex®, Sure-Flex Plus®, G-Flex Grid, L-Jaw, and TurboFlex GC Couplings

Stromag Couplings

Wichita Clutch Standard Vent Clutches; Air Power Take-Offs 6

www.AltraOilandGas.com

TB Wood’s V-Belt Sheaves; Premium V-Belts; Sure-Grip® Bushings Warner Electric CMS Clutch; SF Series Bell Housing Clutch

Mud Pumps Various belted drive solutions including Offset Series MTO sheaves, bushings and belts, as well as couplings from TB Wood’s and Ameridrives are widely used on mud pump drivetrains. Wichita PTOs and SV clutches, along with Stromag limit switches and couplings are also incorporated.

• •

Ameridrives Amerigear Gear Couplings

Boston Gear Series CCC Centric Centrifugal Overload Clutches; Series 2000 Helical Bevel Gear Drives; 800 Series Reducers;

Nuttall Gear Open Gearing Stromag Couplings; Limit Switches

Marland Clutch HBG Series Clutches

TB Wood’s MTO and V-Belt Sheaves; Premium V-Belts; Sure-Grip® Bushings; Dura-Flex®, Sure-Flex Plus®, G-Flex Grid, L-Jaw, and TurboFlex GC Couplings

Nuttall Gear Custom Parallel Shaft Gearboxes Stromag Caliper Brakes; Eddy Current Brakes; Brake Discs

Wichita Clutch Kopper Kool Spring Set Clutches & Brakes; wcbAM Brakes; LI-SSB Low Inertia Brakes; AirMakks SSB Brakes

Bauer Gear Motor BG Series Geared Motors

Marland Clutch CECON Clutches

Industrial Clutch HC Clutch

TB Wood’s Form-Flex® Couplings

Ameridrives Amerigear Gear Couplings

Guardian Couplings Shaft and Flywheel Couplings

Guardian Couplings JF K45 Series Brake Disc Couplings; Shaft Couplings

Svendborg Brakes Hydraulic Disc Brakes; HPUs

Boston Gear Series 2000 helical bevel gear drives and Bauer BG Series geared motors allow for fast and easy installation on mud pump agitators that are used to maintain uniform fluid/solid consistency.

Line drawings of oil and gas applications indicate where each product is used. Products used in each application are listed next to their respective brand names.

Wichita Clutch Standard Vent Clutches; Air Power Take-Offs

For more information, download P-8453-C from www.AltraLiterature.com

Altra Industrial_#2_3-18.indd 24

2/26/18 2:47 PM

Altra Provides Advanced Power Transmission Solutions for Vertical Lift Applications Throughout the industry, it is known that Altra provides superior power transmission solutions for vertical lift applications. A new brochure, P-8378-C, is now available that highlights products used for various applications within that market. Altra products are designed and engineered for superior quality. Those used as power transmission solutions for vertical lift systems include: Clutches, Brakes and Actuators (Warner Electric, Twiflex, Stromag, Svendborg Brakes, Warner Linear, Stieber), Couplings (Ameridrives, Bibby Turboflex, Guardian Couplings, Stromag, TB Wood’s), Controls and Sensors (Stromag), Geared Motors and Enclosed Gearing (Boston Gear, Bauer Gear Motor, Nuttall Gear, Delroyd Worm Gear) and Sheaves and Castings (TB Wood’s). Altra provides product solutions that will fit the needs of many applications. Specific products that are used within these types of environments include: Cranes & Hoists • Traveling Overhead Bridge and Monorail Cranes • Jib/Workshop Cranes • Chain and Wire Rope Hoists & Winches • Nuclear Cranes • Gantry/Port Cranes • Flat Top/Luffing Tower Cranes • Truck-Mounted & Crawler Cranes

Theaters and Stage • Podium Scissors Lifts, Winch-Driven Lifts and Ball Screw Lifts • Automated Seating Systems • Rigid Stacking Chain Platform Lifts • Point Hoists • Silent Chain Hoists • Mobile Points Hoists

Elevators & Escalators • Gearless Motor Elevators • Geared Motor Elevators • Escalators Other Vertical Lift applications where Altra products are used include: Shop Lifts, Moveable Bridges and Dam Spillway Gates, Ski Lifts, Amusement Rides and Overhead Doors.

For more information about power transmission solutions for vertical lift applications from Altra Industrial Motion including case studies, literature, and service manuals, visit www.AltraVerticalLiftSystems.com. CRANES & HOISTS

www.AltraCraneandHoist.com

Traveling Overhead Bridge & Monorail Cranes Robust Bauer geared motors are a preferred choice for use on overhead crane trolley drives. Electromagnetic brakes, hydraulic disc caliper brakes, and braking controls from Svendborg, Twiflex, Warner Electric and Stromag are ideal for use in these slow-running, high torque drivetrains that often operate in harsh environments. Guardian motor mounts and L-jaw couplings, along with Ameridrives and Bibby gear couplings, are also found on these cranes. A variety of Stromag limit switches secure loads and protect equipment including the Series 51 that can limit the hook lift of the crane’s hoist for added safety. www.AltraCraneandHoist.com www.AltraCraneandHoist.com

•

• Steel Mill Cranes

•

Altra power transmission components are designed to withstand the harsh conditions in steel and other metal mill environments. Altra brakes couplings clutches, geared motors and belted drives are utilized on all types of mill bridge and monorail cranes including, ladle cranes, charging cranes, rolling area cranes, shipping area cranes, and slab and billet handling cranes.

•

Ameridrives - Amerigear Gear Couplings - Americarden C Series Wing Bearing U-Joints Bibby Turboflex - Series III Gear Couplings

Flat Top/Luffing Tower Cranes Svendborg Brakes and Stromag hydraulic disc caliper brakes along with Stromag electromagnetic brakes provide reliable stopping and holding functionality on tower crane winches and trolleys. Ameridrives and Bibby gear couplings, as well as Guardian couplings and motor mounts are also utilized on these drivetrains. Crane OEMs often incorporate popular Bauer geared motors for enhanced performance and Stromag cam limit switches for added safety.

Warner Electric - ERD/ERDD VAR Electrically Released Brakes - ERD/ERDD Gen2 Electrically Released Brakes TB Wood’s - V-Belt Drives

•

Ameridrives - Amerigear Gear Couplings

TB Wood’s - V-Belt Drives

Guardian Couplings - Curved Jaw Couplings - E Series Mount - G Series Mount Svendborg Brakes - BSFI Series Brakes - SOBO iQ Soft Braking Controls - Hydraulic Power Units Stromag - TDXB Thruster Disc Brakes - SHD Hydraulic Disc Brakes - SDB Drum Brakes - CSH Hydraulic Power Packs - Light Cam® Series Limit Switches - Series 51 Limit Switches - BCS Barrel Couplings - NFF Motor Brakes

Twiflex - MXEA Electric Brakes - VCS Disc Brakes Stieber - DC Clutch - RSCI Series Clutches

Bibby Turboflex - Series III Gear Couplings

Bauer Gear Motor - BF Series Parallel Shaft Geared Motors - BK Series Helical Bevel Geared Motors - BG Series Helical Geared Motors

Bauer Gear Motor - BF Series Parallel Shaft Geared Motors - BK Series Helical Bevel Geared Motors

•

Jib/Workshop Cranes

Chain and Wire Rope Hoists & Winches

Stromag limit switches are utilized to provide added safety on smaller workshop and jib cranes. Svendborg caliper disc brakes and controls along with Bauer geared motors and Altra gear couplings provide years of reliable service on these types of cranes.

BF Series and BK Series geared motors from Bauer are an ideal drive choice for many types of chain and wire rope hoists and winches. Stromag offers several different limit switch options that are ideally suited for these vertical lift applications.

Ameridrives - Amerigear Gear Couplings Bibby Turboflex - Series III Gear Couplings Warner Electric - ERD Electrically Released Brakes - ERC100 Brake - CBCx-001 Switch

Svendborg Brakes - BSFI Series Brakes - SOBO iQ Soft Braking Control - Hydraulic Power Packs

TB Wood’s - V-Belt Drives

Stromag - SHD/SH Hydraulic Disc Brakes - SDB Drum Brakes - NFF Motor Spring-Applied Brakes - TDXB Thruster Disc Brakes - Electromagnetic Disc Brakes - Hydraulic Power Packs - PHS Hydraulic Buffers - Series 51 Limit Switches - LightXcross LX® Limit Switches - Light Cam® & Light Cam® M Limit Switches - Series 410 Spur Geared Cam Limit Switches - Series 62 Spindle Cam Limit Switches - Flexible/Gear Disc Couplings - SIDEOS One Control System - BCS Barrel Couplings - Electrical Units

Bauer Gear Motor - BF Series Parallel Shaft Geared Motors - BK Series Helical Bevel Geared Motors Svendborg Brakes - BSFI Series Brakes - SOBO iQ Soft Braking Controls - Hydraulic Power Packs Stromag - Series 51 Limit Switches - Light Cam® Limit Switches - LightXcross LX® Limit Switches

Ameridrives and Bibby grid couplings along with Stieber overrunning clutches and Warner Electric brakes are also used on these hoist and winch drivetrains. Ameridrives - Amerigear Gear Couplings Bibby Turboflex - Series III Gear Couplings

• •

Warner Electric - ERD Electrically Released Brakes Bauer Gear Motor - BF Series Parallel Shaft Geared Motors - BK Series Helical Bevel Geared Motors Stromag - Series 51 Limit Switches - Light Cam® Limit Switches - Series 100 Spur Geared Cam Limit Switches - Series HGE Limit Switches

•

Stieber - DC Clutch - RSCI Series Clutches

. .www.AltraCraneandHoist.com

.....

www.AltraCraneandHoist.com

• • •

•

• •

•

•• • •

• •

•

Truck-Mounted & Crawler Cranes Stromag motor brakes and limit switches are installed on all types of truck-mounted and tracked mobile cranes. Smart Cam limit switches control boom extension length. Stromag - Motor Brakes - Series 100 Spur Geared Cam Limit Switches - Series 110 Spur Geared Cam Limit Switches - Smart Cam® Limit Switches Warner Electric - ERD Electrically Released Brakes - ERC Caliper Brakes - CBCx-001 Switch

Warner Electric - FBB Series Electrically Released Brake Modules . .www.AltraCraneandHoist.com

Line drawings of vertical lift applications illustrate where each product is used. Products used in each application are listed below their respective brand names.

• Chain and Wire Rope Hoists & Winches BF Series and BK Series geared motors from Bauer are an ideal drive choice for many types of chain and wire rope hoists and winches. Stromag offers several different limit switch options that are ideally suited for these vertical lift applications.

•

Ameridrives and Bibby grid couplings along with Stieber overrunning clutches and Warner Electric brakes are also used on these hoist and winch drivetrains.

• Truck-Mounted & Crawler Cranes Stromag motor brakes and limit switches are installed on all types of truck-mounted and tracked mobile cranes. Smart Cam limit switches control boom extension length. Stromag - Motor Brakes - Series 100 Spur Geared Cam Limit Switches - Series 110 Spur Geared Cam Limit Switches - Smart Cam® Limit Switches Warner Electric - ERD Electrically Released Brakes - ERC Caliper Brakes - CBCx-001 Switch

Ameridrives - Amerigear Gear Couplings Bibby Turboflex - Series III Gear Couplings Warner Electric - ERD Electrically Released Brakes Bauer Gear Motor - BF Series Parallel Shaft Geared Motors - BK Series Helical Bevel Geared Motors Stromag - Series 51 Limit Switches - Light Cam® Limit Switches - Series 100 Spur Geared Cam Limit Switches - Series HGE Limit Switches Stieber - DC Clutch - RSCI Series Clutches

For more information, download P-8378-C from www.AltraLiterature.com

Altra Industrial_#3_3-18.indd 25

2/26/18 2:48 PM

Backstopping Clutches... Instantaneous Action with No Backlash The FORMSPRAG® design concept is one of simplicity and reliability. Held within cylindrical inner and outer races, the sprags drive in one direction and overrun in the other. The gripping action of the sprags transmits torque from one race to the other. They are used in applications from recreation equipment to conveyors to jet engine starters. Three Basic Types. Simple overrunning design for use in standby and compound drives. Indexing design for reciprocating input and uni-directional output. Backstopping or hold back types to prevent reverse drive rotation. Wide Range of Models. High torque in a small package, with a choice of 230 basic configurations. Torque ranges from 2.0 lb. ft. to 700,000 lb. ft. Shaft sizes from .250” to 20”. Quality Design Features. Free-action retainer insures even load distribution. Centrifugal throwout retainer assemblies eliminate rubbing contact and wear. Ultra-hard Formchrome® sprags extend clutch service life. PCE® sprags overcome effects of severe vibrations and high torque overloads. Formsprag is an ISO 9001 certified facility.

For immediate technical information call 800-927-3262 (586-758-5000 outside of U.S.) or contact your local Formsprag distributor.

www.formsprag.com Altra Industrial Motion Ameridrives Bauer Gear Motor Bibby Turboflex Boston Gear Delroyd Worm Gear Formsprag Clutch

Altra Industrial_#4_3-18.indd 26

The Power Of Experience

Guardian Couplings Huco Industrial Clutch Inertia Dynamics Kilian Lamiflex Couplings

Marland Clutch Matrix Nuttall Gear Stieber Stromag Svendborg Brakes

TB Wood’s Twiflex Warner Electric Warner Linear Wichita Clutch

3/2/18 12:25 PM

Design for Industry Aerospace/military

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

Valve takes advantage of paraffin wax to control temperature and flow

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

Self-actuating, thermostatic valve technology helps control temperature and flow in aerospace and defense projects. Currently

NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

-H

NS US

used in the Patriot missile system, Growler aircraft and other applications, this valve technology is effective in extreme hot or cold temperatures. It is useful in hazardous applications because it operates without the need for external power, and changing pressure does not affect function. Specific uses include freeze protection, scald protection, electronics cooling, mixing and diverting fluids, thermal based permissives and others. The valves use phase change technology to manage temperatureâ&#x20AC;&#x2122;s effect on flow. The key is a highly refined paraffin wax that changes from a solid to a liquid, or vice versa, at specific temperatures. The temperature at which this wax changes phases is so repeatable

DESIGN WORLD

DFI 3-18_Vs.3.LL.indd 27

March 2018

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

2/28/18 11:41 AM

Design for Industry material handling

No Kinks No Hose Twisting

Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime cutting the overall cost of hydraulics.

Available In BSPP

and reliable that the ASTM uses it to calibrate temperature instrumentation. ThermOmegaTech incorporates this substance into its Thermoloid material, that allow its valves to open and close. For example, when the Thermoloid material is heated above its melting point it begins to expand and push on the diaphragm, which in turn pushes on a piston. This piston acts as a valve stem, opening or closing a valve. Then, as the Thermoloid material cools below its melting point it compresses and a spring returns the piston and diaphragm to its cold position. Because of the gradual transition from solid to liquid of this Thermoloid material, these valves act more like modulating valves rather than quick opening/closing valves. These direct acting valves are designed to be open when the actuator is in the cold position while reverse acting valves are open in the hot position. DW

Custom Design & Sizes Available

Hydraulic Live Swivels Inline & 90°

Heavy Duty Ball Bearing Design • Rated To 10,000 P.S.I. • Heat Treated • Available In 304 & 440 Stainless Steel • Custom Design & Sizes Available • Rebuildable Ball Bearing Design • Withstands Heavy Side Loads • Superior Quality Alloy Steel • Full Flow — Low Pressure Drop

ThermOmegaTech www.ThermOmegaTech.com Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423 Email: sales@superswivels.com

WHAT DO YOU THINK?

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

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1-763-784-5531 www.SuperSwivels.com DFI 3-18_Vs.3.LL.indd 28

March 2018

www.designworldonline.com

DESIGN WORLD

2/28/18 11:41 AM

DznWrdStudRolerNB6_03HiRes.pdf

1/6/17

11:20 AM

STUDROLLER

...All In Less Space

Ultra High Capacity, Zero Slippage, Lower Cost.

For rapid acceleration and deceleration: • 30~600mm rail lengths • 2~12 mm rollers • 150 million cycle endurance

CMY

Rail

Now Available in All Stainless Steel.

STUDROLLER Load capacity is increased up to 250% over competition’s by greater roller-to-rail contact Number of rollers is 20% to 55% greater than competitions.

NB Corp 3-18-Studroller.indd 29

Raceway

Stainless Steel retainer

Raceway’s depressions track STUDROLLER’s nodules preventing slippage - in any position. (Patent Pending)

2/28/18 11:02 AM

Design Notes Edited by: Mike Santora â&#x20AC;˘ Associate Editor

Linear actuators keep lean manufacturing in line

The standard designs of these Altra Motion actuators provide load capacities from 200 â&#x20AC;&#x201C; 20,000 Newtons and are usually specified for heavy duty applications.

Across the world, linear actuators perform lifting and positioning functions on a host of equipment. Designed for applications where hydraulic and pneumatic cylinders cannot operate, these vital actuators fulfil a variety of tasks, often in hostile environmental conditions. As part of the Altra Industrial Motion Corporation, Warner Linear, a manufacturer in this sector, has implemented lean manufacturing practices to reduce lead times for all orders, including bespoke solutions.

Linear actuators are well suited for the applications where an alternative to

hydraulic or air cylinders is needed, or where hydraulic power sources are not available. As a leading manufacturer, Warner Linear actuators are found in a broad spectrum of applications such as agricultural vehicles, aircraft, construction machines, medical equipment, military vehicles, packaging machines and offshore vessels; in addition to an increasing market for emerging technologies such as wind turbines.

The actuators operate efficiently thanks to an electric motor combined with a

high efficiency gear train, hardened as standard, and a ball screw and ball nut drive.

March 2018 www.designworldonline.com

Design Notes 3-18_Vs4.LL.indd 30

DESIGN WORLD

2/28/18 11:46 AM

Dressed for Success

These components are durable and require little maintenance, which ultimately reduces their life-time costs and improves productivity.

The standard designs have load capacities from 200 –

20,000 Newtons and are usually specified for heavy duty applications. The overall construction of the actuators minimizes any maintenance requirements and provides a reliable component capable of performing in harsh operating conditions.

Linear actuators are well suited for the most demanding

applications where an alternative to hydraulic or air cylinders is needed. This funtionality is achieved by creating seal designs that have enabled all of Warner Linear’s actuators to have an ingress protection rating of IP69K when static and IP66 when dynamic. The lesser known IP69K rating ensures that equipment is suitable for wash down with high pressure, high temperature water.

Many industries are increasingly coming to appreciate

the benefits that electric actuators can bring to a range of applications. Without the need for a hydraulic or pneumatic supply, both installation and maintenance is simpler. Furthermore, additional controls can be easily added to provide wireless operation or increased automation with limit switches and position feedback.

The growing popularity of linear actuators has been reflected

in Altra’s decision to increase the support for these products by providing new production equipment and the development of manufacturing processes, which have helped to further improve efficiency and product reliability. This support has also enabled the implementation of a lean manufacturing process, which has benefitted the entire company and its customers.

HELUKABEL works with customers who require robotic automation to develop pre-assembled cable protection systems for robots and handling systems.

The standard designs provide load capacities from 200

– 20,000 Newtons and are usually specified for heavy duty applications. Batch production has been replaced with one

ROBOFLEX® 2001-C

Linear actuators are well suited for the most demanding applications

TPE-jacketed, highly flexible, control and signal cable specially designed for resisting torsion and bending stresses in industrial robots. Suited for -40°C to +80°C environments.

where an alternative to hydraulic or air cylinders is needed.

DESIGN WORLD

Design Notes 3-18_Vs4.LL.indd 31

March 2018

Robotics

E-NEWS

3/2/18 9:47 AM

Design Notes piece flow, with a manufacturing

improvements in cost, quality

pressures in all industries to keep costs

stream being created for each product

and flexibility and the relentless

low and improve efficiency.

line. Each stream is staffed by a

elimination of waste.

dedicated team and team leader and

the single piece flow means that any

manufacturing approach has already

delays or issues in production can be

transformed the efficiency of the

immediately identified and addressed.

production process. Components can

If issues do occur, emphasis is placed

now be manufactured and shipped in

not just on fixing the problem, but also

as little as four hours. Even the lead

on preventing its reoccurrence.

time for bespoke products, which

have a more complex manufacturing

The teams working on the line have

The introduction of the lean

been trained in root-cause problem

process, has been halved from 30 days

solving techniques and daily meetings

to 15 days.

are used to review the production

performance and the progress of

management principles has brought

ongoing improvement activities.

additional improvements in quality

The emphasis is on continual

and reliability. With ever increasing

Design Notes 3-18_Vs4.LL.indd 32

Furthermore, the adoption of lean

Altra Industrial Motion | www.altramotion.com

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3/2/18 9:48 AM

Power. Performance. Connectivity. Go beyond micro PLC limits! Available in two types of CPU, the IDEC MicroSmart FC6A series offers feature-packed PLCs able to control everything from simple machines to large systems and small-scale manufacturing facilities. The Plus type has two RJ45 Ethernet ports, embedded web server functions and the capability to expand up to 2060 I/O, while the All-in-One type has an embedded serial port and RJ45 Ethernet port capable of expanding up to 520 I/O. Visit us at: http://FC6A.IDEC.com Key Features • WindEDIT App for iOS and Android

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2/28/18 11:02 AM

Design Notes Edited by: Mike Santora • Associate Editor

“Bionic Aircraft” — Initial results in bionic design and 3D printing

Additive made specimens with support structures— Fraunhofer IAPT conducted systematic studies on criteria such as tensile strength, powder consumption as well as removability of support structures and their influence on component surfaces. It also developed approaches to designing new types of support structure, e.g. graded lattice scaffolds or gyroids.

Since September 2016, IT and software provider CENIT has collaborated with nine international industry and research partners in the EU’s “Bionic Aircraft” project, developing new methods and concepts for additive aircraft design and manufacturing. The overarching goal of this research work is to advance resource efficiency. To do this, the primary aim of CENIT’s tasks is to simplify the design process for lightweight bionic structures. Core aspects of CENIT’s approach include an automated design methodology and a tool for direct generation of specific file formats for 3D printing. The project partners have set themselves the goals of slashing the time needed for end-to-end development of bionic components by about 40% and significantly increasing the weight-saving potential of ALM structures. An ambitious endeavor that is producing the first results: To create bionically optimized components, CENIT engineering team is developing a CATIA-based CAD catalogue of parametrically defined bionic features. “This provides an automated toolbox to support the cost- and time-intensive manual interpretation and design of topologically optimized components in CAD,” says Jochen Michael, Senior Consultant at CENIT, in explaining the objective. “The parametrization of features also lets the designers adjust geometries more easily. That gives us an additional efficiency and quality boost during

the design process.” By the end of the Bionic Aircraft project in August 2019, a CAD catalogue containing about 10 to 15 bionic features is expected. “The declared goal of the project is to show how such a catalogue can be implemented in methodological and practical terms. That places the focus on fundamental research. It has to provide a basis for defining how bionic features can be harnessed to guide topological optimization, and what algorithms are best suited to component recognition and allocation of features,” says Michael. With this research, the project partners are breaking new ground – to date, no CAD program contains bionically optimized features. For expertise on the nature, suitability and functionality of the bionic features integrated into CAD, the project is relying on experts from the Fraunhofer Institute for Additive Production Technologies, IAPT. Based on analyses on qualitative characteristics, uses and benefits of topology-based components, they develop the

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For motion control innovation, Solution City never sleeps. To create bionically optimized components, CENIT is developing a CATIAbased CAD catalogue of parametrically defined bionic features. respective bionically optimized features. The aim is to improve the typical behavior of components in everyday use, and to make them as lightweight and stable as possible. An example of how even minor adjustments can achieve a significant effect: The risk of component failure can be significantly reduced if components subject to tension loads are designed with fillets which replicate models found in nature. Thus, such a feature will be included in the CAD catalogue as a parametric model. After programming the first bionic features in CAD, it will be time to tackle the next project milestone: Feature recognition. This is a software tool that analyzes a topologically optimized component and allocates it – if possible, automatically – to a functionally equivalent bionic feature contained in the CAD catalogue. This capability makes feature recognition an important element in the design of bionic ALM components. In addition to bionic design, the work package also involves print preparation (pre-processing) aspects. Here, the main focus is on CAD-based generation of the support structures needed for 3D printing and optimum alignment/ orientation of components prior to printing. To develop the support structures, Fraunhofer IAPT was indespensible. The institute conducted systematic studies on criteria such as tensile strength, powder consumption as well as removability of support structures and their influence on component surfaces. It also developed approaches to designing

new types of support structure, e.g. graded lattice scaffolds or gyroids. Based on the parameters needed to determine the orientation of a component for additive layer manufacturing, CENIT’s experts worked with CATIA to also develop functions for optimal, automated alignment of components, including the required support structures. This type of project work is now focused on supplying the production process not only with geometry data but also with geometry attributes (e.g. external contour, surface quality, etc.) as well as defining printing methodologies. DW

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March 2018

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Design Notes Edited by: Mike Santora â&#x20AC;˘ Associate Editor

Tips on properly specifying gear oil

For gearboxes operating at a given temperature range or operating condition, OEMs use several standards to define the required gear oil type and performance characteristics.

Often, specifying the proper gear oil for an end user is as simple as following an OEM recommendation. This should always be the first step in identifying the proper gear oil to use. But OEMs use several standards to define the desired performance characteristics and the type of oil for a given application, temperature range or operating condition. So how does the engineer make sure a specification is correct? They start with knowing the common industrial gear oil standards. ISO VG Viscosity of a gear oil is one of the most important physical characteristics to be considered. With so many different international standards defining viscosity requirements, the International Standards Organization Viscosity Grade (ISO VG) was developed with input from all international organizations. This ISO system is

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Design Notes used to minimize confusion between equipment manufacturers, end users and lubricant suppliers by standardizing the different viscosity grades of an oil. The ISO VG is defined as the base oil’s viscosity expressed in the unit centistoke (cSt), which is also equal to mm²/s at a standard temperature of 40°C. There is an allowable tolerance of ± 10% of that standard viscosity grade. For example, the viscosity of an ISO VG 460 oil is acceptable at a minimum of 414cSt at 40°C and a maximum of 506cSt at 40°C. ISO viscosity grades can vary from an ISO VG 2 up to ISO VG 3200 and are defined in standard steps in between.

AGMA Specification The latest version of the American Gear Manufacturers Association (AGMA) specification for the lubrication of enclosed gear drives is ANSI/AGMA 9005-F16. This document provides

both end-users and equipment manufacturers lubrication guidelines for open and enclosed gearing. The standard defines several recommended test requirements for various viscosity grades and various oil types. Previous versions of the document used designations for the different viscosity grades (4EP, 5EP, etc.). The current version of the document has standardized on ISO viscosity grades and oil types (i.e. Antiwear/Antiscuff EP, etc.). There are still gearboxes in industry that will specify the use of a 5EP oil. If this is the case, check with a lubricant manufacturer or old versions of the AGMA document to cross to a current viscosity grade and type. In the past, anti-scuff lubricants were referred to as extreme pressure or EP. The latest release of this standard has transitioned away from the generic term of EP and is now referring to these oils as anti-scuff or AS. The FE8 bearing test

has now been added as a requirement to the anti-scuff lubricant table. There has also been an added section on enhanced lubricant characteristics to discuss the importance of temperature performance, enhanced wear protection, foam behavior and efficiency.

CLP Gear Oils The CLP rating is a German oil standard, similar to AGMA specifications, and is defined by DIN 51517-3. This document outlines the minimum physical test requirements to meet the CLP specification. It covers petroleumbased gear lubricants that contain additives to improve rust protection, oxidation resistance and EP protection. Often, a gear manufacturer will specify a CLP oil and an oil type; for example, CLP HC 220, is an ISO VG 220 PAO gear oil that meets CLP specifications.

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Standard Parts. Winco.

• CLP is typically a CLP mineral oil • CLP HC is typically a CLP synthetic (SHC, PAO, POE) oil • CLP PG is typically a CLP polyglycol PAG oil

Hygienic Design

API Specification The API specification is written by the Lubricants Group of the American Petroleum Institute and is developed to assist automotive manufacturers and end users in the proper selection of transmissions, transaxles and axle lubricants. The test requirements are defined by ASTM D7560 and ASTM D7450. While the API designation is primarily focused on automotive products, there still are a few OEMs that will use this for industrial applications. Currently there are only three API designations that are used. These are API GL-4, API GL-5, and API GL MT-1. • API GL-4: Intended for use in applications with spiral bevel gear sets that operate under moderate to severe conditions. • API GL-5: Intended to be used in hypoid gears that are operating under high speeds and shock loading, or under low speed and high-torque conditions. This is defined in ASTM D7450. • API MT-1: Denotes lubricants that are intended for use in non-synchronized manual transmissions. They are specifically designed to perform under the operating conditions and on the components in a manual transmission. This is specifically true for the compatibility of sealing materials. API GL-1, API GL-2, API GL-3, & API GL-6: These four designations are all not currently in use due to the everchanging application and test requirements. They may still be listed by a manufacturer or OEM, but in the situation, they are the API Designation document should be checked to provide a current and accurate lubricant recommendation. DW

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March 2018

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Internet of Things

EtherCAT I/O module monitors and diagnoses alternating voltages to 690 Vac The EL3783 oversampling EtherCAT Terminal is for power monitoring for standard control systems. Conventional automation and power measurement technology are increasingly converging, and with the integration of the EL3783 I/O terminal, high-precision grid analysis is available for a range of power-generating systems. Up to three-phase ac voltage systems up to 690 V can be analyzed simultaneously on six channels and with 20 ksamples/s directly in the PLC. For each of the three phases, the EL3783 EtherCAT Terminal samples voltages up to 400/690 Vrms and currents up to one or five Arms as instantaneous values with 16bit resolution. The six terminal channels are evaluated simultaneously based on the EtherCAT oversampling principle, with a temporal resolution of 50 µs, which is significantly faster than the cycle time of the controller. Using the EtherCAT distributed clocks functionality, it is also possible to measure synchronously (<< 1 µs) with other EtherCAT devices in systems of nearly any size and precisely detect propagating grid faults. Extensive data with relevant details are available in the control system if true RMS and performance calculations

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or complex user-specific algorithms are used to analyze the voltage and current curves. In addition, the EL3783 EtherCAT Terminal achieves 650% of the nominal one-ampere measuring range through automatic current range switching, offering high accuracy with a maximum measurement error of only 0.2% of the full scale value. DW

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Internet of Things A tool to collate and analyze big data The software tool, Improvidus, enables users to create custom solutions for their unique operational challenges. Improvidus allows access to big data analytics, cloud data storage, training, consulting and projects at the click of a button. The tool offers a collection of visualization tools that can be used according to need. Featured online capabilities include: • The Overall Equipment Effectiveness (OEE) Visualization Tool gives a detailed description of equipment availability, production output and deviation information. • The Multi-Metric Pareto Tool and Multi-Metric Pareto Recommendations Tool improve visualization, filtering and drill down for deviation data sets, which guides users and provides recommendations by locating filtering options. • The Event Correlation Tool gives insight into correlating events and time between those events, enabling users to address the root cause of an issue. • The Word Cloud Tool associates word usage with impact to help pinpoint systemic issues.

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NEW Hollow Bore Absolute Encoder The incredibly versatile Model MA58H absolute encoder offers a range of configurations to fit almost any application – especially where your encoder needs to retain absolute position after a power outage. The MA58H offers: Multi-Turn and Single-Turn Resolution SSI and CANopen Communications 58 mm diameter Operating temperature range of -40° C to 85° C Two flexible mounting options IP67 Seal (IP65 on the shaft) Available with bores up to 3/8” or 14 mm

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LASER

PARTS?

Industrial Software Platform helps users take advantage of IoT

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The Asset Performance Management (APM) solution is an integral component of the Industrial Software Platform. Through investments in the cloud, advanced machine learning and augmented reality (AR), coupled with partnerships, this platform helps users take greater advantage of Industrial IoT (IIoT) and Industrie 4.0 opportunities to improve overall business performance. Machine learning and advanced pattern recognition enable users to more accurately predict – and proactively resolve – issues before they impact their business. Duke Energy prevented an estimated $35 million cost from early warning detection of a steam turbine problem. Ascend Performance Materials responds fast to alerts with actionable intelligence, saving an estimated $2 million through avoided plant shutdowns alone. These predictive and prescriptive maintenance capabilities can now be implemented in locations where it previously was not economically feasible. In the chemical industry, BASF is implementing AR to improve asset performance, reliability and use while increasing production efficiency. During maintenance work execution, technicians can now leverage an augmented digital representation of the asset to improve efficiency and safety. The digital asset model captures years of experience and expertise, which empowers the new workforce. The Industrial Software Platform offers solutions across engineering, planning and operations, asset performance, and monitoring and control. DW

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Internet of Things Is your battery ready for the IoT boom? By 2020, there will be 20.4 billion connected “things” according to research firm Gartner. What challenges will this possibility pose for batteries and designers, especially when choosing batteries for IoT devices? The demand for connected devices continues to grow, with B2B spending on Internet of Things (IoT) technologies, apps and solutions expected to reach $267 billion by 2020 at a compound annual growth rate (CAGR) of 20%, according to research by the Boston Consulting Group. As the cost of embedded electronics, sensors and actuators comes down, it is easier to integrate network connectivity and remote control into a wide variety of devices. The home automation market is seeing a large portion of this growth where previously “dumb” devices are now giving homeowners greater lifestyle flexibility and control over energy consumption. Everything from smart energy meters, light bulbs, voice controllers, thermostats, window blinds, CCTV cameras and door-entry systems exchange information with users in the home. Outside the home, wearable medical devices, fitness trackers and smart watches facilitate better patient care. Health data collected by these devices helps physicians better diagnose and treat long-term acute health conditions, which could reduce overall healthcare costs. In the industrial and commercial sector, businesses are increasingly using IoT in track-and-trace applications for parcel inventory-management and to remotely monitor the condition of machinery so that engineers can maintain equipment before it fails, preventing downtime. The sheer variety of IoT applications means that connected devices can have very different power demands. Some devices might have an infrequent power draw, so the standby runtime might be expected to be high, while other devices might require frequent high-power discharge. This can be reflected in the choice of primary, nonrechargeable and secondary, rechargeable batteries as well as a battery that delivers the optimal discharge profile for the application. With wearable devices, battery size is an issue. These devices continue to become smaller and lighter, but they may also need to conform to the body, requiring a slight curve or flexibility in the shape. Here, the battery may need to be redesigned, removing the outer casing so it can fit into a smaller footprint. As a result, designers may need to consider whether to offer a removable, user-replaceable unit or embed the battery entirely. One option for several of these applications is the Thin Cell range of primary lithium manganese dioxide (Li-MnO²) pouch-cell batteries. They operate at a nominal voltage of 3.0 V, and deliver an energy density up to 1294 Wh/l and 400 Wh/kg. This battery was designed to meet the demands of devices that need high bursts of energy, such as those with radio frequency (RF) transmitters. It operates from -20 degrees to +60 degrees C and retains more than 98% of its capacity after a year of storage at room temperature. DW

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News

Gigabit Ethernet compatible connectors High bandwidth, high speed Ethernet is becoming increasingly important in the digital transformation of manufacturing, enabling data intensive applications as part of Industry 4.0 solutions, and allowing safe, high-speed control while simultaneously handing non control-related data. Harting is highlighting the role of Gigabit Ethernet through its portfolio of high-performance connection technology, including support for CC-Link IE, the gigabit industrial Ethernet version of the CC-Link fieldbus. The range of products comprises connectors, device connection technology and network components for all types of electrical contacts. Harting is seeing growing demand for Gigabit Ethernet and for CC-Link IE compliance, with increasing numbers of customers requesting CC-Link IE compatible products. DW CC-Link Partner Association-America http://am.cc-link.org/en/index.html

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Internet of Things For data collection of an IT infrastructure The BIS V Multi-Frequency processor includes USB and TCP/IP communication. This flexible RFID processor can accept Low Frequency (LF), High Frequency (HF) and Ultra High Frequency (UHF) readers and antennae. The processor is for PC and server-based applications where RFID data is collected over an IT infrastructure as opposed to an industrial network. While the BIS V product line can communicate over all major control networks (including Ethernet/IP and Profinet), this PC-based processor completes the line of RFID processors designed for high speed applications. This reader suits those who need to operate over a TCP/IP network, especially for general traceability applications like work in process or pallet ID. DW

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Server based computer The C114 is part of VME PowerPC SBCs based on NXP’s T1/T2 Series QorIQ System-on-Chip (SoC) multi-core processors, with numerous integrated bus, memory, and I/O controllers. Feature include: • Rugged 6U VME single-slot low power SBC • NXP T1/T2 Series QorIQ SoC • T2081 (4 x e6500 Dual-Threaded Cores w Altivec @ 1.4 GHz • T1042 (4 x e5500 Cores) @ 1.8 GHz • Secure Boot and Trust Architecture 2.0 • 4 GB DDR3L with ECC • 256 MB NOR Flash • Up to 64 GB NAND Flash • 512 kB NVRAM (MRAM) • Versatile Board I/O • USB • Serial • CANbus • MIL-STD-1553B • Ethernet • Discrete • One PMC Slot + One PMC/XMC Slot • WWDT, ETR, RTC, temperature sensors • VxWorks, Linux, INTEGRITY support

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Internet of Things

Industrial Ethernet position indicator is flexible in network integration The SIKO AP20 position indicator detects the position of spindle adjustments in machines. It displays the corresponding positional data to the operator and passes it on to the machine control system. The interfaces provide loss-free data communication between the position indicator and the machine control system. The compact system is suitable for flexible manufacturing with production machines such as packing machines, woodworking machines, printing machines and machines for further processing of printed products. Once installed, position indicators provide 100% process reliability. During product and size changeovers, incorrect machine settings and the associated risk of damage to tools or batches with defects can be eliminated consistently with the AP20. In addition to the SIKONET5 and CAN interfaces already on offer, SIKO is extending its AP series position indicators to include the most common industrial EthernetFieldbus interfaces, Profinet, Ethernet/ IP, EtherCAT and Powerlink. Two M12-D coded bus connections for a bus line design protect the cable in star-shaped wiring to the control system. Diagnostic options extend evaluation of the device status and convert position indicators such as the AP20 into intelligent automation systems. The AP20 has dimensions of 48 x 88 x 61mm. It can be installed in the machine in an area roughly the size of a credit card. All SIKO position indicators feature a hollow shaft for easy assembly. The basic configuration of the AP20 comes with a hollow shaft with a diameter of 20 mm. Hollow shaft diameters up to 25.4 mm are also possible without changing the compact dimensions of the product. DW

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SIKO GmbH | www.siko-global.com

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oem pressure transmitters

The series 30X is a high-accuracy, digital OEM pressure transmitter ready for integration into system designs dependent on reliable pressure measurements. These fully compensated instruments provide dual outputs, pressure ranges up to 15,000 PSI, and are available in vented, sealed, and absolute -reference versions. For more information, contact Keller America toll-free 877-253-5537 or email sales@kelleramerica.com.

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CAE Solutions

Simulate designs in real time

Instant fluid simulations in ANSYS Discovery Live provide insight on a flow diffuser of vehicles.

The demand for smarter, faster, smaller and less-expensive products complicates design. Trends like the Internet of Things, smart connected products and additive manufacturing are merging the physical and digital worlds — creating extraordinary product innovation as well as exponentially increasing cost and design complexity across the entire product lifecycle. ANSYS recent release of Discovery Live aims to empower engineers to confidently simulate designs in real time quickly and more economically. Discovery Live is expanding Pervasive Engineering Simulation — enabling engineers to pose what-if questions upfront in the design process before most of the product costs are locked in. It also lets users rapidly explore thousands of design options and receive immediate feedback. Discovery Live’s instant simulation

tightly coupled with direct geometry modeling in a real-time and intuitive design environment delivers interactive exploration and rapid product innovation. Engineers can immediately examine the impact of their design changes, instead of waiting weeks or months to set up, run and analyze prototypes. Discovery Live works together with ANSYS AIM and ANSYS SpaceClaim into one product family. This product family promotes rapid initial concept exploration and 3-D design to detailed and comprehensive validation. Design engineers can collaborate with simulation experts for even more comprehensive and detailed simulation of complex phenomena.

Users of Discovery Live can test more design iterations in a shorter amount of time, and test ideas users would not otherwise have considered.

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March 2018

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CAE Solutions

CAM software includes virtual machining simulation

The hyperMILL 2018.1 CAM software has a range of new features and enhancements including greater blending capabilities, 3D-optimized roughing, global fitting, rotational abilities for CAD electrode applications and virtual machining simulation. It includes an enhancement to the “soft overlap” feature for blending machining marks found between steep and flat areas, or located at the boundaries of rest machining regions. Using this enhanced feature, the milling tool is briefly lifted to blend milling paths into another, preventing visible transitions from being generated, resulting in better surface quality. The 3D-optimized roughing cycle has been enhanced for applications with high feed cutters. The step-over distance can be calculated from the scallop height measured against the high feed cutter geometry. A special tool path movement removes rest material from corners when there is a large step-over. Intelligent cut division and optimized toolpaths enhabce safety for the remaining thin ridges. A new “global fitting” feature can simplify the definition of complex surfaces or patches of surfaces. Many hyperMILL CAM strategies will recognize and follow the ISO u-v orientation of the surface patch.

The “Soft Overlap” function improves surface quality in transition regions.

The “Global Fitting” features lets users create a single face with a defined ISO orientation to prepare for NC programming quickly.

“Rotational Electrode” saves time during milling and eroding by a circular placement of multiple electrode geometries.

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Your Custom Gearbox Solutions are CGI Standard Products.

Advanced Products for Robotics and Automation CGI Motion standard products are designed with customization in mind. We understand most off-the-shelf products or a complete in-house design may not fit your application, so our standard products are designed for functional flexibility. Our team of experts will work with you on selecting the optimal base product and craft a unique solution to help differentiate your product or application. So when you think customization, think standard CGI gearbox assemblies. Connect with us today to explore what CGI Motion can do for you.

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hyperMILL VIRTUAL Machining simulation enables constant real time bi-directional communication between the machine tool controller and a remote hyperMILL VIRTUAL Machining simulation, improving manufacturing workflow. hyperMILL MAXX Machining finishing is one technique that benefits from having a simplified surface definition. hyperCAD-S Electrode automates the construction and manufacturing of electrodes for die-sinking. Users can choose their electrodes from the face to be die-sunk within the component geometry, with no special expertise required. To save time during milling and eroding, hyperCAD-S in hyperMILL 2018.1 include an easy-to-use “rotational electrode” feature that facilitates the circular placement of multiple electrode geometries with different spark gaps on a holder. Developed with Industry 4.0 in mind, an early release of hyperMILL VIRTUAL Machining simulation is available in version 2018.1, which enables constant real time bi-directional communication between the machine tool controller and a remote hyperMILL VIRTUAL Machining simulation, significantly improving manufacturing workflow. Machining operations can be reliably evaluated, checked and optimized before running a job by using process networking and

virtual mapping found in hyperMILL VIRTUAL Machining. The hyperMILL VIRTUAL Machining NC Optimizer can enhance computed NC instructions to optimize available workspace, manage limited axes and select the best approach for asymmetric machine heads. Safety, reliability, speed and process control optimization from CAD/CAM to machine are all improved with hyperMILL VIRTUAL Machining. DW

Open Mind Technologies AG www.openmind-tech.com

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Coupling Notes Edited by: Mike Santora • Associate Editor

How rigid couplings keep industrial applications in the mix

Mixers are one of the most common industrial applications. They feature a motor coupled to a paddle or propeller. While the connection is simple, mixers can be used in chemical, food, paint, adhesive and other industries, complicating coupling selection.

Set screw type stainless steel coupling

connecting a mixer motor to a propeller.

These types of configurations limit coupling selection to a rigid type as most standard

The versatility and flexibility of mixers is what makes them challenging to specify a

coupling for. The motor will be bearing supported while the paddle or propeller will not. servo couplings are not meant to be used without bearing support. There are three styles of rigid coupling – set screw, clamp screw, and flanged – each with different benefits and drawbacks.

Set screw rigid couplings are the most basic and common style. They are well suited

for mixers in all industries due to their sleeve type construction which allows them to support the paddle or propeller without the need for a bearing. Set screw rigid couplings are machined from a solid piece of material and have two, four, or eight set screws. They derive all their holding power as the screw is tightened on the shaft. The amount of torque the coupling transmits is largely dependent on the material of the shaft which must be softer than the material of the screw to allow full impingement. The nature of the set screw is its biggest fault. When installed, it mars the shaft making removal

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difficult. In applications where frequent

Clamp type steel coupling connecting a mixer motor to a

paddle or propeller change-outs are

propeller.

required, a set screw type may not be the best option.

Clamp style rigid couplings are an

improvement over set screw style. They use compressive forces to wrap evenly around the shaft, leading to a more secure connection. Standard variations include one- and two-piece types. Clamp rigid couplings have the advantages of not marring the shaft and of infinite adjustability. Two-piece styles have all the benefits of one-piece while also allowing for in-place servicing, eliminating the need to remove adjacent components when installation or removal is required. Mixer designers benefit from quicker change-overs and less damage to propeller or paddle shafts. The primary drawback to using standard clamp type rigid couplings is the cross cut which is a point of weakness and can over time cause the coupling to fail. While this type of failure is rare, designers who want to use a clamp type coupling and prevent this failure can opt for a three-piece style or no-cross cut.

Flange type rigid couplings function

similarly to set screw type couplings. They are comprised of two independent hubs connected to each other by a series of bolts to join the coupling halves together. Each hub will have one or two set screws to hold the shaft in place. This design is best suited for applications where space is limited and standard rigid coupling benefits are desired. The primary drawback is assembly time which is significantly increased as all bolts must be completely removed to disassemble the coupling. This is the least common style of coupling found in mixers as they are generally more desirable in

DESIGN WORLD

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Coupling Notes applications with space restrictions or large shaft sizes of over 2-in.

Rigid couplings are available in a

variety of materials for mixers including steel, 303 and 316 stainless steel, and aluminum. Steel is the most common and available with a zinc plated or black oxide finish. It is well suited for most industrial applications such as large volume paint mixers. Stainless steel types are used in food and high corrosion chemical mixing applications. The grade

Example of a three-piece style rigid coupling that

of stainless used is largely determined by the corrosiveness of the environment

removes the risk of a cross cut failure present

and regulatory requirements. When using 316 stainless steel it is important

in traditional clamp type rigid couplings.

that hardware is of like material to ensure consistent corrosion resistance. Aluminum is not commonly used, however could be desirable if low inertia

is required.

of equipment in industrial production

Mixers have been an important piece

for many years, however selecting the correct coupling can be challenging. The designer must understand the operating environment, frequency with which the propeller or paddle will be changed, and system requirements to specify the proper coupling. DW

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Design World 2017-18 FPB.pdf

Design-2-Part Show 3-18.indd 60

6/29/17

8:51 AM

2/28/18 11:10 AM

A supplement of Design World March 2018

let software do the for additive manufacturing 64

62 Additive manufacturing salariesâ&#x20AC;&#x201D;experience pays off

COVER_MPF 3-18_Vs1.indd 61

70 How HP slashes design cycle time

72 3D printing and surgical simulation tackle tough medical challenges

2/28/18 8:36 AM

Edit o r ia l L e s l ie La n g n a u • M a n a g i n g E ditor

Additive manufacturing salaries— experience pays off

Additive manufacturing (AM) is being promoted as the beginning of a revolution in manufacturing. The revolution is to make manufacturing digital where everything is connected through a digital thread. Because AM can be connected to the cloud and other forms of “digitalness,” it is being viewed as a natural evolution of manufacturing. Thus, much effort and research is going on to turn what once was a prototyping tool into a production tool. One example, Airbus plans to produce 30 tons of 3D printed parts per month this year.

As companies move down this digital manufacturing path, they seek engineering talent, but from a limited talent

pool. This challenge for companies is good news for engineers with skills in additive manufacturing and 3D printing. According to a 2017 Wohlers Associate report, 97 companies produced and sold 3D printing systems, up from 62 companies in 2015. According to a 2017 Worldwide Additive Manufacturing Salary Survey conducted by Alexander Daniels Global, the AM industry has an unemployment rate close to zero. The expected growth of AM will be higher than the number of professionals entering the field for a number of years. Thus, additive manufacturing is a good field for engineers and aspiring engineers. According to the Alexander Daniels Global report, North America had the largest share of the market in 2016 (40%), followed by Europe (36%) and Asia Pacific (16%). Noted the report, the experience levels break out like this: 27% of professionals have 2 years or less; 42% of professionals have 2 to 5 years, and 18% have 5 to 10 years. The study notes that AM companies across the globe will have a high demand for sales, R&D, materials science, production and service professionals. So what can you expect as far as salary ranges? The report breaks it down like this:

For service engineers in the U.S. (depending on location):

• With 0 to 2 years experience in AM, the minimum salary is about $45,000. The maximum salary is about $63,000. The average is $55,000. • With 2 to 5 years experience, the minimum salary is $60,000; the maximum is $90,000, with $68,000 being the average. 62

• With 5 to 10 years experience, the minimum salary is $70,000; the maximum is $100,000, with $87,000 average. • With 10 to 15 years experience, the minimum salary is $100,000; the maximum is $140,000, and $126,000 is the average. • More than 15 years experience, the minimum salary is $140,000; the maximum is $180,000, and $170,000 is the average. For additive manufacturing sales people:

• With 0 to 2 years experience, the minimum salary is $45,000; the maximum is $67,000, with the average being $58,000. • With 2 to 5 years experience, the minimum salary is $70,000; the maximum is $130,000, with the average being $85,000. • With 5 to 10 years experience, the minimum salary is $90,000; the maximum is $165,000, with an average of $135,000. • With 10 to 15 years experience, the minimum salary is $140,000; the maximum is $220,000, with an average of $192,000. • More than 15 years experience, the minimum salary is $200,000; the maximum is more than $250,000, with an average of $245,000. For R&D and Engineering professionals:

• With 0 to 2 years experience in AM, you can expect a minimum salary of $52,000, a maximum of $73,000, and an average of $62,000.

March 2018 www.designworldonline.com

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DESIGN WORLD

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| istockphoto.com

“As companies move down the digital manufacturing path, they seek engineering talent but from a limited talent pool. This challenge for companies is good news for engineers with skills in additive manufacturing and 3D printing.” • With 2 to 5 years experience, the minimum salary is about $75,000; the maximum is $130,000, and the average is $100,000. • With 5 to 10 years experience, the minimum salary is about $88,000; the maximum is $170,000, and the average is $132,000. • With 10 to 15 years experience, the minimum salary is about $170,000; the maximum is $220,000, and the average is $190,000. • More than 15 years experience, the minimum salary is about $180,000; the maximum is more than $250,000 max, and the average is $210,000. For application and consulting engineers:

• With 0 to 2 years experience, the minimum salary is about $50,000, the maximum is $68,000, and the average is $61,000. • With 2 to 5 years experience, the minimum salary is $70,000; the

DESIGN WORLD

MPF Editorial (Leslie) 3-18_Vs3.LL.indd 63

maximum is $115,000, and the average is $90,000. • With 5 to 10 years experience, the minimum salary is $100,000; the maximum is $145,000, and the average is $130,000. • With 10 to 15 years experience, the minimum salary is $140,000; the maximum is $210,000, and the average is $172,000. • More than 15 years experience, the minimum salary is $200,000; the maximum is more than $250,000, and the average is $216,000.

For AM software engineers,

• With 0 to 2 years experience, the minimum salary is $48,000; the maximum is $75,000, with an average of $60,000. • With 2 to 5 years experience, the minimum salary is $67,000 min; the maximum is $120,000, and an average of $88,000.

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• With 5 to 10 years experience, the minimum salary is $85,000; the maximum is $160,000, and an average of $122,000. • With 10 to 15 years experience, the minimum salary is $140,000; the maximum is $200,000, and an average of $170,000. • More than 15 years experience, the minimum salary is $200,000, the maximum is $250,000, and the average is $220,000. You can get a free copy of the survey at alexanderdanielsglobal.com/the-salary-survey

n MPF

March 2018

2/28/18 12:30 PM

let software do the for additive manufacturing Leslie Langnau Managing Editor

Additive manufacturing offers unique opportunities to save on design costs and get to market fast. But it can be a struggle for the designer to fully take advantage. This situation is changing as CAD companies deliver design software specifically to take advantage of additiveâ&#x20AC;&#x2122;s capabilities.

March 2018 www.makepartsfast.com

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S o f t w a r e

The number of partnerships between

additive developers and Dassault Systèmes’ that were announced at the recent SOLIDWORKS World should convince any designer that CAD companies are taking Additive Manufacturing (AM) seriously.

PTC’s Creo 4.0 lets users create parametrically controlled lattice structures for 3D printers. Designers can create both 2.5D and 3D lattice structures, optimizing the lattice structure even to the point of varing the size and shape of the lattices throughout a design.

DESIGN WORLD

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www.makepartsfast.com

Capabilities you can expect to see include automatically generated design suggestions and the ability to stay within a CAD program while addressing additive design requirements like overhangs, lattice needs, part orientation, and so on. The bottom line is that it is getting easier to design for additive manufacturing. Part of this change in CAD programs is the result of additive successes in the aerospace and automotive industries. But another aspect is the shift to digitalization—the connection of all of the steps of part manufacturing planning and production with a single source of information, or digital thread. Additive manufacturing will play a stronger role in the making of parts because of digitalization. The benefits of a digital strategy, according to developers, is that it will enable part manufacturers to take greater advantage of automation, adopt 3D printing for production, and ultimately expand into new market opportunities and reduce time to delivery. Additive manufacturing / 3D printing is unique in its ability to build parts with complex geometries and less weight. The newer software is often labeled as topology optimization, generative design or algorithm-driven programs. This software has emerged for additive manufacturing as “spearpoint investment areas for every leading provider of engineering modeling and simulation technology,” said Bruce Jenkins of Ora Research. The software will address the concerns of designers on AMs trialand-error methods and the trust issues designers have of AM material properties. Companies developing software to handle additive manufacturing include: Dassault Systems SolidWorks, Catia, and 3Dexperience; Autodesk Inventor and Project Dream-Catcher; Siemens

March 2018

2/28/18 9:19 AM

S o f t w a r e

Recently, 3D Systems announced it is combining 3DXpert with SOLIDWORKS, which will enable SOLIDWORKS users to prepare and optimize designs for plastic and metal additive manufacturing.

The shift to digitalization, where all of the steps of part manufacturing production are connected with a signal source of information (digital thread), gives additive manufacturing an opportunity to play a strong role in manufacturing.

PLM Software’s Solid Edge and NX; and PTC’s Creo versions. Of course, Altair’s SolidThinking Inspire was one of the earliest programs for topology optimization. The newer software takes advantage of algorithms and knowledge gained from FEA, CFD and other analyses. A designer will give these programs parameters to design to, such as load, size dimensions, operation needs (based on collected sensor data), and so on, and the programs form-generating engines deliver organic or unusually shaped objects that meet the design criteria but that a designer may not have considered. Thus, designers will need to become more than problem solvers. These programs require that users know how to formulate a problem; how to ask “what” questions, such as What is the best design option for specific conditions? Designers will need to apply realistic engineering constraints that will guide the software into developing several options.

March 2018 www.makepartsfast.com

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Here’s a look at some of the newer programs available. 3D Systems 3D Systems is combining 3DXpert with SOLIDWORKS, which will enable SOLIDWORKS users to prepare and optimize designs for plastic and metal additive manufacturing. 3DXpert for SOLIDWORKS provides a new layer of tools in a CAD environment to prepare and optimize designs for additive manufacturing. Designers using 3DXpert for SOLIDWORKS will be able to: • Maintain design integrity by working with native CAD solids without converting them into STL, or toggling between several software programs to accomplish all tasks. • Optimize structures with rapid creation of lattice-based structures for lightweighting and applying surface textures. • Ensure quality printed parts by using real-time analysis for best-fit positioning and orientation of the part. DESIGN WORLD

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S o f t w a r e

• Accelerate preparation time by employing automatic features such as tray setup, and estimation of material usage and build time. Altair Altair recently released Inspire 2018 simulation-driven design software. Applied at the beginning of design Inspire simulation-driven design software lets designers: • Rapidly assemble and simulate dynamic mechanical systems to automatically resolve loads on components • Generate weight-efficient design proposals unique to specified conventional or additive manufacturing processes • Simulate the performance of competing design concepts for static loads, normal modes and buckling • Directly export Inspire CAD geometry to 3D printers. • Generate optimized lattice and mixed solid-lattice structures, visualize simulation results in 3D, and export lattice designs in .stl file format for 3D printing • View and interactively assign loads to load cases and import / export design loads in .csv file format with the new Load Cases Table

• Design for additive manufacturing with overhang shape controls to help reduce overhangs to create more self-supporting structures • Automatically optimize the fit of PolyNURBS CAD geometry to generative design results with the new PolyNURBS Fit Tool ANSYS ANSYS offers several tools for simulation-driven additive manufacturing. The design for additive manufacturing tool includes CAD geometry creation, faceted data editing and smoothing tools, latticing, topological optimization, and design validation. Print design will automatically generate support structures for a design. Tools are offered that analyze material, geometry, part orientation and other parameters to determine potential residual stress distortion. These tools will also aid in distortion compensation to correct part geometry, and can help predict build failure before a build. Finally, there’s a tool for in-depth microstructure prediction, which will detail the thermal history during printing, defect generation, melt-pool characteristics and crystal structure.

3DSIM offers exaSIM simulation software for metal additive manufacturing. This software lets designers use simulation rather than trial and error to develop parts suitable for additive manufacturing, particularly laser powder bed fusion.

3DSIM, an ANSYS Company Metal additive manufacturing can be a challenge. The dominant method is to use a laser to melt specific areas of metal powder to adhere together in the proper shape. But, the level of melt must be controlled. The level of melting may be dense or not dense enough. Rapid heating and cooling can introduce stresses into the part that could result in part failure when the part is in use. Most metal additive machine developers are introducing programs that let users view the melting process and tweak to control density levels. One example of such software is from 3DSIM, headquartered in Park City, UT. The company develops simulation software, exaSIM, for metal additive manufacturing, targeting such industries

Siemens NX AM software helps designers plan the build of multiple components for an HP 4200 Multi Jet Fusion 3D printer. The Simcenter 3D will simulate applications as part of Siemens’ end-toend additive manufacturing solution.

DESIGN WORLD

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www.makepartsfast.com

March 2018

2/28/18 9:19 AM

S o f t w a r e

Altair’s recently released Inspire 2018 simulation-driven design software generates optimized lattice and mixed solidlattice structures, visualize simulation results in 3D, and export lattice designs in .stl file format for 3D printing

as aerospace and automotive OEMs, parts manufacturers, metal AM machine producers and leading research labs. The goal of this software is to use simulation rather than trial and error to make suitable parts. The software examines the processes involved in laser powder bed fusion. The software will recommend practical solutions to prevent residual stress and distortion. The AM builds will still be to tolerance, and physical experimentation (especially that involving part failure) is not necessary. STL files can be automatically distortion-compensated to counteract the distortion that occurs during part production. Autodesk Project Dreamcatcher, from Autodesk, is marketed as the next generation of CAD. Dreamcatcher is a generative design system. Designers give the program goals and constraints, including functional requirements, material type, manufacturing method, performance criteria, and cost restrictions. Then the system searches a procedurally synthesized design space to evaluate a number of generated designs that could satisfy the design requirements. The resulting design alternatives are presented back to the designer, along with the performance data of each solution. Designers can evaluate the generated solutions in real time, returning at any point to the problem definition to adjust goals and constraints to generate new

results that fit the refined definition of success. Once the designer selects a final solution, the designer can output the design to fabrication tools or export the resulting geometry for use in other software tools. Dreamcatcher has roots in Autodesk Inventor, a program that delivers professional grade engineering solutions for 3D mechanical design, simulation, tooling creation, and design communication. Autodesk Inventor software is the foundation of the Autodesk solution for product development. The Inventor model is an accurate 3D digital model that helps designers validate the form, fit, and function of a design, minimizing the need to test the design with physical prototypes. Autodesk Inventor includes shape generator tools that work directly inside of Inventor for the optimization and lightweighting of components. Through shape generators, designers specify loads and conditions components will face and provides an optimized design based on target weight reduction and geometry requirements. PTC The additive features of Creo 4.0 deliver a “What you see is what you print” format. Creo 4.0 closes the gap between 3D CAD and 3D printing. Creo addresses the multi-step process of developing a part for additive manufacturing. It’s Additive Manufacturing Extension enables designers to design,

March 2018 www.makepartsfast.com

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optimize, validate, and print all within a single piece of software. Creo 4.0 lets users create parametrically controlled lattice structures, connect directly to 3D Systems and Stratasys printers, and track, validate, and manage print jobs. Designers can create both 2.5D and 3D lattice structures. The lattice data can be fed into Creo Simulate, a structural analysis tool, where designers can optimize the lattice structure, even to the point of being able to vary the size and shape of the lattices throughout your design. A new feature in Creo gives designers the ability to take the existing geometry of a design, add constraints, and optimize the geometry similar to topology optimization programs. Several topology optimization programs return tessellated geometry, which means the geometry may need reverse engineering to rebuild the CAD data. Creo will automatically handle the conversions for the designer. Creo 5 will be introduced in a few months with additional support for metal printers, including the ability to visualize and edit the support structures that go along with metal printing. Siemens Siemens expanded the NX toolset to help designers take advantage of digitalizing the machine shop. The NX software unites the tools for additive manufacturing, computer numerical control (CNC) machining, robotics, and DESIGN WORLD

2/28/18 9:24 AM

S o f t w a r e quality inspection within a single, integrated, end-to-end system. A new module in the software is NX AM for HP Multi Jet Fusion. Certified by HP and powered by Materialise, it prepares print jobs for HP Jet Fusion 4200 3D printers. Additionally, Siemens developed applications for additive manufacturing process simulation in Simcenter 3D. These simulation applications are an integral part within the Siemens’ end-to-end additive manufacturing solution. Powder bed printers remain the most popular option for printing of metal parts and NX 12 has a robust, integrated connection with these printers, enabling users to connect them as a single system. This new module also includes facilities for the creation of support structures as well as for the setup of the build tray, positioning and patterning of parts in the build tray, and a build processor framework for connection to powder bed printers. To manage component weight and improve resource usage, NX 12 helps users develop regular lattice structures as well as random structures within a volume. When combined with Convergent Modeling Technology, users can work directly with facet geometry. Thus, additive manufacturing is still on the cusp of growth. More CAD tools will continue to make it easier to design for additive manufacturing. n MPF

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C a s e

H i s t o r y

The pace of design is always fast, especially so when designing for consumer markets. Here’s how HP

How HP slashes

gets new printer cartridge designs to market faster.

design cycle time

The goal—make parts fast. The challenge, make prototype parts fast with custom materials. This was the goal of engineers at HP Inc.’s New Product Innovation Team based in Corvallis, Oregon. HP Inc. controls the largest share (approximately 36%) of the world’s highly competitive desktop paper printer market notes research firm International Data Corporation (IDC). Canon is second at 23.1%. Thus, the research, development, and design of the next generation of printer models at the $50 billion global technology giant are vital elements to maintain and grow that position. The engineering team develops consumer and business inkjet printers and cartridges. To meet their goal of making parts fast, they turned to Proto Labs for help in reducing design cycle time; the quick-turn supplier could deliver parts within days and in a custom material that HP had created. The team works on products and parts that will be in direct contact with ink. When developing the design, the team prefers prototypes made with materials that match as closely as possible the final shipped products. Because of multiple design iterations, getting prototypes quickly is important. “HP uses exotic engineering resins that we’ve worked with our materials suppliers to develop,” said J.D. Hankins, new product introduction engineer, HP Inc. “The materials give us a high heat deflection for our components, because some parts of the printers do get warm.” These materials include custom versions of thermoplastics such as PET, a glassbuilt PETG, a clear PET, and other plastics and blends.

A variety of parts, such as this frame component, have been produced for HP using Proto Labs rapid prototyping and manufacturing services.

March 2018 www.makepartsfast.com

Case History MPF 2-18 Vs4.LL.indd 70

DESIGN WORLD

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CS Hyde Company

Kapton®

Film, tape, Die-cut parts

Type HN (.0003-.005) Type FN Type VN Type XC Type MT Cirlex® Kapton® (.008”-.125”)

ROLLS SHEETS DIE CUT PARTS WITH OR WITHOUT ADHESIVE

Thanks in part to Proto Labs design for manufacturability capability, HP was able to reduce its design cycle time from six to eight weeks to two weeks or less.

Proto Labs was able to manufacture the parts in the time needed using the custom resins HP provided. Recognizing that injection molding is an art and a science, experienced application engineers and mold technicians at Proto Labs work to control the many process variables involved with using customersupplied materials. To assess these variables, the Proto Labs team reviews a range of items, such as the Material Safety Data Sheet (MSDS), technical data, and mold-processing information to ensure the material sent can be molded using Proto Labs’ processes and would not be harmful to the operators. “That’s huge for us to be able to use these materials in the rapid prototype phase,” Hankins said. “In the past, we could use machined parts, but it’s not the same, not always the same finish.” A variety of parts such as frame components were produced for HP, but because the printer models are still in development stages and designs may change, the next-generation model is under wraps. “Working with Proto Labs was seamless,” said Hankins, “starting with the early stages of uploading a CAD file online to Proto Labs’ quoting system for pricing information and design feedback. “We were able to do it all online and have a quote back within hours,”

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continued Hankins. “We’re normally pushing for three to five days to try to get a quote back from a standard injection molding firm.” The design for manufacturability (DFM) analysis was useful as well. “Looking at mold flow, ejector pin and gate locations, all of that back and forth that usually happens, and other adjustments along the way, was very helpful to the process,” Hankins said. HP has now produced parts for close to 20 different designs with this project alone, plus multiple iterations within some of those designs. “Proto Labs is actually reducing our design cycle times,” Hankins said. “Normally, it takes six to eight weeks or longer to build an injection mold, and then another week or two to develop and process it. Proto Labs reduced that time to two weeks or less.” For now, the prototypes manufactured for HP are “in the development phase,” Hankins said, and are part of a longer product development cycle that can take up to two years or more. Going forward, Hankins expects Proto Labs to continue to play a key supplier role as his team works on “testing printers, testing cartridges, and testing ideas.” n MPF

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3d printing

and surgical simulation tackle tough

medical challenges The use of 3D printed models for surgical planning significantly reduces costs when designing and fitting implants, in addition to saving time during surgery. The overall prognosis is better patient care.

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March 2018 www.makepartsfast.com

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53-year-old woman had been turned down by several hospitals in Germany and beyond due to the complexity of her health issue—she had a large aortic malformation

close to her heart and was suffering from a bulging blood vessel on her neck. She finally approached Prof. Dr. Dorweiler, Head of the Department of Vascular Surgery at University Hospital Mainz, Cardiothoracic and Vascular Surgery Department, for help. Due to his experience with 3D printing to model similar surgeries, Dr. Dorweiler thought he and his team could handle the complex procedure. Surgeons at the University of Mainz Cardiothoracic and Vascular Surgery Department have been using a Stratasys Polyjet 3D printer to transform the hospital’s surgical planning process for life-critical vascular cases.

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Transparent Stratasys 3D printed model of a patient-specific aortic arch, used by the University Hospital Mainz to practice complex endovascular surgeries.

“The practice on the 3D printed model enabled the surgeons to ensure the correct design and fit of the stent implant the first time – significantly reducing time and cost in the operating theatre.”

According to the University hospital, the use of 3D printed models for surgical planning has resulted in a significant reduction in costs when designing and fitting implants, and saving time during surgery, leading to an overall improvement in patient outcomes. As an internationally recognized Center of Excellence for Cardiothoracic and Vascular Surgery, the University Hospital Mainz provides research and patient care in areas related to the heart, thorax and blood vessels in the human body. The hospital treats patients suffering from life-threatening aortic illnesses needing immediate attention and patient-specific surgical treatment. “On average, each vascular-related patient case can have 1000-2000 CT scans, which the surgeons use to analyze and diagnose an illness. This can be ambiguous and time-consuming when the issue is complex,” says Prof. Dr. Dorweiler. “Looking through the CT Scans, it was impossible to clearly visualize the anatomy,” says Prof. Dr. Dorweiler. “So we decided to 3D print a model, and it was then for the first time that it became clear what the origin and magnitude of the problem was. Not only did we

March 2018 www.makepartsfast.com

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use the model to explain our findings to the patient to increase her compliance for the planned 3-step operation, but we even took it into each of the three surgeries as a point of reference during operation, which was crucial to the successful outcome.” To date, treatment of complex aortic illnesses with the endovascular method has been a difficult procedure. Surgeons rely on a monitor to implant a small wiremesh tube (stent) through the arteries to be placed at the affected area of the aorta. In a separate recent case, Prof. Dr. Dorweiler and his team faced this challenge with a complex case of aortic arch aneurysm. Requiring an intricate implant, the team undertook a preoperative simulation of the surgery using a stent prototype and 3D printed aortic arch model of the patient. The practice on the 3D printed model enabled the surgeons to ensure the correct design and fit of the stent implant the first time – significantly reducing time and cost in the operating theatre. “As pointed out in current published studies, there are savings in operating time of 5-45 minutes when using 3D printed models prior to surgery,” says Prof. Dr. Dorweiler. “Research is still DESIGN WORLD

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DW_In

ongoing, but if you take an average surgery time of 2-4 hours, you are looking at time savings of up to 40%. When you are dealing with complex vascular cases every day, these timesavings can be the difference between life and death.” Training future vascular surgeons for success At the forefront of German medical research and development, the Vascular Surgery Department at the University Hospital Mainz has an extensive training facility, in which 3D printing is integral. “We use the Stratasys Eden260VS 3D Printer in our BiomaTicS research platform to produce models of aortic anatomies from real-life cases, so that we can use them to teach future vascular surgeons how to successfully

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perform complex endovascular surgeries,” says Prof. Dr. Dorweiler. “With 3D printed patient-specific aortic models in clear transparent material, the trainees can practice endovascular procedures and learn difficult WireSkills using the accurate replicas of blood vessels. For healthcare, it is crucial that we continue to leverage the capabilities of 3D printing for medical training, education and research for future breakthrough-implementation.” Rene Martin, Business Manager Healthcare EMEA, Stratasys, concludes: “The pioneering use of 3D printing witnessed today underpins why the University Hospital Mainz is at the forefront of German medical research and development. Leveraging high resolution 3D printing, the ability to

replicate patient-specific anatomy is enabling physicians and surgeons to quickly plan, practice and determine lifesaving surgical approaches – not only to improve patient care and outcomes, but also mitigate risk and reduce costs.” n MPF Stratasys Ltd. | www.stratasys.com

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Thermal time constants and

PMAC servo motor overloads When high intermittent power density is required, using classic RMS calculations and speed-torque performance curves as the sole selection methods may be problematic. That’s because such approaches might cause motor or drive undersizing.

Hurley Gill | Senior applications and systems engineer | Kollmorgen

Using classic performance curves with RMS calculations is perfectly acceptable for most servo applications. However, if an application’s intermittent torque is large relative to its motor’s continuous capability for some relative time period, the thermal time constants of the proposed setup need consideration. Tight or enclosed design spaces can exacerbate thermal issues. This article presents visuals for understanding how significant dynamic effects are on servo motor thermal time constants — especially when the application requires an I_ actual > I_continuous for an extended time. Servo motors generate heat due to internal losses, and each motor’s distinct ability to dissipate its internally generated heat determines its rated continuous capacity. Conventional servo motor applications see various velocity demands, with torque requirements that enter and exit the intermittent capability over the defined motion profile. Traditionally, peak currents

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Many factors need attention during machine design planning. Servo motor and drive selection for a given application affects the mechanism’s chance of success for delivering top performance under all conditions — including normal operation, E-stops, and other anticipated events. Where a motor’s torque and current must exceed its continuous capability for an extended time, using a simplified graphical approach (as in Figure B later in this article) can prevent design issues.

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Many applications need torques (and thus currents) above the motor’s continuous capability at the required rpm. exceeding a servo motor’s continuous capability help the motor meet acceleration and deceleration requirements. Motion profiles most often need these peak currents for short periods of time (often in the millisecond range) not exceeding the typical maximum of 4 to 5 seconds available from a drive amplifier. In these routine cases of intermittent-duty operation, it’s usually unnecessary to select a motor with a continuousduty capability that satisfies the application’s peak-torque requirement. Instead we simply: • Use a root mean square (RMS) equation to find the application’s effective continuous torque (Trms) and velocity (Nrms) requirement and then … • Ensure that this equivalent operating requirement falls within the continuous (and thus thermal) capability of the chosen motor chosen … • While verifying that the required peak Torque (Tpk_required) is less than available peak torque (Tpk_available) from the selected motor and drive, at its needed rpm. Special application conditions The expansion of closed-loop motion control technology into unconventional applications often results in conditions that exceed ordinary intermittent-duty operation. However, even conventional applications sometimes present special conditions.

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For example, a design may specify that in the event of an emergency stop (E-stop) all controlled motion must halt before the removal of mains power and within a specific amount of time. For most applications, this isn’t usually an issue … but on large machines with significant kinetic energy, time needed to bring an axis’ motion to a stop can easily exceed the typical maximum 4-to-5 seconds of available peak current from a paired motor-drive combination [Ic(drive) equal to approximately Ic(motor)]. This requirement, though generally not demanding a larger motor, often requires a higher continuous current drive to ensure the needed peak current (Ipk_required) is available during an E-stop deceleration. For large machines, E-stops requirements in the 20 to 40-second time range are somewhat common.

Many pulse width modulation (PWM) drives are designed with foldback overload circuits or an algorithm using the thermal time constant of the copper coil (TCT_coil) — whether the current is folded back to the continuous current of the drive or motor. But to satisfy some of these atypical servo applications, the typically paired motor-drive combination that would otherwise be selected is unsatisfactory.

Servo motor application operating conditions and potential events must be addressed during sizing and selection. Consider some examples: There could be a vertical-axis requirement necessitating a servo motor capable of holding a load greater than its continuous capability for a specific amount of time before engagement of a static brake. (That’s especially relevant as it’s typically undesirable to cycle a static holding brake through engagement and disengagement during normal production cycles.) There could be an axis requirement that necessitates a motion system to handle undesired events in which load becomes stuck or otherwise hindered from movement. Here, the motor must be capable of surviving some peak current for the full duration of the commanded move (even when not properly functioning). DESIGN WORLD

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Whether it’s easy or impossible to replace a motor once it’s installed (in a normal environment, in space or underwater, or in an area exposed to radiation) it’s always best to select a servo motor-drive combination that minimizes the risk of failure due to atypical events or normal operating requirements — as these in turn maximize reliability and safety. Overload and the effect of power losses Depending on the complexity of requirements, many of these applications need torques (and thus currents) above the motor’s continuous capability (Ic or I_rated) at the application’s required rpm (such as Npk or Nrms). Hence, the potential limiting or control of the motor’s power losses must be considered so that the motor can execute the necessary work or specific event — while the motor’s insulation system is protected from thermal overload. Here, the motor’s demanded current (I_actual) is greater than the motor’s continuous rated current (Ic) capability for a significant enough period of time relative to the motor’s overall thermal time constant (TCT_motor), that the TCT_motor becomes dominated by the TCT_coil due to the relative heat transfer rates between the used non-homogeneous materials. For these specific cases or events under evaluation, the previously referenced RMS calculations over a given motion profile are usually invalid, though still calculated to ensure overall product selection requirements; because events needing overload situations can differ greatly from one application to the next. To satisfy applications with potential events or conditions requiring a peak current (I_actual) to deliver a peak torque (Tpk) for a qualified period of time, we also need to determine if the motor’s winding (coil) can sustain the overload current needed without sustaining motor-insulation damage.

Available life of a motor’s insulation (based on its continuous rating) is halved for every 10° C the motor experiences beyond its continuous rating.

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March 2018

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M o t i o n

C o n t r o l

We can estimate the time to rated ultimate temperature (t_ ultimate) of the motor’s coil (winding) from a cold start (ambient) using: t_ultimate = -TCT_coil(mounted) x ln[1(W_loss(rated)/W_loss(actual))] or t_ult. = -TCT_winding x ln[1-(Ic²/I_ actual²)] where W_loss(rated) is substituted with: Ic² or I_rated² and W_loss(actual) with: I_actual²

Figure A — Shown here is the thermal time constant (TCT) effects as I_actual is increased to beyond Ic.

Figure B — Shown here is the thermal time constant (TCT) multiplier for I_actual (from slightly greater than Ic up to 4.5Ic).

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Note that for these conditions I_actual is greater than the motor’s Ic (continuous rated current of the servo motor at low or stall rpm). What’s more, under this condition, actual W_loss will continue to exceed rated values — potentially causing thermal runaway if there’s a delay in power removal.

Formula assumptions Of course, the above substitution (with the appropriate I² for watts in both the numerator and denominator) assumes constant power dissipation with a constant applied [step input] current. That value — due to the actual winding temperature rise from ambient temperature (e.g. Rm(25° C)) to the target temperature based on W_loss(actual) — is incorrect. However, that value offers a conservative approach with Rm(hot) assumed constant (versus solving a dynamic nonlinear differential equation). What’s more, even further manipulation of the formula is required for real-world application of the motor starting from a non-ambient temperature based on an Irms value. However, whether the equation is manipulated or not, the preformed calculations tend to be done at only one or two points when needed. Unfortunately, that means that the substantial effect of actual current (I_actual) exceeding continuous capability (Ic) is often missed. So in this article, we present a plot in Figure A to demonstrate the effects of demanded Watts_loss exceeding the design’s continuous capability. The plot also lets us graphically determine a relative (if not effective) TCT for a specific condition under DESIGN WORLD

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evaluation. That in turn provides a way to overcome design challenges where the ratio: I_actual (under evaluation) / Ic (continuous current) is greater than one and known for the production of the application’s needed torque (T_required). This article also lets us compare effective TCT_motor and TCT_coil(air) under their specific condition using Figure B.

HALF THE SIZE. TWICE THE TORQUE.

Most of today’s servo motors have excellent thermal conductivity between the motor windings, laminations, and frame — especially in motors with epoxy encapsulation. That said, these nonhomogeneous materials still have vastly different heat-transfer capabilities.

However, under the subject condition, the thermal time constant of the motor’s mounted coil (TCT_coil(mounted)) is the dominant factor. In addition, the TCT_coil(air) is likely too conservative to be of reasonable use, as it’s calculated from the magnet wire’s specific mass without any consideration of it being mounted within the motor’s frame. The TCT_coil(mounted) value (henceforth identified as the TCT_winding) represents the first level of materials contact of the thermally nonhomogeneous motor materials — more specifically, at the interfaces between the coil and epoxy and air and laminations. Because I_actual (under evaluation) > Ic, the published TCTs [coil(air), winding (coil mounted), and motor] are no longer constant as when I_actual <= Ic, the thermal time constant under consideration is dynamically changing with the motor’s actual watts loss (W_loss(actual)). For example, when the actual current (under evaluation) is <= Ic, the published TCTs for a given servo motor may have a relative range of TCT_coil(air) = 25_seconds, TCT_ winding = 60_seconds, and TCT_motor = 600_seconds.

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However, when I_actual > Ic the effective TCTs will be significantly reduced from those published as a function: W_ loss(actual) verses W_loss(rated). bodine-electric.com | info @ bodine-electric.com | 7 73.478. 3 515

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For some large machines (such as this one for printing) E-stops of 20_seconds to 40_seconds are often acceptable.

Effects of overload on TCT Figure A shows the significance of I_actual greater than Ic(motor) under a specific condition by the resulting percentage of W_ loss(actual) / W_loss(rated) — both plotted against the calculated thermal time constant (TCT) multiplier. For example, an I_actual = 5xIc requires that the winding dissipate 2,500% (25x) more watts than its rated continuous capability. Figure B lets us graphically determine

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a specific TCT and the time to ultimate temperature for specific situations. This is through application of the graph’s X-axis’ corresponding (TCT) multiplier as a function of needed I_actual against a known TCT — and multiplying that result by five to reach the time to ultimate temperature. To illustrate: Question One: Irrespective of the drive’s

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ability to supply current, can our motor handle 20_seconds of a peak current = 3xIc assuming we begin with an ambient temperature of 25° C? Assuming we’re using the initially proposed motor, the application’s normal operation spurs a TCT_winding = TCT_coil(mounted) = 60_seconds. Answer One: Using Figure B, we simply go to the vertical scale on the left at 3 (3xIc) and move horizontally until we intersect with the curve. Then we read the corresponding X-axis multiplier on the semi-log scale and apply its value to the published TCT_winding. This intersection for 3Ic occurs at about 0.023 on the X-axis log scale ... so at 3Ic, the effective TCT_ winding(3Ic) = 0.023 x 60 = ~1.38_sec.

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Note that 95% of the thermal rise will occur in 3x (thermal time constant) or ~4.14_sec [3x1.38_sec] where 5xTCT = 99.3% of rise or 6.9_sec (the total time to ultimate rated winding temperature). So, for this application, we’ll need to select either a larger motor or a motor with a longer TCT_winding … or change the application requirements. As an aside, if we had used the formula for calculating t_ ultimate = -TCT_winding x ln[1-(Ic/I_actual)²]; t_ ulimate = -60_ sec. x ln [1-(1 /3)²] = 7.06_seconds ... yielding a TCT_winding(3Ic) = 7.06/5 or ~1.41_ seconds. Question Two: Because 3Ic is impossible for 30_seconds with

the target motor of Question One, can we use an Ipk of 2Ic for 20_seconds? Answer Two: Again using Figure B, the intersection for 2Ic

occurs at about 0.057 on the X-axis log scale. Thus, at 2Ic, effective TCT_winding(2Ic) = 0.057 x 60 = ~3.42_sec. Knowing that 5 x TCT = 99.3% of the temperature rise is ~17.1_sec, it is still less than the proposed specification: 20_seconds. So even with this changed specification: 2Ic for 20_seconds, we’ll need to select a larger motor or one with a longer TCT_ winding or again change the specification for the condition under consideration. Note: Smaller multiples of Ic will present a less physically dominant TCT_winding over the motor’s overall thermal time constant (TCT_motor). Where I_actual/Ic approaches unity (1), the motor’s other thermally nonhomogeneous materials (as of the aluminum housing, for example) come into play.

In conclusion, this article illustrates the severity of the I_actual/ Ic overload conditions. Where I_actual/Ic is high, one can fairly accurately estimate TCT_winding(new) or the time to ultimate temperature due to the inability of nonhomogeneous materials to transfer heat quickly enough to maintain TCT_motor dominance. However, as the ratio: I_actual/Ic approaches one, the thermodynamic response engages two exponential functions — each with its own time resulting constant (of TCT_winding and TCT_motor). This blending of vastly different thermal time constants due to the nonhomogeneous materials is beyond the scope of this article (and often necessitates further evaluation and understanding). DW

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Difference between XY tables and Cartesian and gantry designs There are many ways to build linear systems for motion in the X, Y, and Z directions — also known as Cartesian coordinates.

Industry terms for these multi-axis linear systems depend on how the axes are assembled, where the load is positioned, and (to some extent) the application for which the systems are designed. In many industrial applications, Cartesian and gantry-style robots are prevalent ... but in precision applications, XY tables are often the better choice because they have a compact and rigid structure — and very high travel and positioning accuracies as well. Cartesian systems and robots Cartesian systems consist of two or three axes for X-Y, X-Z, or X-Y-Z setups. They often incorporate an end effector with a rotational component for orienting the load or workpiece … and always provide linear motion in at least two of the three Cartesian coordinates. Where Cartesian systems are used, the load is usually cantilevered from the outermost axis — Y or Z. For example, in an X-Y setup the load is mounted to the Y axis — either to the end of the axis or at a distance from the axis to creating a moment arm on the Y axis. This can limit load capacity, particularly when the outermost axis has a very long stroke (and

creating a large moment on the lower supporting axes). Cartesian systems are suitable for myriad applications with maximum strokes on each axis typically one meter or less. The most common of these applications include pick-and-place, dispensing, and assembly.

Gantry systems and robots To address the issue of outer axes causing a moment load on the inner axes, gantry systems use two X axes or (in some cases) two Y and two Z axes. Gantries almost always have three axes … X, Y and Z. The load on a gantry system is located within the gantry’s footprint and the gantry is mounted

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Aerotech’s PRO series industrial linear motor and ballscrew positioning stages come in multiple versions. Noncontact linear encoders enable minimum incremental motion to 5 nm and sub-mm repeatability. Optional HALAR factory calibration improves positioning accuracy to ±0.75 µm. Travel is 50 to 1,500 mm for standard models to 2 m/sec.

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This is an example of a simple application-specific (dispensing) Cartesian robot from machine builder Dispense Works Inc. It reaches 36 x 20 in. with preloaded leadscrews, ball slides, and brushless servomotors and a ground machine bed surface for reliability in fixturing and tooling. Parts remain stationary while a dispense head moves overhead on a gantry. Users can use preprogrammed moves or import patterns from CAD files.

over the working area. But for parts that cannot be handled from above, gantries can be configured to work from below. Gantry systems are suitable in applications with long strokes (greater than one meter) and can transport very heavy payloads that are unsuitable for a cantilevered design. One of the most common uses for gantry systems is overhead transport, such as moving large automotive components from one station to another in an assembly operation. XY tables: Industry classifications XY tables are similar to XY Cartesian systems in that they have two axes (X and Y as their name implies) mounted on top of each other â&#x20AC;&#x201D; and typically have strokes of one meter or less. But the key difference between XY Cartesian systems and XY tables lies in how the load is positioned.

Instead of being cantilevered, as in a Cartesian system, the load on an XY table is almost always centered on the Y axis, with no significant moment created on the Y axis by the load. This is where the principle of how the system is used helps distinguish between the various types of multi-axis systems. XY tables generally work only within their own footprint, meaning the load does not extend beyond the Y axis. This makes them best suited for applications where a load needs to be positioned in the horizontal plane (X-Y). A typical example is a semiconductor wafer being positioned for inspection or a part being positioned for a machining operation to take place. So-called open-

This miniature positioning stage is an H2W VCS20-020-CR-01-MC-F3K voice-coil-based design that runs under closed-loop position control (with force monitoring) or force control (with position monitoring). The voice-coil motors generate a continuous and peak force of 2.0 and 6.0 lb with strokes to 2.0 in.

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L i n e a r

PI (Physik Instrumente) LMS-180 ironless linear-motor stages are suitable for precision automation. Travels are from 155 mm to 508 mm. The ironless electromagnetic linear motor allows for 15-nm resolution and repeatability down to 0.05 µm. An SMC Hydra closed-loop motion controller allows speeds to 500 mm/ sec; load capacity is to 56 lb.

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frame or open-aperture designs have a clear opening through the center of the table. This allows them to be used in applications where light or objects need to pass through, such as backlit inspection applications and insertion processes. Because XY tables are primarily used for very high precision applications, the guideway of choice is that based on crossed-roller slides, as these provide extremely smooth and flat travel. Drive mechanisms are typically ball screw or linear motor, although very fine pitch lead screws are also common. DW

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S e n s o r s

Beyond standard

sensors Some less common sensor types

can provide a solution to presence or motion sensing needs.

Andrew Waugh | Product Manager for Sensor and Safety Products | AutomationDirect

While photo eye, limit switch and dc proximity sensors are the most commonly used types in machine automation applications, there are many other sensors available to help solve application issues. Here’s a look at some of the less common sensor types, along with selection criteria and common uses. See colors Color sensors are one of the few options available—other than much more complex and expensive vision systems—for color object detection, color quality control and color print accuracy applications. These sensors typically use a white light source to evaluate ROYGBIV colors. The mnemonic ROYGBIV defines the order and colors of the rainbow—red, orange, yellow, green, blue, indigo and violet. These color sensors, usually with small spot diameters, reliably detect colored objects at varying scanning distances in automated high-speed applications, based on the previously defined (taught) reference colors. Integrated LED technology is often used to create the white light, with automatic adjustment of intensity. Settings, such as taught samples, output functions, and switching output tolerances are frequently adjustable at the sensor through buttons and an OLED display. Some sensors provide the ability to select settings and configuration parameters with an IO-Link interface, expanding capability.

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This Wenglor 30 color sensor and 12-color fiber optic amplifier sensor system provides reliable color recognition, even at varying scanning distances.

Typical color sensors are available for simultaneous detection of 3 to 12-colors. Each color or switch output is taught using an “okay” sample, which is the color of the object to detect, and a “not okay” sample, usually the background. Semiconductor color chip technology can divide a selected color into six or more spectral ranges, with separately adjustable tolerance or switching thresholds for each. Color sensors can be configured with single-lens optics or fiber optic cable extensions to provide flexible mounting options at a variety of sensing distances. Single-lens optics use a reflective (diffuse) method to detect color, bouncing the light off the object. When used with glass fiberoptic cables, a sensor can be operated in a reflective mode, as well as a through-beam mode to look through an object. Some sensors can distinguish among up to twelve colors, each with a related and teachable switch output.

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Common applications include verifying color in a painting process, measuring color in a printing operation, part sorting based on color, and detection of color registration markings on labels and packages. While color sensors are robust and reliable, problems can occur. Glossy surfaces can cause sensor errors, which can often be addressed by mounting the sensor at a 10° to 30° angle from perpendicular to the surface or object being sensed. Too little reflected light can also be a problem with small or irregular shaped objects. And although there is a range of working distance, sensors must be mounted within this distance, and not too close or too far away from the object. Presence through contrast Contrast sensors are photoelectric sensors that evaluate contrast by sensing the red, green or blue (RGB) light reflected by the object when using a suitable light source. www.designworldonline.com

It is worth mentioning that safety switches are used to protect personnel and equipment from hazards by monitoring the position of movable guarding.

March 2018

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S e n s o r s

The sensor detects the difference in the light wavelength when reflected by an object, a mark or a background. Contrast sensors typically have a sensing distance of 6 to 40 mm, and use either a white light, or an RGB light with adjustable color. White light sensors evaluate the reflected light based on a teach-in function used to set the target and background colors. In more advanced applications, RGB lights can automatically select the optimal color light source for an application based on the colors of the target and background, usually determined using a teach function. The sensor then uses a threshold halfway between the target and background values to trigger an on and off sensor state. These contrast sensors are used in a variety of industrial applications including paper and printing machinery, packaging lines, and beverage and bottling lines. They typically have a fast switching frequency of 5-50 kHz, making them suitable for use in these and other high-speed applications. Some sensors are built with a stainless-steel housing to provide IP69K washdown protection for use in pharmaceutical, food and beverage applications. Another common application for a contrast sensor is detecting print marks such as lines or boxes of solid color in the margins of printed material in a web application. Due to the detection speed and repeatability of the sensor, they can be used to confirm or

A Datalogic contrast sensor with RGB light emission is used to detect the registration mark in this high-speed, cutto-length web handling application.

adjust position in web cutting or printing equipment. These sensors can also be used to detect presence of shrink-wrap seals, tamper-proof seals, labels, inserts and barcodes. Ac proximity switches While dc proximity switches are far more popular than their ac counterparts, the technology used in the ac version is similar to the dc version, and the operation is nearly identical. On new designs, if dc voltage is not available, the use of ac proximity switches is a reliable choice. Proximity sensors detect the presence of metallic objects, typically at a range of less than 1.5 in. The sensing distance varies depending on the diameter of the sensor, with detection of ferrous metals allowing the greatest distances to the sensor. Other metals, such aluminum, reduce the detection range. Many low-cost, reliable ac proximity sensors are available in a variety of shapes and sizes for a wide range of applications. Popular sizes include M8 (8 mm), M12 (12 mm), M18 (18 mm), M30 (30 mm) metal barrel, all for shielded and unshielded use. These ac sensors operate on a wide range of voltage from 20 to 253 Vac, and typically use a 2-wire electrical hookup. These sensors are commonly used in many applications, similar to dc proximity switches. In the past, many applications used ac control circuits that today are now commonly dc control circuits. Fortunately, there are still options for replacement ac proximity sensors. Area sensors properly applied An area sensor can be thought of as a multi-beam array of photoeyes. It is used to detect presence within the controlled area of the sensor array, typically a square or rectangular plane. These sensors provide a simple method to detect different sized and shaped objects as they drop or pass through the two-dimensional target area. An area sensor emitter produces near-infrared light at nondangerous levels. The object is detected by reducing or obscuring the intensity of the reflected light beams hitting the receiver. The sensorâ&#x20AC;&#x2122;s photoelectric arrays use a linear series of lenses, usually with a 5-mm or 10-mm pitch. The sensor pitch, height and teach method affect the minimum detectable object size, as well as the maximum response time. The smallest detectable objects range from 1.5 mm to 10 mm. These multi-beam and through-beam sensors can cover wide areas and are available in basic and advanced versions. The height of the area can range for approximately 70 mm to almost 1000 mm, with up to a 6-meter sensing distance between the emitter and receiver. Discrete outputs of these devices are typically two states, light or dark, off or on. Some also have an analog output of 4-20 mA or 0-10 Vdc proportional to the unblocked detection height. When installed on a machine, some beams may be blocked, so a blanking function allows the active optic window to be adjusted to the specific application. Applications include detecting a part dropped into another part, or into a reject bin for part counting and error proofing. Poka-yoke mistake proofing is another suitable application, and, by using several area sensors, a matrix of manual pick or place positions can be sensed

March 2018 www.designworldonline.com

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using row/column logic. Sensors with an analog output can also be used as a coarse height or area measurement device. Area sensors must not be considered safety devices. While similar in appearance and function to a safety light curtain, they are not suitable for safety applications, such as protecting an operator for a machine hazard. Optical rotary encoders A rotary encoder senses rotary position using an internal coded disc and a sensing head. Encoders are used to sense position, rotation and speed on machines, tooling and actuators. An incremental encoder can connect to a high-speed PLC input or counter module for accurate position monitoring and control. Some absolute encoders can be wired to standard PLC dc input cards where the Gray code represents position, so high speed input modules are not required. Accessories such as mounting brackets and flexible couplings in aluminum and glass-reinforced resin simplify installation. A variety of encoders are available in light-, medium- and heavyduty configurations with various body diameters, shaft diameters and environmental ratings. Open collector, totem-pole or line driver outputs can be specified. Different pulses per revolution (PPR) can also be specified depending on application requirements. There are some rules to follow when specifying PPR to simplify design and integration. The PPR frequency must not exceed that of the input device. The frequency is the encoder revolutions per second times its PPR. Some encoders have quadrature outputs, which increase the readable frequency by a factor of four. Selecting a PPR that is an even multiple of the engineering units used is good practice. For example, if one revolution is one inch of travel, then consider choosing an encoder with a 1000 PPR. This simplifies calibration as each pulse is 1/1000th of an inch. When it comes to sensors, keep in mind that there are more than photo eyes, limit switches and dc proximity sensors. Adding less common sensors makes sense in many applicationsâ&#x20AC;&#x201D;and can dramatically improve operation. DW AutomationDirect | www.AutomationDirect.com

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E l e c t r o n i c s

IoT could owe further E l e c t r o n i c s

advances to

Power-over-Ethernet cabling Updated PoE specs let significant amounts of power flow down networking cables, so

much that Ethernet wiring now can double as a power delivery system.

Back in 2003, you could read Leland Teschler | Executive Editor

Ethernet Cable Data + Power PoE Network Switch

PoE Device

(Wireless AP, CPE, Router, etc.)

Power Supply Ethernet Cable

Ethernet Cable

Data Only Non-PoE Network Switch

Data + Power PoE Injector

PoE Device

(Wireless AP, CPE, Router, etc.)

Power Cable Ethernet Cable

Ethernet Cable

Data + Power PoE Network Switch

Data Only Non-PoE Device PoE Splitter

(Wireless AP, CPE, Router, etc.)

The power supplied in PoE installations can come from three different sources, a PoE network switch, a PoE injector, or a PoE splitter.

March 2018 www.designworldonline.com

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articles about a new networking standard called Power over Ethernet (PoE). It allowed network devices to get dc power directly over Ethernet cabling. Promoters of PoE gushed that it would banish the wall-wart transformers otherwise necessary to power such appliances as wireless access points, docking stations for personal digital assistants, and IP phones. (The first iPhone didnâ&#x20AC;&#x2122;t come out until 2007.) The problem was that the 2003 PoE spec only let networks deliver 13 W of dc power from each Ethernet port. This was long before the invention of LED bulbs drawing less than 10 W but able to put out as much light as 60-W incandescents. All in all, the low power capability of the early PoE spec kept it from shrinking the market for wall-wart transformers by much. Fast forward to today. LED technology has reduced the power necessary for lighting applications, while advances in technology have yielded substantial increases in how much power can be delivered to a device over a network cable. A revision of the PoE spec in

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E l e c t r o n i c s

In tests run at a DoE National Lab, researchers gauged cable losses while powering a 51-W PoE-powered luminaire, illustrating the sensitivity to the power source output voltage and DCR, the max-rated dc resistance of the cable. Researchers note that I2R losses are nonlinear, so average cable power losses for a system of equal-power luminaires with 50-m average cable length would exceed 5% if a 50 m length had exactly 5% losses. However, the expected headroom at 50 m suggests that cable power losses for a system with 50 m average cable length should still be less than 5% when following ANSI C137.3, the spec spelling out minimum requirements for PoE lighting.

One appliance segment that is making ample use of PoE capabilities is that for smart LED lighting. Today several suppliers make PoE-powered luminaires targeting uses in open offices and meeting rooms.

Losses vs. cable length

2009 boosted the available power to 25.5 W per port. A draft standard now on the drawing boards will increase that figure to 72 W normally, 95 W under special circumstances. One consequence of this rising power capacity is a proliferation of apps that use Ethernet wiring as a source of electrical power. Video cameras, point-of-sale machines, access control card readers, LED luminaires, and other industrial and building automation applications now avoid the need for a wall socket by using PoE connections. Some vendors of networking equipment arenâ&#x20AC;&#x2122;t waiting for the new standards. Cisco, for example, developed its own PoE variant called Universal Power over Ethernet that delivers 60 W to each Ethernet port. It works with existing Ethernet cabling and handles devices with higher power requirements such as telepresence systems, Virtual Desktop Infrastructure (VDI) clients, nurse call systems, LED lighting fixtures, and digital signage. Instead of delivering power over two of the twisted pairs in Ethernet cable, UPoE uses all four of them for power. It does this by using two power sourcing equipment controllers to power both the signal pairs and the spare pairs.

March 2018 www.designworldonline.com

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One advantage of using PoE as a primary source of power is that the network cable (usually Cat 5 twisted pair) neednâ&#x20AC;&#x2122;t be put in metal conduit like regular ac lines. This drastically reduces installation time and effort. It also facilitates IoT schemes that involve building automation. For example, fire alarm systems can also trigger blinking and a color change of network-connected lighting over emergency exit paths; lighting moods in individual offices might be set with a few keystrokes on an IP phone. One appliance segment that is making ample use of PoE capabilities is that for smart LED lighting. Today several suppliers make PoE-powered luminaires targeting uses in open offices and meeting rooms. Employees can personalize the lighting around their desks from luminaires that each have their own IP address so they can be individually monitored, managed, and controlled. Sensors in the luminaires sense whether office occupants are around and kill some of the lighting to save energy in empty areas. Power lines Devices that send power to PoE loads such as luminaires are either PoE network switches, a midspan (also known as a PoE injector), or a PoE splitter. PoE network

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switches have the ability to send out both Ethernet signals and PoE power. The switch can detect whether a given Ethernet connection needs PoE or not through a handshaking arrangement. PoE switches resemble ordinary Ethernet switches in that they can range from inexpensive unmanaged devices with a few ports to complex multiport versions with sophisticated management functions. A midspan is used to add PoE to ordinary Ethernet connections. It basically accepts an Ethernet line from a network switch or other source and outputs a PoE version that goes to PoE loads. Finally, a device called a PoE splitter accepts a PoE line and splits out power for use by the Ethernet load. It has two output cables, one for Ethernet data, the other strictly a dc power cable that runs the load. One complication that arises out of using Ethernet lines for power is that the cabling must be treated more like conventional power-carrying wire than like data lines. That means the cable dc resistance factors into the installation design more so than if the wires handled just ordinary 5 Gbit/sec Ethernet.

Concerns about PoE wiring resistance prompted the Dept. of Energy to investigate how much power is likely to be dissipated in PoE cable. Researchers at the Pacific Northwest National Laboratory (PNNL) measured the amount of power dissipated in the cable itself rather than in the PoE load. After evaluating nine different brands of Cat5e and Cat6 cable, DoE researchers concluded that energy lost in the cable stays below 5% of the total load in PoE lighting applications so long as the average cable length doesn’t exceed 50 m. Cat5e twisted-pair cable has been the standard Ethernet cable for some time. But Cat5e has trouble handling the climbing data rates specified in next-generation Wi-Fi devices and Ethernet links. Specifically, Wi-Fi equipment on the drawing boards will transmit at data rates greater than 1 Gbps, possibly reaching up to 7 Gbps. Ethernet lines will hit 10 Gbps and higher. Cat5e can’t handle 10 Gbps speeds up to the 100m distances called out in Ethernet specs. Cat6A cables with their larger 23 AWG wires will probably handle these high-speed applications. Consequently, the PNNL group tested

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Here’s how the Dept. of Energy sizes up the way LED power requirements are converging with PoE power capabilities spelled out in new IEEE standards.

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E l e c t r o n i c s

Here are samples of the cables used in the DoE test of PoE cable losses.

both Cat5e and Cat6 cables. As you might expect, the PNNL group found cables with bigger conductors exhibited less dc resistance. In general, Cat6 cables carry larger-gauge wire than Cat5e versions, though there are exceptions. ANSI C137.3, the standard for PoE lighting systems, recommends at least 24 AWG wire for PoE loads drawing less than 55 W and at least 23 AWG wire for higher-power four-pair PoE applications. In addition, several manufacturers market even bigger 22 AWG cables, both in Cat5e and Cat6, specifically for PoE applications. The Cat5e cables in the DoE test carrying 24-AWG wire all had a rated dc resistance, called DCR, of less than 9.38Ω/100 m. Most Cat6 wires with 23-AWG had a similar rating though a few of them were rated to have less resistance, as low at 7Ω/100 m in one case. The 22-AWG Cat6 cable carried a 6.5Ω/100 m rating while the Cat5e cable with 22-AWG wire didn’t have a rating for dc resistance.

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One concern PNNL researchers noted was that DCR ratings are maximum ratings. A few cable makers put out nominal resistance ratings, as well as a DCR, for their products. The nominal ratings can be significantly lower than the DCR figure and may be more helpful for calculating expected power losses. Another concern the PNNL researchers voiced was that they found PoE luminaire designs appeared to differ in how they treat cable shields and drain wires connected to shielded (metallic) RJ45 plugs. The problem emerged when researchers tried to hook a shielded version of a PoE cable to a luminaire; that action apparently fried the PoE network switch providing the power. It emerged that some PoE luminaires energize the shield in the RJ45 plugs while others do not. The lesson: At least today, not all PoE loads exactly follow the IEEE 802.3 PoE spec.

March 2018 www.designworldonline.com

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This realization led the PNNL group to suggest buyers and specifiers only use products independently certified (e.g., by the Ethernet Alliance) as IEEE PoE compliant. Researchers further suggested that manufacturers of Ethernet cables and connectors (RJ45 plugs) publish lists of compatible cabling products or parameters relevant to compatibility (e.g., tolerances for overall diameters of cable and insulated conductors). Difficulties with shielded PoE cable are worth noting because some cables marketed as UTP (unshielded twisted pair) contain “isolation wrap” that resembles the foil used in F/UTP cables, those which have an overall shield containing all eight conductors. Shielded cable definitions vary, and several manufacturers market or recommend shielded cables for use in PoE applications. Some PoE luminaire makes claim their products are compatible with shielded cables. Both others are silent on this point. DW

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Turning two

into one

Single-cable solutions for servomotors are becoming increasingly popular as they require less connection technology, which leads to quicker installation and overall cost savings. Edited by Mary C. Gannon | Senior Editor

Unlike the traditional two-cable solution in which the servomotor is connected to the controller by separate power and feedback cables, the singlecable solution integrates the motor feedback cable into the servoâ&#x20AC;&#x2122;s power cable. However, there is a downside to this solution: the power conductors could impair data transmission if the proper shielding is not on each cable element. Thanks to continuous drag chain tests, HELUKABEL was the first cable manufacturer to prove in the spring of 2014 that its hybrid cables were capable of error-free, digital data transmission using the HIPERFACE DSL protocol, even after more than five million cycles. The high durability and reliability of HELUKABELâ&#x20AC;&#x2122;s hybrid cables in daily use has been frequently endorsed by machine builders. One of the latest recommendations is from IMA Klessmann, who recently implemented single cable solutions. The company, based in Luebbecke/Westphalia, Germany, is a global manufacturer of assembly lines and woodworking machinery for the furniture industry. The furniture industry deploys IMA drilling machinery as both stationary and through-feed machinery. With feed speeds of approximately 100 feet per

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In a hybrid cable, the feedback conductors are integrated into the servo power cable. | All images courtesy of HELUKABEL USA

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I n t e r n e t

o f

T h i n g s

A multitude of information and operating parameters, such as the required temperature range, chemical resistance, mechanical stress, approvals, and norms, must be known to provide expert technical advice about which cable to use.

minute, multiple drills simultaneously drill horizontal and vertical holes into workpieces, which are later assembled into living room, bedroom and office furniture. Up to 90 axes can be involved in such applications. IMA had been using OCT (one cable technology) from Beckhoff Automation in their CNC drilling systems and complex manufacturing equipment since the beginning of 2015. This required a cable conversion and after being advised by HELUKABEL, the machine builder chose to use TOPSERV Hybrid servomotor cables, which have been rigorously tested and are ideally suited for highly dynamic drag chain applications. “The cables have already proven their worth in many of our IMAGIC drilling systems despite the high levels of mechanical stresses, such as narrow bending radii and fast changing

HELUKABEL’s Dirk Spranger (left) with Marcel Sulewski (right) on a company visit to IMA Klessmann. They’re examining HELUKABEL’S TOPSERV Hybrid cables, which easily withstand high levels of continuous mechanical stress.

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bending cycles in the drag chains, as well as abrasion from wood dust,” explained Marcel Sulewski, electrical purchasing team leader at IMA. “IMA has already updated their drilling applications to one cable technology. As far as I know, there’s only one motor left to be changed over in the CNC machining centers; the new generation will then be complete.” Expert technical advice As the key account manager, HELUKABEL’s field technical sales representative Dirk Spranger often gets involved at IMA as early as the test construction phase. “If the cables move as a result of being integrated in a drag chain, for example, I need to know the traverse paths, speed, acceleration, number of cycles and, of course, the bending radius in order to provide the right product,” he explained. “Thanks to our cable know-how, we are supporting their engineers and giving specific advice on cable constructions.” A multitude of information and operating parameters, such as the required temperature range, chemical resistance, mechanical stress, approvals and norms, must be known to provide expert technical advice about which cable to use. “We have relatively specific applications. Therefore, the advice provided by HELUKABEL is unique to us. It’s very much a give and take situation,” explained Sulewski. “There’s a large technical component to the decisionmaking in purchasing. We discuss the general technical framework in detail with Dirk who then makes specific suggestions, which we analyze together.” Spranger added, “We regularly discuss customer requirements with our engineering department at the Windsbach plant. The information provided by our customers is very valuable to further develop our hybrid cables. With specific test scenarios, our engineering department can run simulations to verify if our cables can meet customer requirements.” For IMA,

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I n t e r n e t

o f

T h i n g s

IMA relies on single-cable technology in its woodworking machinery.

these tests proved that HELUKABEL was able to provide an appropriate solution for its drilling applications using standard hybrid cables from stock. Reduced installation times With the single-cable solution, IMA was able to reduce the installation time for drilling machinery by an estimated 20 to 30%. “Cable assembly, installation and wiring is now quicker,” said Sulewski. ”The space savings with the singlecable solution was lower than expected though, despite there being half the number of cables. This was due to larger cross sections in the drag chains; a factor which needs to be considered as well.” Far more important than the space savings from fewer cables are the reduced cable assembly and installation times. Cable replacement is also quicker and the spare part stocking levels are reduced. This occurs because it’s no longer necessary to keep one set of cables for the feedback signal and one for power. But what about the costs of these high-tech cables, one might wonder? “I only need one cable, but it’s a more expensive one,” pointed out Sulewski. “That may not initially appear to be an argument in favor of the single-cable solution. However, if you include the cable assembly and installation time savings, the single-cable solution soon pays for itself. In technical purchasing, the focus should be on the solution as a whole, not just on the product’s price,” Sulewski said. At IMA, some of the applications that use single-cable technology are 100 feet away from the switch cabinet. The first machines have been successfully operating at

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the customer’s facility for more than a year now. “In the periods between scheduled maintenance, the cables have shown themselves to be very resilient and absolutely reliable,” said Sulewski. “Even after more than five million cycles, there’s never been an outage, as far as I know.” It‘s the shielding that does it At the Hannover Fair in the spring of 2014, HELUKABEL announced the addition of a new hybrid cable for single-cable technology to its highly successful and well-known TOPSERV product family. At that point in time, drive manufacturers had no long-term field experience with one cable technology. This made it even more important for HELUKABEL to prove within realistic drag chain tests that their hybrid cables were properly shielded and transmitting signals error-free via the HIPERFACE DSL interface, even after more than five million cycles. “If a motor is working properly, the quality of the signal received is the key factor,” explained Thomas Pikkemaat, drive technology product manager at HELUKABEL and business manager at the Windsbach plant. “Reducing external interference on the feedback conductors increases the reliability of the data received. Protection from EMC interference is provided by data pair shielding. The longer the shield keeps working, the longer interference protection can be maintained.” In static applications, shielding lasts practically forever. However, this is not the case for applications

2/28/18 10:51 AM

With the single-cable solution, IMA was able to reduce the installation time for drilling machinery by an estimated 20 to 30%. like robots, machine tools and handling equipment, etc., where cables are moving in drag chains and along various axes. If the shield degrades, the worst outcome is an unreadable feedback signal. Hence, the result of choosing an unsuitable cable might not be noticed until the machine has been operating for several months. What measures can be taken to ensure permanent and reliable shielding in such dynamic applications? “Mechanical tensile loads on the outer radius can cause the bare or tinned copper braided shield to break which, over time, can reduce the shield’s effectiveness,” Pikkemaat continued. “To avoid this, the braiding angle and level of coverage of the woven shield in the hybrid cable must be optimized to the dynamics of the application and the required bending radii, as well as the speed and acceleration parameters. This

is the only way to guarantee the EMC shield, even after several million cycles.” For maximum shield durability, the braid should always be wrapped around the conductors at an obtuse angle. Not only does this result in higher coverage, it also improves elasticity, which reduces the tensile forces. Alongside the braided shields, the hybrid cables can also contain a special metallic, evaporated fleece. New technologies such as singlecable solutions for drives are challenging cable manufacturers to develop and test innovative solutions. Thanks to the close relationship with leading machine builders such as IMA Klessmann, HELUKABEL is able to further develop its products in a realistic environment. DW HELUKABEL | helukabel.com

Multiple drills prepare the piece of furniture for further processing.

DESIGN WORLD

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How to use an

oscilloscope: the basics

Oscilloscopes, those stalwarts of electronic design, can seem puzzling if youâ&#x20AC;&#x2122;ve never used one. Getting a good grasp of the basics, like signals and probes, can go a long way toward demystifying their operation.

| istockphoto.com

David Herres | Contributing Editor

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T e s t

M e a s u r e m e n t

Today, the dominant oscilloscope type is digital, with a relatively small number of analog oscilloscopes still made for educational purposes and low-end DIY kits. The digital revolution in oscilloscope design, initiated by Walter LeCroy over 50 years ago, made possible vast new capabilities and features. Still, it’s worthwhile for perspective to look back at the old analog scope in order to get an overview of the basics. These two instrumentation subspecies have much in common, beginning with probing. Signals and probes If possible it’s best to connect a signal to an oscilloscope input via a BNC cable. This method is convenient and works well when the signal source is hardwarecompatible. An example is connecting a synthesized signal from an internal or external arbitrary waveform generator to an oscilloscope input. Often, however, the source of the signal is a trace or component pin on a printed circuit board, or a device terminal or wire in electrical equipment. In these situations, probes are essential. The most-used oscilloscope probe attenuates the signal by a factor of 10. Known as a 10:1 or 10X probe, this probe is appropriate for most applications. Its resistive (dc) impedance, 1 MΩ, makes the oscilloscope-probe combination invisible to the circuit, component or network. So at moderate frequencies, loading is not an issue. But parallel capacitive loading can be problematic when the signal under investigation is high frequency. This is inevitable when you consider the probe with cabling together with circuitry within the oscilloscope. Probe input capacitance, seen by the circuit under test, is typically 100 pF. When looking at a 60-Hz sine wave or any audio frequency, the capacitive reactance is not significant, but even in the low megahertz range, you may be down to a couple hundred ohms of capacitive reactance. The will cause some circuits to oscillate, rendering measurements invalid or actually damaging the circuitry.

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T e s t

M e a s u r e m e n t

Today, the dominant oscilloscope type is digital, with a relatively small number of analog oscilloscopes still made for educational purposes and low-end DIY kits. Without upgrading to a low-capacitance probe, a good practice is to carefully compensate the probe. Each probe must be compensated to its channel, and it should be color-coded so the dedicated probe is always paired with its correct channel. To perform probe compensation, oscilloscopes are equipped with external terminals that provide a square-wave signal. Turning a knob or screw on the probe body, the user compensates the probe so that a well-formed square wave is seen in the display, without overshoot or rounded corners. For example, the Tektronix TPP1000 probe works somewhat differently in conjunction with an MDO3000 series oscilloscope. The user clips onto the square-wave terminals and chooses menu items, whereupon the instrument automatically performs the compensation. Each channel can store compensation values for 10 individual probes. If you try to compensate an 11th probe on a channel, the oscilloscope will delete the values for the least recently used probe and add the values for the new probe.

To view low-amplitude signals, 1:1 (1X) attenuation probes are needed. (Some probes have a slide switch on the probe body that toggles between the two attenuations.) To view highvoltage signals, specialized high-voltage probes are used. They incorporate guarding that protects the user from shock. Differential probes are used to display voltage oscillations between two terminals when both are referenced to, but float above, the ground level of the ac electrical system that powers the instrument. Differential probes are necessary in this instance because connections via a standard probe with a ground-return lead will create a direct short through both the circuit under test, the ground return lead and the oscilloscope, with possible severe damage. This can happen even if the oscilloscope is powered down and only the ground return lead is connected. Differential probes have an additional advantage which is that they reject any common-mode voltage, signal or noise. This feature can be useful in that it cleans up the desired signal so that accurate measurements can be made.

A Tektronix MDO3000 series oscilloscope accepts analog, digital, and even RF inputs. Up to six instrument functions can be integrated onto the scope including a function generator and spectrum analyzer.

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T e s t

M e a s u r e m e n t

Seeing the signal The most common problem in using an oscilloscope is failing to get a signal to display in a meaningful way, or to display at all. Here are some strategies to ensure that the signal displays correctly:

The TPP1000 probe from Tektronix is a passive probe for low-voltage applications. The probes provide up to 1 GHz of analog bandwidth with less than 3.9 pF of capacitive loading.

Current probes are expensive, but they can enable new oscilloscope uses. In the Math mode, current and voltage waveforms can be multiplied to display power, with implications that are interesting and useful. The oscilloscope current probe works like the electrician’s clamp-on ammeter. Rather than cutting into a conductor (with eventual resoldering) the current probe clamps around the wire with no direct electrical connection. The magnetic field surrounding the currentcarrying wire induces a voltage in the probe that displays on the oscilloscope with divisions calibrated to display amps or milliamps. To detect extremely low currents, the wire can be coiled and made to pass through the jaws two or more times. The displayed current is then divided by the number of turns to calculate the actual current flowing through the conductor. Getting more information Oscilloscope manufacturer websites are a great resource for technical information. Perusing the available products with specifications, prospective users quickly acquire an overview of oscilloscope instrumentation currently available. Some websites also provide pricing. Others want visitors to register, provide an email address and create a password with all that entails. Once into the site, visitors can access a great many application notes, register for webinars, and a lot more Choosing an oscilloscope can be a long and involved process. However, one of the downsides is that pricing for this laboratory grade instrumentation can be in the stratosphere. Most of us are compelled to compromise in some areas. We all enjoy high bandwidth and four (or more) channels, though for most applications two channels will often be plenty. The ultimate way to economize is to be content with a two-channel, 50-MHz PC-based oscilloscope. This solution is vastly less expensive than the venerable bench-type scope. But there are some disadvantages in terms of connectivity between

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Press default settings – This will clear the slate, so to speak. It is possible that in a previous work session the instrument was configured in a way that is not compatible with the current operation. Some of these configurations persist through successive power cycles. Some of them go away when the oscilloscope is turned off. Most of the time, pressing Default Settings takes care of this problem.

Press Autoset – The instrument then analyzes the signal and automatically chooses the optimum settings in terms of frequency, amplitude, and scaling. Verify – Verify there is a signal at the oscilloscope input. Measure it with another oscilloscope or with a multimeter.

Test another signal – See if another signal, from a different source, will display. The square-wave probe compensation signal is a good source, but be aware that in a Tektronix oscilloscope, the square wave is present at the terminals only momentarily as the probe compensation takes place. Try different channels with different probes.

Firmware upgrade – If the problem has been found to be within the oscilloscope, download the latest firmware, which is free at the manufacturer’s website.

the oscilloscope module and the owner-supplied PC with proprietary software installed. What is impressive, however, is the extensive functionality and advanced features that reside in the PC once the software is installed and the owner is up to speed. Oscilloscope technology has come a long way since the post-WWII years when consumer electronics expanded rapidly. These old tubetype machines were eminently repairable. Technicians injected signals into various stages and looked at the waveforms downstream. This procedure allowed them to zero in on the defective component(s) that could be easily replaced in the spacious chassis. Now, of course, it’s a different world. Ultra-compact printed circuit boards populated with numerous ICs having multiple leads are difficult to replace and the circuitry is highly complex. The oscilloscope has evolved, becoming more of a developmental instrument rather than a repair tool. DW

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Dissolved oxygen sensor E+H us.endress.com The Memosens COS81D hygienic optical sensor is for measuring

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oxygen and temperature with accuracy up to ±0.2%. It works in process temperatures from 15 to 280 °F and pressures from 0 to190 psi. The sensor also provides temperature and partial pressure, as well as raw measured values. The sensor connects to a transmitter via a cable that transmits an optical digital signal.

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Distributed modular I/O Balluff balluff.com Ballscrews & Rollerscrews

This is the industry’s first machine mount, IP69K protection rated, ECOLAB certified distributed I/O modules powered by EtherNet/IP, PROFINET, and IO-Link. End users and machine builders of automation in food, meat, dairy and beverage industries that need to follow Industrial Robots

stringent food safety requirements can now use the full benefits of distributed modular I/O architecture for all the required I/O and sensor connectivity.

The IP69K portfolio includes network I/O, IO-Link masters and IO-Link I/O

hubs. These distributed I/O modules can be mounted right on the machine closer to sensors and actuators to reduce troublesome cable routing. The entire portfolio

Linear Motors

of IP69K modules utilizes standard M12 connections to sensors eliminating need for cable terminations in the cabinet. All the modules are equipped with onboard diagnostics for ease of integration and maintenance. Linear Actuators

12-volt dc linear actuator

Linear Guideways

MMP www.midwestmotion.com The Model # MMP LA3-12V-5-A-SP-100 accepts any 12 Vdc Input, including automotive battery power, and has a compact, lightweight

Linear Encoders / Positioning Measurement Systems

design, measuring just 8.5-in. Long (fully retracted) by 1.65-in. wide and 3.25-in. tall. Mounting is accomplished with 0.25-in. diameter through holes on the rear end of the actuator and near the end of the extending cylinder.

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This rugged and reliable linear actuator has been designed with a

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Manual cartridge valve with zero-leak option Doering doering.com The demand for redesigned manual cartridge valves has grown

WE Series Linear Guideway Wide Series Ball Type.

rapidly for a range of applications. They are suitable for use in equipment, such as an emergency stop valve on hydraulic systems for oilfield iron roughnecks and industrial instrumentation systems that test product to one-eighth of a drop of water. These valves are also used in food industry test systems that measure carbon dioxide and nitrogen in the parts per billion.

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Linear shafts, shaft supports and rotary shafts Automation Direct automationdirect.com

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SureMotion hard-anodized aluminum supports offer superior shaft

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Product World 2680 world-wide voltage pressure/vacuum pumps Thomas gd-thomas.com The 2680CWW40 is a Nexus 2.75-in. [69.85 mm] bore, 0.40-in. [10.16 mm] stroke unit and has the reliability and features/benefits the industry has come to expect but uses a next generation 4.8 in. [121.9 mm] frame P.S.C. motor that can be operated anywhere in the world at 100-127V and 200-240V 50/60Hz.

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Low power active mixer Analog Devices analog.com The LTC5562 is a low power, active double-balanced mixer, capable of 50Ω matching over a very wide frequency range of 30 MHz to 7 GHz. This mixer can be used in either frequency up conversion or down conversion applications, with a conversion gain of 2 dB. The device runs on a single 3.3 V supply rail, drawing 40 mA nominal operating current. If lower power consumption is needed, the mixer can be configured to operate as low as 15 mA, supporting a range of portable and transportable RF applications. Moreover, the mixer has a strong dynamic range performance: +20 dBm OIP3 at 3.6 GHz frequency.

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CSA-certified stepper and servo motors Applied Motion Products applied-motion.com

LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

This range of UL-Listed and CSA- Certified stepper motors and servo motors are for use in applications requiring certifications in North America and Canada. Units are recognized to Standard UL-1004-6 for Servo and Stepper Motors, UL 1004-1 Standard for Rotating Electrical Machines, and Canadian CSA Standard C22.2 No. 100-14 for Motors and Generators. Users are now assured that Applied Motion stepper and servo motors meet standards for electrical safety associated with UL and CSA certifications.

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

Applied Motion UL-Recognized stepper motors include both single and double-shaft

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KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

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Multi-section linear encoder Heidenhain heidenhain.us

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

The AMO LMF 9310 multi-section linear encoder is specifically designed for long length applications (over 10-ft) on manually operated machines and is compatible with HEIDENHAIN’s ACU-RITE brand of digital readouts.

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Ad Index

SALES

ACE Controls .................................................. 54

HELUKABEL USA .......................................... 31

Aignep USA .................................................... 45

HIWIN ....................................................115,117,119

Allied Electronics &

IDEC Corporation .......................................... 33

Automation .................................Cover, 2,3

J.W. Winco, Inc. .............................................. 39

AllMotion .............................................................4

Keller America ................................................49

Altech Corporation ...................................17,19

Key Bellevilles Inc. ........................................94

Altra Industrial Motion

Keystone Electronics Corp. ....................... 11

Tom Lazar

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Jim Powers

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Corp. .......................................... .23,24,25,26

Kuriyama ..........................................................99

AMETEK DFS .................................................. 35

Lillbacka USA, Inc. ........................................ 93

Analog Devices, Inc. ..................................... 41

Mach III Clutch Inc. ........................................ 51

Atlantic Spring .............................................. 58

Maryland Precision Spring ........................ 37

Aurora Bearing Company ......................... 39

Master Bond .................................................. 45

AutomationDirect .............................................1

maxon precision motors ............................ 97

Beckhoff Automation ................................IBC

Memory Protection Devices ........................9

mference@wtwhmedia.com 408.769.1188 @mrference

Bimba ...................................................................5

Miki Pulley US ................................................ 44

Bodine Electric Company .......................... 83

Nason .............................................................. 38

Michelle Flando

C-Flex ................................................................94

NB Corporation ............................................. 29

Cadence Inc. .................................................. 43

NTE Electronics, Inc. ....................................116

Canfield Connector ..................................... 57

OKW USA .......................................................... 15

Central Semiconductor Corp. ..................101

Opto 22 ............................................................ 55

Century Spring .............................................. 95

PHD Inc. ........................................................... 47

CGI Motion ...................................................... 53

Phoenix Contact ..............................................7

CIT Relay & Switch ......................................107

Prince Manufacturing Co. .........................46

Components Corporation .........................118

Rotor Clip Company, Inc. ............................ 85

mfrancesconi@wtwhmedia.com Scott McCafferty 630.488.9029 smccafferty@wtwhmedia.com 310.279.3844 David Geltman @SMMcCafferty dgeltman@wtwhmedia.com 516.510.6514 EVP @wtwh_david

Del-Tron Precision, Inc. ................................ 81

SEW-EURODRIVE .........................................BC

Design-2-Part Shows ..................................60

SIKO Products ................................................84

Neel Gleason

Digi-Key Electronics ...................................... 13

Super Swivels ................................................ 28

DMIC ................................................................... 111

Tensility International Corporation ........ 32

Dorner Mfg Corp ...........................................89

THK TOS .........................................................IFC

Eagle Stainless Tube ............................. 20,21

Tompkins Industries, Inc. ..........................105

Encoder Products Company .................... 42

Trim-Lok ........................................................... 22

Fabco-Air, Inc. ................................................. 14

Whittet-Higgins ............................................. 27

Jessica East

jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

Michael Ference

mflando@wtwhmedia.com 440.670.4772 @mflando

Mike Francesconi

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director

Marshall Matheson

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Make Parts Fast CS Hyde Company ..............................................71 LEE Linear .............................................................76

A supplement of Design World March 2018

Renishaw ...............................................................77

Tormach ................................................................ 69 let software do the

Xcentric Mold & Engineering ..........................75

for additive manufacturing 64

62 Additive manufacturing salariesâ&#x20AC;&#x201D;experience pays off

70 How HP slashes design cycle time

COVER_MPF 3-18_Vs1.indd 61

72 3D printing and surgical simulation tackle tough medical challenges

2/28/18 8:36 AM

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March 2018 www.designworldonline.com

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DESIGN WORLD

3/2/18 3:05 PM

| PC11-48USA |

Meet the smallest Industrial PC from Beckhoff. The ultra-compact C6015 IPC for automation and IoT.

82 mm

40 mm

www.beckhoff.us/C6015 With the ultra-compact C6015 Industrial PC, Beckhoff has again expanded the application possibilities of PC-based control. Wherever space or cost limitations previously prevented the use of a PC-based control solution, this new IPC generation offers an excellent price-to-performance ratio in an extremely compact housing. With up to 4 CPU cores, low weight and unprecedented installation flexibility, the C6015 is universally applicable in automation, visualization and communication tasks. It is also ideal for use as an IoT gateway. Processor: IntelÂŽ Atomâ&#x201E;˘, 1, 2 or 4 cores Interfaces: 2 Ethernet, 1 DisplayPort, 2 USB Main memory: up to 4 GB DDR3L RAM Housing: Die-cast aluminum-zinc alloy Dimensions (W x H x D): 82 x 82 x 40 mm

2018 Flexible installation via rear or side panel mounting, or on DIN rail.

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HONORABLE MENTION

2/26/18 2:36 PM

We kick acid. Having washdown or corrosion issues? It’s time to kick acid with our Food Industry Package. It conquers corrosion with its epoxy primer, USDA finish, fully encapsulated stator, epoxy conduit box, and stainless steel TorqLOC® keyless hollowshaft. It’s no wonder that our motor lasts 10 times longer than the competition in extreme environments such as the poultry industry!

seweurodrive.com / 864-439-7537

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2/26/18 2:36 PM