DESIGN WORLD MARCH 2019

www.designworldonline.com

March 2019

inside: MOTION CONTROL: Don’t forget these two

things when selecting an amplifier

p. 72

TEST &

MEASUREMENT:

On the “edge” of a revolution

p. 86

INTERNET OF

THINGS:

Distributing IoT information

p. 94

Roller-screw actuators: what’s new page 78

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How will AI affect engineers?

Richard Pak is an associate professor in Clemson’s psychology department and director of the Clemson University Human Factors Institute. We spoke recently about how he sees the relationships between humans and machines advancing over the next five years.

Pak said that the relationship will grow much closer simply because more people will be exposed to autonomous systems, whether that be in their car, at work, or at the doctor’s office. In addition, because of rapid advances in their capabilities, it may become harder to distinguish some types of machines as a machine — imagine talking to AI on the phone or in your car that is so capable it can fool you into thinking it was a human.

But for mechanical and electrical design engineers, there will be changes, too.

“On the short time scale, AI will free designers and engineers from repetitive or low-level tasks,” Pak said. “Automation already does this for many physical or manual tasks. But AI will have a similar effect for cognitive tasks (like design and engineering). So, for example, instead of a designer having to come up with optimal designs for a problem, AI might be able to generate an initial set, based on existing designs, allowing the designer to focus their efforts on more demanding tasks. But as advanced AI seems to be, it is still very narrowly capable and will not completely replace knowledge work.”

From an industry standpoint, Pak said that industries heavily dependent on data are the most likely to be affected.

“Just as automation revolutionized manual work, AI will alter occupations that we once thought to be non-auto able. Occupations where massive amounts of data must be examined, and patterns found are good candidates for rapid change: finance and medicine come to mind. Regarding medicine, AI is already being trained to detect diseases before symptoms appear only by using basic information (e.g., medical scans, gait changes). Subtle changes that are difficult for human doctors to detect but readily recognizable by trained AI.” So, what does that mean for our kids with good technical aptitude — should we still be encouraging them to study a field like engineering today?

“I do not think future students need to be experts in machine learning, but such knowledge is useful as ML is being applied and used in the most unlikely of places (e.g., in your phone),” he said. “The fundamentals of engineering education should not be too affected … but if job safety is of concern, one area where AI will have the most difficulty is generating novel, creative solutions to complex problems. In those situations, AI will always be an aid but human creativity and ability to make disparate connections will always be more valuable.”

Pak said that the coming of highly autonomous systems (backed by advanced AI) is inevitable. Advancements are moving so fast, whole industries will be affected very quickly. As a result, we have to be equally urgent about understanding the political, moral, society implications. And we have to understand how human behavior will change when these systems become widespread. DW

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Teschler on Topic Forget the psych tests — Head shrinkers can’t predict who’ll be a good engineer The process of finding productive knowledge workers has become a high-stakes game. In the effort to weed out weak job candidates, one of the tools businesses have employed is the personality profile. Consider a few selected comments from one such analysis of an engineering job candidate: (the candidate) tends to be a slow worker who often takes more time to complete an assignment than most other professionals….Also, he is a slow starter who has some trouble getting himself moving … and may need some time to warm up to his tasks… Along with this, the candidate seems to have trouble concentrating when faced with interruptions or distractions.. he may be too patient with those who resist changes that are necessary.

All in all, it sounds as though this candidate might be kind of a stiff. But maybe not. After reviewing a century’s worth of research on selecting job candidates, researchers from the University of Iowa, Temple University, and West Texas A&M University concluded that personality profiles like this one don’t predict how well job candidates are likely to perform. In fact, they found the best tests for predicting

job performance were those assessing only general intelligence and integrity.

University of Penn. Wharton People Analytics Initiative researcher Reb Rebele recently explained some of the problems with trying to infer things from tests of job candidate personality.

Some such assessments, he says, are little more than what some scholars call “pseudo-profound BS” – the results sound meaningful, but they bear little resemblance to any objective truth.

More troubling, though, is evidence that an individual’s personality can vary dramatically over the span of a couple weeks. Moreover, people can shift their personalities to some degree in the interest of near-term benefits and long-term goals, Rebele says. For example, one study has found that people tend to become more conscientious right before getting a job.

These studies help make the argument that personality tests are a poor way of judging job candidates.

But Rebele claims there are approaches that show promise. In one case, he helped an organization in the health care field devise a test for that assessed candidates’ situational judgement. It asked them to make decisions in hypothetical situations that closely mimicked those likely to crop up on the real job. It turned out giving good answers to questions along these lines was a much better predictor

of job performance than any other measure the researchers tried.

In another study, George Mason University researchers found that employees with consistent personalities more generally went beyond the call of duty at work.

But measurements of personality consistency would involve multiple, extended testing, something not likely to happen when sifting through a pile of job candidate resumes.

Results like these make it clear personality tests have the potential to give misleading results about potential job candidates. That brings us back to the engineering applicant pegged as a “slow worker” by the head shrinkers who tested him. You may have guessed that I was the applicant.

Fortunately, the guy who hired me didn’t put much stock in personality profiles. He gave me my psych test results when he retired.

And for the record, I can’t recall ever taking heat for being a slow worker or for being a slow starter during a working career that now extends past forty-plus years. DW

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

6

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Technology Forward Keep up with additive manufacturing technology

Throughout 2018, additivemanufacturing vendors introduced a number of enhancements that make these systems faster at producing parts. And you can expect this trend to continue through 2019. Staying on top of this innovative, fast moving technology can be a challenge. In a few weeks, though, you will have a chance to learn more about these developments at the annual Additive Manufacturing Users Group Conference, which will be held in Chicago, IL, at the Hilton Chicago, from May 31 through April 4, 2019.

I’ve attended this conference for a number of years and it continues to impress with the access you have to the original inventors of this technology and to expert users of these machines. This conference emphasizes learning. Attendance will increase your understanding of additive technology in ways other shows cannot. Plus, this conference gives you wonderful opportunities to really connect with your fellow users and learn and find answers to some of your most pressing problems.

Meeting and getting to know your fellow attendees during the breakfasts, lunches, dinners, and evening events are terrific resources to go in depth about this technology. You will also develop friendships and helpful connections.

The AMUG Conference is a community; competition takes a back seat to spreading knowledge.

Plus, the conference is filled with sessions that cover a range of topics, such as working with metals and other materials, using AM in specific industries, and overviews of the latest software geared to easing the build of a 3D printed part, just to mention a few subjects.

Speakers showcase their research in how to improve the use of various additive machines and tout discoveries that will make it easier for users to work with this technology. Workshops often involve

hands-on training. Past examples taught attendees to use simulation to avoid typical casting defects, such as air entrapment, shrinkage porosity, cold shuts and mold degradation.

Then, there’s the AMUGexpo and Training Lab. This two-day event lets you see some of the technology and discuss it with sponsor vendors.

The Innovators Showcase is always a highlight of this conference.

In past years, attendees have had a chance to meet and hear what drove this industry’s initial innovators Chuck Hull, Scott Crump, and Fried Vancraen to create their developments in this technology.

This year it will be Professor Gideon Levy, M.SC and D.Sc., of Technology Turn Around (TTA).

The Technical Competition is a great way to see just how innovative users can be. You can examine the entries and speak with the developers. The entries display users unique applications and finishing capabilities. It’s another opportunity to pick up a few tips and techniques.

All of these opportunities give you the information you need to work with additive manufacturing in whatever capacity is coming your way. See you there. DW

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

8

March 2019 www.designworldonline.com

Tech Forward 3-19_Vs2.LL.indd 8

DESIGN WORLD

3/1/19 2:41 PM

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Green Engineering Paul J. Heney

• VP, Editorial Director

Creating better materials for renewable fuels

E-fuels are expected to improve the climate footprint of conventional powertrains. New findings in material research by Freudenberg Sealing Technologies show the impact that OME (oximethylene ether), a substitute for diesel fuel, has on the long-term stability of seals. The research has found that seals made from an already widespread material, fluoro rubber (FKM), are basically suited for renewable fuels. But there are surprisingly large differences between specific FKM varieties.

The automotive industry is not simply betting on electric powertrains as a way to reduce CO2 emissions from road vehicles. Even conventional internal combustion engines are expected to become more climate-friendly, thanks to e-fuels. They are liquid or gaseous vehicle fuels that are not refined from fossil petroleum — but instead are created from carbon and hydrogen with the help of solar and wind energy.

They can be mixed with conventionally produced fuels, bringing a reduction in CO2 emissions if the carbon employed is either extracted in advance from the air or from unavoidable industrial emissions. Until now, there

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Green Engineering 3-19_Vs3.indd 10

has been very little experience with the effects of the new fuels on the long-term stability of seals in fuel systems.

Freudenberg has now explored the behavior of sealing materials that are exposed to OME in exhaustive testing for the first time. The fuel used in the tests consisted of mixtures of standard diesel fuel and OME, which was present in concentrations ranging from 10 to 30% of volume. Other tests were carried out with pure OME and with 100% fossil diesel fuel as references.

DESIGN WORLD

3/1/19 2:45 PM

“We could immediately substitute OEM for a

certain share of fossil diesel fuels ... but especially outside of Europe actual fuel quality can fluctuate greatly due to uncontrolled impurities.”

The volume expansion and the change in mechanical strength of various sealing materials, namely FKM with different levels of fluorine content, FFKM, NBR and EPDM, were measured. In line with industry standards, they were stored for 168 hours at a temperature of 125° C in the test media. Additional exposure tests were carried out with specific fuel combinations over a period of 1,000 hours so long-term effects could be studied. The more the material swelled over this period, the lower its strength, which becomes especially clear from a decline in elongation at break.

Why do experts immediately turn to relatively expensive polymers such as FKM in the evaluation of a new fuel system? According to Dr. Boris Traber, the head of Global Material Development at Freudenberg Sealing Technologies, “Fluorine atoms are significantly larger than carbon atoms, so they form a kind of protective shield for the seal’s basic material,” he said.

“Fluorine-carbon compounds are also highly symmetrical, which neutralizes their charge concentration. The effects that we were able to observe are not unlike a coated pan upon which both water and grease form droplets.”

Carried over to fuels, this shields the nonpolar ingredients such as hydrocarbons and the polar ingredients such as water and ether, which leads to less swelling.

The results even surprised the experienced material experts: In nearly all of the seal materials that were tested, pure OME led to volume expansion that far exceeded the usual swelling values. The image that emerged in FKM compounds was one surprise: it was expected that the swelling volume would decline with rising fluorine content. But that wasn’t the case. The

DESIGN WORLD

Green Engineering 3-19_Vs3.indd 11

expansion in volume was not linear in relation to the fluorine content.

This anomaly can be traced back to a correlation with hydrogen content in this kind of FKM. A higher proportion of hydrogen also leads to high swelling values. Accordingly, the perfluoro rubber (FFKM) that was tested exhibited very good values as well, although it is significantly more expensive than other options. An EPDM also showed low swelling in pure OME. The test series also showed that the tested FKM materials showed a much lower level of swelling in an admixture with up to 30% OME by volume, an encouraging result.

“We could immediately substitute OME for a certain share of fossil diesel fuels,” said Traber. “But our experience shows that — especially outside of Europe — actual fuel quality can fluctuate greatly due to uncontrolled impurities. So, experts should always be consulted during the selection of sealing materials.”

The FKM materials proved to be superior in all the test series. It was not just the fluorine content but rather the entire material structure that was crucial for strength and leak tightness.

As a result, Traber sees no fundamental obstacle to the introduction of renewable fuels: “Even today we have suitable materials available if the configuration is right.” DW Freudenberg Sealing Technologies www.freudenberg.com

www.designworldonline.com

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Contents 3 • 2019

•

vol 14 no 3

•

designworldonline.com

A supplement of Design World March 2019

78

WHY is the new tool for surgeons

72 _MOTION CONTROL

94 _INTERNET OF THINGS

Don’t forget these two things when selecting an amplifier

Distributing IoT information

Using software to size motion designs is rewarding because engineers can efficiently predict which products are suitable for the application. Key considerations when selecting a servo amplifier include dynamic braking and regenerative resistor braking.

78 _LINEAR MOTION Roller-screw actuators: what’s new

Variations on the design often offer advantages over other linear actuation.

86 _TEST & MEASUREMENT On the “edge” of a revolution

New computing architectures are changing industrial applications, impacting the way measurements are made, data are collected, and how it all gets processed.

A better light for

big difference in additive

3D printing

COVER_MPF 3-19_Vs1.indd 59

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58-71

Web servers can be an ideal method for distributing IoT information. Here’s a look at the advantages and disadvantages for two different development approaches.

100 _ELECTRONICS Modern practices in PCB design verification

New software platforms can head off the subtle errors that sometimes creep into manual printed circuit board review processes.

104 _CONNECTORS Connectivity options: DIN and Deutsch connectors

Choosing pre-wired connector solutions for hydraulic valves eliminates time-consuming terminations of hundreds of wires for easy installations.

ON THE COVER Roller screws are becoming more popular due to better design options that fit a wider range of applications. | courtesy of Steinmeyer.

A | S | B | P| E

A | S | B | P| E

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Revenue of over $3 million

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The right motor makes a machine performance

Fostering B2B editorial excellence

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DESIGN WORLD

3/4/19 2:30 PM

181231_AutoM_DW_US.indd Digi Key — PE 02-19.indd 13 1

12/14/18 3/1/19 3:45 8:22 PM AM

5.55 [.22]

"A"

4.70 [.19]

0.50 [.02] 3.18 [.12]

15.75 [.62]

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

3.18 [.13]

3.19

1.22 [.05]

• contents departments 04 Insights

25.20 [.99]

06 Teschler on Topic

22.00 [.87]

Ø21.80 [.86]

13.20 MAX [.52]

08 Technology Forward

Y ELA

2.00 [.08]

R CIT

10 Green Engineering

25.75 [1.01]

M19x1.0 7.75 [.31]

4.65 [.18]

18 Design For Industry

5.80 [.23]

2.75 X 0.50 TYP [.11 X .02]7.00 [.28]

(2X) Q0.40 [.02]

15.00 [.59]

30 Design Notes

4

2.54 [.10]

2.60 [.10]

5.08 [.20]

5.08 [.20]

38 CAE Solutions

6

(2X) 0.50 [.02]

(2X) 0.30 [.01]

2.54 [.10]

48 Coupling Notes 52

16.00 [.63] 20.20 [.80]

15.35 [.60]

2X 4.75 [.19]

2.80 TYP. [.11]

11.00 TYP [.43]

7.80 [.31]

111 Product World 22.00 [.87]

23.70 [.93]

8.00 [.31]

0.80 TYP. [.03]

4.0 [.16]

0.80 TYP [.03]

Internet of Things

120 Ad Index

2X 6.35 [.25]

12.1 [.48]

Ø1.55 [.06]

LEADER

1.75 [.07]

11.5 [.45] 15.1 [.60]

24.0 [.94]

16.0 [.63]

14

CONTENTS 3-19_second page_Vs1.indd 14

March 2019

DESIGN WORLD

3/4/19 8:41 AM

Compact, strong, reliable.

No matter what.

The Optimax series of gearboxes with high overload capacity and long service life.

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

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March 2019

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3/4/19 8:16 AM

Aerospace/military

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

High torque gear coupling for steel

mill roughing stand

A

A major steel manufacturer needed a large replacement gear coupling as part of an

upgrade for a roughing stand drive at one of its U.S. mills. Positioned on the low-speed, high-torque shaft between the gearbox and pinion drive, the gear coupling rotates at approximately 10 RPM. The goal was to ensure that the new coupling was capable of transmitting the new, higher torques.

The mill contacted several coupling manufacturers, including the original coupling OEM. Ameridrives was the only coupling manufacturer that was willing and able to provide a reliable replacement coupling in the large size needed within the required delivery timeline.

The engineering team used the original drawing for the 20-year-old existing coupling to ensure that the new coupling was a size-for-size drop-in replacement. The solution was a massive, torque-dense, size 230, 80-in. diameter gear coupling with a torque rating of 60,000,000 in.lb.

The engineering team incorporated a fully crowned tooth design which increases torque capacity by 300% and operates effectively with up to 3/4° of angular misalignment per gear mesh. The crowned gear tooth design also prevents end loading of the gear teeth when operated within the rated misalignment. The tooth design minimizes wear within the gear mesh. DW

Ameridrives | ameridrives.com 18

March 2019 www.designworldonline.com

DFI 3-19 Vs2.LL.indd 18

DESIGN WORLD

3/4/19 8:45 AM

M a c h i n e To o l

Exchange bearing for linear guides

In extreme circumstances, abrasive sand or glass dust can cause wear of the liners on linear guide rails. Linear guides and axes are also used in around-the-clock operation in automation equipment.

To replace the previous liners, the entire linear carriage needed to be slid off the rail. Especially for linear axes or multi-axis linear robots with belt drives, this could only be done through costly disassembly and recommissioning. igus has developed an exchange bearing for its drylin W linear for swift replacement in high-frequency applications.

For exchange, users unlock the bearing, push out the old liner, and replace it. The exchange bearing saves time and cost and is available in sizes 16 and 20 for linear guides on the drylin W series, besides the standard installation size 10.

The lubrication-free, corrosion-resistant liners are made of polymers for silent and precise sliding of linear guides.

This exchange bearing, made with igus’ iglide J200 material, allows easy replacement directly on the linear rail in a few steps. The bearing reduces downtime, saves set-up costs and ensures 24/7 operation.

A practical, free tool enables safe installation of the liners in very little time. The bearing is available for installation sizes 16 and 20, in addition to installation size 10. Linear robots, linear axes, and drylin W linear guides can thus be easily retrofitted.

Replacing the bearing is simple: First, users loosen the side cover of the linear housing with a screwdriver. With the free tool supplied, which the users can also 3D print, the liner can now be slid out of the housing and directly removed from the rail. The lining made of the wear-resistant and abrasion-resistant high-performance plastic iglide J200 is then clipped onto the rail and inserted into the carriage with the mounting tool.

Users then put the side cover back on the linear housing and the bearing change is finished. With this simple step, the rail is not damaged, and the bearing housing can be reused without disassembly of belts or lead screws.

A pin located in the middle of the side cover secures the liner in the linear housing.

Alternatively, replacement can also be executed with a screwdriver. On the new liner and in the carriage, igus has provided special recesses for this purpose.

DW

igus | igus.com

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Design for Industry Aerospace/Military

Custom flexible shafts for aerospace applications

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The modern airplane is a marvel of engineering. Designs cost billions of dollars and take years to develop, with experts in all manner of mechanism working together to build a craft that works in harmony. Of course, in the field, all that harmony is subject to defeat by circumstance. When one or several of the many valves controlling the movement of fluids fails, a system built to be controlled from the cockpit falls apart. These fluid systems are responsible for vital functions such as anti-icing and even engine ignition. So, the mechanism responsible for quickly bringing inaccessible valves out to a point where the mechanic or flight crew can manually operate the valves is vitally important. Without it, the flight might not be able to depart. Flexible shafts are the components given this critical task. However, until recently, the design of these shafts was completely reliant on one method: simple trial and error.

Each flexible shaft is made of layers of carbon steel wire.

Often these wires number forty or fifty around a core or mandrel. Each layer consists of a handful of wires wrapped in the same direction relative the center, and layers alternate in direction: left, right, left, etc. Depending on how the wires are wound, the top layer will tighten when the shaft is twisted in one or another direction, closing down on the layers underneath. The layer it closes on, in turn, opens up to resist it. This interaction enables the transmission of torque. A good flexible shaft has to have good bending flexibility, but it should not have torsional flexibility – when you rotate it, it should not wind up.

It is a relatively simple design, but many variables can affect the performance of a shaft. The thickness of wires in each layer, the number of wires in each layer, the number of layers, and so on can all change how a shaft acts. Generally, the two outermost layers define the shaft’s torque, but each layer is subject to influence from

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other layers. In a four-layer shaft, for example, layers three and four define the torque characteristics with influence from layer two.

These subtly influential variables seem to be unpredictable. By adding a wire or by removing one, by changing a wire’s thickness (diameter), a shaft can be tweaked closer and closer toward the required specifications.

Now S.S. White’s PERFLEXION analyzes all these factors and predicts performance on several key characteristics, like torsional stiffness, bending stiffness, and torque carrying capacity. With the breakthrough software, flexible shaft design takes about a week, start to finish. If engineers had to experiment with actual shaft designs, it could take months.

For a time, the mysteries refused to reveal themselves. Engineers toiled over successive formulas for years without developing a DESIGN WORLD

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reliable solution. “My degree of confidence was only 50%” says Rahul Shukla, Chief Executive Officer and President of S.S. White, “When the coefficient of correlation is only 50 percent, the relationship is not strong at all. The coefficient of correlation should be 80% or .80 for you to have confidence in your mission.”

Then, an S.S. White engineer bumped the level of confidence to 65%, but it was not Shukla. Adam Black was a newly hired mechanical engineer at the company when he took the formulas to the next level. He had developed a spring formula which described a flexible shaft as a series of springs wound around the core. Shukla took notice and encouraged Black to pursue the project as a doctoral study. After a few years, Dr. Black presented his dissertation, replete with page-and-a-half long formulas describing the mechanics of the flexible shaft.

Promptly, Shukla translated the academic findings into a computer program. The result: PERFLEXION, proprietary software that can accurately predict flexible shaft characteristics. With it, Shukla surpassed his goal of 80% accuracy with prediction, and as a computer program, PERFLEXION does in minutes what would have taken weeks.

With PERFLEXION cutting time costs of the flexible shaft design process down in a profound way, flexible shafts are poised to continue their integration into ever more applications.

The flexible shaft can be extremely valuable to engineers. By design, a flexible shaft takes up misalignments, so it can save engineers time that would otherwise be spent ensuring tight drive system tolerances. Its freedom of movement makes it suitable for hand tools and other applications which require a lot of movement. It also tolerates vibration, works bidirectionally, and ensures reliability with very few moving parts.

Shukla also points out that engineers often first unlock the technology for their practice by interacting with the S.S. White design team. “No universities teach flexible shaft; no textbook has a chapter on flexible shaft.” Over the years, S.S. White has added to PERFLEXION with supplementary calculations and tools to predictively calculate fatigue life, determine limit torque parameters, and predict a host of other characteristics.

Aerospace applications range from TRAS (Thrust Reverser Actuation Systems) that drive multiple actuators from a single point or synchronize multiple actuators, to flap actuation systems that extend flaps from aircraft wings on take-off and landing, to manual override for valves, but the list is not exhaustive. Applications range from thermostat control on gas boilers or furnaces to docking systems on spacecraft, from abattoirs to ophthalmic surgery. DW

S.S. White Technologies | sswhite.net WHAT DO YOU THINK?

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Design for Industry Aerospace/Military

Displacement sensors for rocket and turbine engine validation

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This line of extreme environment displacement sensors and systems has an all-welded and hermetic construction. The sensors and systems are well-suited for rocket and turbine engine validation testing. They are also a solution for other applications that require high accuracy, high reliability, and structural integrity, including nuclear reactors, steam and gas turbines, chemical processes, and hightemperature processing.

Three separate systems are available, specifically designed for high pressure, low temperature, and high-temperature conditions.

The extreme environment sensors and systems work in operating temperatures ranging from -320°F to +1000°F (+1200°F short term).

Displacement systems withstand pressures up to 5000 poundforce per square inch (psi). Their dual-coil sensor design effectively minimizes temperature effects. All of Kaman’s high-temperature transducers are made with hermetically sealed, all laser-welded Inconel housings and use and Inconel-jacketed, mineral-insulated cable. The sensors are unaffected by environmental contaminants and can withstand corrosive gas or liquid environments.

The KD-1925, KD-1950, and KD-1975 Extreme Environment displacement sensors use KDM-8206EE signal conditioning electronics. Available are a full variable channeled rack (with up to 12 channels), a half rack system (with up to 6 channels) and the NEMA housing enclosure. The Measuring Division of Kaman Precision Products has a manufacturing facility that is certified to AS9100 and ISO 9001. DW

Kaman | kamansensors.com

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Power Review

Altra Motion Vol. 8 | No. 1 | 2019

The Power Brands in Power Transmission

Featured in this Edition...

Industrial Internet of Things

Smart Marland Monitoring System NEW Warner Electric Catalogs TB Wood’s Specify the Difference Improvements to Online Product Selection Tools: Boston Gear, Formsprag, TB Wood’s, Warner Electric & Warner Linear Let Nuttall Gear and Delroyd Worm Gear Be Your Partner for Gear Box Rebuilds & Repairs

NEW Smart Marland Monitoring System Remotely monitor equipment operating conditions

Follow Altra Motion on:

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

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

Marland Clutch Matrix Nuttall Gear Portescap Stieber Stromag Svendborg Brakes

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

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

Scan to download the interactive version of the Power Review

3/1/19 1:47 PM

Smart Marland Monitoring System The Smart Marland Monitoring System provides up to the minute access to critical system operating conditions including Vibration, Temperature and Oil Level.

You can now remotely monitor the condition of your equipment from anywhere using your computer or cell phone.

Performance Capabilities: • Monitor up to 6 devices from a single gateway • Set desired report intervals • Perform statistical analysis to identify maintenance and repair needs • Alarm notifications

Simple System Requirements: • Power supply (24VDC, 120/240 VAC, 50/60 Hz) • Less than 200m line of site between gateway and devices • Access to local network or cellular signal

Reporting Capability: • Current measurements • Historic trending • Vibration analysis

Industrial Internet of Things

For more information, download P-8666-MC from www.AltraLiterature.com

NEW Warner Electric Catalogs Warner Electric has released five new catalogs detailing electromagnetic clutches/brakes. Packaged product overviews and the full engineering section are included in all catalogs.

P-8586-WE NEMA C-Face Clutches, Brakes and Clutch/Brake Combinations

Packaged product overviews

P-8587-WE Shaft Mounted Clutches & Brakes P-8588-WE Base Mounted Clutch/Brake Combinations P-8589-WE Electrically Released Spring-Set Brakes & Unibrake AC Motor Brakes P-8590-WE Permanent Magnet Electrically Released Brakes

For more information, download the catalogs listed above from www.AltraLiterature.com

TB Wood’s Specify the Difference TB Wood’s is highlighting what sets them apart in the industry in the areas of SERVICE, SUPPORT and STRENGTH. STRENGTH

• We provide fast answers, with a “live” customer service associate based at our factory • Our manufacturing plants are structured to provide short lead times • We provide fast, accurate quote turnaround • We’re responsive to ensure that our customers questions and issues will be promptly and properly addressed

• We provide the right solution, the first time, every time.

• Our customer service team is very knowledgeable • We’re extremely experienced with more than a century of manufacturing in Chambersburg, PA • We’re problem solvers for the tough applications many competitors can’t handle • We provide exceptional field support

• We provide the best-in-class design and materials • We deliver consistent product quality you can depend on • We maintain complete control of product specifications and design flexibility

For more information, visit www.tbwoods.com

Altra Industrial_#2_3-19.indd 24

Scan to see the Specify the Difference overview video

SERV IC

SUPPORT

E

SUPP O RT

SERVICE

y the nce f i c e p S re s Dif fe ’ d o o TB W H ST RE NGT

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Improvements to Online Product Selection Tools: Boston Gear, Formsprag, TB Wood’s, Warner Electric & Warner Linear The Boston Gear, Formsprag Clutch, TB Wood’s, Warner Electric and Warner Linear eCatalogs have been updated to a more user-friendly interface with simplified navigation tools. Line drawings are now expandable for easier reading and new CAD models have been added. Easily select filters and compare products to meet specific requirements and applications. Request quotes, view related literature and product models. eCatalogs are also mobile device and tablet friendly.

View 3D Models

Filtered selections now remain at the top of the page and scroll with the user

Hover on a product image to zoom or click to view larger image

Formsprag added a large number of 3D CAD models

Boston Gear one page specification sheets are now available

Quickly download related product literature For more information, visit the brand sites below and click on the eCatalog link in the menu bar or the eCatalog icon: www.bostongear.com www.formsprag.com www.tbwoods.com

www.warnerelectric.com www.warnerlinear.com

Let Nuttall Gear and Delroyd Worm Gear Be Your Partner for Gear Box Rebuilds & Repairs Nuttall and Delroyd have extensive experience in gear drive applications, combined with the total manufacturing and design capabilities that enable them to provide a single, comprehensive source for improving productivity, and offers a cost-effective repair solution for any manufacturer’s gear drive.

All complete rebuilds include new factory warranty.

• Repair and Rebuild • Redesign and Rerate • System Analysis • Quality Assurance • Load Testing

• Field Service - 24-Hour Emergency Service - Mill Outage Support Services - Predictive Maintenance Services - Repairs - Torque Measurements - Training Seminars

For more information, visit: www.nuttallgear.com/services/rebuild-services www.delroyd.com/services/rebuild-services

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

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

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

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

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

Duraflex®

E

SUPP O

RT

SERV IC

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

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

• Minimizes Stress: Patented shoe design minimizes bond stress to ensure long life.

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

• High misalignment capability – up to 4°.

• No lubrication or maintenance.

• Available in standard and metric versions.

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

y the nce f i c e p S if fere D s ’ d o TB Wo H ST RE NGT

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For more information call:

1.888.829.6637

or visit www.tbwoods.com

3/1/19 1:44 PM

Design for Industry Packaging

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

Photoelectric sensor

with long distance detection

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BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

The Allen-Bradley 42AF RightSight M30 photoelectric sensor from Rockwell Automation was designed for long-distance detection and increased

PRECISION NUTS & WASHERS

environmental tolerance for material handling and packaging and more. Built with improved environmental resistance and long-distance detection in a mid-sized, right-angle housing, the RightSight M30 smart sensor has the flexibility and performance specs required for a range of high-demand applications. “This photoelectric sensor was developed to help increase reliability in harsh environments where dirt or undesired particles could accumulate on the sensor lens,� says Adonis Evangelista, product manager, Rockwell Automation.

Built with IO-Link capability, the sensor easily integrates into The Connected Enterprise by delivering data and diagnostics from the sensor directly into a control system to help minimize downtime and increase productivity. With this capability, the sensor provides information such as signal strength, location, proximity alarms and timing functions that help create operational efficiencies and streamline troubleshooting. The 360° high visibility LED power and status indicators further assist in setup, monitoring, and troubleshooting.

The right-angle housing has a universal 30 mm nose and 18 mm base mount for fast, flexible installation and replacement.

The IP67/IP69k/1200 psi rated housing is fully sealed, enabling the RightSight M30 to withstand tough industrial environments, including those involving high-pressure and high-temperature wash-downs. Featuring multiple sensing modes, the sensor is also available in adjustment-free models and teachable versions that adjust sensitivity and output configuration at the push of a button. DW

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

ADAPTER SLEEVE ASSEMBLIES

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

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

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ET

-H

IG

GI

NS US

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

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

or a good distributor.

Rockwell Automation | rockwellautomation.com

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

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Design for Industry Packaging

Robotic End-Of-Arm Tooling helps build automated systems

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Robotic End-Of-Arm Tooling (EOAT) products help engineers to

build automated systems that perfectly fit their specific applications.

This complete set of off-the-shelf standard components can be used to solve the real automation challenges facing manufacturers.

The EOAT component line is well suited for the automation challenges facing the packaging industry. A full and flexible assortment of modular EOAT components makes it possible to rapidly put together an automated handling/gripping system that is configured for any packaging or palletizing task. The EOAT line offers products of the performance required for high speed automated robotic systems as well as for a variety of materials.

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Made up of several different families of components, this EOAT line offers standard products in a range of sizes and dimensions, resulting in a modular automation technology set comprising 600 different pieces of equipment.

“The EOAT line is a bit like a Lego technic set. It enables our customers to quickly build the specific automation tooling systems that they need for whatever application challenges they encounter on their manufacturing floors,” explains Anton Kullh, Vice President of Piab’s Robotic Gripping Division.

Drawing on the experience of the Robotic Gripping Division’s development and manufacturing units in the United States and Germany, Piab has put together a set of standard components designed for any automated handling process.

The modular nature of these EOAT components offers a high level of customization that is perfect for manufacturers of, for instance, injection molded plastic parts for automobiles. Often quite fragile and featuring fine design details, such parts require automation tools of precision and flexibility. Piab’s EOAT line helps manufacturers to meet such specific challenges. DW

Piab | piab.com

WHAT DO YOU THINK?

TRANSFORMING CONVEYOR AUTOMATION We get your product to the exact location, in the exact position, at the exact time it needs to be there for the next phase in the process.

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The Result? ✔ Optimal Performance and Efficiency ✔ Maximized Production Output

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✔ Reduced Waste ✔ Less Downtime

www.dornerconveyors.com/dwm | 800.397.8664

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Design Notes

Safety is an integral part of the 120-volt Electro-Lift as it leverages a sealed gear-driven system, which ensures the frames will not drift down when changing screens.

Electro-Lift platform speeds screen changes

Edited by Mike Santora • Associate Editor

Midwestern Industries, Inc. has been a manufacturer for the screening industry since 1953 and has recently launched its Electro-Lift separator screen changing system. Engineered with a 120-volt sealed gear-driven system, this design’s operation involves simply plugging into any outlet and pressing a switch.

The system’s configuration assists with the lifting of separator frames to eliminate the need for two people to remove each frame — making screen changes virtually a one-person operation. Typically, screens must have hands on them when changing out. However, Electro-Lift is mounted independently to the frame so there is no need for it to be locked out when you are working under them with your hands. The

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Electro-Lift is adaptable to fit a variety of different frame deck configurations and most makes and models of other round separators can easily convert to this system.

This engineering versatility also allows operators to change screens and gain access to the interior of the unit for cleaning or inspection — which is exponentially faster than using comparable systems. The system can also be used to inspect the screens to ensure quality control. Ultimately, the system

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changes screens faster with no lifting of heavy frames, which drives the ElectroLift system’s key attribute of reducing downtime to a minimum.

Safety is an integral part of the 120volt Electro-Lift as it leverages a sealed gear-driven system, which ensures the frames will not drift down when changing screens — even if the power fails. Unlike traditional hydraulic or pneumatic changing systems, if the power does go out during screen changes, the frames will not fall. Because the unit is 120-volt, it can be plugged into any convenient outlet, which eliminates the need for customers to provide compressed air.

Whereas most competitive versions will use some form of clamping device if power is lost, Electro-Lift uses two mechanical screws powered by the actuator. Additionally, there are no cumbersome hoses to deal with, and the sealed system eliminates the need for greasing which makes it environmentally cleaner.

The Electro-Lift separator screen changing system is a solution for myriad processing industry applications including Pharmaceutical, Food & Beverage, Chemicals, Waste Water, Shot Peening, Plastics, Roofing Granules, Ceramics, and Powdered Metals, amongst others. DW

Midwestern Industries | midwesternind.com The Electro-Lift separator screen changing system is suitable for applications including Pharmaceutical, Food & Beverage, Chemicals, Waste Water, Shot Peening, Plastics, Roofing Granules, Ceramics, and Powdered Metals,

WHAT DO YOU THINK?

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THIN ENOUGH?

amongst others.

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

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

DESIGN WORLD

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March 2019

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Design Notes

PLM streamlines operations for medical device startup

Edited by Mike Santora • Associate Editor

The EchoNous high-performance miniaturized ultrasound’s tablet display.

When ultrasound and bioengineering company, EchoNous began to scale out its operations, their team realized that it needed robust management software tools to control its Bill of Materials (BOM). Many employees had worked with PLM systems in the past, but many were labor intensive to configure and customize. Also, they demanded significant IT involvement to maintain the necessary on-premise hardware infrastructure and were difficult to integrate with manufacturing, ERP, and CRM systems.

The EchoNous team evaluated a variety of product lifecycle management systems. As part of the search process, the company met with IMAGINiT Technologies and learned about Autodesk Fusion Lifecycle. This solution seemed like a good fit for a lean, startup firm for several reasons. Fusion Lifecycle is cloud-based, so IT resources were not needed to configure and maintain hardware or handle software upgrades. The platform was designed for easy integration with other information systems, and it could

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be easily customized without a team of dedicated configuration analysts.

EchoNous signed the agreement with IMAGINiT; the company’s first Fusion Lifecycle workspaces were up and running in 2 months. The system implementation was divided into three phases, each lasting around 20 days.

During Phase 1; IMAGINiT implemented the workspaces needed to support Items and BOMs, Change Management, and Assets and Records Management.

Phase 2 was focused on standard operating procedures for Training and Deviations. And during Phase 3 both companies worked together on Supplier Management, CAPAs (corrective and preventative actions), Complaint Handling, and Audit Management.

The EchoNous was able to create a predefined list of approvers for change notifications to save time and they took over some manufacturing processes from

an Australian subsidiary. In the coming months, EchoNous plans to expand its use of Fusion Lifecycle. The company is automating more tasks and will be integrating Autodesk Fusion Lifecycle with NetSuite, Salesforce, and a Manufacturing Execution System (MES) to create a robust IT infrastructure for the business. DW

EchoNous stand and tablet configuration.

IMAGINiT | www. imaginit.com

Linear and bearingless rotary encoders for motor feedback

Absolute and incremental magnetic measurement     

Contactless and completely wear and maintenance-free Extremely precise, even in the presence of contamination of the scale Flexible sizing of measuring lengths and diameters Easy handling, high positional accuracy of highly dynamic processes Customized, individual PCB solutions

Design Notes 3-19_Vs3.LL.indd 33

SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com

3/5/19 9:06 AM

Design Notes

Hydraulic internal gear pump system used for automatic transmission

Edited by Mike Santora • Associate Editor

A company contacted Technymon G.B.T. for assistance in solving a reoccurring transmission failure due to oil leakage when it suspected that the problem stemmed from a sliding bearing (MU material) suffering from extensive wear out.

The Technymon engineering team began the investigation with an analysis of the dimensional tolerance and operating parameters used for the application: 1. Shaft surface roughness Ra: = 0,1 to 0,3 µm 2. Shaft dimension used by customer: 31,960 to 31,990 3. Roughness of housing Rz: 10 4. Housing dimension: 36 H7 5. Minimum/maximum pressure generated by pump: 10-25 Bar 6. Application motion: Rotatory 7. Minimum/maximum RPM: 1500-4000 8. Turning direction of shaft: Clockwise 9. Oil temperature in working condition: 100°C, 10. Highest temperature peak for short time: 150°C The engineering team noted that all the parameters were within the material performance/working range and observed that analysis performed at the company’s test bench was satisfactory and showed almost no wear.

So why were there such significant variations in failure hours for different automatic transmissions working in field?

The sliding bearing in stock was dimensionally perfect, but photographs indicated that wear behavior was concentrated on

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Design Notes 3-19_Vs3.LL.indd 34

certain angles and these angles were not constant. Since the part moved in a rotary motion, that wear would be expected to be more uniform.

Next, the company provided ten failed pieces from the field to investigate further. The wear angle on the sliding surface was entirely different in almost every piece and ranged from 145° to 65°.

This inconsistent wear pattern pointed towards an external element/parameter causing the variation.

The investigation directly indicated that the frequency generated by the engine caused the vibration, which lead initial cavitation. After generating the cavitation — coupled with the high limit of the operating pressure in relation to the bearing material and size — the bearings were being rotated inside the assembly.

DESIGN WORLD

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Change the way you look at pressure measurement

oem pressure transmitters

kelleramerica.com

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3/1/19 2:27 PM

Design Notes The Technymon engineering team analyzed the wear pattern in detail, and the initial indication was a problem concerning insufficient lubrication. The oil used had a viscosity of 10 mPa. ·s and was perfectly compatible with the sliding bearing, but data indicated that the viscosity was changing drastically during the working cycle and indicated clearly that that the lubrication was insufficient.

So why was the oil viscosity changing?

Oil temperature and working pressure were the likely answers, so the technical team observed the supplied bearings once again. Due to high pressure, the bearing was rotating inside the assembly and creating the rise in temperature of hydraulic oil, which was leading to the change in viscosity and in turn the excessive unpatterned wear with variation in failure hours.

After requesting that the company check their mounting pressure during

assembly and determining there was no issue, the technical team began investigating the frequency generated by the engine and operating parameters of the application, which would ultimately lead them to the solution.

The investigation directly indicated that the frequency generated by the engine caused the vibration, which lead initial cavitation. After generating the cavitation — coupled with the high limit of the operating pressure in relation to the bearing material and size — the bearings were being rotated inside the assembly.

This rotation caused metal-on-metal contact between sliding bearing’s outer diameter and housing’s internal diameter.

It increased the flash temperature of the system and fundamentally altered the oil viscosity, which resulted in insufficient lubrication during the operations. The

unpatterened wear that was observed could be explained by variations in the engine frequency and miscellaneous field conditions.

The technical team was able to provide two solutions to remedy the problem: modify the assembly housing with location fit to provide the bearing additional support and prevent rotation or suggest a different product material and size. DW

Technymon | technymon.com

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Design Notes 3-19_Vs3.LL.indd 36

800-933-4915 WWW.TRIMLOK.COM INFO@TRIMLOK.COM DESIGN WORLD

3/4/19 2:05 PM

HELPING YOU PROTECT WHAT

MATTERS

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CAE Solutions NX Software includes Artificial Intelligence and Machine Learning features

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The latest version of NX software includes an expansion of the Digital Innovation Platform that has been enhanced with machine learning (ML) and artificial intelligence (AI) capabilities. These new features can predict next steps and update the user interface to help users more efficiently use software to increase productivity.

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The ability to automatically adapt the user interface to meet the needs of different types of users across multiple departments can result in higher adoption rates, leading to a higher-quality computer-aided technology (CAx) system and the creation of a more robust digital twin.

Machine learning (ML) is increasingly being leveraged in the product design

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process for a competitive advantage. ML can deliver valuable business insights quickly and efficiently, and it has the power to process, analyze, and learn from large volumes of data. AI and ML can also be used to monitor the actions of the user, their success and failures, to dynamically determine how to serve up the right NX commands and or modify

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HELUKABEL offers plug-and-play solutions for Industrial Ethernet systems.

the interface and leverage learned UI usage knowledge for CAx environment personalization.

“There’s always been a capability-usability tradeoff with CAD applications. The more expansive it gets, the more difficult it is to use and master,” said Chad Jackson, Chief Analyst at Lifecycle Insights. “The Adaptive UI in NX, however, circumvents that issue. It guides users, new and old, to the right function at the right time. Many will benefit.”

The Siemens Digital Innovation Platform is continually expanding to enable customers to create the most comprehensive digital twin of a product, the production environment and of the performance of the product.

Integrating ML and AI into NX software offers benefits of speed, power, efficiency and intelligence through learning, without having to explicitly program these characteristics.

Customers can enhance the design process and reduce time to market. DW

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Siemens PLM Software www.siemens.com/plm

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CAE Solutions

Materials intelligence for engineering modeling & simulation: ANSYS to acquire industry leader Granta Design

By Bruce Jenkins • Ora-Research

A

ANSYS reached agreement to acquire Granta Design, the premier provider of materials information

technology for engineering and manufacturing. The acquisition “will give customers access to [a] rich source of intelligence for materials selection and management,” ANSYS said. The move “will expand ANSYS’ portfolio into this important area, giving ANSYS customers access to material intelligence, including data that is critical to successful simulations.” The transaction is expected to close in the first quarter of 2019.

Terms were not disclosed; ANSYS said it will provide further details of the transaction and its impact on the company’s 2019 financial outlook after the closing.

Headquartered in Cambridge, UK, Granta Design reports more than 180 employees. Its customers are a blue-chip list of the world’s leading engineering and manufacturing names—Airbus, General Motors, Emerson Electric, Lockheed Martin, NASA, Saudi Aramco Rolls-Royce and numerous others.

“With advances in the performance of metals, plastics and other materials, including innovations in areas such as composites and additive manufacturing,

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manufacturers have a wealth of material choices when developing products,” ANSYS notes. “At the same time, they require accurate, traceable and reliable materials information to make smart materials choices and to ensure simulation accuracy.”

With this acquisition, ANSYS says its “customers can benefit from access to the world’s premier system for managing corporate material intelligence and the market-leading solution for materials sources, selection and management.” For Granta customers, they “can expect even easier access to ANSYS’ goldstandard simulation technology.”

March 2019 www.designworldonline.com

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ANSYS: “Granta will continue its open ecosystem” Granta has a long track record as a provider of application-vendor-neutral technology, one of the keys to its standing as the most widely used and accepted industry standard for materials intelligence today. Given that critical success element, ANSYS wisely pledged that “Granta will continue its open ecosystem, integrating with a wide range of leading product lifecycle management, CAD and computer-aided engineering solutions.”

Product line: GRANTA MI, CES Selector, Data Products, CES EduPack Its products include GRANTA MI, the “leading system for enterprise materials information management,” and CES Selector, which enables users to explore

the impact that different materials have on the behavior of their product designs.

Its Data Products are a “comprehensive library of materials reference data” assembled by Granta. The company also develops CES EduPack, “the world’s leading teaching resource for materials topics in engineering, science, processing and design,” used by more than 1,000 universities worldwide, according to the company.

“Granta Design has pioneered the field of materials information technology,” said ANSYS vice president and general manager Shane Emswiler.

“With materials engineering becoming an increasingly important aspect of product development, our customers require high-quality and comprehensive materials information for accurate simulation results. Integrating Granta’s

solutions into the ANSYS portfolio will provide a seamless user experience—and enable our customers to innovate like never before.”

“For nearly 50 years, ANSYS has been the leader in engineering simulation,” said David Cebon, cofounder and managing director of Granta Design. “Combining that expertise with Granta’s decades of experience in material intelligence will help our customers make smarter decisions when developing their nextgeneration products.” DW

Granta Design www.grantadesign.com ANSYS www.ansys.com

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CAE Solutions hyperMILL 2019.1 expands finishing capabilities, process optimizations and more

Conical barrel cutter: finish prismatic fillets with an extremely high feed rate

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hyperMILL 2019.1 CAD/CAM software suite has a range of new features and enhancements including an expanded Finishing Module in the hyperMILL MAXX Machining Performance Package, process optimizations such as a new thread milling module, a new function for reducing calculation times, tool database flexibility, and CAD optimization.

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• 5-axis prismatic Fillet Finishing The 5-axis Prismatic fillet finishing function in hyperMILL MAXX machining enables the geometry and automatic inclination of barrel cutters to be applied similar to high feed cutters, using a plunging and pulling movement at extremely high feed rates. Maximum performance is attainable using conical barrel cutters (also known as arc segment or circle segment end mills). Ball or bull nose end mills can also be efficiently used.

March 2019 www.designworldonline.com

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• Improved surface finishes The Profile Milling technique in 2019.1 has a new option that improves the quality of machined surfaces. Traditional CAM software processing uses a close-approximation mesh surface for machining calculations. A benefit of the mesh approach is to standardize CAM processing, even in cases when the design model has imperfections. OPEN MIND has implemented new techniques in hyperMILL

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CAE Solutions 2019.1 for machining directly to the model surface, which has substantially improved surface finishes.

• Enhanced process optimizations Among the process improvements in 2019.1, the updated Thread Milling module is easy to program and supports a number of thread milling types, while simplifying selection and milling direction options.

Also new to 2019.1 is the elimination of cycle recalculation requirements, improving processing speed.

Recalculation cycles are no longer required when job I.D. numbers are changed or when fixture positions change. In addition, for improved tool management users now have the option to individually expand the tool database

in hyperMILL 2019.1, allowing the ability to store order numbers, pricing and tool life detail. hyperCAD-S in the 2019.1 suite, which is optimized for CAM requirements, includes polyline management, enabling CAD functions such as lengthening or shortening to be applied by the polylines element type. Polylines can also be machined similar to all other elements, with trim, join, orient or select. DW

OPEN MIND Technologies AG www.openmind-tech.com

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Innovation Driving Quality

NKK Switches (NKK) is a world leading designer and manufacturer of innovative electromechanical switches. By designing, producing and selling the industry’s most extensive selection of electromechanical switches, NKK sets the standard for quality, stability and reliability in switch solutions.

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CAE Solutions

3D print parts without supports

Flow is a simulation driven, process aware print preparation software.

Flow ensures predictable print outcomes while significantly reducing print preparation time

V

VELO3D announced advances to its print preparation software, Flow. Driven by

an integrated simulation engine, Flow ensures predictable print outcomes, while its native CAD workflow controls performance consistent with the design intent and reduces print preparation time. Working in concert with VELO3D’s Sapphire system Flow enables next generation SupportFree additive manufacturing for parts previously not possible.

Flow is designed for Sapphire, VELO3D’s laser fusion metal additive

manufacturing system. It includes tools that help with part orientation, support generation, simulated print predictions, per-surface process application, slice composer and process review. As a result, manufacturers can print complex part geometries SupportFree, enabling volume manufacturing of parts that are otherwise impossible or uneconomical to print due to hard-to-remove support structures.

Manufacturing any design VELO3D’s ability to print low angles and overhangs below five degrees, as well as large inner diameters and tubes up to 40 mm without the need for supports eliminates most post-processing cleanup. This capability breaks the limiting boundary of other systems that require supports for most angles below 45 degrees, constraining design freedom and limiting the number of designs that can be produced with additive technology.

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DESIGN WORLD

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Top: Conventional metal 3D Printing adds supports for surfaces below 45 degrees.

Internal supports become inaccessible making the part impossible to make.

Bottom: Velo3D eliminates the need for internal supports making these parts viable with metal 3D Printing

Flow key features include: A physics-driven simulation engine built from the ground up, optimized for VELO3D process capabilities and the Sapphire system. It contributes to a first print success rate of up to 90%, preventing many failed iterations. Â The simulation utility predicts the print outcome, applies print deformation correction and validates the execution feasibility of the print prior to starting the build process. It ensures that the print outcome results in dimensionally accurate design intent.

A sophisticated composer detects geometric features and applies the optimized, proven print process to specific features for predictable print outcomes.

The integration of print preparation, simulation and composing capabilities into a single software eliminates historic incompatibilities, simplifying the workflow. Native CAD workflow helps with smart selection, refinement, and

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CAE Solutions 3-19_Vs2.indd 47

filtering of part features and reduces hundreds of manual steps to a few clicks.

Flow print preparation software manages print outcome based on design intent. With the native CAD import, the design intent is preserved, and users can optimize for target cost and quality parameters by surface. It enables selection of areas to optimize the surface finish, and others for throughput. DW

VELO3D www.velo3d.com

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March 2019

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3/4/19 9:19 AM

Coupling Notes Edited by: Mike Santora • Associate Editor

Damaged coupling calls for flying rotors in for fast repair

150 MW generators provide power for around 100,000 homes; minimizing downtime is crucial for keeping the lights on in a local population. For one power plant in the Philippines, the swift repair of a steam turbine rotor was essential. It was airfreighted to a service center in Indonesia where specialists completed the repairs within eight weeks.

After just eight weeks, the rotor was shipped back to the customer.

Steam turbines require constant monitoring and some of the most useful performance indicators are the vibration sensors used across the turbine. Highspeed rotating equipment can be affected by several issues and many of them will cause increased vibration readings.

In this case, the steam turbine rotor consisted of a high-intermediate pressure (HIP) section connected to the low pressure (LP) rotor, which together powered the 150 MW generator. The power plant engineers were studying elevated vibration readings on one of the steam turbines. Further investigation revealed a severe crack in the coupling of the HIP rotor, which condemned the rotor without immediate repair.

Also, there was damage to the coupling bolts’ holes of both HIP and LP rotors, which together suggested a possible alignment problem.

After dynamic balancing, the rotor was packaged ready for transport. The power plant was faced with two options: to replace the cracked rotor with a new rotor or

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3/4/19 9:21 AM

find a specialist with the expertise to complete an effective repair of the rotor.

A new rotor would take at least a year to arrive; engaging a specialist maintenance provider could see the turbine back in action much more quickly. Rotating equipment service specialist Sulzer’s engineering team was only a short flight away in neighboring Indonesia, where the engineers could not only repair the coupling but also improve the rotor alignment and reduce stress levels within the coupling.

Hepy Hanipa, Head of Turbo Services South East Asia, explains: “With time of the essence, both the HIP rotor and the LP rotor were loaded onto Antonov cargo planes and shipped to our facility in Purwakarta. Here, an initial inspection confirmed that the coupling was no longer operational and would need to be repaired.”

Having removed the original coupling, Sulzer engineers used reverse engineering techniques to recreate a 3-dimensional drawing of the part and apply stress analysis to ensure a flawless design. The coupling, which connects the HIP rotor to the LP rotor, must be manufactured to very tight tolerances to ensure perfect alignment of the complete rotor shaft.

The process of repairing the coupling involves gradually building up material using an automated submergedarc welding process. Once complete, and having passed non-destructive examinations (NDE), the residual stresses caused by the welding process were removed by post weld heat treatment and the machining process of the repaired coupling could begin. Using a large precision lathe, engineers established the exact dimensions of the original coupling, ready for the machining

of the bolt holes. These were completed along with the holes in the LP rotor coupling flange that also needed to be repaired.

The calculations for the alignment were made along with a simulation of the rotor alignment that took into consideration the thermal growth of the rotor train during operation. The original alignment had been suspected as one of the contributors to the damage to the rotor, so the new calculations were implemented in the field, making adjustments to the bearing pedestals.

In the meantime, with all of the machining operations complete, the two rotors were dynamically balanced in-house to ensure optimum performance once they were installed.

Dynamic balancing is done at relatively low speeds, so in most cases, some minor adjustments, known as trim balancing, are required once the

After dynamic balancing, the rotor was packaged ready for transport.

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March 2019

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Coupling Notes rotor is installed and able to operate at higher speeds.

In all, the workshop operations were completed within eight weeks, after which the rotors were carefully packaged and airfreighted back to the Philippines to minimize the overall project duration.

The protective shipping containers were slightly modified to ensure they would fit into the aircraft, preventing any delays in the process.

Hepy concludes, “While everyone involved with the project expected the rotor to need some trim balancing, none was required, and the turbine achieved a full 72-hour period of initial operation without any incidents. Since then, the vibration levels have been monitored continuously during operation and no anomalies have occurred.” DW

The coupling repair process began with submerged-arc welding.

Sulzer | www.sulzer.com

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Internet of Things

A tradeshow for the Industrial Internet of Things

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Hannover Fairs USA and Deutsche Messe, the organizers of

the HANNOVER MESSE and its North American edition, HANNOVER MESSE USA, will debut a new trade show. This show is the Digital Industry USA (DIG/IN USA), a biennial Industrial Internet of Things (IIoT) trade show that will take companies through the adoption of connected technologies, from the proof-of-concept phase to a fully connected enterprise. It will debut at the Kentucky International Convention Center, Louisville, KY from Sept.

10-12, 2019 Exhibitors will demonstrate how to implement digitalization by featuring smart factory case studies and real-time IIoT solutions, such as Production Efficiency, Data Analytics & Cloud, AI & Intelligent Machines, Security, Robots/Cobots and Additive Manufacturing. The goal of DIG/IN USA is to empower thought leadership from the factory floor staff to the C-Suite with a focus on advancing small to large companies in the automotive, aerospace and defense, machinery and equipment, energy/oil and gas, food and beverage, packaging and assembly, science lab equipment and logistics industries.

“DIG/IN USA blends a focus on IIoT, automation and controls technology and follow-ups to HANNOVER MESSE USA 2018, which was a huge success for industry exhibitors and attendees alike,” said Larry Turner, CEO of Hannover Fairs USA. “DIG/IN USA will be an IIoT event as innovative and forward-thinking as the industry it supports.”

DIG/IN USA will feature hands-on demonstrations, workshops and educational sessions across the trade show floor. The direction of DIG/IN USA is being steered by a show committee comprised of industry experts from ARC Advisory Group, Beckhoff, Forcam, Hiwin, Microsoft, Nikola Industrial & Manufacturing Solutions and SAP. “Creating a trade show and educational conference that is focused more intently on the increasing needs of IIoT and Industry 4.0 is so crucial,” said Brian Pitzer, Global VP of Nikola Industrial & Manufacturing Solutions. “This area will continue to grow at an astounding rate over the next 10 years as it is easily the single biggest challenge facing the manufacturing and industrial environments today.”

DIG/IN USA attendees will see and experience critical IIoT solutions to understand better how they interconnect in the factory. The show will host educational discussions and experiences across all levels of IIoT adoption, allowing attendees to foster long-lasting business relationships and address their most pressing needs.

“DIG/IN USA offers attendees the opportunity to identify the products and make the contacts necessary to further their automation goals. With

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the growth of automation in small and medium sized companies who may not have the engineering or IT resources to identify the right components to produce a complete solution, a ‘one stop shop’ with education offerings will be a valuable opportunity,” said Shawn Lawrence, product marketing manager of HIWIN Corporation USA. In addition to exhibits, learning labs and on-floor educational presentations, DIG/IN USA will feature a start-up area and hackathon, as well as virtual reality space to demonstrate a variety of technologies such as digital twin. Off the show floor, HFUSA will host a highlevel executive conference the day prior to the event and local area tours of a distillery using IIoT equipment, the Toyota plant and the UPS distribution center in Louisville.

“I am pleased to hear that Hannover Fairs USA is planning a new, immersive IIoT trade event that attracts highly automated companies, as well as those wanting to be more competitive, analytical and interconnected,” said Mark Gallant, senior director of marketing IoT manufacturing solutions at PTC. Leading the Digital Industry management team are Chicago-based Adrienne Zepeda, show manager of North American industrial technology events at HFUSA, and Raymond Bianchi, VP of events & business development at HFUSA. DW

Digital Industry USA www.digitalindustryusa.com

DESIGN WORLD

3/4/19 9:34 AM

IoT demand drives production of 200 mm wafers

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Strong 200 mm wafer growth mirrors sound capacity demand seen across various industry segments. From 2019 to 2022, for example, wafer shipments for MEMS and sensors devices are expected to increase 25% while shipments for power devices and foundries are forecast to jump 23% and 18%, respectively, the SEMI Global 200 mm Fab Outlook shows. The increases in 200 mm fab count and installed capacity reflect continuing 200 mm industry strength as it continues to add capacity and even open new fabs.

The SEMI Global 200 mm Fab Outlook report added seven new facilities, with 160 updates to 109 fabs, since its most recent publication in July 2018. A total of 16 new facilities or lines, 14 of them volume fabs, are expected to begin operation between 2019 and 2022. The report takes into account both equipment transferred from one fab to another and equipment revitalized after being held in storage, such as for SK Hynix and Samsung.

Across the industry, recent sudden changes in investment plans for leading-edge devices such as memory have triggered a projected double-digit decline in spending in 2019. However, with demand for mature devices using wafers 200 mm and smaller stable or evening growing, it would be no surprise to see plans emerge for even more 200 mm capacity and new fabs to meet growing demand. DW

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Internet of Things

EtherCAT products assist real-time control

I

If you plan on attending ProMat 2019 in Chicago, at McCormick Place from April 8 through 11,

you will have a chance to see a number of EtherCAT products. One will be the North American debut of the ultra-compact CX7000 embedded controller and a preview of EtherCAT G gigabit industrial Ethernet technology.

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Expanded EtherCAT offerings will include the EK1000 EtherCAT TSN Coupler and EtherCAT G offerings. The EtherCAT TSN approach assists distribution centers in the implementation of real-time systems. For new installations or retrofits, this flexible technology will keep pace with rapidly evolving networking methodologies in the material handling industry. EtherCAT G and EtherCAT G10 will provide communication at 1 Gbit/s and 10 Gbit/s, respectively, in conformance with the IEEE 802.3 Ethernet standard. A branch controller model will enable the parallel operation of standard 100 Mbit/s segments with EtherCAT G or G10 as the main trunk, or vice versa, to provide the fast communication needed in today’s distribution centers.

The CX7000 embedded controller is a compact yet powerful EtherCAT controller, with a single-core, 400 MHz ARM Cortex-M7 processor. The DIN rail-mountable controller maintains minimum footprint with dimensions of just 49 x 100 x 72 mm. Along with the ability to directly connect to the full range of Beckhoff EtherCAT I/O modules through a backplane, it has eight 24 V digital inputs and four outputs built in. It leverages the TwinCAT 3 automation software, enabling the CX7000 controllers to act as a distributed control device on the EtherCAT network across distribution centers.

The compact multicore C6015 Industrial PC (IPC) with an Intel Atom processor and the C6030 IPC with Intel Core i-series processors suit mid-

March 2019 www.designworldonline.com

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range to complex machine control, but they can also be used for other functions such as edge computing and IoT gateway devices to connect existing systems to major cloud platforms, such as Microsoft Azure, Amazon Web Services (AWS) and SAP HANA. The AMP8000 distributed servo drive system with One Cable Automation combines a servo drive and servomotor in one space-saving device enabling enclosure-free motion control architectures. The system integrates STO and SS1 motion safety functions.

DW

Beckhoff Automation www.beckhoff.com

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Internet of Things PC card family supports CC-Link

C

CC-Link is the leading fieldbus in the Asian region and

is the fieldbus of choice for manufactures of automation devices who want to expand their business to Asia.

These cards are part of additional products in the cifX PC card family that support CC-Link IE Field. The CC-Link IE Field cards are Intelligent Device Stations in the network and offer a fixed baud rate of 1Gbit/s. Acyclic communication is available with SLMP (Seamless Message Protocol).

The cifX PC cards are a unified standard supporting all Real-Time Ethernet and Fieldbus systems, like CC-Link, CC-Link IE Field and CC-Link IE Field Basic. The protocol stack will be executed on the PC card and exchange of process data with the host is done with Dual-Port-Memory or DMA (Direct Memory Access).

All of these PC cards use the same driver and tools independent of protocol and card format. Always included in the scope of delivery is a complete software package, consisting of configuration tool, device drivers, examples and documentation.

DW

Hilscher Gesellschaft fĂźr Systemautomation mbH www.hilscher.com CC-Link Partner Association (CLPA) Am.cc-link.org/en

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A supplement of Design World March 2019

WHY is the new tool for surgeons 64

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The right motor makes a

A better light for

big difference in additive

3D printing

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WHY is the new tool for surgeons Edited by Leslie Langnau • Managing Editor

Surgeons at Biodonostia Health Research Institute use advanced 3D printing to improve treatment of thoracic wall tumours.

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3D printing continues to be an important tool in surgical planning. In thoracic surgery, the ability to measure screws and pre-bend titanium plates in advance eliminates several hours of opearting time.

A

As physicians increasingly face challenging surgical cases, new tools, like 3D

printing, are helping them find viable solutions.

For example, a 64-year-old man came to Dr. Jon Zabaleta and his team with an extremely complicated tumour on his thoracic wall. Dr. Zabaleta is Thoracic Surgeon at Biodonostia, Health Research Institute, founded in 2008 as the first institute for medical research in the Basque region of Spain. Over the course of two years, the patient’s tumour had slowly grown up his chest cavity and spread across multiple ribs.

The man was in intense pain, with surgeons concerned about his respiratory function.

“Ordinarily, in a case like this, we would remove the affected ribs and correct the defect by covering the area with a titanium plate,” says Dr. Zabaleta. “These plates are a standard size, designed for men of 100 KG or women of 50 KG, and need to be altered and rotated during surgery to suit each patient specification. In a complicated surgery, this can add hours to the operating time.”

In this case, removing the tumour would require removal of more than one rib, an unusual method of treatment that increased the risks associated with the surgery.

As a result, the surgeons needed to find the best way to correct the defect with the strength to protect the lungs, while maintaining flexibility and movement in the chest.

To explore and plan the surgery, the surgeons turned to their partnership with Tknika and Tecnun to produce an advanced, patient-specific 3D model of the patient’s thoracic wall on a Stratasys Fortus 450mc 3D Printer. For the tumour, the surgeons required a model strong enough to replicate human bone. The teams at Tknika and Tecnun converted a conventional CT scan of the patient into an engineering-grade thermoplastic 3D printed model and returned it to the surgical team within 24 hours.

“By creating a precise, anatomically accurate 3D model of the thoracic wall, we were able to plan and perform the resection on the 3D model ahead of the surgery,” explains Dr. Zabaleta. “This allowed us to measure the screws and pre-bend the titanium plates and helped reduce the overall operating time by 2 hours. For the patient, this meant a significant reduction in time under anaesthesia, and for our hospital, freeing up time in operating rooms saves costs.”

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p r i n t i n g 3D printed model of the thoracic wall enabled surgeons to perform and perfect the resection on the 3D model ahead of the actual surgery.

Teamwork Such a favorable outcome often involves research in seven subject areas that bring together more than 350 researchers across 26 groups. Daily, the Biodonostia, Health Research institute, and the co-located Donostia University Hospital where all treatment takes place, face challenging surgical cases. These all require precise, complex and often difficult surgeries during which surgeons need to make the most of every tool in their arsenal to ensure a safe clinical outcome.

Thanks to the partnership with Tknika, a Research and Applied Innovation Centre for Vocation Education and Training in the Basque region, and Tecnun, a specialist division of Universidad de Navarra, the surgical team has access to more advanced 3D printing technology.

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“3D printing is an essential surgical tool for us,” explains Dr. Zabaleta.

“Previously, no 3D printed model we created in-house could meet the level of detail and accuracy we needed.

However, thanks to our partnership with these local institutions, we now have access to advanced 3D printing technology from Stratasys that enables us to meet the demands required to create highly-accurate, patient-specific 3D models.”

Our partnership afforded us access to the necessary technology to produce a large and complex model that was incredibly strong, close to the real bones we would face during surgery. Without the strength of this model, we could not have prepared for the surgery in the same way,” explains Dr. Zabaleta.

In addition, Dr. Zabaleta credits an improvement in patient-doctor communication to the 3D models. For

the patient, using the 3D printed models to explain how they intended to protect his lungs helped to alleviate his anxiety ahead of a complicated operation and enabled informed consent. Additionally, the surgical consult was faster and more efficient.

Extending the use of 3D printing to other disciplines Dr. Zabaleta believes that the next natural step will be for all surgical disciplines at Biodonostia to use Stratasys 3D printing to prepare and plan for surgeries, as it offers the hospital the opportunity to innovate their treatment procedures and improve patient care.

“The use of the 3D printed model was so essential to this case, and we are working to apply this to many other surgical disciplines across the

hospital, from pancreatic tumours to airway stenosis, and these 3D printed models are already being used to help train our future surgeons,” explains Dr. Zabaleta.

Ultimately, the goal of the partnership with Tknika and Tecnun is to create a multidisciplinary team that collaborates to create the best possible 3D printed surgical models for the hospital on-demand, with Tecnun’s involvement centering around the segmentation and reconstruction of the models, and Tknika producing the final 3D printed versions. But this collaboration is not just limited to Biodonostia, as the hospital is currently working to provide 3D printed models to 23 other hospitals across Spain.

“We’re thankful to have such knowledgeable partners in Tknika and Tecnun. Coupled with the dedicated local support of Stratasys distributor, Pixel Sistemas, we’re confident that the hospital can continue to help patients with access to the most advanced 3D printing solutions,” concludes Dr Zabaleta. n MPF

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A d d i t i v e

T e c h n o l o g y

The right motor

makes a big difference in additive machine performance To meet manufacturing needs

for better accuracy and speed, additive manufacturing vendors are installing servo motors to better control their equipment motion.

W

Matt Hardenbergh • Regional Motion Engineer • Yaskawa America

When desktop 3D printers and mid-size additive manufacturing systems were used primarily for

prototyping parts, the common motor that delivered motion was a stepper motor. Brushless dc electric stepper motors have been the industry standard for 3D printing motion control. These motors divide a full rotation of the motor into equal steps.

But stepper motors do not use any position feedback and have a typical acceleration of 0.25 Gs, which makes them less than optimal for most industrial applications. In the early days of the 3D printing industry, despite these drawbacks, they offered vendors key advantages: low cost, with acceleration

and accuracy that was acceptable to most users.

Now, however, vendors of 3D printing/additive manufacturing technology are attempting to find a place in manufacturing for their machines. And they are finding that the needs and requirements of this industry are different than those from users in the early days.

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“We can’t point to high speed and accuracy as innovations anymore,” said Clay Guillory, President of Titan Robotics, an acknowledged industry leader in large format 3D printing. “Super precise, high productivity printers need to become the norm because end users are putting as much trust in them as

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they are in the other pieces of industrial equipment on their plant floors.”

Thus, additive machines need better performance in motion control; performance aimed at reducing overall print time and improving the dimensional precision and superior finish of 3D printed components.

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The Sigma-7 servomotor helps the Atlas 3D printer accelerate up to 5Gs to achieve a travel speed of up to 1,500 mm/sec. With standard 3D printer sizes of up to 42 in. x 42 in. x 48 in., a single rapid move can be completed 70% faster using servomotors based on the given speeds and accelerations.

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Servomotors like the Yaskawa Sigma-7 servo system are increasingly being used on 3D printers. On the Atlas 3D Printer from Titan Robotics, for example, the servomotor enables the printer to reach print speeds of 350 mm/sec.

Stepping up to servos The latest introductions of additive systems are turning to servomotors for motion control, particularly in the control of the print head. Servomotors offer two significant advantages in managing a print head’s motion.

Precision is achieved through a closed-loop feedback system centered around a high-resolution optical encoder, which offers exacting and continuous feedback on the accuracy of motion.

Speed is gained from the ability of a servo to settle at a particular point more quickly than a stepper motor can. And

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servomotors higher rates of acceleration move print heads into proper position more rapidly.

“When a print head can get to precisely where it needs to be faster than before, the outcome is better productivity,” said Michael Miller, Manager of Regional Motion Engineering, Yaskawa. “You don’t need to slow the system down to get the finish quality you’re looking for. That means more parts per hour without sacrificing quality.”

For example, the Atlas 3D Printer from Titan Robotics, a Colorado-based

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printer manufacturer, comes standard with a Yaskawa Sigma-7 servo system.

The 3D printer can reach print speeds of 350 mm/sec. Depending on the 3D printer, this speed can be more than double the speed of 150 mm/s for 3D printers using stepper motors.

In addition, the servomotor helps the Atlas accelerate up to 5Gs to achieve a travel speed of up to 1,500 mm/sec.

With standard 3D printer sizes of up to 42 in. x 42 in. x 48 in., a single rapid move can be completed 70% faster using servomotors based on the given speeds and accelerations.

A key to a servo system’s performance is the resolution of the servo encoder. For example, the Sigma-7 uses a 24-bit encoder, giving 16,777,216 bits of closed-loop feedback resolution.

Servo control is particularly important on some large-scale 3D printers whose size requires quick and precise gantry movement across a horizontal axis of 40 feet or more.

Other benefits of servomotors include: • Easy installation. Many servomotors automatically perform their own custom tuning, which makes it possible to adapt to changes in the mechanics of a printer or variances in a printing process. Stepper motors do not use position feedback, so they cannot compensate for changes in processes or discrepancies in mechanics.

• A place called home. A lack of encoder feedback means that an additive manufacturing machine using stepper motors must also be homed every time it is powered up.

Servo systems with absolute encoder feedback only need to perform a homing routine once, which saves printing time.

• Continuous deposition. The extruder of a 3D printer can often be a bottleneck in the printing process. A stepper motor doesn’t have the feedback sensing ability to detect an extruder jam, a problem that can ruin a print. Servos can detect extruder backups and prevent filament stripping. Absolute encoder feedback also helps a servo system maintain a constant material velocity output from the extruder.

Every manufacturer in the additive manufacturing space is facing the need to respond to heightened customer expectations of what 3D printing can do. “We’ve been hearing for years about the ways 3D will revolutionize manufacturing,” adds Miller. “It’s come to the point where the revolution needs to begin, and better motion control technology is bound to be a big part of that formula.” n MPF Yaskawa America | yaskawa.com

News for control freaks Machine designers in additive manufacturing are also turning to servos for better control. The servo drives that power the Titan Atlas use two vibration suppression filters, two anti-resonance filters and up to five notch filters to provide smooth motion. This technology helps eliminate the stepped lines common on 3D printed parts. Stepper motor ripple may be a cause of the stairstepping effect.

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A d d i t i v e

T e c h n o l o g y

A Better Light for 3D printing Digital Light Processing (DLP) technology is used in a number of industries, including additive manufacturing. With a new chipset available, these tips will help designers successfully implement the chips in their additive designs.

D

Leslie Langnau • Managing Editor

Some of these SLS 3D printers may use high-powered carbon dioxide or NIR lasers to fuse plastic, nylon and metallic powders. Using a DMD as part of the exposure head enables the printer to expose a 2D area to NIR light, enabling it to print more complex images faster than with point-by-point laser steering.

DLP was developed in 1987 by Larry Hornbeck of Texas Instruments. When

used in an additive process, DLP functions as the light source that projects the image of the 3D model into a vat of photo-reactive polymer. The light hardens the polymer to create the three-dimensional part. TI recently introduced a new chipset for this technology, which several additive vendors use in their machines.

At the heart of DLP technology is a Digital Micromirror Device (DMD), which is a micro-electromechanical system (MEMS). A DMD contains an array of highly reflective aluminum micromirrors that can spatially steer light. In the case of high-power laser applications, DMD features can bring many benefits.

The DLP650LNIR DMD from TI, supports an optical power-handling capability of 500 W/cm² across 950-1,150-nm NIR wavelengths. The device can vary optical power at the pixel level and introduce high-speed 2D patterns in a single exposure for faster imaging. In addition, dynamic mirror programming can compensate for process shifts that may occur, such as attenuating power or exposure levels to overcome surface non-uniformities.

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The sky’s the limit Cut cost and cut production time without cutting corners HP Jet Fusion 3D Printing hp.com/go/3DPrint © Copyright 2018 HP Development Company, L.P. Data courtesy of Nacar.

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3/1/1917:20:52 2:58 PM 20/06/2018

Additive Technology

The DLP650LNIR 0.65-in. WXGA highpowered DMD. Using a DMD as part of the exposure head enables the printer to expose a 2D area to NIR light, enabling it to print more complex images faster than with point-bypoint laser steering.

“There are several types of 3D printing technologies, and they generally fall into these categories: • Fused deposition

Steering 1 million points of light simultaneously Having an x-by-y array of mirrors helps bring more programmability and flexibility to designed laser exposure systems. Using optical imagecompression techniques in combination with the DLP chipset can increase or vary the power per pixel based on application needs. The DLP650LNIR has 1280 x 800 (or over 1 million) micromirrors for spatial light modulation. The mirror size is 10.8 μm, which enables print features in the sub-50 μm resolution without image demagnification.

modeling • Vat polymerization • Sintering • Jetting.”

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The digital nature of the DLP chipset helps designers create system designs with fewer mechanical parts and less calibration maintenance. Industrial systems using high-power near-infrared (NIR) lasers and DLP technology include selective laser sintering (SLS) for 3D printing.

There are several types of 3D printing technologies, and they generally fall into these categories: • Fused deposition modeling • Vat polymerization • Sintering • Jetting Each technology pairs with different material types like plastics, nylons, ceramics or metals; resulting in different object properties related to strength, elasticity and finishes. Each technology is suitable for different build areas (centimeters to meters) and feature sizes (microns to millimeters).

Selecting a 3D printing technology often depends on the desired object properties. A second consideration then The micromirrors on a DMD switch very fast – in microseconds.

Individual mirror control enables adaptive patterns, and in 3D printing systems, helps preheat a powder bed for more even sintering.

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Image compression can increase the power per pixel. For example, designing the output optics with 1:16 compression to spread 100 W across 1280 x 50 rows of mirrors at the material surface (rather than 1280 x 800 rows) increases the power per pixel by 16 times to 1.6 mW.

becomes whether you need to print one prototype or mass-produce multiple finished goods. In either case, you need fast printing speeds.

Many SLS 3D printers use high-power lasers to fuse together small particles of plastics, nylons and metals. SLS additive manufacturing systems can print complex 3D geometries such as interior features, undercut structures or thin walls. The sintering of powder materials often enables mechanical traits and strengths similar to injection-molded parts.

In SLS 3D printers, lasers move across a powder bed plane, sintering one slice of the object point by point. A roller adds another powder layer and the process repeats until a 3D object is produced.

Some of these SLS 3D printers may use high-powered carbon dioxide or NIR lasers to fuse plastic, nylon and metallic powders. Using a DMD as part of the exposure head enables the printer to expose a 2D area to NIR light, enabling it to print more complex images faster than with point-by-point laser steering.

Given the fast switching speeds of DLP chipsets, the printer can vary the power per pixel in real time based on application needs or compensate for temperature discrepancies.

NIR wavelength support DLP technology is often combined with various light sources and is compatible across ultraviolet, visible and NIR wavelengths.

The DLP650LNIR DMD, for example, can be used with light sources in the 800-2,000-nm range but is optimized for 950-1,150 nm, where it can handle

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134 W/cm² of input power. NIR lasers are widely used across sintering, digital printing and other markets since a number of powders, inks, media, substrates and thermally sensitive coatings interact in this wavelength region. The DLP650LNIR can add advanced illumination, exposure and thermal control to these applications.

The micromirrors on a DMD switch very fast – in microseconds. The DLP650LNIR pairs with the DLPC410 controller, DLPR410 programmable read-only memory and DLPA200 driver for a complete chipset that offers 12,500-Hz binary pattern rates.

By controlling DLP mirrors, you can use DLP to preheat a powder bed for more even sintering.

Key considerations to jump-start an NIR system design When integrating high-power illumination with DLP technology, managing the DMD’s temperature is important. Light engine designs should keep the mirror array temperature at or below 70ÅãC and the backside of the DMD package at or below 30ÅãC. In the case of high-power lasers, liquid cooling of the backside of the DMD is a requirement in the system design. If you are trying to maximize the power output, you also need forced airflow across the front of the DMD. When starting a design, you typically know the power of your laser source, as well as the energy you need to expose or interact with the intended material.

When incorporating DLP chips into the design, there are places where light efficiency losses will occur. The main

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locations will be the input illumination optics, DMD and output projection optics.

As an example, a design might lose 25% of the light in the DMD and 17% in the output optics. If a design starts with 160 W of incident power on the DMD, 120 W would leave the DMD and 100 W of energy would leave the projection optics and hit the substrate or surface.

Spreading 100 W of energy across 1280 x 800 pixels equates to 0.1 mW per pixel.

These are just estimations that will depend on specific optical engine designs, but they are meant to offer guidance on how to determine power per pixel.

Image compression is a powerful technique that can increase the power per pixel. For example, designing the output optics with 1:16 compression to spread 100 W across 1280 x 50 rows of mirrors at the material surface (rather than 1280 x 800 rows) increases the power per pixel by 16 times to 1.6 mW. There are any number of imagecompression combinations, depending on your unique end-equipment design specifications and required power at the surface. You will need to evaluate several system considerations and tradeoffs when pursuing a high-power NIR system design with DLP technology. n MPF TI | www.ti.com Some material for this article came from a TI whitepaper, High-power NIR laser system benefits with TI’s DLP technology.

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M o t i o n

C o n t r o l

Don’t forget

these two things when selecting an amplifier Using software to size motion designs is rewarding because engineers can efficiently predict which products are suitable for the application at hand. But key considerations (sometimes missed) when selecting a servo amplifier are those of dynamic braking and regenerative resistor braking.

By Sixto Moralez Regional Motion Engineer Phil Drexler Regional Motion Engineer Yaskawa America Inc.

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Design engineers who are running sizing calculations for a servo application should consider dynamic braking as well as regenerative braking requirements when selecting a servomotor and digital amplifier for that design. The terms are sometimes used interchangeably, as both types of braking involve processing regenerative energy. But as we’ll explore, there is a subtle difference between these two forms of braking.

We’ll also explore how to leverage the benefits

of servo amplifiers that include dynamic-braking provisions.

Though no one size fits all, servo systems verified upfront for dynamic braking and regenerative resistor braking will deliver longer life. Yaskawa’s networkable digital amplifiers (Sigma-7 Series Servopacks) include dynamic braking provisions in their amplifiers.

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| istockphoto.com

What is dynamic braking?

If the servo axis suddenly turns off while the servomotor is operating and the axis is running at some non-zero velocity — for example, due to loss of power or an emergency stop triggered by an alarm — the digital servo amplifier can no longer control the servomotor. That means unless there’s some mechanism to prevent coasting, that axis will indeed coast until all of the kinetic energy from the load and its own rotating inertia is expended.

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M o t i o n

C o n t r o l

FIGURE 1: DYNAMIC BRAKING

Engineers running sizing calculations for a servo design should consider regenerative braking and dynamic braking and requirements when selecting a servomotor and digital amplifier.

B1/ + B2

B3

Fan

SERVO MOTOR

L1 Varistor

Main circuit power supply

U V

+

L2

−

CHARGE

M

W

L3 -1

Dynamic brake circuit

-2

Dynamic braking is the quick stopping of a spinning servomotor by connecting resistance between the Servomotor’s terminals.

FIGURE 2: CONSIDERING ALL PARAMETERS AND OPTIONS NO

USING THE DYNAMIC BRAKE?

YES NO

USING THE BUILT-IN DYNAMIC BRAKE? YES

SELECT THE DYNAMIC BRAKE RESISTOR.

CONNECT THE DYNAMIC BRAKE RESISTOR.

SET THE ALLOWABLE ENERGY CONSUMPTION AND RESISTANCE OF THE DYNAMIC BRAKE RESISTOR. (PN601, PN604) SET THE MOTOR STOPPING METHOD

SET THE MOTOR STOPPING METHOD. (PN001 = n.

SET THE MOTOR STOPPING METHOD.

X)

(PN001 = n.

WHEN NOT USING THE DYNAMIC

X)

BRAKE. (PN000 = n.

PREPARATIONS COMPLETED WHEN NOT

PREPARATIONS COMPLETED WHEN USING THE DYNAMIC BRAKE.

the digital servo amplifier will apply dynamic braking to stop the servomotor when a Group 1

USING THE DYNAMIC BRAKE

OFF AND GROUP 1 ALARMS TO 2

PARAMETER

MEANING

n.

0 (default setting)

STOP THE MOTOR BY APPLYING THE DYNAMIC BRAKE

n.

1

STOP THE MOTOR BY THE APPLYING DYNAMIC BRAKE AND THEN RELEASE THE DYNAMIC BRAKE

2

COAST THE MOTOR TO A STOP WITHOUT THE DYNAMIC BRAKE

n.

alarm occurs. The user can modify the setting of this parameter by using Yaskawa’s free SigmaWin+

ROTARY SERVOMOTOR DYNAMIC-BRAKING EXAMPLE VALUES 4.0 INSTANTANEOUS MAXIMUM DYNAMIC BRAKE TORQUE (NM)

With default parameter settings,

X)

SGM7G-05D

3.5

SGM7J-04D

3.0 2.5 2.0 1.5

F F

SGM7G-03D

F

SGM7A-04D

F

SGM7A-02D

F

1.0

SGM7J-02D

F

0.5 0.0 0

Version 7 software.

LINEAR SERVOMOTOR DYNAMIC-BRAKING EXAMPLE VALUES

200

400

600

800

1000

1200

DYNAMIC BRAKE RESISTANCE

SGD7S-1R9D

INSTANTANEOUS MAXIMUM DYNAMIC BRAKE FORCE (N)

350.0 300.0

SGLFW-35D230A SGLFW2-30D230A

250.0

SGLFW-35D120A

200.0

SGLFW2-30D120A

150.0

SGLFW2-30D070A

100.0 50.0 0.0 0

200

400

600

800

1000

1200

DYNAMIC BRAKE RESISTANCE

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FIGURE 3: POWER-REGENERATION DESIGN EXAMPLES Because mechanical losses in the system usually expend only a small amount of energy, the coasting distance can be quite long. This long stopping distance may spur equipment damage and/or personal injury.

Here, dynamic braking is helpful. It uses the regenerative power produced by the rotating servomotor to brake the servomotor. The servomotor’s kinetic energy converts to electrical energy and is expended as heat (through resistors) to stop the servomotor. In short, dynamic braking is the quick stopping of a spinning servomotor by connecting resistance between the servomotor’s terminals U, V, and W. Consider some examples of when the dynamic braking circuit might be activated.

Servo alarm: With default parameter settings, the digital servo amplifier will apply dynamic braking to stop the servomotor when a Group 1 alarm occurs. In some cases, users can modify the setting of this parameter by using drive-manufacturer software.

Over-travel: Hitting the over-travel limit

switches in the forward or reverse direction.

MOTOR DRIVE TO LOWER OBJECTS WITHOUT A COUNTERWEIGHT

MOTOR DRIVE FOR FEEDING TENSION

SERVO MOTOR

SERVO MOTOR NEGATIVE LOAD THAT FEEDS A MATERIAL AT A CONSTANT SPEED UNDER TENSION

SERVO MOTOR

These are a couple examples of where regeneration is helpful — where gravity and tension come into play.

FIGURE 4: REGENERATIVE ENERGY FROM BACKDRIVE REGENERATION CIRCUIT B1/ + B2

B3

FAN

SERVO MOTOR L1 Varistor

Main circuit power supply

U +

L2 CHARGE

−

L3 -1 -2

V

M

W

BACKDRIVEN SERVO MOTOR

DYNAMIC BRAKE CIRCUIT

Here’s how Yaskawa’s networkable Sigma-7 Series Servopack digital amplifiers can handle the energy from a backdriven motor.

Main power off: Turning off the main

power supply to the digital servo-amplifier circuit or servomotor.

What is regenerative energy?

In a servomotor system under the control of a digital servo amplifier, when the output torque of the servomotor is opposite the direction of the shaft rotation, the motor acts as a generator … and the resulting energy flows back into the drive. The energy returned to the drive is regenerative energy.

Three examples of when regeneration occurs during motor operation are decelerating a moving load; lowering a vertical load; and an overdriven nip roll.

That leads to the next question — what is regenerative resistor braking? Here, regenerative energy is returned to the drive during deceleration because the motor must apply torque opposing the rotation’s direction to stop the load.

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FIGURE 5: REGENERATION PROFILE AT DECELERATION TORQUE SPEED DOWNWARD MOVE

REGEN

Shown here is a sample regeneration profile upon axis deceleration.

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The Evolution of Brewery Hoses

M o t i o n

C o n t r o l

FIGURE 6: SOFTWARE TO SETUP REGENERATIVE ACTION

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• Versatile hose for applications requiring superb flexibility and light weight, while still maintaining high strength and durability.

This example of sizing software (on the Yaskawa SigmaSelect software’s regeneration tab) shows how such tools can identify whether the design will need additional components such as external resistors.

Figure 7: When the servomotor operates as a generator, power returns to the amplifier — often to charge the drive’s bus-smoothing capacitor. Beyond this capacitor’s capacity, a regenerative resistor goes into action to consume the remaining power. But where such an approach is still insufficient (or the drive doesn’t have regenerative resistors) an external regenerative resistor must connect to the drive to handle the remaining power. That’s common for axes with high load-to-motor-inertia mismatches. External regenerative resistor units such as the one shown here connect between drive terminals; then software configuration of the amplifier allows identification and handling of the external

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resistor unit’s power capacity.

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For example, when lowering a load without a counterweight, the force of gravity drives the load down, and the motor must apply torque opposite the direction of downward rotation to control the load.

Likewise, in the case of an overdriven nip roll, the motor must apply torque opposite the direction of rotation. In both cases, regenerative energy returns to the drive. Whenever regenerative energy returns to the digital servo amplifier, the bus capacitors absorb the energy … and the dc bus voltage rises.

Of course, if there’s a large amount of energy, the energy must dissipate to protect the drive. A braking transistor turns on to let current flow from the bus through a braking resistor. This process is known as regenerative resistor braking.

Digital servo amplifiers from some manufacturers have built-in resistors to dissipate some regenerative energy … though if the amount of regenerative energy processed by the built-in resistor is exceeded, the design will need an external regenerative resistor.

Word to the wise: Use (fullfeatured) servo-sizing software Using servo-sizing software from some manufacturers to size motion applications lets engineers verify the regenerative and dynamic braking parameters specific to the application. Here the engineer can enter details about the system mechanics, motion profile, and other details such as input voltage and the servomotor brake parameters. Such software ultimately identifies one or multiple servomotor and digital servo amplifier combinations that will work in the application at hand. Some such software can even return speed-torque curves and regeneration values for each machine-build option. DW

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Roller-screw actuators: what’s new Variations on the design often offer advantages over other linear actuation.

By Lisa Eitel | Motion Editor

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Roller screws are also called planetary roller screws or sometimes

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satellite roller screws for how their nut-encased rollers orbit the drive-shaft axis during operation. These mechanical rotary-to-linear devices work in an increasing number of electromechanical actuators. Planetary rollerscrew geometry includes far more internal contact between load-bearing subcomponents than their ballscrew cousins, and that boosts rigidity and dynamic load capacities. What’s more, fine pitches of their subcomponents’ grooves or threads often impart top mechanical advantage … so less input torque is needed to move a given load.

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Here’s how they work: Standard planetary roller screws consist of a precision-threaded spindle called a screw shaft (like those in ball and leadscrews) that mates with threaded cylindrical rollers encased and evenly spaced around the I.D. of a nut. The cylindrical rollers — sometimes just called planets — also stay axially centered inside the nut with no relative movement between the two in this working stroke axis. Nut and screw shaft have matching multi-start threads; the single-start threads on the rollers have an angle matching that of the nut’s inner thread to maintain axial centering between nut and rollers. Each end of the nut body has a roller-spacer ring and geared ring; the rollers’ ends include pins to ride in holes on the spacer rings as well as toothed sections near these ends to engage (and stay synchronized with) the nut’s geared rings.

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Exlar roller screws serve as alternatives to ballscrews and fluidpower devices. | courtesy Curtiss-Wright

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Planetary roller screws deliver high loads, speeds, and accuracy. | courtesy Creative Motion Control

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In some designs, the ring gear engages with geared roller ends. | courtesy Tolomatic

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Roller-screw actuators often include electric motors, servodrives, switches, and even controls. Shown here is a roller-screw actuator from Creative Motion Control that is oil filled to address the heat associated with high speeds and loads … and for installation-orientation flexibility as well as zero-maintenance operation. Circled in red is the actuator’s CMC Grooved Roller Bearing (GRB) based on the same fundamental concept as the roller-screw mechanism — except with a zero lead. Force density is high, and load capacity and life are matched to that of the roller screw (with its roller assembly circled in purple).

Wehr, Germany-based Kownatzki Technology manufactures planetary roller screws with G1 0.006 mm, G2 0.012 mm, G3 0.020 mm, and G5 0.024 mm (per 300 mm) tolerance classes and lead accuracies. The devices can replace hydraulics with dynamic load capacity 10 times that of ballscrews; speeds and accelerations to 3,000 rpm and (with a Ø45 version) 12,000 rad/sec² … and life to 18 times that of a ballscrew, according to the manufacturer.

The screw-shaft diameters of Kownatzki Technology are 5 to 1,000 mm and beyond.

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In many cases, rotary motion from an electric motor causes the screw shaft to turn; this causes the nut rollers to concurrently twirl and orbit … and induce advancement of the nut along with an affixed push tube with it. This (often corrosion-resistant) force or thrust tube delivers linear motion to the load via a spherical eye, internally or externally threaded rod end, clevis end, or some other end mount.

Other standard roller-screw actuators prioritizing compactness affix motor magnets to the nut’s outer diameter. Then motor-stator windings incorporate into the actuator housing’s I.D. to wrap around the nut and electromagnetically interact with the magnets. This in turn prompts nut rotation and (via the rollers) advancement of the actuator shaft.

actuators based on roller screws maintain efficiencies to 90% compared to hydraulic-cylinder efficiencies to 50% or so.

• Speeds and accelerations comparable to those of pneumatics … exceeding 40 in./sec and 3 g in some cases. Such output is possible because the load carrying rollers in roller screws don’t contact one other — unlike the balls in ballscrews that collide and strike recirculation end caps to generate forces and heat in the process. So even where the high forces of roller screws aren’t required, their high speeds and acceleration is useful: Roller screws (instead of ballscrews) to replace pneumatics gives designs heightened ability to withstand continuous-duty and frequent cycling conditions.

How do planetary roller screws compare to other technologies?

Roller screws often compete with ballscrews and fluid-power-based cylinders for linear motion … capable of delivering:

• Stroke lengths and accuracies comparable to (or exceeding) those of ballscrews ... to 3 ft and ±0.003 in. respectively for fairly typical offerings. In fact, planetary roller-screw designs are manufactured to ballscrew precision classes, which • Forces comparable to those of similarly means lead deviation and positioning sized hydraulics — typically from accuracy are easily defined. Note that 20,000 lbƒ to 800,000 lbƒ depending on roller screws have load capacities to size and design — and high thrust 15 times that of comparable ballscrews, capacity thanks to the numerous and though are not exempt from buckling and relatively large (line) contacts between critical-speed limitations. nut rollers and screw. In addition,

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Differential roller screw | courtesy Steinmeyer

Planetary roller-screw design variations Planetary roller screws don’t come in just one standard design described above. Let’s consider a few other variations.

Reverse or inverted planetary roller screws also have rollers with gearing on their ends, but this gearing engages mating gear geometry on the screw shaft (and not at the nut ends like on standard offerings).

That makes the rollers move axially within the nut … necessitating an elongated nut to accommodate the full stroke of the assembly.

In fact, the nut essentially takes the form of a long tube with a threaded I.D. Because the roller array stays parked on one section of the screw shaft, only that small section

is threaded; the rest of the screw shaft is smooth steel or other bar. Depending of the motor connection and design, output can come either from the screw shaft or the nut.

Inverted roller screws can be more costly than other roller-screw offerings, as they require precision threading within the nut’s long I.D. In some cases, these threads are also relatively soft … which somewhat degrades load ratings; they can also necessitate special procedures for relubrication. But inverted screws can be more compact than other roller-screw designs.

Spiracon or bearing-ring roller screws include rollers that orbit in sync with nut rotation. (Note that Spiracon is a registered

trademark of U.K.-based Power Jacks Ltd.) In contrast with other roller-screw types (that directly transmit nut-to-screw or screw-to-nut load via the rollers) this design also includes an intermediate bearing ring.

So rollers still interface the screw shaft … but between the nut and rollers is this internally grooved subcomponent. (The rollers are also grooved to engage this ring and not threaded as in other roller-screw designs.) The ring transmits load to the outer nut subcomponent through roller thrust bearings. The nut housing includes nonrotating spacer rings to hold the rollers’ ends as in other designs, but there’s no gearing ring or roller-end teeth. Orbitally locked in place, the rollers can induce the screw shaft of the assembly to advance and contract … or screw rotation turns the rollers and bearing ring with them.

Recirculating planetary roller screws let the rollers move axially relative to the nut, but a reset puts them back to a start position after each orbit around the screw shaft. At this reset point, one roller at a time falls into an axial channel on the nut wall. Then twin cam rings (aligned with this channel) push the roller to the nut’s axial midpoint

Shown here is a riveting application that uses a roller-screw-based linear actuator from SKF Motion Technologies to boost process speed and throughput.

Joining with riveting is common in automotive and other industries that aim to keep vehicle or design weight low and strength high, because riveting doesn’t deform sheet metal or change its material properties. SKF roller-screw actuators exhibit excellent shock resistance thanks to fullground 60 Hrc steel roller screws.

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PWG differential roller screws from Schaeffler Group deliver the high forces of a traditional ground roller screws but at a price that’s closer to that of ballscrews, according to the manufacturer.

while allowing a shift by one screw-shaft lead length. Reengaged with nut and screw shaft, the roller begins its next orbit.

Grooving (not threading) on the rollers allows axial moves during engagement with nut and screw — shifting up or down by one lead every orbit. Like Spiracon-brand roller screws, recirculating roller screws don’t include ring gears; nut and screw shaft mate via fine grooves … and small groove leads actually let these roller screws deliver high positional accuracy.

In some cases, a cage inside the nut holds the rollers in evenly spaced slots that allow axial and rotational motion. In other cases, recirculating roller screws without cages have rollers disengage from the screw but not the nut when they arrive at the axial-channel reset point. In this design, the channel has grooves to return the roller to start position. Cams at the roller ends can ensure consistent pressure between nut and rollers — to synchronize roller rotation and thrust the rollers into the channel. Without the ring gears and cages of other designs, these “cage-free” roller screws can be more efficient and power dense than comparably sized alternatives.

Differential roller screws are a variation of recirculating (and standard) roller screws that can change the screw shaft’s flank angles and contacts … and effective lead with them. That in turn varies the roller-toscrew rpm ratios. Note that in some cases,

manufacturer-specific naming conventions distinguish differential roller-screw offerings from standard versions by calling the former planetary screw drives. In these and other roller screws, preloading to reduce or eliminate backlash is possible with the use of a split nut — in which a transverse cut of the nut makes two nut halves for a precision spacer to work between them. Double nuts and oversized rollers are other anti-backlash options.

Roller-screw actuator options and considerations Roller-screw actuators that include a servomotor and drive and often include feedback devices as well. Many track incremental motion; for hot applications in aerospace or steel-mill settings, resolvers rated for high temperatures are sometimes used. But devices to track absolute position can make homing routines and limit switches unnecessary; these take the form of rotary encoders or even linear position sensors based on magnetostrictive operation. Feedback from these devices can ensure accuracy to within tenthousandths of an inch. Output signals are via HIPERFACE, SSI, analog, and CANopen, and other industry-standard options to ensure compatibility with the actuator’s motor controller.

When built into pre-engineered linear actuators, planetary roller screws can integrate into a fully enclosed housing … usually of anodized or powder-coated aluminum. Some such housings may also borrow from the design of hydraulic cylinders and include tie rods for strength.

Spiracon-brand (bearing-ring) roller screws from Power Jacks Ltd. have rollers that orbit with the nut. Screw-to-nut power transmission is through the rollers and an intermediate bearing ring.

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We’ve already considered actuator designs that build motor windings into the actuators housing (to induce a magnet-studded nut’s rotation). In contrast, other planetary rollerscrew actuators come in a pre-engineered housing sans motor. This lets design engineers select a motor to best match application requirements … and easily swap out the motor if needed. One variation from Creative Motion Control isolates the mounted motor from side loading to protect its subcomponents from premature wear.

Many manufacturers sell roller-screw actuators that let the nut rotate — for easier mounting and alignment. If such actuators go on axes that don’t employ linear guides or bearings on the load being moved, some type of anti-rotation mechanism is necessary. Anti-rotation devices internal to the roller-screw actuator are often preferable for their simplicity and maintenance of design compactness.

Additional design features in preengineered planetary roller-screw actuators of standard design include a thrust bearing at the drive end and a plain bushing for guiding the shaft as it extends and retracts into and out of the actuator body. A seal (such as an O-ring or elastomeric seal) or wiper wraps the shaft port to keep contaminants out of the actuator body; lubrication is with oil … and some lubedfor-life designs leverage oil filling to reduce maintenance requirements.

Many fully enclosed roller-screw actuators are IP rated for splash or even

In standard roller screws, rollers ride the nut’s inner threads while spinning on their axes and orbiting in that nut … and concurrently engaging a threaded or grooved screw shaft (or spindle) going through the nut center. This in turn causes axial advancement of the shaft. | courtesy Bosch Rexroth

washdown conditions — particularly useful in food and packaging applications.

Elsewhere, the rugged actuators resist ingress of dirt, grease, and metal chips.

Where do planetary roller screws make sense?

Two drawbacks of roller screws include their higher cost (even to 100% more than comparably sized ballscrews) and their being less ubiquitous — which can require more effort finding a manufacturer and keeping lead times short. Even so, roller screws excel in the machine-tool and packaging applications mentioned, as well as weld guns, injection-molding equipment, and presses. Axes that are traditionally driven by hydraulics (as in sawmills and lumber-processing machinery) are another place where roller screws make sense, as the omission of hydraulic fluid prevents staining

of end product even while maintaining the power required for intensive large-scale processes. Other roller-screw applications include those with large temperature variability or high-force operations. DW www.linearmotiontips.com

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Roller screws require none of the valves, filters, and pumps of fluid-power systems. In some cases, parts count is further reduced by the integration of motor windings into the actuator. | courtesy Diakont

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On the

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New computing architectures are changing industrial applications, impacting the way measurements are made, data is collected, and how it all gets processed.

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The Internet of Things (IoT) continues to influence how industrial systems are designed and built. The core of IoT systems is the collection of data at the device level and either processing it or sending it elsewhere for further processing.

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The next stage in this evolution is the move to edge and fog computing models. Both of these models move computing functions closer to the device itself rather than offloading computation to an external controller. (See box on basic definitions.) It’s a convergence between several areas of technology, and only now is the infrastructure in place and the technology available to put it all together.

In one sense, the trend toward edge computing is not such a foreign idea. This is because the controls industry is already well versed in this sort of architecture.

Historically control architectures were so-called central control. In this scheme, all

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control data and inputs from feedback devices and outputs were sent to a central controller that did all the calculations and then sent outputs or initiating actions back out to the component level.

A different type of control architecture gradually arose which challenged this central scheme. Known as distributed control, this type of architecture pushed some control and calculation functions out closer to the actual devices being controlled. This put less burden on central controllers and meant that systems could be more responsive to changing conditions at the control site itself, rather than have to rely on central processing and the associated time delays.

Both fog and edge computing and related industrial IoT (IIoT) are changing many industrial areas linking them up with higher enterprise IT functions and allowing for more precise control over manufacturing processes.

Recent moves highlight the growing connectivity between edge and fog computing and the IIoT and their influence on one another and the larger industrial world. For instance, one group working to raise awareness of this next wave in industrial automation is the Industrial Internet Consortium (IIC), together

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with the OpenFog Consortium. In fact, the two trade groups merged recently to form the largest international consortia for IIoT, fog, and edge computing. The move will bring OpenFog members into the IIC organization at a time when their complementary areas of technology are emerging in the mainstream.

The combined memberships continue to drive the momentum of the industrial internet including the development and promotion of industry guidance and best practices for fog and edge computing.

The organizations expect the details to be finalized in early 2019.

The Industrial Internet Consortium together with the incorporated OpenFog will be the largest organization focused on IIoT, AI, fog and edge computing in the world with members from over 30 countries. The Industrial Internet Consortium is the world’s leading membership program by accelerating the Industrial Internet of Things. The OpenFog Consortium was founded to advance fog computing and address bandwidth, latency and communications challenges associated with IoT, 5G and AI applications.

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The groov EPIC (Edge Programmable Industrial Controller) system from Opto 22 includes a chassis and power supply together with a processor and software. Individual I/O modules provide a mix of analog and discrete signals for edge computing applications.

Meanwhile, manufacturers are developing new products and devices and offering services to aide companies in taking advantage of these new computing developments. One company pushing the boundaries of edge computing is Opto 22.

The company’s groov EPIC series of control products is said to be the world’s first edge

programmable industrial controller. The new groov EPIC series allows designers to collect, process, view and exchange data where it’s produced, at a network’s edge, thus bypassing issues of data latency and network speed limitations.

Data can be securely shared among databases, cloud platforms, web services,

PLC systems and other systems via typical network standards. It allows data to be moved around efficiently, decreasing network load and reducing reliance on IT. Data can also be visualized on the controller’s integral touch-screen, an external monitor, or from any web browser or mobile device.

Cutting through the fog Cloud. Edge. Fog. What do these terms mean? And what do they have to do with computing and measurement data in industrial systems?

Cloud is probably the most familiar term and refers to both software and services that run on the internet instead of on a local computer. Most people are familiar with cloud services such as Google Drive or Apple’s iCloud. The advantage of cloud computing is that it makes data accessible from any internet-connected device.

Edge computing takes its name from the ability to process data at the “edge” of a network; that is, locally at the device level instead of collecting it and sending it across a network for further processing. This lessens the strain on network resources and decreases data latency issues.

Fog computing is often times confused with edge computing as being pretty much the same thing, but there are important differences. The biggest difference is that fog architecture resides between the device level (edge) and the cloud and pools together individual edge components into a single fog node. Individual fog nodes can be industrial controllers, PLCs, switches, routers, and even intelligent IoT devices themselves.

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The system can be programmed using the flowchart based control language known as PAC Control. Other options include using the IEC 61131-3 compliant CODESYS Development System and CODESYS runtime. Here, data can be exchanged using the visual, flow-based editor and runtime Node-RED, with its free pre-built nodes for databases, web services, and more. There’s also the capability to run custom-developed C, C++, Java, Python, or other customdeveloped applications on an open, Linuxbased automation system, using secure shell access.

The controller features an integral touch-screen for local configuration, commissioning, and troubleshooting with no PC required. It also uses a real-time, open-source Linux operating system, multitasking real-time control engine and a dual independent Gigabit Ethernet network interface to help securely segment the control network from the business network.

Other offerings simplify the link between plant floor and larger enterprise IT systems.

For instance, Hewlett Packard Enterprise’s (HPE) HPE Edgeline Converged Edge System solutions speeds the deployment and simplifies the management of edge applications, letting engineers act on the vast amounts of data generated by machines, assets and sensors from edge to cloud.

Based on an open platform, enterprises can seamlessly integrate a broad ecosystem of applications and operational technology (OT) devices for edge deployments – driving efficiency and innovation in industries like manufacturing, energy, and telecommunications.

The new solutions consist of four components; HPE Edgeline OT Link Platform, HPE Edgeline systems management, HPE Edgeline EL300 Converged Edge System, and HPE Edgeline Field Application Engineering Services.

The HPE Edgeline OT Link Platform

software is an open workflow engine and application catalogue that allows for the orchestrating of components, data and applications via a graphical drag-and-drop user interface. The software integrates an ecosystem of third-party applications running from edge to cloud – including AWS, Google, Microsoft, SAP, PTC, GE, and more – to make insights from the edge available across the enterprise and supply chain.

Together with HPE Edgeline OT Link certified modules, HPE-developed adapters connect to a broad range of OT systems, enabling bi-directional, time-sensitive and deterministic control and communication, including high-speed digital input/output, CAN bus, Modbus or Profinet.

The HPE Edgeline Integrated System Manager is embedded into HPE Edgeline Converged Edge Systems and features one-click provisioning, ongoing system health management, remote updates and

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management even with intermittent wired and wireless connections. It also supports advanced security functions like preventing system boot file changes and remote system disablement during a security event.

The HPE Edgeline EL300 Converged Edge System is a fan-less, low-energy system equipped with Intel Core i5 processors, up to 32GB of memory and 3TB of storage. It will also support Intel Movidius Myriad X vision processing units to enable video analytics and AI inference at the edge. It provides enhanced resiliency against shock, vibration, humidity and dust, including IP50 and MIL-SPEC certifications, and can operate from –30 to 70 °C. These features make it suitable for use as an embedded system, for example, in production machines.

Lastly, the HPE Edgeline Field Application Services help designers plan,

design, build and run IoT, edge and cyberphysical systems to accelerate deployment and ensure reliable and secure operation.

These services include the evaluation of use cases, proof of value, solution deployment and management of ongoing operations.

On the high precision measurement end, Beckhoff Automation offers a new, lower cost measurement module with accuracy of 100 ppm. The company has extended its EtherCAT measurement module portfolio with the new ELM314x economy line, supplementing the established ELM3x0x line with a lower cost 1 ksps (kilo samples per second) class.

This I/O system expansion simplifies the use of system-integrated precision measurement technology, which taps significant optimization and efficiency potentials both in production machines and for inline test benches.

The new modules are available in two, four, six and eight-channel versions. Highprecision measurements with an accuracy of 100 ppm are possible over a wide temperature range from 10 to 40 °C. Each channel in the measurement modules can be set to current or voltage measurements with a sampling rate of up to 1 ksps per channel. Analog signals can be processed in ranges from ± 1.25 to ±10 V, 0 to 10 V, ±20 mA or 0/4 to 20 mA. The new economy line offers considerably reduced channel costs, but provides the same wide range of functions as the ELM3x0x line. These include freely adjustable two-stage filters, oversampling, distributed clocks, true RMS and scaler functions. The extensive diagnostic features for unattended, long-term use familiar from the ELM3x0x line are also implemented.

Sampling at 1 ksps per channel is suitable for a wide range of applications.

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In particular, the processes of moving machine components or the final inspection stage of inline test benches can be optimally mapped with the economy line in order to reliably control the processes. Typical examples include part geometry measurement on the fly, as well as fast yet highly precise weighing procedures, such as in bottling plants. In general, the ELM314x EtherCAT measurement modules are ideal for recording data from 10 V/20 mA sensors and for feeding real-time information directly back into the process. The speed, reliability and accuracy of production and test processes can be increased significantly with these insights.

Efficient data logging for subsequent process analysis and optimization is also just as easy.

If increased requirements necessitate higher sampling rates, the ELM3x0x measurement modules with up to 50 ksps can be used instead.

These are suitable for vibration measurement on fast-running machines in order to implement active vibration compensation or predictive maintenance, for example. DW Industrial Internet Consortium www.iiconsortium.org/ Opto 22 www.opto22.com Hewlett Packard Enterprise www.hpe.com Beckhoff www.beckhoff.com

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Distributing IoT information Web servers can be an ideal method for distributing IoT information. Here’s a look at the advantages and disadvantages for two different development approaches.

Internet of Things (IoT) implementations deliver the most value when they distribute information through the Internet. One of the best ways to do this is by using a programmable logic controller (PLC) or a human machine interface (HMI) with web server capability to create web pages, which can then be viewed on any remote device connected to the internet and capable of supporting a web browser.

These web pages can also be used to change values within the PLC or HMI, providing two-way interfacing from remote devices such as laptops, smartphones and tablets.

Don Pham, Sr. Product Manager at IDEC Corporation

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A main challenge with this approach to IoT information distribution is creating the detailed web pages for viewing and interaction with remote devices. Hard-coded HTML programming is an option, providing the opportunity for virtually unlimited customization, but requiring a high degree of expertise on the part of the HTML programmer.

Another alternative is to use a specific web page editor tool within the PLC or HMI programming environment, but such tools are not provided by all PLC and HMI vendors. Even when this feature is provided, care must be taken to evaluate the offering for ease of use, ability to customize, and other capabilities.

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Fig 1. Some PLCs, such as IDEC’s MicroSmart FC6A Plus, include a web page editor with their programming software, providing an alternative to hard-coded HTML programming.

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Fig 2. PLCs with web-server capability can process incoming IoT data and present it in a web page format to any device capable of hosting a web browser, such as a PC or smartphone.

Implementations of the Internet of Things deliver the most value when they distribute information through the internet.

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We will compare the two main methods of creating PLC/HMI-based web pages: HTML programming versus using a web page editor incorporated within the PLC or HMI programming software. While we focus on PLCs (Figure 1), much of the discussion is also applicable to HMIs. We will look at the advantages and challenges of each method, and show how each can be implemented with a PLC-based automation system.

But first, let’s look at why web servers are often the best choice for distributing IoT information.

Serving information to browsers The “T” in the term “IoT” can refer to any number of individual smart devices, as well as somewhat larger intelligent equipment.

Basically, any low-level networkable device capable of transmitting status information and possibly accepting commands can be included under the IoT umbrella as a “Thing.” These IoT devices are often spread over a large area within a building, facility, or outside.

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End users would usually prefer to view IoT information through a handy web browser interface, but a few steps are required to achieve this goal. Coordinating the data flow to users can be a challenge with so many disparate sources. A brute force approach where all top-level systems, such as a supervisory control and data acquisition system, interrogate all low-level resources could be complex and inefficient.

A better approach is to incorporate local elements that can concentrate and preprocess the data and organize the traffic.

For most facilities looking to take advantage of IoT devices, it is quite common for PLCs to already be distributed throughout the site to perform local automation tasks. These systems are ideal for IoT edge data processing because they normally have the requisite computing power and connectivity options, including the Ethernet connectivity needed to interface with the IoT. Not only that, but they are engineered for the more difficult and harsh environments encountered in field locations.

When the right PLCs are already in service and positioned, it makes sense to use these platforms to locally aggregate IoT communications by performing edge data processing. Otherwise, it is still economical to add PLCs, or upgrade those in operation with contemporary versions offering the right features.

When configured to process the incoming IoT data and present it in a web page format, PLCs can become a universal bridge to higher-level web-based users. They

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represent a convenient and cost-effective solution to the problem of serving information up to any web browser, whether it’s hosted on a PC, smartphone or tablet (Figure 2).

But having the hardware in place is just the first step; configuring it is the next.

HTML programming Web pages are traditionally coded using hypertext markup language (HTML), which is a standardized text-based way to describe how dynamic information and static content will be displayed on a client’s web browser when viewing the page. HTML is flexible and is a foundational part of most modern internet web pages.

Unfortunately, web developers must have significant programming experience to fully harness this power (Figure 3). The programmer needs to identify tagged “live” information within the PLC and connect it to meaningful displays. This sort of data linking is a native ability of web-capable PLCs. Programmers then need to incorporate images, text and other features to represent the information in a useful manner on the web page. Writing HTML in this way to end up with a suitable result is not a trivial undertaking.

To be sure, a PLC offering web page serving capabilities is a vast improvement over previous generations, which required proprietary visualization software. While dedicated HMI software offers specific configuration features to help users create graphics, it also imposes licensing and deployment constraints far more restrictive than an open web browser implementation.

Fortunately, some vendors now offer a hybrid approach where a user-friendly configuration environment enables developers to create PLC-based web pages using the PLC programming software.

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Fig 4. IDEC’s native web page editor, included with its WindLDR PLC programming software, provides hundreds of pre-built objects and symbols that can simply be dragged-and-dropped onto a web page configuration.

Built-in web page editor Consumer-oriented software products are heavily focused on delivering an intuitive user interface, but industrial and IoT applications aren’t always known for such niceties. That’s why it is notable for

a PLC platform to offer a built-in web page editor that can help users create professional, interactive and dynamic web pages—while minimizing the required effort and cost.

For instance, the IDEC MicroSmart FC6A Plus PLC family includes a native web page editor within its WindLDR PLC programming software.

Some other PLCs and HMIs offer similar capability, which should be evaluated prior to purchase to verify ease of use, features and performance.

This embedded web page editor means no separate product or installation is needed, and it is designed for any skill level from novice to advanced. In fact, the web page editor operates within the standard web browser of the user’s choice, such as Internet Explorer, Chrome or Firefox.

No programming experience or HTML knowledge is needed, which represents a major advantage over similar products.

To make things as easy and intuitive as

Remote users can interact with web pages created using IDEC’s WindLDR PLC programming software to monitor and control machines and processes.

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possible, there are pre-built objects and symbols, which can simply be dragged-and-dropped onto a web page configuration (Figure 4). The range of available dynamic objects includes typical operator interface symbols such as buttons, numerical indicators and bar graphs. Other symbols include factory equipment images such as vessels, pipes, and valves. These libraries enable users to efficiently construct detailed and professional web pages to represent control and IoT systems.

When objects are dropped into the web page editor, available PLC addresses from the PLC programming software are automatically populated for users to select. For example, a user could drop in a tank image and superimpose a vertical bar graph indicating the tank level monitored by the PLC (Figure 5). Users can focus their efforts on applying their creativity to the design, since the technical details are handled by the configuration software. The end result is that IoT devices can be accessed with basic default or fully customized web pages.

Web pages are stored in the PLC’s on-board 5 MB of internal memory, or more extensive configurations can be saved in the optional 32 GB SD card. There is therefore plenty of space for professional web pages with significant graphical content. The PLC is simply connected into the user’s network using one of the two built-in Ethernet ports to make the web pages available to any browser, once proper security procedures are satisfied.

With proper IT configuration to grant the site network internet connectivity, even more advanced notification capabilities such as emailing or text notifications (using third party servers such as Gmail or Yahoo!) are possible. This extends the web page solution from being a user-initiated event and makes it into an automated alert generation system.

Through the web (page) The increasing availability of IoT products and other intelligent devices means end users need ways to access and take advantage of this newly obtainable data delivered by these devices. Web browsers viewed on laptops, smartphones, and tablets provide an easy and natural way to deliver this content through web pages.

PLCs are often conveniently located in close proximity to field-installed smart devices, and durable enough to install in remote environments. Hosting web pages at the PLC level is therefore a logical and cost-effective fit, with the only downside being the need to generate complex HTML coding as required for traditional web page design.

A web page editor integrated with the PLC programming software address this issue. This type of intuitive and easy-to-use web page creation tool is built in to the programming software at no extra cost and enables users to readily create rich and functional web pages with minimal effort. These web pages painlessly deliver IoT information on-demand to any user with a browser-capable device, and also offer these remote users the ability send commands to the PLC. DW IDEC | Us.idec.com

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Modern practices in PCB design verification New software platforms can head off the subtle errors that sometimes creep into manual printed circuit board review

David Wiens, Kerry Thalmann | Mentor Graphics, a Siemens Business

The growing complexity of printed circuit boards and multi-board products has rendered traditional design analysis and verification techniques obsolete.

Manual reviews are no longer up to the task. Reliance on experts for all design analysis creates bottlenecks that delay project schedules.

It is easy for the complicated PCBs of today to contain a number of subtle errors that escape the notice even of experts in a traditional manual peer review process. It takes a modern, automated verification approach to catch schematic errors at the source.

To reduce reliance on experts, the trend is to provide analysis tools that engineers who are non-specialists can use within their familiar design authoring environment.

These modern approaches provide significant benefits for both design engineers and engineering project managers.

In the past, peer reviews done before PCB layout worked reasonably well for simple designs on a single PCB. This manual process became unwieldy for bigger designs.

Schematic errors that got past the manual review went into PCB layout. They often

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The traditional board design process usually starts with a schematic that gets turned into a PCB layout. The next step often takes place on a new product introduction (NPI) platform that handles PCB design-to-manufacturing handoffs. Next comes a prototype board that undergoes a reliability check before the design hits manufacturing. A point to note is that there are manual peer-reviews after each of these procedures.

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remained undetected until the prototyping phase. These errors typically caused failures that require lab debugging time to identify the root cause. Errors that should have been caught prior to layout, where they are easily corrected, ended up causing costly design respins.

To eliminate such inefficiencies, design automation providers now advocate what’s called a shift-left approach. The idea is to integrate verification earlier in the design process. The benefit is an increased likelihood of catching errors and potential issues at the source, before they can propagate forward into subsequent phases of the project.

In the shift-left approach, automated schematic integrity analysis replaces manual reviews. It enables full inspection of all nets in the design, for both single and multiboard systems. It makes this inspection using pre-defined checks for common schematic errors and an intelligent component model library. The analysis takes place in parallel with schematic entry and eliminates most common schematic errors before layout starts.

Typical problems that verification can expose include missing power and ground connections, incorrect diode orientation,

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missing or redundant pull-up and pull-down resistors, capacitor voltage derating, nets missing a driver or receiver, driver/receiver technology matching, boardto-board connectivity, bus flip errors (MSB to LSB), etc.

Replacing the manual review process with an automated methodology results in greater coverage and gives design engineers a much higher probability of entering layout with a schematic that will provide first-pass success.

Automated verification can also force good PCB design practices. Routing constraints for signal and power integrity, as well as design-for-test constraints, are factors that should be specified during schematic capture, not shoe-horned in at the layout phase. Signal and power integrity, EMI compliance, thermal analysis and vibration analysis should all be validated during the layout process.

Multi-dimensional verification schemes include a broad range of analysis and verification tools deployed during the schematic and layout phases of the project.

These tools are simple enough to be used by non-specialist PCB design engineers and layout designers. These individuals can work within the authoring environments they’re familiar with to identify potential problems as early as possible in the design flow.

During schematic capture, automated schematic integrity analysis takes place to eliminate common errors often overlooked in manual reviews. Signal integrity and power integrity analysis takes place to determine a set of placement and routing constraints. The constraints get passed forward to layout. Also advisable during schematic

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A modern multi-dimensional analysis and verification platform undertakes a number of analysis steps in the schematic and layout phases of board development as a means of reducing the need for input from human engineering specialists and to reduce the need for design re-spins caused by over-looked problems in the initial board design.

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entry is a testability analysis. Here, the software identifies test-point requirements and passes them to layout as additional constraints.

Several analyses take place as component placement progresses during layout. These analyses include EMI validation, thermal analysis, vibration/acceleration, and manufacturability assessments. In traditional design flows, these issues might only emerge after physical testing in EMI, thermal or HALT test chambers. Issues not caught during layout that impact the mechanical integrity of the design are usually the most expensive and time consuming to fix. Such issues often require board re-spins and tooling changes to correct. Simulations during layout greatly boost the likelihood of avoiding such difficulties and getting first-pass success.

All in all, a shift-left verification process significantly improves the design before it reaches the PCB specialist.

It greatly reduces the need for exhaustive full-board screening and lets these specialists focus on just the critical second-order issues that remain.

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Engineering project managers The traditional design flow is frustratingly unpredictable thanks to the many sources of potential problems. As a result, experienced managers typically bake at least one design spin into the project schedule, but even that is rarely enough to cover all contingencies.

Studies show (Lifecycle Insights – September 2018) the typical project using the traditional process flow goes through 2.9 re-spins, with an average schedule hit of 8.5 days and a cost of $44,000 per re-spin. For highperformance designs, the costs are often much higher.

Thus the traditional approach wastes time, talent, materials, and puts projects at risk for cancelation.

Clearly, traditional methods can result in the discovery of problems late in the project that can put the schedule at risk. In such emergencies, engineering “tiger teams” are often assembled by pulling engineers off other projects, delaying those project schedules. Technicians often must put in overtime to rework and test boards. Any additional board spins or mechanical design changes required this late in the game bring expensive rush charges. Last minute surprises can bring schedule delays and expanded project budgets. The left-shift approach invokes verification and analysis at an earlier point in the schedule to eliminate these last-minute surprises.

A reliance on engineering specialists can also bring schedule delays. These individuals are always in high demand and often support multiple projects concurrently.

But bottlenecks caused by reliance on specialists can all but cease when design authors get powerful, easy to use analysis tools. Designers themselves can significantly improve the quality of the design before it reaches the specialist, reducing the need for exhaustive full-board screening by experts.

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A shift-left methodology demands a fully-inclusive system design platform for upfront design analysis and verification. Mentor, a Siemens business, is the first electronic design software company with a broad portfolio of proven technologies to enable shift-left design verification.

The fully-integrated Xpedition verification platform for single and multi-board PCB system design includes automated schematic integrity analysis with builtin automated design checks and an extensive library of intelligent models. Testability analysis, automated component modeling for vibration analysis, dc voltage drop analysis for rigid-flex and multi-board designs, as well as concurrent DFM analysis during layout, are additional technologies integrated within the authoring environment for easier, faster validation. The benefits of this new multidimensional verification platform are the reduction of costly design re-spins, improved time-to-market for new products, and the development of higher quality products with fewer defects. DW References Mentor Xpedition Enterprise platform, https://www. mentor.com/pcb/xpedition/

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Screen shots from the Xpedition platform depict integrated testability analysis (left), automated schematic verification (top), and concurrent design-for-manufacturing analysis that takes place during board layout (bottom). Previously, these procedures would likely have taken place later in the board design cycle, perhaps making necessary changes more costly.

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Connectivity options:

DIN and Deutsch connectors Choosing pre-wired connector solutions for hydraulic valves eliminates time-consuming terminations of hundreds of wires for easy installations.

Paul Badowski | OEM Account Manager | Cross Co.

M

Many benefits can be seen from using pre-wired DIN-style cables on mobile

machinery, particularly for use on solenoid valves, pressure switches, and other devices. DIN connectors have been used in the industrial and mobile market in these devices for decades.

They can be ordered from a variety of sources, as pre-wired, molded, and tested. Users can select the length of the cable, type of wire, and even add circuit protective diodes, resistors, timers, or indicator lights. Their use and design are simple and intuitive.

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Taking this a step further, adding a secondary connector on the opposite end allows you to plug the connector directly into a remote output block that is hooked into the machine network. This removes the need for complicated termination of hundreds of wires and only requires the network connection. Each connector is factory tested and plug-and-play. Wiring labor costs are dramatically reduced.

the DIN-style plug. Many wiring harnesses use the multi-pin Deutsch configuration and then break out into the smaller twopin Deutsch for direct connection into the device. However, the 12- and 24-V mobile systems don’t have the third or fourth wire requirement that is available in the DIN style connector.

Hydraulic valve manifold often use pre-wired DIN and Deutsch connectors for simple and intuitive design. | Courtesy of Cross Co.

Selecting between DIN and Deutsch Canfield Connector has been supplying preIntroduction of Deutsch connectors wired DIN connector solutions since the early Over the last few years, mobile machine 1980s. Reviewing two of its available options products have seen rapid growth in the use will help determine which connector is best of Deutsch-style connectors. The smaller size, suited for the changing industry. improved environmental sealing, and push The first Canfield product is simple — to-lock connection are an improvement over a pre-wired Deutsch two-pin connector

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Many benefits can be seen from using pre-wired DIN-style cables on mobile machinery, particularly for use on solenoid valves, pressure switches, and other devices. | istockphoto.com

with indicator. Canfield’s GatorMate GT connector allows smaller OEMs to use Deutsch connectors without having to purchase special crimping tools and supplies required to use the Deutsch style connectors. Many Deutsch connectors require multiple steps and tools for installation.

According to Pat Byce, Marketing Coordinator for Canfield, its series GT male plug is available in both 2 and 3 pin versions both with or without LED indicators. A receptacle option is available for the 2 pin version and provides a complete molded solution for both connector ends.

The GatorMate GT series molded receptacle and plug mobile connectors have all the positive attributes of the basic Deutsch style but enhance the wired section of the connectors accommodating a molded-jacketed cable with added features of indicator lights. These rugged connectors feature an IP67 rating and are shock, vibration, moisture and dust resistant.

The compact and robust design gives the user the ability to see power applied and holds transient voltage/current within the connector.

Using a DIN connector to a 2-pin Deutsch adaptor is another option. Here,

this pre-wired design allows you to use the Deutsch technology on applications that already have the DIN style in place or where there is not an option to change the product to Deutsch connectors directly at the source. Simply plug in the adapter and you’ve now changed the connector style to Deutsch.

“The Series 5JGT allows anyone to use a series GT Connector or ‘Deutsch’ style connector with their existing solenoid valve din coils,” Byce said. “Users like the idea of using the Deutsch style because of how simple it is to connect and disconnect, plus it takes up a smaller space. The 5JGT makes it simple so that nothing else but the connector would need to be changed.”

The rugged 5JGT connector marries Canfield’s popular fully molded 5J connector to the Deutsch style GT 2 pin receptacle connector, exceeding expectation. The overmolded 5JGT mobile hydraulic DIN Style “A” EN175301-803 (Formerly DIN 43650) to GT DT04-2P Adapter/connector solution is designed for use with hydraulic valves to facilitate connection to the DT06 mating connector. The connector is available with indicator lights and surge suppression and unlighted black or grey housing for “A” and “B” solenoids.

The difference is in termination The key difference between the DIN and Deutsch connectors is the requirement for multiple parts and special tools. If you buy

GatorMate series 5JGT Din to GT (Deutsch adapter), left, and Series GT 2-pin (Deutsch style) molded plug. | Courtesy of Canfield Industries.

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buy an un-wired DIN connector, it comes with all of the parts necessary to wire the connector yourself. You simply need to disassemble the connector, insert the wire, strip back the individual wires, and install into the terminals. The only required tool is a small electrician screwdriver to loosen and tighten the terminals.

With the Deutsch connector, users must specify several parts. Depending on the wire size and connection type (male or female), you’ll need to order socket or pin type, solder or crimp type. The connector body, a wedge, and the connector cover and seal are also required. The parts are relatively inexpensive and many options are available.

If you choose the crimp style, you will also need a specialty crimper to ensure a positive and secure connection.

Once the wires are attached to the connections, the connections are pushed

into slots until positively seated and then the wedge, connector cover, and seal are installed. Although the process is somewhat complicated, after several times it becomes intuitive. But in the end, the electrician can spend their time doing much more meaningful tasks, so using pre-wired designs should be chosen to save time and cost.

Conclusion When selecting hydraulic valve connectors, consider the cables that come with them.

Pre-wired two-pin Deutsch connectors come standard with a 6 or 15-ft long cable and would cover most requirements.

Specialty lengths are also available. Use is simple — plug in the cable and terminate the two wires. In quantity, you can order these with an additional cable installed on the opposite end for a complete plug and play system.

These cables are available unlit or with choice of an indicator light, solenoid valve, and pressure switch. With the solenoid style indicator, the indicator glows when there is power to the solenoid. With the pressure switch style indicator, the indicator glows when the switch contacts are made. A variety of ac/dc or combination voltages are available with a 10 A rating. DW Cross Co. | crossco.com Canfield Industries | canfieldconnector.com

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Product World Single-phase solid state soft-starters Carlo Gavazzi gavazzionline.com RGTS Series single-phase motor soft-starters can control 120 or 240 Vac induction motors up to 25 A / 3 Hp. The RGTS Series is a fully solid-state solution. Wire bonding technology reduces the thermal and mechanical stresses of the output

Conveyor configurator Dorner dornerconveyors.com

chips resulting in a longer lifetime compared to other assembled technologies or electro-mechanical solutions.

The AquaGard 7350 V2’s Positive Drive

and LPZ (Flat and Cleated belt) models now

The RGTS is a simple soft starter requiring just two user adjustments. The motor ramp-up time, and initial torque can be independently adjusted via the built-in potentiometers. The green LED indicates

on D-Tools give project engineers, plant managers, and others the ability to easily design an AquaGard conveyor to fit their exact

the supply voltage presence. The ramp-up and

application in a matter of minutes. D-Tools,

full-voltage indication are provided through

which includes 2D and 3D CAD libraries and

an orange LED. The RGTS does not require a

other functions, lets users construct simple

dedicated control signal. Hence less wiring

or complex conveyor packages, as well as

is involved. Despite its simplicity, the RGTS

individual components such as gearmotors

solution that can help to reduce motor starting current by 40% compared to a direct on-line start.

and mounting packages, support stands, and accessories.

The AquaGard 7350 V2 is built for

numerous sanitary applications within baking, snack food, pharmaceutical, pet food,

Low viscosity, thermally conductive underfill epoxy

packaging and other industries that require occasional wipe-down cleanings of the conveyor. The new conveyor comes in belted, modular belt and positive drive models.

Master Bond masterbond.com The EP3UF-1 is a single component epoxy that is not premixed and frozen. With a viscosity of 5,000-15,000 cps, this heat curable thixotropic compound is suitable for underfill and many bonding applications. EP3UF-1 delivers high bond strength and dimensional stability with a compressive strength of 18,000-20,000 psi and a tensile modulus of 450,000-500,000 psi.

EP3UF-1 has a thermal conductivity of 9-10 BTU•in/ft2•hr•°F [1.30-1.44 W/(m•K)], making

it an effective thermal interface material. It contains a special filler with a small particle size. This allows it to be applied in bond lines as thin as 10-15 microns imparting a low thermal resistance of 5-7 x 10-6 K•m2/W. It offers electrical insulation with a low dielectric constant of 4.5 at 60 Hz as well as a dielectric strength of 450 volts/mil (for 1/8” thick test specimen), both measured at 75°F.

DESIGN WORLD

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March 2019

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congratulates

Boker’s, Inc., celebrating over 100 years of experience, offers a wide selection of non-standard washers and spacers, as well as a broad range of stamping capabilities. Washers are available in over 32,000 non-standard sizes with no tooling charges, outside diameters ranging from 0.080” to 5.140”.

800.927.4377 • www.bokers.com

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

Stepper motor module B&R br-automation.com Ballscrews & Rollerscrews

The X20SM1436-1 module from B&R is a new X20 module for direct control of stepper motors.

The module runs stepper motors with operating voltages from 18 to 60 Vdc at currents to 2.5 A. Plus integrated current reduction function increases

Industrial Robots

performance and reduces energy consumption.

With the current reduction function, B&R has

integrated sensorless load-dependent current control, increasing the performance of the module.

By regulating the current downwards depending on the operating situation and load, the module allows

Linear Motors

energy savings of up to 75%.

The current reduction function also significantly

reduces power dissipation and heat accumulation in the module. At the same time, current control also results in the stepper motor running more smoothly. For self-protection, the stepper motor module has an inrush current limiter and a motor outlet with short circuit and overload protection.

Linear encoder for absolute applications

Linear Actuators

Linear Guideways

Heidenhain heidenhain.us Long machine tool axes are increasingly being equipped with linear drives, and the LC 201 absolute linear scale was introduced specifically to meet those drive position feedback needs.

Linear Encoders / Positioning Measurement Systems

This single-section METALLUR tape encoder is suitable for use in linear motor applications that may need to reach high acceleration levels within the linear drive systems.

The encoder has an absolute 2-track graduation and a large single-field scanning window

— using a reflective light method of scanning. This produces high signal quality, resistance to contamination — all with no homing routine required at start-up. This new single-section encoder

AC Servo Motors

is available in measuring lengths from 440 to 4240 mm, and the multi-section version goes up to 28 meters or more with the TNC Control.

Hiwin D1 and D2 Servo Drives

For more information visit

www.hiwin.com

DESIGN WORLD

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S U M M I T

&

E X P O

The International Design and Development Event for Robotics and Intelligent Systems The Robotics Summit & Expo emphasizes the design and development of commercially viable robotics and intelligent systems products – wholly new products and services that are to be used outside of laboratory environments and sold at a profit.

Dedicated tracks provide professionals with the information they need to develop the next generation of commercial class robotics and intelligent systems products and services.

Robotics Summit Tracks Technologies, Tools and Platforms Design and Development Manufacturability, Business Models and Business Development Workforce Engagement and Development

2019ATED C CO-LO T E EV N nce onfere c g n i ad ch The ler the medte . y t fo i n u comm

june 4-6, 2019

SEAPORT WORLD TRADE CENTER BOSTO N , M A

ro b o t i c s s u m m i t . co m EXHIBIT AND SPONSORSHIP OPPORTUNITIES For more information, contact Mike Emich 508.446.1823, memich@wtwhmedia.com, P RESE NT E D BY:

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Product World Protect against EMC noise Helukabel helukabel.com The HELUTOP MS-EP5 is a fifth-generation EMC gland that is used to ground a cable system WE Series Linear Guideway Wide Series Ball Type.

and protect against EMC noise when bringing cables into panels or enclosures while providing strain relief. The nickel-plated brass cable gland is IP68 – 5 bar rated and is cable of performing in environments that range in temperature from -40°C to +100°C. It is suitable for application areas such as manufacturing facilities, wind turbines, and railway engineering to name a few.

There are three main advantages when using the MS-EP5: • Maximizing the number of EMC contacts – Increasing the total contact area between the cable’s shield and gland improves the EMC protection at high frequencies.

• Strengthened EMC contacts – This reduces ohmic resistance, voltage drop and heat loss in applications that experience heavy mechanical stress and strong vibrations.

• Flexible contact system – This prevents damage to the shield during cable installation, which could impact EMC protection.

PG Series Linear Guideway Integrated Magnetic Encoder.

Low-profile direct drive motor Mitsubishi Electric us.mitsubishielectric.com These Low-Profile Direct Drive Motors (TM-RG2M / TM-RU2M) are built with speed and precision in mind. They have a MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

smaller footprint to allow for more compact, efficient, and precise machines than those typically built using rotary servo motors. Applications that are well suited for the new motor include coating and vapor deposition systems, index tables, tool changers, rotary material handling robots, and rotary axis on XYθ inspection positioning systems.

Unlike rotary servo motors that are coupled to a load with a mechanical transmission

such as a gear, coupling, or belt, the TM-RG2M / TM- RU2M Low-Profile Direct Drive Motor is coupled directly to a load, resulting in greater positioning accuracy, reduced energy use, and less maintenance. It is suitable for use in industries such as semiconductor / LCD

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

manufacturing, machine tool, material handling, and inspection.

DESIGN WORLD

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Product World Hollow-core motorized rotary stage Optimal Engineering Systems oesincorp.com The AY110-300 motorized rotary stage has a 180 mm (7.087 in.) open aperture. This precision, large open aperture (hollow core), low profile rotary stage is just 65 mm (2.559-in.) high and its footprint is 303 mm by 319 mm (11.929-in. by 12.559-in.) not including the motor.

The rotary table of the stage has a precise pattern of threaded holes for mounting custom tooling and fixtures, and holes

in the base for easy integration into new and existing applications. The diameter of the rotary table is 300 mm (11.811-in.) and the range of travel is a full 360° and it is capable of continuous rotation. The table is driven by a smooth 288:1 worm gear and has a resolution of 0.000625o with a 10 micro-step per step stepper motor driver. The AY110-300 Rotary Stage is also available with a servo motor and optical encoder. The standard model is equipped with stepper motor and a knob for manual adjustment which can be replaced with an optical encoder for precision position verification.

The Industry Leader in Test Point Technology for More Than 70 Years Components Corporation’s signature line of printed circuit board test points delivers top-fight performance and cost-efciency.

Contact and contactless slip rings Kuebler kuebler.com

• Cost-efective, time-saving solution for PCB test applications.

• Mission critical performance in the harshest of test environments.

This standard Slip Ring SR120 has a three-

• Broad range of product oferings for specifc design requirements.

chamber system and shield to enable parallel,

• RoHs/Reach/Confict Materials compliant.

500 million revolutions—reducing maintenance

interference-free Ethernet transmission up to 100 Mbps. The series achieves a service life up to cycles and downtime. It also has a rugged, modular structure that can be expanded up to 20 channels.

DesIgneD for VaLue. VaLueD for PerforMance.

The SR120 is suitable for industrial

automation, bottling plants, labeling machines, rotary tables, and other applications requiring high

cc

COMPONENTS CORPORATION

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March 2019 www.designworldonline.com

Product World 3-19 Vs5.LL.indd 116

transmission rates.

DESIGN WORLD

3/4/19 1:38 PM

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Configurable controls for brushless dc motors Minarik Drives minarikdrives.com

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

The MDBL Series is a family of configurable controls for brushless dc motors. MDBL drives control motors ranging from 90 to 280 Vdc, up to 5 amps/1.5 HP, using either 115 Vac or 230 Vac line sources. On-board trim pots allow operators to quickly set minimum/maximum speeds, acceleration/deceleration rates,

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

motoring and regening current limits, as well as the proportional and integral feedback gains.

An onboard microprocessor allows for custom programming the MDBL Series —

for tasks as simple as changing the purpose of a jumper or trim pot, or as complex as programming an entire application-specific routine. The MDBL also integrates PLC-like functionality into operations, eliminating the need for a separate PLC or enhancing systems without PLCs. These controls are positioning-application capable, with feedback sampling rates of 16Khz. Each drive is designed for feedback from 120° hall effect sensors and can

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

be commanded with a wide range of analog inputs with Minarik Drives’ built-in isolation.

Rotary ball spline for sub-millimeter accuracy NB nbcorporation.com KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

This rotary ball spline can be used for both rotational motion and linear motion. Popular applications include SCARA robots, the vertical shaft of assembly equipment, automatic tool changers, and loaders, and more, This rotary ball spline has a nut that rolls on the ball spline shaft. It provides sub-millimeter accuracy every time.

AC Servo Motors.

Splines feature arch-shaped grooves on both the shaft and inner portion of the cylinder.

These grooves approximate the diameter of the ball bearings, allowing them to carry a high load in a linear motion. A ball spline’s forte is the transfer of torque. In addition, it can even be customized so cabling can run the length of the robotic arm by using a hollow shaft ball spline.

Ball splines with cross rollers as opposed to balls in the rotary motion increase load rating

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

without increasing size.

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Product World Collaborative robot for automating repetitive tasks

Remote monitor for outdoor use

Omron omron247.com

Pepperl+Fuchs pepperl-fuchs.com

With built-in vision and a plug-

The19-inch VisuNet IXD 2100 remote monitor is

and-play programming interface,

for outdoor use in IECEx/ATEX Zone 1/21 rated

this TM Series Collaborative

hazardous locations. Tailored to meet the harsh

Robot works seamlessly with

demands of the oil and gas industry, the IXD features

humans to enhance productivity and

a marine-grade aluminum housing that can withstand

ensure safety. Designed to enable an

extreme temperatures up to 60 ºC and thermally

innovative manufacturing environment,

hardened glass for high impact resistance.

this transportable robot complies with

safety requirements for human-robot

client or as PC. The thin client option comes equipped

collaboration specified in ISO 10218-1

with RM Shell 5 firmware. This latest-generation

and ISO/TS 15066. It can be easily trained

firmware, which is based on Microsoft Windows 10

to perform almost any repetitive task in

IoT Enterprise LTSB, supports easy integration and

any location thanks to a manual teaching

management of VisuNet remote monitors and thin

function that allows operators to teach the robot

clients. RM Shell 5 allows users to create profiles and

with hand-guidance without needing for Software.

connections to access their applications on a process

control system via standard Ethernet networking.

• The programming interface is intuitive and quick to set

The VisuNet IXD 2100 is available either as thin

up. The robot reduces installation and setup times compared with traditional industrial robots thanks to a flowchart-based programming interface and intuitive teaching. No prior robot programming experience is necessary.

• Integrated on-arm vision system further reduces setup time. The robot comes with built-in vision and integrated lighting for capturing products with a wide viewing angle. Image sensing functions include pattern matching, barcode reading, color identification and more.

• Compliance with human-machine collaborative safety standards. The robot ensures safe cooperation between humans and machines and reduces installation time by eliminating the requirement for industrial safety guarding.

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SHACEY PETROVIC President & CEO; INSULET

2019 CO-LOCATED EVENT S U M M I T

&

E X P O

SAVE THE DATE:

JUNE 5-6, 2019

Boston

Seaport World Trade Center presented by:

boston.devicetalks.com

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Sponsorship opportunities are available for future DeviceTalks programs.

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DTBoston19_housead_1-19.indd 56 119 DeviceTalks - Boston 2019_DW.indd

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Ad Index Advanced Energy, Inc. .................... 103 Allied Electronics & Automation ....................... Cover,2,3 AllMotion .................................................. 4 Altech Corporation ................................. ......................... Cover inside gate, 19,21 Altra Industrial Motion Corp. .................23,24,25,26 Aurora Bearing Company ...............97 AutomationDirect ...................................1 Bodine Electric Company............... 102 Boker’s Inc. ............................................112 BRECOflex CO., L.L.C. ........................93 Brother Gearmotors ..........................45 Cadence Inc. .........................................91 CGI Motion ............................................43 CIT Relay & Switch ..............................14 Components Corporation .............. 116 Del-tron .................................................. 77 Digi-key ................................................... 13 Dorner .....................................................29 ebm-papst, Inc. .................................... 15 Elesa U.S.A. Corp ............................... 88 Encoder Products Company ..........92 Fabco-Air, Inc. ..................................... 110 HELUKABEL USA ...............................39 HIWIN ......................................... 113,115,117 icotek Corp ............................................97 J.W. Winco, Inc. ....................................53 Keller America ......................................35 Key Bellevilles .................................... 108

SALES

Keystone Electronics Corp. ...... 5,109 Kuebler ...................................................55 Kuriyama of America, Inc. ................76 Master Bond ........................................53 maxon precision motor ..................... 51 Memory Protection Devices ........... 37 MICROMO ............................................ IBC Miki Pulley US ....................................... 31 MW Industries - Atlantic Spring .... 57 Nason .....................................................50 New England Wire Technologies & .

New England Tubing Technologies ...................................................................83 NKK Switches of America, Inc. .......44 Novotechnik ...............................Cover,9 OKW USA ...............................................47 Opto 22 ...................................................16 Oriental Motor.......................................85 Renishaw .............................................. 89 Robotics Summit ................................114 ROLEC ..................................................... 17 Rotor Clip Company, Inc. ................. 99 Servo Kinetics, Inc. ........................... 107 SEW Eurodrive ................................... BC SIKO Products ......................................33 Smart Products USA ..........................7 Super Swivels ........................................ 11 THK America, Inc ................................IFC Trim Lok ..................................................36 Vlier ..........................................................41 Whittet-Higgins ................................... 27

Make Parts Fast Supplement 3D Systems ............................ 58 CS Hyde Company ............... 66 HP 3D Printing ....................... 69 PBC Linear .............................. 62,63

Jami Brownlee

jbrownlee@wtwhmedia.com 224.760.1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

Bill Crowley

bcrowley@wtwhmedia.com 610.420.2433

Michael Ference

mference@wtwhmedia.com 216.386.8903 @mrference

Mike Francesconi

Neel Gleason

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Jim Powers

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LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

mfrancesconi@wtwhmedia.com 630.488.9029 Managing Director

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dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

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smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

A supplement of Design World March 2019

WHY is the new tool for surgeons 64

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The right motor makes a

A better light for

big difference in additive

3D printing

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17mm ø

FAULHABER coreless (brush) DC motors feature compact dimensions, low power consumption, high efficiency, and low noise, making them ideal for challenging medical equipment applications requiring high precision and smooth motion.

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