Design World May 2016 by WTWH Media LLC

May 2016

www.designworldonline.com

INSIDE:

MOTION CONTROL: Direct-drive motors need direct-position sensing PAGE 58

LINEAR MOTION Designing linear motion tracks for robotic positioning PAGE 66

ADDITIVE MANUFACTURING: 3D printing a better car PAGE 136

Hoverboards POSTAL BOX HAS TO BE IN THIS POSITION DO NOT MOVE

get their own UL standard 94

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IT’S

BETTER

Each and every member of the Bimba team is working to deliver innovative solutions you can trust and superior support you can count on. INNOVATION

MEET THE PEOPLE THAT ARE MAKING IT BETTER AT BIMBA WATCH THE VIDEOS AT

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Engineering a better experience

DELIVERY

CUSTOMIZATION

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Dedicated to going above and beyond At Bimba, the customer always comes first. That means doing whatever it takes to keep you up and running at your very best.

SERVICE

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MANUFACTURING TECH

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I nsi g hts

Get more out of your associations I’m fortunate to attend a lot of conferences and conventions put on by industry associations. These events are not only great networking opportunities, but they allow attendees to learn more about niches of their industry, as well as gain 30,000-ft views of things like engineering design trends and economic factors that are affecting their business. Yet, there is so much more to these groups—and I’m surprised that many individuals and companies don’t get involved. So I spoke with four association executives recently, to get their take on things. “The power of the trade association is the members work together to make themselves better businesses and better managers,” said Ann Arnott, EVP and CEO, of PTDA, the Power Transmission Distributors Association. “If you’re looking for companies to buy from, you should consider how involved and active that company is in the trade associations they belong to because they learn so much from participation and have access to many resources that make them stronger, better companies.” The International Fluid Power Society (IFPS) is a fluid power technology industry group that is dedicated to individuals, and its focus spans manufacturers, distributors, OEMs, end users, educators and students. Donna Pollander, the group’s executive director, noted that certification and professional development were ranked #1 and #2 in the group’s recent membership satisfaction survey. “Our members love the recognition they receive from being part of an industry organization. They also rely on the ability to get reputable information, especially when it comes to safety, when they need it,” Pollander said. “Our members value their certification above all. In addition, members receive every study manual for every certification

DESIGN WORLD

Insights 5-16_Vs2.MD.indd 4

May 2016

at no cost. These documents are not only useful as study guides for certification testing; they can be used as stand-alone reference books.” NAHAD, the National Association for Hose and Accessories Distribution, is active in developing the industry’s future workforce, keeping public policy interests engaged on Capitol Hill, helping members expand their exports overseas, developing more useful business intelligence tools, and more. “Associations should not simply mirror the ups and downs of their members’ businesses,” said Joseph Thompson, EVP. “Strong associations push the proverbial envelope by identifying trends and purposely preparing their members for the business realities that they will face in the future. In order to properly lead, support and strengthen their members, associations must anticipate the future, innovate for creative options and collaborate with their members and with other leading industry stakeholders. Successful associations gain the active participation and engagement of their members in identifying, developing and nurturing the services, programs and benefits that can help all members succeed.” Thompson noted that globally, businesses and industries are being held to higher standards of safety, quality and performance, as evidenced by an ever-increasing number of industry standards organizations, certification qualifications and demands by customers. “Associations often serve as the incubators and managers for such industry standards,” he said. “NAHAD’s Hose Assembly Guidelines initiatives and its Hose Safety Institute are the products of our members’ commitment to addressing hose assembly safety; a topic that resonates well with end users and the public. Through education, training, testing and certification, NAHAD’s Hose Safety Institute has greatly enhanced our

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I nsi g hts Bearing Service Inc. is a mid-size power transmission distributor located in Livonia, Mich. John Masek, the SVP there, has spent 34 years at the company and working in the industry. He’s been an active volunteer at PTDA for more than 20 years. “Bearing Service got deeply involved in PTDA when we were a small organization, knowing it might take some time to build relationships with other industry leaders. Through our attendance at Industry Summits, as well as involvement in committees and the governance of the Association, we did just that,” Masek said. “Our company is a testament to the saying that the more you put into the organization, the more you get out of it. Being involved gives you the opportunity to serve your industry, while learning from others to be able to benefit your own company and yourself. But in order to fully participate, you need buy-in and support from ownership of your own organization. I would encourage every senior manager and owner of any company, no matter the size, to allow their up-and-comers to get involved in trade associations. It will groom those participants for taking on more responsibilities and help your organization grow.” DW

members’ commitment to safety, quality and reliability, and to serving the needs and interests of their customers worldwide.” While there are commonalties among associations, each brings unique value to its members, and members join for varied reasons. Pete Alles, director of Membership and Communications for the National Fluid Power Association, said that some benefits may be undervalued by some. “One of our long-term core benefits has been statistical and market information that we offer members to help them plan ahead through economic cycles and unique market conditions. Some may step back feeling overwhelmed by the amount of information available. We think NFPA is unique in the extent that we strive to make it more relevant and easily usable. We’re soon launching our new Stats Toolkit Pro, a software that enables members to easily work with our multiple data sources and customize the results to support their decision needs,” said Alles. In workforce development, Alles said NFPA is working to develop a pipeline of engineers and technicians with fluid power training, and its programs are producing results—an unseen benefit that is very real.

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

On Twitter @ DW—Editor

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May 2016

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

High profits, sick economy The U.S. Treasury recently announced rules meant to curb so-called tax inversion deals. An inversion is where a U.S. company merges with a foreign firm, then locates the headquarters of the resulting entity offshore as a way to dodge U.S. corporate taxes. For example, that’s why U.S. industrial giant Eaton Corp. is now headquartered in Ireland. Judging by the belly aching of companies that go through inversions, you might think that putting their headquarters outside the U.S. is the only way corporations can make any money these days. But there is now an assertion that the profits of U.S. companies are too high. In fact, their profits are high enough to be a detriment to the overall economy. The interesting thing about this assertion is that it doesn’t come from a politician trying to get votes. The claim that U.S. profits are too high comes from The Economist magazine. It says that profits have risen in most rich countries over the past decade, but the highest increase has been for American firms. Simultaneously, industries have become increasingly concentrated as big

firms have bought out smaller competitors. The result is that the fruits of economic growth benefit an ever tightening circle of a lucky few. The Economist bases its claims on data from the U.S. Bureau of Economic Analysis and corporate performance analytics from McKinsey & Co. These reveal profits at near-record highs relative to gross domestic product and free cash flow. Return on capital is at near-record levels as well, The Economist says. And though U.S. companies now make a fifth of their profits abroad, their return-on-equity is 40% higher on their operations in the U.S. You might think high profits are something to be celebrated, but The Economist says high profits across a whole economy can be a sign of sickness. The sickness the magazine refers to is a lessening of competition. When there’s less competition, companies have little incentive to cut prices or boost the pay of superproductive employees. By and large, that seems to be the case: The Economist says in a market the size of the U.S., prices should be lower than in other industrialized economies. Generally speaking, they aren’t. And the U.S. Bureau of Labor statistics says wages for all industries other than investment bankers have risen only 21% (adjusted for inflation) in the past 25 years.

The concentration of profits is particularly high in manufacturing. The Economist reports that just four U.S. manufacturing firms are now responsible for about 44% of the total annual U.S. manufacturing revenue. The only other industry that has this kind of revenue concentrated in so few companies is IT/ telecom/media. Which bring us back to the caterwauling that arose when rules to curtail tax inversions went into place. Companies that claim they need to reside offshore to make a decent return certainly seem to have a lot of money to spend—on their own executives. That is a conclusion you might come to from the reporting of Michelle Leder, an SEC filings expert. She points out that several tax inversion companies are disclosing hefty allowances for their top executives to live overseas in places like Ireland and Switzerland. She says oil driller Transocean Ltd., for example, spent over $1.6M last year on housing allowances and related expenses for its top executives. Transocean CEO Jeremy Thigpen got $90,722 in housing expenses and $136,693 in education expenses. The company says its executive management team is based in Switzerland—interesting, seeing that Thigpen is on the board of directors for the Boys & Girls Clubs of Greater Houston. In this era of a “rigged” economy, it is nice to know that at least some people are making out alright. DW

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

On Twitter @ DW—LeeTeschler 8

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l Contributors Spotlight

CHRIS HARRIS

Team Lead, Technology Assistance Group AutomationDirect.com

Applying industrial ethernet Chris Harris spent many years designing, programming, installing and maintaining factory automation systems before coming to AutomationDirect 17 years ago. He has a background in Aviation Electronics and Computer Science, but he has been in the Industrial Automation business for 24 years.

MARK HOWARD Managing Director Zettlex

WALTER BRENNER, PHD

Founder Master Bond

Advanced epoxy adhesives revolutionize structural bonding Walter Brenner is a professor of chemical engineering, inventor and (co-)author of several patents, technical papers, magazine

Direct-drive motors need direct-position sensing

articles and books. He is recognized as having pioneered the development of high energy

Before joining Zettlex, Mark worked for Siemens in Switzerland as Head of Technology Strategy and has a BSc First Class Honors degree in Mechanical Engineering from Coventry Polytechnic in the UK. Mark said it drives him crazy when people assume that engineers “wear overalls and come to fix the washing machine, air conditioner, car and so on.” Along that same vein, he thinks that poor public perception of the profession, particularly in the West, is a major issue among engineers today, leading to a low propensity for children to choose engineering as a career. Q:

ionizing radiation for polymers to be used for industrial, aerospace, medical and consumer applications. Walter and his family emigrated from Austria to the U.S. in 1938 to escape the Nazi occupation. He studied under the famed Dr. Donald Othmer while doing his graduate work at Brooklyn Polytechnic Institute.

What is the funniest thing that’s happened to you at your current job?

Walter served as a full professor at New York University for more than 25 years teaching chemical engineering. In 1976 he founded

A: I am a native English speaker but can speak some German. While

speaking German to a customer, I inadvertently made some highly inappropriate remarks which, luckily, he realized were due to my poor German rather than anything else.

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May 2016

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

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Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting

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Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora Assistant Editor Michelle DiFrangia mdifrangia@wtwhmedia.com @wtwh_michelle

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Te c h n o lo gy Fo r wa rd

Additive manufacturing—after the hype How has the all the hype around 3D printing/ additive manufacturing (3DP/AM) prototyping and manufacturing endeavors affected you? According to the Gartner hype curve, we are probably now in the trough of disillusionment. Except for metal AM, which is still experiencing the effects of hype. The situation, however, is not at all bad. More companies are entering the 3DP/AM industry, such as Trumpf and Toshiba. The hype served a purpose. It helped fund a number of improvements and new developments within this field. But as the hype dies down, we will no longer have a new “advance a week,” noted Todd Grimm, founder and president of T.A. Grimm & Associates Inc. “We can get back to sanity,” he said. “This is the era where practicality reigns.” Major introductions have emerged already and more are on the way. “We will see better tools, more applications, more innovation, and some disruption. We will be able to do more, and do more with more types of parts,” Grimm continued. The Additive Manufacturing Users Group (AMUG) Conference is not normally a venue for new product introductions. But it is a place where developers give presentations on new technology or equipment they have created. Several companies at AMUG took advantage of this opportunity. Carbon, for example, had already introduced its first machine, the M1, prior to AMUG. Attendees lined up to hear more about how this AM machine works. Impossible Objects discussed how it prints with carbon fiber material. EOS showed its M 100 system that it introduced late last year. Attendees had an opportunity to find out how this smaller laser sintering machine could fit into their application needs.

3D Systems returned to AMUG and showed its SLABot system, Feature 4. By lining up several stereolithography systems and connecting them with a couple of robots, the Feature 4 is a mini 3D printing manufacturing system. And XJet gave a presentation on its nano-particle jetting additive machine, which binds stochastic metal cut into nanoparticles in a patented liquid and jets them through standard ink-jet heads onto a build platform. The initial metal is stainless steel. But this system delivers speed and fine resolution detail. Grimm also noted that a number of 2D printing companies are moving into 3D printing, including Canon, Richo, Fuji

and Epson; not a development you would see if, according to the trough of disillusionment, this industry was in trouble. More development is in the works thanks to the earlier hype heaped upon 3D printing. The Carbon and XJet processes definitely deliver something new. And more is coming. Said Grimm, between 2016 and 2026, we will see a number of new ways to additively make products side by side with traditional manufacturing. We’ve only seen the tip of what is possible in additive manufacturing. DW

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

On Twitter @ DW—3Dprinting 14

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May 2016

Leslie Column (Technology Forward) 5-16 Vs3.LL.MD.indd 14

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Co nten t s |

May 2016 • vol 11 no 5

designworldonline.com

F E AT U R E S

CONTROL 58 MOTION Direct-drive motors need

ELECTRONICS Hoverboards get their own UL standard

direct-position sensing

Battery fires in hoverboards have made headlines and garnered the attention of regulators who are devising safety standards aimed at heading off future troubles.

Direct drives differ from traditional drive arrangements. These motors impart many design advantages, but perform best with specialty feedback.

66 Designing linear motion tracks

102

SENSORS Solving tougher sensing requirements in industrial applications

LINEAR MOTION

Manufacturers are tackling more difficult—and unique—design problems with the newest generation of sensors.

for robotic positioning

Robot-positioning tracks can add flexibility to manufacturing spaces, but must be fast, accurate and safe to be truly useful. Here we take a look at drives that deliver.

110

BEARINGS The care and handling of precision ball bearings Miniature ball bearings are high precision devices compared to many mechanical parts. Good performance will therefore require treatment that takes into account their characteristics and operating environment.

ETHERNET 78 INDUSTRIAL Applying industrial ethernet Tips and techniques that will help you set up and maintain an industrial Ethernet network

118-138

Inside: 120 Advances in additve manufacturing 126 3D printed end-of-arm tooling lightens load on robotic packaging line

A supplement of Design World • May 2016

Sensor www.sensortips.com

A Supplement to Design World - May 2016

139-146

132 Metal additive manufacturing enables lean, green heat exchanger

88 Advanced epoxy adhesives

Design sensors faster,

3D printing

FASTENING & JOINING

smarter, and under budget with TiPS from

a better car

leading suppliers

136

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revolutionize structural bonding

Structural polymers offer distinct advantages over traditional fastening methods. Here, we explore the cornerstones of successful structural bonding.

ON THE COVER UL develops safety standard for hoverboards to head off future troubles.

2015

2015 O N LIN E

Courtesy of HoverBoard Technologies.. revenue over $3 million

DESIGN WORLD

CONTENTS MAY 2016_first page_Vs3.LL.MD.indd 16

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F R E E C A T A L Con O G te & nBts ROCHURE

WASHERS & STAMPINGS

5 .2 01 6 36

D E PA R T M E N T S 04 Insights 08 Teschler on Topic 11 Contributors

Call (888)-WASHERS

(888)-927-4377 • 612-729-9365 • sales@bokers.com

12 Technology Forward 20 Green Engineering 24 Design For Industry

BOKERS.COM/DW

32 Design Notes 48 CAE Solutions 52 Internet of Things 147 Products 1 56 Ad Index

52 SIKO MagLine Absolute: ■

■ ■ ■

Measuring length of up to 20 m with a large reading distance Contactless and wear-free Accuracy up to 10 µm Simple and fast installation

24 visit website

SIKO OptoLine: ■ ■ ■ ■

High-precision, optical measurement Accuracy up to 5 μm Repeat accuracy up to 0.05 µm Large reading distance

open flyer

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Contents MAY_second page_Vs1.indd 18

DESIGN WORLD

May 2016

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» G re e n E n g i n e e ri n g

n Paul J. Heney • Editorial Director

Biopolymers in the spotlight Dr. Jay Golden of the Center for Sustainability and Commerce at Duke University spoke at the recent Innovation Takes Root Conference, sponsored by Natureworks. Golden discussed the U.S. BioProducts sector and quantifying efforts to drive its growth. Although his focus was primarily on the consumer market, it provided a lot of insight into the growing demand for biopolymer products and the expansion of biopolymers’ capabilities. Here are highlights of what he covered. • There are a variety of reasons that large companies (especially large retailers) want transparency in their green practices. There is the differentiator, the competitive advantage of being green. There are insights to inefficiencies and lifecycle assessment. That allows you to find inefficiencies in your full supply chain, reducing the cost. If you have a private brand, maybe there’s some information that you want to use for your private brand that could be more selective. It’s all driving forward greener and greener products and pushing towards the bio economy.

• Apps like GoodGuide allow consumers to quickly check the environmental and health impacts of a product. Golden’s students use it all the time when they go shopping, and we should expect this type of demand for green information to continue in the future.

• A sustainable apparel coalition is forming that represents approximately 35 to 40% of all apparel and footwear sold around the world. The consortium is interested in all products, all sectors. They’re actually moving faster, in regard to impact, for bio- based products, than many other sectors.

• Golden’s grad students have crunched more than 300 million lines of data in regard to how all the different products and sub products fit each other and what industries they are used in. They are working with large analytics firms to make this a searchable freeway across the globe. A manufacturer will be able to go in, pick your crop and within your crop you can analyze to see: Who are the top producers? Where do they produce? What’s the embedded energy? What’s the embedded blue water, green water, phosphorus, nitrogen, and so forth? Where do they flow in the economy? What if this type of industrial product takes off or what if the EU really increases bio diesel? What are the implications for where these crops are produced and the land use, and what are the trade flows, so you can break this down by country? Which are the top producers, where are they trading and how are they being used as they are traded, and what type of industrial processes are they using? DW

• For the U.S. in 2013, the bio products industry was worth $369 billion dollars. Golden’s team used end plan modeling, and that number represents both direct, indirect through supply chain, and induced numbers.

Center for Sustainability & Commerce center.sustainability.duke.edu Natureworks natureworksllc.com 20

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May 2016

4/27/16 12:24 PM

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military/aerospace

» Design for Industry

material handling

Increasing flexibility in material handling

In a flexible transport system, carrier movement can be adapted quickly and easily to different formats, sizes and types of product, and even to seasonal requirements. Flexibility in this context means that transport carriers can be freely fed into and out of a multi-carrier system. Transport carriers can be accelerated, slowed down and positioned freely. The transport carriers can be deployed independently of one another. It is also possible to mix different carrier and product configurations within a single system. The system also has application-specific holders and adapters for the carriers. Plus, a motion profile can be freely created for each carrier. This Multi-Carrier-System travels at up to 3 m/sec and offers acceleration of up to 40 m/sec²— jerk-free. It can be started and stopped at any desired position. And it can be freely synchronized with the process.

DESIGN WORLD

DFI 5-16_Vs5.LL.MD.indd 24

May 2016

www.designworldonline.com

4/28/16 8:59 AM

machine tool/aerospace/military

Did you say seal of approval?

This system incorporates options relevant for Industry 4.0. These include, the flexible electromechanical design for economic production down to batch sizes of one, as well as the decentralized sensors and intelligence within the work piece carriers and drives. The modular servo controller and the motion controller also reflect the Industry 4.0 concept. Program data can be generated even from the simulation. The OPC-UA interface enables open integration into Industry 4.0 host environments.

In addition to meeting our customers’ applicationspecific requirements, many of HELUKABEL’s products comply with multiple international approvals. Designed with the export manufacturer in mind, our cables can be used all over the world; reducing country-specific material costs and saving time. No matter the location, HELUKABEL products will put the final seal on your project.

The Multi-Carrier-System complements classic transport solutions. The other transport routes remain unaffected or can be implemented using a low-cost classic transport system or conveyor belt. Linear motors drive the transport carriers and provide precise positioning. Integrated control handles both transport motions and motion-control functions as well as the coordination of further machine modules. Carriers can be moved toward each other without the risk of collision and are easy to position. In addition, several transport carriers can be grouped together and moved synchronously at fixed distances. The modular basic mechanical system consists of linear motors, a base profile and a roller conveyor; customer-specific configurations can be created and precisely matched to individual applications. The Siemens controller allows full integration of the control and motion control functions for the overall system. In addition, the controller can also coordinate motion with other servodriven machine modules such as fillers or cartoners. DW

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DESIGN WORLD

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military/aerospace

0 90

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medical

Easier tracking of medical tools 91

Tube bending

perfection in stainless Eagle has the expertise and the specialized machinery for bending tubing exactly to spec. Call us for a quote !

Marking surgical instruments and tools with unique device identification (UDI) numbers is easy with the MPX-90M direct part-marking device. Unlike traditional dot peen technology, the MPX-90M can accurately imprint permanent two-dimensional DataMatrix barcodes as small as 1 mm2 on hard metals for product tracking and traceability. Medical device manufacturers can quickly imprint large amounts of data in a compact barcode format as small as one square millimeter. For direct part marking of medical devices, components and surgical instrumentation, this marking device prints on materials ranging from surgical steel, titanium and aluminum to matte plastics and acrylic. It marks GS1 DataMatrix barcodes for UDI compliance as directed by the FDA. It uses a diamond-tipped stylus that permanently marks hard materials up to 200 HV, including surgical steel, titanium and aluminum, as well as matte plastics and acrylics. It comes bundled with METAZAStudio software, for quick setup of DataMatrix barcodes and QR codes, as well as text, symbols, photos and graphics. Its medically safe marking will not corrode or degrade materials over time, and the 30-Âľm imprinting depth assures that barcodes will not be affected by scratches. A built-in laser pointer and adjustable XY vise make setup quick and easy, while the automated head height function ensures proper image placement. The MPX-90M also features two different nose cones for marking on flat and curved surfaces, plus an adjustable XY axis clamping table for holding flat and oddly-shaped tooling. Software-supported variable data printing lets users automatically customize tools with unique serial numbers, production lot dates and other data. DW Roland rolanddga.com

Eagle Stainless

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www.eagletube.com DFI 5-16_Vs5.LL.MD.indd 26

DESIGN WORLD

May 2016

4/28/16 9:00 AM

s e m i c o n d u c t o r » Design for Industry

Improve semiconductor process yields The GF100 series MFC with high-speed EtherCAT connectivity and the GF135 IS

ISO 13485

advanced diagnostic MFC help users meet critical gas chemistry control challenges and improve process yields for sub-20 nm nodes. Responding to rapidly evolving requirements for next-generation tools and fabs, the GF100 series features several additions to help boost process yields and productivity: • embedded diagnostics to leverage real-time EtherCAT data acquisition capabilities for fault detection and classification • an ultra-stable flow sensor (less than 0.15% of S.P. drift per year) enables tighter low set point accuracy and reduces maintenance requirements • improved valve shutdown reduces valve leak-by, minimizing potential first wafer effects • enhancements to the GF100 pressure transient insensitivity to less than 1% of S.P. with 5 psi/sec pressure perturbations, which reduces crosstalk sensitivity for consistent mass flow delivery.

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The GF135 is a “smart” pressure transient insensitive (PTI) MFC that can perform self-diagnostics, such as integral rate-of-decay flow measurement, without stopping the flow of process gas. This helps semiconductor manufacturers verify process gas accuracy, check valve leak-by, and monitor sensor stability in real time without removing the flow controller from the gas line, reducing downtime. With this real-time error detection technology, users can reduce wafer scrap and lost production time from unacceptable flow deviations and unnecessary preventative maintenance checks. The GF135 PTI MFC also offers process gas accuracy and fast flow settling time for ascending and descending set points, helping improve productivity and chamber-tochamber matching. DW

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

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Eagle Stainless

Tube & Fabrication, Inc. Franklin, Massachusetts

Phone (800) 528-8650

May 2016

DFI 5-16_Vs5.LL.MD.indd 27

DESIGN WORLD

www.eagletube.com 4/28/16 9:00 AM

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» Design for Industry

safety

A simple way to connect robots to machine tools This controller makes it easier to connect different types of robots designed by different manufacturers to CNC machine. The Sinumerik 828D family using the Sinumerik Integrate Run MyRobot/ EasyConnect interface performs the handling tasks. Users can set up automated cells even with different types of CNCs using the same standard interface. The Sinumerik interface is based on a standard defined by the German Machine Tool Builders’ Association (VDW) and the German Engineering Association (VDMA) for connecting robots or handling systems to machine tools. The robots are connected through Ethernet

(Profinet RT) or using I/O signals. Using the interface, operators can synchronize processes between the machine tool and robots. A range of smart operation features is available for integration into the production environment. Machine operators can access the factory network and can inspect contract documents at the user interface. Users also have access to remote diagnostics using a corporate network or Internet access. The basic Access MyMachine/P2P application exchanges data with connected machines from a Windows PC. Machine tool operators can access the machine over the Internet or outside the company network if the application is appropriately configured.

Sinumerik Integrate Access MyMachine/Ethernet (ASP) provides a quick overview of the machine history in addition to machine access. The Sinumerik CNC uploads and downloads machine data, files, trip recorders and configurable PLC traces. Text message (SMS) or email notifications in cases of unusual machine conditions are also possible. ASP allows costefficient monitoring of fault states and comprehensive integration of in-house service and maintenance processes. DW

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DFI 5-16_Vs5.LL.MD.indd 29

May 2016

CARLO GAVAZZI Automation Components

DESIGN WORLD

4/29/16 1:49 PM

DznWrldBallSplineNB3.pdf

7/13/15

4:17 PM

Ball Splines

No Backlash No Vibration Higher Loads

• 6 Nut Shapes • 16 Shaft Diameters (4 – 100mm) • Custom Modifications Twice As Fast • 10X Load Capacity* • Longer Travel Life* • Nut and Shaft Available in Stainless Steel

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No backlash because precisely ground (not drawn) raceways conform to shape of ball in nut and shaft so opposing raceways have same angles of contact. Wiper Seal. Anti-rotation torque transmission. Spline shaft is straighter than competitions’ – eliminating rotational vibration. Greater ball contact in nut permits compact single shaft applications.*

*When compared with ball bushings.

NB Corp 5-16.indd 30

All ball tracks are in contact with raceways only half of competitions’ are in contact in any one direction.

4/27/16 1:34 PM

packaging

5 POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

Eliminate system vibration

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

These CPU pin-type couplings effectively dampen system vibration, especially on packaging systems. Designed using a simple pin and bushing connection that minimizes vibration, these couplings handle angular misalignment of 4Â° and parallel misalignment of 0.5 mm. The design maintains zero backlash for smooth system operation. Also, the couplingsâ&#x20AC;&#x2122; aluminum construction makes for a lightweight yet strong coupling body capable of absorbing and dissipating heat from adjacent sources in a system. Clamp style hubs slip easily onto two connecting shafts with the coupling locked into position with recessed tightening screws. The coupling handles system speeds up to 4,000 rpm, is RoHS compliant, and available in three models in bore sizes ranging from 6.00 to 22 mm. Transmittable torque for these sizes range from 2.2 to 25 Nm. DW

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4/28/16 9:04 AM

» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

New motor technology lowers energy and noise for extruder When designing its synchronous reluctance motor and drive (SynRM) packages for twin extruder applications, ABB had several objectives. The goal from the outset was creating 15% lower energy usage, lower motor maintenance costs and a drop in audible noise. Radius Systems’ plant in Derbyshire, UK, houses 14 extrusion lines, each of which produces polyethylene pipes from 16 to 1,200 mm, together with an injection molding facility making fittings for utilities companies’ gas and water transfers. Eight lines are powered by dc motors, many of which are more than 20 years old. In spite of Line 12’s high use rate, the 182-kW dc motor was regularly failing, leading to an increase in downtime and rising maintenance costs. The company estimated that the annual static and dynamic checks, brush changes and outsourced labor costs alone were about £2,000 per motor.

erbyshire, s’ plant in D m te ys S s iu Rad pipes from polyethylene UK, produces ith an injecm, together w 16 to 1,200 m g associated facility makin ng di ol m on ti companies e by utilities fittings for us ater transfer. for gas and w

DESIGN WORLD

Design Notes 5-16_Vs3.LL.MD.indd 32

Before and after monitoring Inverter Drive Systems (IDS), was tasked with carrying out “before” and “after” monitoring of the dc motor on Line 12. This would determine the energy savings while confirming that an investment in an ac motor and drive would meet Radius Systems’ three year capital payback policy. “Monitoring of the application is critical to the success of any installation,” explained Phil Nightingale, sales engineer, IDS. “It allows us to determine real energy saving potential which means we can size the ac motor and drive correctly. We are often able to reduce the size of the motor and drive package required while exceeding production targets.”

May 2016

4/28/16 9:49 AM

When Size and Performance Matters Medical-Industrial In spite of Line 12’s high use ra te, the 182-kW dc mot or was regularly fa ilin g, leading to an in crease in downt ime and rising maintenan ce costs.

IDS determined the speed range of the line’s dc motor which revealed that it was over-sized for the application, hence consuming more energy than necessary. Also, despite the motor having been regularly maintained, it was 20 years old and nowhere near the efficiency for which it was originally designed.

Energy saving bandwidth It was estimated that potential energy savings from a SynRM package for Line 12 would be in the range from 8 to 15%, with a return on investment within two years. In addition, an excess of £2,000 cost avoidance was estimated with the removal of dc motor maintenance.

Actual Micro-Coax cable bundle diameter compared to a penny.

7.7mm

“To pick an exact production run that can give an accurate energy measurement is very difficult to quantify, hence the range from 8 to 15%,” explained Rob Betts, engineering manager at Radius Systems. “The actual energy savings is dependent on several process variables such as raw material type, different product ranges and profiles, the temperature at the die and the barrel and the general ambient environmental conditions. For instance, energy consumption is higher on a cold day as more energy is needed to warm up the process.” The SynRM, a 200-kW, 1,500-rpm, IE4 component, together with the industrial drive ACS880, created a much higher efficiency

19mm

Bundle of 128 Micro-Coax Cables (42AWG/85 ohms)

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W, is a 200-k The SynRM nt; e n o IE4 comp 1,500-rpm, strial ith the indu together w a 80, created drive, ACS8 than cy n r efficie much highe n c inductio standard a drives. motors and

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Design Notes 5-16_Vs3.LL.MD.indd 33

May 2016

DESIGN WORLD

4/28/16 9:49 AM

» D e si g n N o tes

than standard ac induction motors and drives. It’s also a quieter package than the existing dc motor. However, a challenge was presented by the physical footprint of the existing dc motor. “Dc motors tend to be long and thin,” explained Betts, “whereas ac motors tend to be shorter but bigger in diameter.” The SynRM can be up to two frame sizes smaller than a conventional induction motor which is a benefit in the direct replacements of dc motors.

Challenges of constant torque While SynRM is well tested on quadratic torque applications, like pumps, fans and

compressors, there are fewer constant torque references, such as extruders. Despite the shortage of constant torque references, Betts was confident in the solution. “At no time did we feel that we were taking a risk with this new technology,” he said. “It had been widely tested and we had every faith in the outcome. As such, we did not consider it to be a risk at all. We were able to meticulously

plan the changeover of the dc drives to SynRM so that the entire installation and commissioning was carried out in just five days.” DW ABB abb.com

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Design Notes 5-16_Vs3a.LL.MD.indd 34

May 2016

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Designing and Manufacturing Custom Products for

HEAVY TRUCK

» De sign Note s

Edited by: Mike Santora • Associate Editor

SPRINGS, MACHINED PARTS, WIRE FORMS & STAMPINGS

Livestock feed maker speeds palletizing changeover operations

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Design Notes 5-16_Vs3.LL.MD.indd 36

MADE IN THE USA

Installing a second auto mated palletizing lin e in the Sou th plant proved to be the right cou rse of action Form-A-Fee . d wanted to a void the programmin g challenge s it faced wit the North p h lant’s autom ated line.

Managers at Minnesotabased Form-A-Feed, a maker of livestock feed, planned a new production line as they saw business growing. As part of the planning process, Form-A-Feed called on engineers from Hamer-Fischbein, a company that designs and integrates bagging equipment and Yaskawa Motoman robotic packaging solutions. The engineers looked at ways to boost speed so the feed maker could bag and palletize products at its South plant production facility. Because the feed company’s North plant uses bagging equipment and a robotic palletizer, the robot integrator looked at the needs for the new line and also assessed Form-A-Feed’s experience with its existing equipment. 36

DESIGN WORLD

May 2016

Form-A-Feed and the robot integrator agreed that installing a second, automated palletizing line in the South plant was the right course of action. But Form-A-Feed wanted to avoid the programming challenges it faced with the North plant’s automated line. For example, when changing the configuration of pallets for the North plant’s line, the production facility’s supervisor would have to stop production, turn off the robotic palletizer and plug in a laptop to instruct the robot to handle a new size of bag and pallet. Automating the bagging and palletizing process saved time at the North www.designworldonline.com

4/28/16 10:04 AM

Designing and Manufacturing Custom Products for

INDUSTRIAL plant, but the time-consuming programming steps for the changeover process reduced the cost savings gained from automation. Another challenge for Form-A-Feed was the footprint allotted for installation. Managers wanted to leave room in the South plant for other operations. The space for the South plant’s new line was “L” shaped, measuring approximately 370 m2. The focus for the project was designing a bag palletizing solution that ensured less robot downtime, was easy to program and increased productivity for the South plant. To simplify the challenges of the existing solution and fit the system inside a relatively small footprint, the engineering team designed a new, semiautomatic line for the South plant, including a duplex Hamer 600NW Belt Feed bagging scale, which dosed product to a 1200BH bag hanger. The system also included two conveyors and a Hamer RPM Robotic Palletizing Module which includes an MPL160 robot and controller. This is a 4-axis robot with 160 kg payload.

Robotic palletizing made easier The integrators installed the system at Form-A-Feed, and managed to fit the required technology inside the footprint. To operate

the line, one worker facilitates the bag-labelling step along a conveyor and positions bags before they reach the sew-top sealer. After the bags are filled with product, they travel along a second conveyor and are picked by the robot and placed on one of two pallets located on either side of the robot’s station. A second worker removes completed pallets with a forklift and takes these to a wrapping station for shipping. At the South plant, the installation took two visits, and product changeover now happens faster. The South plant’s palletizing line now operates at 20 bags per minute (BPM)—slightly faster than the North plant’s line. However, it is often the scale or bagging machine that sets the pace of total production. For instance, the 1200BH bag hanger runs at a maximum rate of 18 to 20 BPM; the MPL160 robot can operate much faster depending on the size of the bag. DW Yaskawa Motoman motoman.com The South pl

ant includes a 600NW Belt Fe ed bagging scal e, which dosed product to a 1200BH ba g hanger. The system also includes two co nveyors and an RPM Ro botic Palletizin g Module that includes an MPL160 robot an d controller, which is a 4-axis robo t with 160 kg payload .

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May 2016

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» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

Whether oneoff manufacturin g or serial produc tion—the highes t demands are pl aced on each individual med ical engineering workpiece.

CNC technology helps makes high precision medical implants Substantial legal requirements have resulted in more complex specifications for implant manufacturers: From the design through production, the complete process chain must be documented and validated. CNC-controlled machines support prosthetics manufacturers and permit highquality products to be manufactured, despite being subjected to continuing high cost pressures. 38

DESIGN WORLD

Design Notes 5-16_Vs3.LL.MD.indd 38

May 2016

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4/28/16 10:05 AM

The idea for a new medical implant normally arises to meet a practical need. It is a long process before the implant can be produced in quantity; it takes approximately 12 to 18 months from first drawing, to design and job planning, and through to the completed, approved implant. “After receiving a request for a new product from an orthopedist, we first design and develop a prototype”, said Hans-Joachim Mahr, production manager at implantcast Corp. in Buxtehude, Germany. “The CNC controller assumes an important function for the transfer of the CAD/CAM data to the actual production. It supports the idea and the virtual model in a workpiece that the orthopedist then can hold in his hands for the first time.” Artificial bones made of titanium are mainly manufactured using the stock-removal process. At implantcast, for example, the production of hip implants runs on DMG turning-milling centers equipped with the Siemens CNC Sinumerik 840D sl. Each implant also has an associated, speciallytailored set of instruments required for the implantation. This includes, for example, a surgical rasp used to prepare the bone. Because its machine functionality is suitable for both complex single parts and large production runs, the fast data processing of the 840D sl is a particular advantage for the standard implants produced in quantity. implantcast also offers, for particularly complicated applications such as cancer patients, the manufacturing of patient-specific implants. In this case, the implants and instruments are cut precisely to the associated bone structure with the help of a CT or MRI picture. For this single part production, implantcast uses the setup functions of the Sinumerik that permit the fast machine setup. For example, the CNC user interface has selfexplanatory icons that can be configured as popular keys. Furthermore, many functions are available that assist in the measuring of tools and workpieces. These measuring functions can be used both for the setup and process measurement, that is, the overall quality assurance during the machining. The Sinumerik Operate user interface also integrates simple swivel commands May 2016

Design Notes 5-16_Vs3.LL.MD.indd 39

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Design Notes 5-16_Vs3.LL.MD.indd 40

ts with th to orthopedis for the joint implants ation of proper prepar the bone.

that simplify the machine setup. The swivel functions are available both for the swiveling in a machine axis and also in an axis of the workpiece coordinate system. The CNC also handles any required coordinate transformation. Whether a one-off component or a quantity run, the highest demands are placed on each individual medical engineering workpiece. It’s obvious that there can be no letdown permitted from quality and precision standards. Furthermore, the manufacturer is responsible for validating the complete production process, which means that even prototype construction must satisfy the same conditions as the subsequent volume runs. 40

DESIGN WORLD

May 2016

Artificial hip sockets in twelve standard sizes The number of artificial bone implants is increasing continually, while operations such as the use of a replacement hip made of titanium also belong to the standard daily program in orthopedic surgery today. In 2010, one million artificial hip and knee joints were implanted in the U.S. Forecasts expect this number to exceed 4 million by 2030. This number, however, does not obviate the fact that the highest demands are placed on each individual medical implant, whether a one-off or production run. Standard implants are now available in various sizes as required for the physique www.designworldonline.com

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DMG turningmilling center s equipped with the Sinumerik 840D sl CNC co ntroller technology.

Âť D e s i g n N o tes

of the patient. The NC programming that defines the functions for machining the workpiece is fast. The Sinumerik 840D sl provides a range of turning and milling cycles. Because all operator functions and cycles are supported with animated elements, the operator intuitively knows how the function is to be used, without needing to consult the instruction manual. Dynamic vector graphics can be used when the animated elements do not suffice to explain the purpose of the individual input values, such as the parameterization of complex cycles. These graphics reflect the current input values with their proportional representation.

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» D e s i g n N o tes

At EMO 2011 in Hanover, Germany, Siemens presented dual-channel production of bone rasps on machines with two slides. This allowed turning-milling centers such as the DMG CTX alpha 450TC to be operated more effectively, because the complete programming functionality is available in both channels. The Programsync function synchronizes the machining channels, whether or not the programs have been programmed in DIN/ISO. The increasing complexity of the turning-milling machines and the possible production programs also increase the risk of programming errors that, under some circumstances, can cause machine damage.

For this purpose, the Sinumerik 840D sl offers a program simulation that shows the stock removal process in virtual 3D. In addition to the complete representation of the cutting actions, the expected machining time corresponding to the programmed technology values is also displayed, before the production of a single workpiece. A short machining time, however, is critical for production economy. The turning-milling center with the 840D sl used at implantcast, with cross slides for Y and B axes, permits 5-axis simultaneous machining. The implants are manufactured here in a single operation, with parallel machining on the main and counter spindles. For the complete machining,

the Sinumerik 840D sl provides turning-milling functions that can be used in combination. Bone rasps are an example of complex workpieces, because their basic form represents a significant challenge in machining, namely, a rasp body with many rasp teeth located on the contoured outer surfaces. The Sinumerik MDynamics technology package ensures the required surface quality at high machining speed; even for difficult materials, the “Advanced Surface” motion control produces milling results that meet the stringent requirements placed on medical implants and instruments. Each individual part is subjected to quality control. Sensing probes check the accuracy

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nsk k1TM lubricaTion uniT Experience long-term, maintenance-free operation with NSK K1™ Lubrication Units. These patented units provide fresh, continuous oil flow onto the rail or shaft during operation, making them ideal for environments where grease replenishment is undesirable or where grease is easily washed away. Available on NSK linear guides, ball screws, Monocarrier™ actuators and Robot Modules, K1™ Lubrication Units prolong life for up to 5 years or 10,000 km operational distance. 1.800.255.4773

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of the contour and the peak-to-valley height and scan the surface for even the smallest damage. To check the material structure, X-ray examinations are also made on some parts. Only when all these hurdles have been overcome are the implants passed to the internal department at implantcast for sterile packaging and subsequent shipping. A patient with bone prostheses receives a prosthesis pass. This document allows the complete manufacturing process of the prosthesis to be reconstructed at any time. Whereas in other industry sectors, such as the automotive or food processing industry, products must be able to be tracked batchrelated; this tracking requirement in the

orthopedic world is specific to each individual patient’s medical implant. This is a major challenge, considering implantcast produces about 3,000 items, each week. Despite the use of sophisticated technology, at the end of the process chain there is still a suffering patient who must be helped. There is a difference between manufacturer medical industry parts and making those for machinery construction. For example, when Hans-Joachim Mahr himself delivers a package to the post office, the trip is not actually part of his job. “The patient whose prosthesis is in the package would need to wait one day longer for his/her operation, were we not to act immediately,” explained Mahr.

For such late requests, and these are not infrequent, it is quite possible that he will personally start the prosthesis on its journey to a patient in need. DW Siemens usa.siemens.com/cnc

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The NEW encoder module that gets the job done. With its compact size and ﬂexible installation options, EPC’s new 30M Incremental Encoder Module can ﬁt in tight spaces. Its bearingless design allows the 30M to work at high speeds – yet it’s tolerant of shaft misalignment, thanks to an air gap up to twice the size of other encoders in its class. The magnetic sensor and optional IP69K seal mean it can go into your dirtiest, dustiest, wettest applications and it’ll keep going. Call EPC today. Discover how the 30M can tackle your tough application.

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»»

» CA E S o lut i o n s

Inventor 2017 offers design, interoperability and communication capabilities Inventor 2017 is 3D modeling software for manufacturing industry professionals. It delivers professional-grade design, interoperability and communication tools. As the mechanical engineering function changes, this software helps manage the tasks of product definition as well as design and delivery. Professional-grade Design Tools help users design faster and optimize performance. Enhanced sketching, part modeling, assembly management, surfacing and sheet metal capabilities help users capture and develop design ideas quickly and easily.

Additional Shape Generator capabilities, such as symmetry and member size controls, help users explore lightweight designs and improve product performance. Interoperability Tools help to pull disparate aspects of a project together, regardless of the discipline or software originally used. Expanded AnyCAD tools let users easily integrate non-native mechanical design data into Inventor models without translation. These now include associative connections with the industry standard STEP format. Other enhancements that facilitate data and process management range

from improved mesh handling to new connections with Vault for customers using Inventor for factory design. Enhanced Communication Tools help customers share information with anyone on a project team, regardless of their role, company, location or software package. Design Shares on A360 accelerate feedback and approvals on designs in progress. They help users lift the 3D graphics off the screen and instantly deliver them to anyone in the world and on any device so collaborators can easily collect design feedback in a single secure location. Enhanced animation capabilities show assembly sequences and 3D PDF publishing to document designs. With this release, the standard-level Inventor product is no longer available as subscription, and is being consolidated with Inventor Professional to create one subscription offering. New subscribers will now get the Inventor Professional product at a lower price that matches the old price of Inventor standard. DW Autodesk autodesk.com/inventor

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May 2016

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2015-D

» CAE S olut i ons

Model and create fixture setups FixtureBuilder is a 3D-modeling software package that allows offline creation and documentation of fixturing setups. The software can be used with a CAD model of the part to be inspected, which is imported into FixtureBuilder, so that the fixture can be built around it. The entire setup, along with the part, can then be exported into inspection programming software, using universal file formats such as IGES, SAT, STEP, and so on. FixtureBuilder offers a range of customer benefits and ease of use thanks to: • clear and well-organized component libraries • intelligent drag-and-drop functions • quick manipulation of parts and easy-to-use constraint mechanism • user experience is enhanced by the software’s full CAD compatibility and the availability of custom libraries.

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The “Build it” function is one of the key benefits available to users. It automates the production of work instructions and bill of materials for every fixture setup, to help ensure compliance with quality standards and assist with product ordering. DW Renishaw renishaw.com/fixtures

3/6/2015 11:34:56 AM 4/28/16 11:56 AM

»»

» CA E »Solu CA Et iSo onlut s ions

Simulation app for virtual prototyping of surface-mount devices Engineers at BE CAE & Test (Catania, Italy) have taken the simulation process well beyond the typical approach of “run a test/ deliver a report.” Instead, using the COMSOL Multiphysics software and the Application Builder, they have created a series of easy-to-use custom applications for virtual prototyping of customers’ surfacemount device designs. The apps hide the complexity of the underlying detailed model, yet still provide access to the functionality of the simulation. Thermal management techniques ensure the efficiency of electronic devices, improve reliability, and prevent premature failure. Numerical simulation is an important part of the process, allowing engineers to analyze and optimize temperature and air flow early in the design. BE CAE & Test is creating custom applications to give designers interactive tools to access, analyze and share the vast amount of information available from the mathematical models they

CAE Solutions_Simulations 5-16_Vs3.LL.MD.indd 50

created without needing app users to be simulation specialists themselves. The app created by BE CAE & Test conducts a thermal analysis that lets users evaluate important thermal characteristics. The temperature distribution within the device, maximum temperature reached, junction-to-case thermal resistance as a function of solder thickness, and dissipated power and constitutive material of the solder and the die are among the results presented to the app user. DW BE CAE & Test www.be-caetest.it COMSOL comsol.com

4/28/16 11:58 AM

» CAE Solu t i ons

Program ensures CAD model quality and supports additive manufacturing 3D CAD model quality is the backbone of an efficient Model Based Enterprise (MBE). Support of model based engineering processes requires robust and stable CAD model geometry and associated 3D Product Manufacturing Information (PMI). The CADIQ program lets users check CAD models, ensuring they are fit for reuse in downstream manufacturing processes. Checking model quality and finding unintentional changes and issues early in the design phase avoids rework and the potential for downstream design deviation, ultimately reducing expensive part recalls. Other vital aspects of quality assurance supported by CADIQ include comparison of CAD models as they are translated for collaboration or when the customer delivers new

revisions to a manufacturing company. These tools help when customers release new revisions of a CAD model and the manufacturing partner needs to quickly check for and communicate design changes within the organization so that decisions, such as retooling, can be made quickly. As a partner in the European Hyproline project, International TechneGroup Inc. has added capabilities to its CADfix solution to improve the quality of parts produced in advanced Additive Manufacturing processes. CADfix improves STL program accuracy by basing the slice generation on curved triangles, and checks to assess the quality and manufacturability of the slices generated.

New functionality within CADfix allows users to import point cloud data from a scan and accurately compare it to the original CAD model to identify excess material for removal. DW International TechneGroup Inc. iti-global.com

Invented here. Perfected here. Poorly copied over there. We’re flattered that our competitors have admitted the superiority of Rittal’s patent-protected modular enclosure system. With more than 10 million Rittal TS 8 modular enclosures sold worldwide, it’s clear to see why Rittal is acknowledged as the industry leader. So why settle for a cheap imitation when you can have the original? Rittal…when quality matters. And to our hopeful competitors…nice try.

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... ..

More data leads to greater efficiency for brewery For South African Breweries (SAB), an automated and networked Ethernet/ IP-based control system will integrate traditionally disparate, malt-production processes into a single, networked, Ethernet/IP-based solution for plant-wide visibility and actionable data. The maltings plant in Alrode, South Africa, will account for more than half of the brewery’s South African and Namibian malt production when fully commissioned early in 2016. The brewery will increase local malt production from 60 to 90%, reducing the financial impact of imported malt. The plant will enhance the production capabilities of its predecessor by increasing malt production from 42,000 to 150,000 tons per year. SAB contacted Rockwell Automation to design the networked Ethernet/IP system. It connects all data from the plant floor to the rest of the SAB enterprise, transforming the plant into a Connected Enterprise. “By converging operations technology and information technology, we deliver SAB secure access to operational, business and transactional data to improve the malting plant’s supply-chain, economic and sustainable performance,” explained

DESIGN WORLD

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May 2016

Adrian van Wyk, Rockwell Automation business manager for power and components in Johannesburg, South Africa. All devices and processes within the plant are integrated in a single, secure network with dualport, Ethernet/IP-based hardware connected in a device-level-ring (DLR) configuration. Controlled by Allen-Bradley ControlLogix controllers and Allen-Bradley Stratix industrial Ethernet/IP switches, the motor control centers comprise more than 500 E300 intelligent electronic overload control relays, 70 Allen-Bradley PowerFlex 750 ac drives, and 50 Allen-Bradley SMC Flex smart motor control soft starters for motor starting, stopping, control and protection with greater production efficiency.

www.designworldonline.com

4/28/16 12:01 PM

Retrofitness

To address the plant’s energy metering, energy consumption, load shedding and harmonics analysis, Rockwell Automation supplied a range of its Allen-Bradley PowerMonitor metering solutions. Technical partner, MSE, provided all packaged motor control centers distributed throughout the plant to reduce cabling costs. “The new automated system gives SAB personnel plant wide control, from plant floor to executive level, through a single, secure and integrated Ethernet/IP network,” added van Wyk. “By enabling secure access to actionable, run-time production data, machine diagnostics and automatic fault-finding, SAB gains full visibility of the maltings plant, ultimately facilitating faster time-to-market, lower total cost of ownership, improved asset utilization and enterprise risk management.” To keep the plant running nonstop, all motor control center, device-level hardware is equipped with the Rockwell Automation automatic device configuration (ADC) for automatic self-healing and configuring of replaced components. ADC, paired with the Rockwell Automation DLR network, ensures uninterrupted, real-time device communication, providing SAB with network resilience and reducing unplanned downtime. DW Rockwell Automation rockwellautomation.com

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IoT wireless I/O module The WISE-4012 wireless Ethernet I/O module can be used without a gateway. Deployment is easy due to a limitless number of I/O modules that can gather data from any third party analog sensor and connect to an existing network. With integrated analog and digital input in the same channel, this module provides a flexible combination of I/O to acquire different kinds of signals. It can also send out the engineering or physical value as sensor input using a scaling function, which makes the data more readable for further analysis. The WISE-4012 has high resolution, high accuracy and isolation protection so it can provide quality data for smart factories and smart city data acquisition solutions. The WISE-4000 Data Logger can send time-stamped information to a Dropbox account or a private cloud and buffer device data so that should the network fail, no data are lost before transmitting to the administrator. DW Advantech Corporation, Industrial Automation Group advantech.com/ea BRA-201604-DesignWorld Half Pg.qxp_Layout 1 4/11/16 10:57 AM Page 1

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The gigabit managed Ethernet switch line (LMX-0800G series) handles applications in harsh or outdoor environments. These applications include: power/utility, solar grids, windmills, mining infrastructures, and factory/process control automation. The LMX-0800G series is an 8-port industrial gigabit managed Ethernet switch with a 12 to 48 Vdc power input range. Each unit is designed with eight 10/100/1000Tx RJ45 ports. A 16-Gb backplane speed supports Jumbo Frame and wide bandwidth for large Ethernet data packet transmission for edge level connectivity solutions. The product series provides high EFT, surge (2,000 Vdc) and ESD (6,000 Vdc) protection. It is also built with a dual power input design with reverse polarity protection, and has a built-in relay warning function to alert maintainers when power failures occur. This makes it ideal for applications demanding a high reliability and distance extension This product series is pre-loaded with “Layer 2” network management software that supports an ease of use Web Console or Telnet through the serial console by CLI configuration. These managed switches provide the ring network redundancy function with STP/RSTP/MSTP and the ITU-T G.8032 (ERPS – Ethernet Ring Protection Switch) protocol which supports a less-than-50-msec network recovery time, eliminating the compatibility issue for any existing network concerns. In addition, the built-in SNMP, VLAN, IGMP, QoS features support network planners to increase data transmission performance within the network. The external USB 2.0 port lets users export and save all the configuration settings. Lastly, the flexible “custom label” feature allows networking planners to name each connection port. By naming each port, the networking planners can manage remote field devices. The LMX-0800G series units are IP30 rated, compact, fanless, DIN-Rail and wall mountable. Each series is built to withstand industrial networking hazards like shock, drop, vibration, electromagnetic interference (EMI) and extreme temperatures. There are two operating temperature version models for either standard temperature (−10 to 70° C) or extended temperature (−40 to 75° C). The models have the dimensions of 54 × 99 × 142 and a unit weight of 2.1 lb. DW Antaira Technologies antaira.com

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....................................... ............................. ..................... ................ ........... Time synchronization ........ ..... ... . in the nanosecond range IEEE 802.1AS is an adapted version of the IEEE 1588 profile for AVB and TSN systems (audio/video broadcasting and time-sensitive networking). It enables high-precision time synchronization of devices and systems. The 802.1AS protocol software offered by HMS comes as ANSI C code with a modular structure with a clear separation of the media dependent and media independent layers. This enables easy porting and fast implementation into various target systems. As a time-aware, slave-only end station, the software is the receiver of time-synchronization information provided by a grandmaster and enables synchronization of local Real Time Clocks (RTCs). The software supports the Best Master Clock algorithm, which can be optionally disabled. DW

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Direct drives differ from traditional drive arrangements. These motors impart many design advantages, but perform best with specialty feedback.

Direct-drive motors need direct-position sensing Mark Howard • Managing Director • Zettlex

Direct-drive motors have been around for a while, but only recently have OEMs and system integrators begun to leverage the advantages of this technology. Over the last few years, there’s been a huge increase in the number of applications using direct-drive motors. As we’ll explore, some types perform best when designers fit them with a feedback device called an incoder. Basic direct-drive terminology The term direct drive can apply to any motor that directly drives a load or rotor without mechanical power-transmission components such as gears, pulleys or chains. Usually though, the term refers to brushless permanent-magnet motors—synchronous motors—that transmit torque directly to the load or rotor. Often, axial height is shorter than the diameter; many versions also sport a large through-bore in their centers. Another common term for direct-drive motors that produce a constant torque when stationary or moving over small angles is torque motor.

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Inductive encoders called incoders have the right form factor to supply feedback in direct-drive design setups with a low axial height and relatively large bore. They are also lighter and less costly than the resolvers often used with direct drives.

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Classic examples of direct-drive applications are gimbals in antennas and satellites, such as the one pictured here. More engineers are turning to the combination of incoders with direct drives as the pairing continues to demonstrate highly reliable and dynamic motion control for applications in the medical, aerospace, defense and industrial sectors.

Depending on the version, other direct-drive motors are sometimes called Lorenz-force motors and pancake motors.

Advantages of direct-drive motors are increased positional, speed, and dynamic accuracy. They attach directly to the load so there’s no hysteresis, backlash or lost motion in any direction of movement.

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How direct-drive motors work Direct-drive motors work much like other brushless dc motors. Magnets on the motor’s rotor and windings on the motor’s stator interact when a power supply energizes the windings. That’s when the windings produce electromagnetic fields that attract or repel the rotor’s magnets. Precise commutation of power to the windings spurs controlled motion. Both rotary and linear direct-drive motors exist, but rotary types are most common. Direct-drive motors usually have many poles—more than 30 and sometimes more than 100. This lets them output high torque at no or low speed, usually slower than 1,000 rpm. Direct-drive motors with diameters of more than 3 ft (1 m) can produce torque of more than 10,000 Nm. Many direct-drive motors are frameless. Manufacturers sell these without bearings, housing, or feedback sensors. Such products let machine builders and system integrators streamline housing, bearing and shaft design to optimize machine weight, size, shape and dynamic performance. Direct-drive motors have higher torqueto-inertia ratios than traditional motor arrangements, and they have a low electrical time constant. So, the motors promptly

output torque when supplies feed voltage to the windings—getting what control engineers call “good servo stiffness.” More traditional motors generate maximum torque at higher speeds, typically at speeds greater than 1,000 rpm, and engineers size and specify them on their power rating. In contrast, engineers usually size and select direct-drive motors by maximum or continuous torque instead of power. Advantages and disadvantages Direct drives offer excellent dynamic performance and accurate control of position and speed. They are reliable and exhibit no backlash or wear thanks to their low part count and elimination of gears, pulleys, seals and bearings. In addition, they offer: • low torque ripple or cogging • low acoustic noise and minimal self- induced vibration • compactness, with low axial height and large bore • high torque-to-inertia ratio and high torque-to-mass ratio; high torque at low speeds • energy efficiency thanks to elimination of intermediate mechanical friction and inertia • relatively large airgaps to resist shock and survive dirty environments • minimal cooling requirements due to advantageous thermal geometry

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Design engineers choose direct drives for their dynamic performance and shape. The latter is relevant when the motor takes a flat form with a big hole in the middle to let slip rings, pipes and cables pass through. The main disadvantage of directdrive motors—that of high cost—is often exaggerated. Direct-drive motors are more expensive than traditional motors in a simple 1:1 comparison. However, cost analysis that accounts for the savings in omitting intermediate gears and couplings (and associated maintenance) and overall mechanical simplification often finds directdrive arrangements the most cost effective option. What’s more, the cost premium for directdrive motors is coming down as direct drives are increasingly common, and there’s more availability of powerful neodymium-ironboron (Nd-Fe-B) magnets. Case in point: The current cost-to-performance point of direct-

drive motors is making them increasingly common in cost-sensitive applications such as washing machines. Here, engineers are replacing traditional motor-and-belt-andpulley systems with quieter and more reliable direct-drive motors. More classic examples of directdrive applications are gimbals in antenna systems (such as vehicle mounted satellite communications), electro-optics, scanners, rate tables, telescopes, surveillance and CCTV cameras, radar and weapons systems. There are also applications in packaging equipment, CNC machine tools, robotics and even high-end record turntables. Most traditional motors exhibit positional torque ripple known as cogging. At high speeds, this effect is usually inconsequential, as the frequency is so high that it has negligible impact on performance. Direct-drive units suffer more from this phenomenon unless the motor controls

use feedback to counteract the effect. One factor that may have slowed the uptake of direct-drive motors is that they need precise electrical control. Only in recent years have sufficiently responsive and fast controllers with update rates of more than 4 kHz become widely available at realistic costs. High-resolution position feedback hard to find A major advantage of direct-drive motors is increased positional, speed, and dynamic accuracy. Direct-drive motors attach directly to the load so there’s no hysteresis, backlash or lost motion in any direction of movement. The only caveat is that they need highresolution position feedback to complete the servo loop. Sometimes designers use Halleffect sensors for commutation of power to the motor’s windings. But other feedback is necessary where this setup is insufficient to get precise position or speed control.

Traditional motor-drive arrangement versus direct-drive arrangement Traditional

Direct Drive

Load

Bearing Angle sensor

Drive gear

Motor

Reduction gearbox Motor

Here, the angle sensor is a low-profile incoder.

Commutation encoder

Direct-drive designs are more compact than traditional setups, and angle sensors called incoders help maintain their compact footprint and high performance, even at slow speeds.

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If the direct-drive bore is fairly small, say less than 2 in. (50 mm), there are several position-feedback options based on optical, magnetic, capacitive and inductive sensing. However, many sensors don’t have the right morphology for larger motors. Remember that key factors for choosing a direct drive are form factor and a large through bore of more than 2 in. Because most position sensors are for installation on a small input shaft or small through bore, options for suitable position sensors for direct drives have, until recently, been limited. Options for precise position or speed control One option is optical ring encoders. These run off a simple dc input and then output absolute or incremental digital signals. Unfortunately, they’re unsuitable for dirty or wet environments because the optical sensor’s path must stay clear. These also don’t withstand extreme temperatures or shock and need accurate installation to get good measurements. Capacitive encoders present similar issues and complicate installations due to their need for dissipation of staticcharge buildup on the rotor. Another option is magneticring encoders. Their advantage over commutation-tracking Hall-effect sensors is modest, as magnetic hysteresis limits their precision. Because they use sensing of dc magnetic fields, they are also susceptible to stray magnetic fields from the motor. The third and most common option is a brushless resolver. Resolvers use electromagnetic physics, much like the motor itself, to sense rotor position relative to the stator. Debris doesn’t affect resolvers; they have an unrivalled reputation for ruggedness, reliability and safety. For this reason, resolvers are the standard choice in many high-reliability and safety-related applications, especially in aerospace and defense. But resolvers can also be bulky, heavy and expensive, especially in large-bore formats called pancake or slab resolvers. In fact, the use of these resolvers is probably responsible for the misperception that direct-drive systems are overly expensive for some applications. 64

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New option: Inductive encoder Now, a new type of sensor delivers direct-drive position feedback. Called inductive encoders, or incoders, these are new-generation inductive sensors that work like traditional inductive sensors for noncontact measurement. But instead of bulky spools of wire, these sensors use printed circuits on flexible or rigid substrates. Such incoders greatly reduce production cost, size and weight. They offer greater form-factor flexibility, too. There aren’t any sources of inaccuracy from the winding process. They are capable of complex measurement geometries such as curvilinear, 2D and 3D position sensing. In addition, multiple sensors can work in the same space thanks to multi-layer circuit boards (to function as redundant sensors in safety-related applications). EMC performance is as good as that of resolvers or LVDTs. In fact, incoders are already going into aerospace and military applications. One catch is that incoders are more expensive than potentiometers. However, incoders excel because they don’t need the complex ac supply and signal processing that resolvers need. Instead, incoders use simple electrical interfaces similar to those offered by optical encoders. So they take dc power input and output digital electronic signals. Incoders come in absolute or incremental (A/B pulse) formats with resolutions to about 4 million counts per revolution and accuracies better than 40 arc-sec. Until recently, incoders were too slow for dynamic applications, but new versions offer update rates to 10 kHz. In addition, frameless formats without bearings or couplings can mechanically fix to the machine. DW

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L i n e a r

M ot i o n

Designing

linear motion tracks for

robotic positioning

Lisa Eitel â&#x20AC;˘ Senior Editor

DESIGN WORLD

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Robot-positioning tracks can add flexibility to manufacturing spaces, but must be fast, accurate, and safe to be truly useful. Here we take a look at drives that deliver.

Robot positioning systems are long tracks in warehouse, aerospace, and automotive facilities to let one robot perform multiple tasks. Also called robot-transfer units or RTUs, these motion designs are increasingly common for assembly, largescale welding, and warehousing. In contrast with typical setups in which a robot bolts to a floor, RTUs move robots through work-cells and factories and shuttle them between stations. The best setups for RTUs are those just being built or ones where processes and related machines can be put in a straight row. Where RTUs move six-axis robots, the linear tracks are also sometimes called the

seventh axis (or less commonly, when the robot itself has seven degrees of freedom, the eighth axis). When these tracks are part of a frame, including frames from which the robot hangs, they’re gantries. No matter the robot or track morphology, the point of the extra axis is to add translational motion. This either extends the work

HepcoMotion Heavy Duty Slides from Bishop-Wisecarver Group work for longlength transport applications such as pick and place or robot translation stages. V-slide rails are made from high quality bearing grade steel and come in sections to 4 m long. The V slides typically bolt to aluminum extrusions or supporting back plates. They can be butt joined for extremely long travel lengths. The largest carriage contains 4 V bearings with 150 mm diameters to provide up to 100,000 N of radial load capacity.

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M ot i o n

This Acieta RTU services a coordinate measuring machine, four precision lathes, and a parts washer. A forklift puts part in racks which the robot unloads using machine vision. The RTU track provides the link to make the whole work cell automated.

envelope or lets a robot transport workpieces or tools. In some arrangements, the former lets a robot tend multiple machines or pick pallets from rows, or machine very large components. For the latter, common applications are packing, welding, plasmaarc cutting, and other mechanical tasks. Here we focus on drive options for RTUs. However, note that engineers must also decide between an array of guides and bearings (usually in the form of cam followers or profile guides).

Design and drive options for RTUs abound Though some gantries include framing to invert robots and suspend them for better access into machines from above, RTUs that bolt to the floor and orient the robot upright are most common. These RTUs have higher payloads on average, carrying robot arms and grabbed loads weighing thousands of pounds. Engineers can buy pre-engineered RTUs or build RTUs in-house using 68

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motion-system expertise. The simplest are linear-track pairs that bear platforms to which the robot bolts. However, many OEMs enlist dedicated integrators for situations where robots on RTUs will perform high-precision jobs—for example, a cutting task (where the design must synchronize the articulation of multiple axes) or moving castings through various machine tools for processing. The biggest challenge to engineering robot-transfer units is programming them to synchronize with the articulation of the robot arms they carry. The second-biggest challenge is getting RTUs to maintain accurate linear motion over many meters.

Meeting physical requirements for long strokes Sometimes speed is the overriding RTU design objective. That’s especially true when RTUs take robots over a couple hundred feet or even more in specialty setups. High speed in the context of moving robots—sometimes arms weighing

thousands of pounds plus their payloads— is relative. However, some RTUs can move at more than 10 ft/sec with acceleration to one g. But often, accuracy is the overriding RTU design objective. Consider an application where a robot helps a cooperative work-cell with machining, for example. Here, speediness and the extension of the robot work envelope are only useful if surrounding framework can hold accuracy tight. Such designs often need accuracy to 0.02 mm and positioning repeatability to ±0.2 mm or so during track movements. In contrast, if an application uses a robot arm for applications that put adaptive controls through the paces but are less dependent on absolute precision, other setups may work. This may even take the form of a mobile vehicle fitted with a robot arm—for example, to unload shipping containers. No matter the design, low maintenance and long life are crucial for all RTU setups, as they are usually associated with more than one plant function and several other pieces of machinery. Therefore, RTU downtime often takes other stations out of commission. Integrated safety is also important because many RTUs move robotics through fields populated expensive equipment such as machine tools or even workers— especially where they operate around zones with assembly personnel.

Belts, screws and pneumatics for RTUs Robot gantries traversing mid-range linear distances often use motors paired with belt drives. These are relatively simple systems that use electric-motor-driven pulleys to create tension along a belt and quickly accelerate. However, as they reach longer strokes, issues can arise with belts sagging if the system can’t maintain tension over the whole length. To be clear, the issue isn’t payload limitation. Rather, it’s a risk

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L i n e a r

M ot i o n

This is a configurable third-generation RTU called a TMF robot track from Güdel. It uses a rack-and-pinion set for the long RTU axis. Four frame sizes support almost all robot models at full payload and under dynamic loading.

of lost motion from belt compliance. There are exceptions to the scalability caveat. In some RTUs, belt axes (driven from a common driveshaft) drive harmonic cranks. Here, belt drives can maintain accuracy for long-stroke robotic positioning under the right conditions. Most successful belt-driven RTUs use framing and linear tracks in complementary orientations to get more precision from the belt-driven setup. Some such RTUs with a belt-driven rail actuators can hold repeatability to ±0.001 in, even while moving one-ton robots over

dozens of feet. Here (thanks to the right rails) belt-driven actuators make for RTUs that are cheaper and more flexible than alternatives. Another option for the seventh axis is a ballscrew-driven axis. This setup addresses vibration and springing that can arise in belt drives. Essentially a fixed mechanical element maintains control for precise stopping and positioning. Ballscrews generally work well in setups to about six meters long with the help of intermittent bearing supports. On longer axes, the main problem is that screws whip at high speeds, especially if they don’t get enough support. That’s because ballscrew shafts bend under their own weight. Then at critical speed (a function of screw-shaft diameter, straightness, alignment, and unsupported

length) movement excites the shaft natural frequency. So maximum speed goes down as ballscrew length increases. Some setups use bearing blocks that separate and collapse together—and then stay and support the screw for longer whip-free extension. However, for extra-long ballscrew-driven tracks, manufacturers must join multiple screws (usually with glue instead of welding to avoid warped geometry). Otherwise, the screw must have an extra-large diameter to address the issue of whip. Strokes from some such ballscrew-based setups reach 10 meters and run to 4,000 rpm. Another caveat: Screws in robot tracks need shielding from dirt and debris. However, where they work, RTUs using electric motors paired with ballscrews handle larger loads than belt-driven axes. Fluid power for long-stoke setups also exist. Such pneumatic RTUs are usually a low-cost solution for applications that only need back-and-forth two-stop positioning. Average offerings move 2 m/sec and integrate with other robot controls.

Linear motors for precision RTUs Long-stroke RTUs (for use in laboratory robotics, for example) can use linear-motor drives. Most such RTUs also include state-

This belt-driven robot track from Macron Dynamics is an RTU that holds repeatability to ±0.001 in. while moving a 3,000-lb robot over 30 feet. One of the company’s MacBUILT designs, it’s a custom configuration of standard Macron components. The actuator beam is a composite construction of standard aluminum extrusions with integrated round rail with track roller guidance. The belt drive system provides a flexible rack and pinion style linear motion with a motor mounting on the cart. A wrap-around cart design ensures solid load carrying capacity. 70

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This pneumatic robot transfer unit from Easom Automation is a low-cost solution for applications that only need back-and-forth two-stop positioning. It moves robots to two meters per second and integrates with other robot controls.

of-the-art electronics, absolute encoders, and motion control for tracking axes, even after errors or shutdowns. More typical of a linear motor’s reach is four meters or so. Such reach is more suitable for pick-and-place and semiconductor wafer handling than heavier RTU applications. In short, linear motors in RTUs are particularly challenging because they deliver on the mechanical accuracy but must carry heavy payloads. This necessitates more of

the expensive permanent magnets that make linear motors perform so well. There are exceptions. One worldrecord RTU with tandem linear actuators was commissioned and custom built for an automation setup needing precision moves to 12 m. Rigid aluminum support rails work with two six-row linear recirculating ball bearings and guideway assemblies. Twin slotted synchronous linear motors output force to 4,200 N.

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Rack-and-pinion sets for RTUs Commercially available RTUs using rack-and-pinion sets are most common. Typical lengths reach 15 meters. Control of the linear unit is integrated as a mathematically coupled axis in the robot controller, which eliminates the need for an additional controller. Many such RTUs maintain accuracy even to strokes of 30 meters by pairing a brushless ac servomotor and planetary gearbox with ground helical rack-and-pinion sets. Other setups use a carriage that moves over a single-edge rail on heavy-duty rollers in a block. Here, the rails are usually rectangular with a rack cut into an inside edge. These can join with curved segments where that’s a helpful layout. Some RTUs that move the robot about the traveling platform use flat-surface rails made of hardened steel and pair these with cam-follower clusters. Others use an electric motor with a helical bevel reducer and belt to power the platform. Then on the long shuttle axis, the RTU sports an electric gearmotor driving a pinion engaging a rack. Simulation and programming RTUs Tools exist to let engineers plan the paths of RTUs and coordinate those with the robot functions. Robot simulation software and even some motion-controller 74

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modules let engineers plan tracks, load resulting software onto a controller, and then control the robot and RTU with that one piece of hardware. Another option is software from dedicated software companies that sell robot development kits, which allow programming of most any brand of robot through APIs. These and myriad other software tools make robot setup easier than ever, especially for teams with moderate motion-control or CNC experience. Initial design iterations usually happen through offline PC programming. Then when personnel install the robot and RTU, the programming software spawns code that loads onto controls. The software drives the RTU and robot through programmed paths to test for problems. Next the installer uses a pendant to position the robot’s gripper, cutter, or end effector to job-specific points in space while the controller records the moves. Otherwise, installers can use a pendant for the entire setup and then polish trajectories on the backend—an increasingly common approach.

Caveat: RTUs complicate robot calibration After physical setup, RTUs and robots need calibration. The catch is that industrial robots paired with RTUs often make repeatable but not accurate moves, so yield output motion that differs from simulation approximations. Alone, industrial robots average unidirectional repeatability of 0.1 mm to 0.01 mm. Typical axes pair a zero-backlash gearhead and motor, and a controller tracks them all with high-resolution encoders. Boosting output motion accuracy any further gets pricy, as assemblies and components such as gearing introduce lost motion (mostly May 2016

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This ABB IRBT 2005 robot track has 50% shorter cycle times than alternatives. Multiple carriage options (two for the robot and three for transfer applications) and optional carriage plates let the RTU carry multiple pieces of equipment—particularly useful for arc welding and sealing applications.

Positioned for Tough, Compact Applications Novotechnik’s TX2 Series’ pivot-head mounting can handle up to ±12.5° of offset from misalignment without affecting performance. The TX2 is designed for mobile and other tough environments with heavy-duty construction featuring a stainless steel rod and metal housing. It is sealed against ingress of dust and liquids. Specifications • Stroke lengths from 25 to 300 mm • Very long life to 50 million movements • Resolution better than 0.01 mm • Repeatability to 0.01 mm • Linearity up to ±0.05% For complete TX2 information, visit www.novotechnik.com/tx2 Novotechnik U.S., Inc. 155 Northboro Road • Southborough, MA 01772 Telephone: 508-485-2244 Fax: 508-485-2430

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test point kits. Made for maximum portability and immediate use, Tompkins Test Point Kits are portable, compact, and durable. Since the fittings are designed to be connected under pressure, you can test quickly and at multiple points while feeling confident that they won't leak under vibration or peak pressure. You can create your own custom kit online or select from either the JIC or Flat Face Kits.

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L i n e a r

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This is Kawasaki’s RTU-45. It can carry 2,930 kg and has repeatability to ±0.2 mm with a maximum stroke to 30 meters. One of the most common RTU applications is where a facility has multiple operations that are sort of slow. Here, RTUs are more cost-effective than a swath of separate robots … especially where the factory floor can change to accommodate sharing.

due to mechanical compliance). Therefore, controls must often compensate for positional error on the scale of millimeters in some cases. Traditional robot calibration uses costly laser alignment. Sometimes this can decrease output error twentyfold. Otherwise, robot manufacturers offer factory calibration. Dedicated robotcalibration companies also offer services that can account for the effect of an added RTU on overall robot-precision output. Otherwise, dual-camera sensors allow for probing inspection and dynamic measurement via optics and special lighting. Mechanical modes of calibration are another option, though they’re harder to apply to robots on long tracks. DW Macron Dynamics macrondynamics.com Güdel gudel.com/us ABB Robotics abb.us/robotics

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I n d u s t r i a l

E t h e r n e t

Tips and techniques that will help you set up and maintain an industrial

Applying

Ethernet network

industrial ethernet

Chris Harris Team Lead - Technology Assistance Group at AutomationDirect.com

Industrial Ethernet is used to connect devices such as PLCs, local and distributed I/O, servo controllers and drives on the plant floor and in industrial facilities. In this capacity, it links many pieces of hardwareâ&#x20AC;&#x201D;and has many cables, connections and configurations options. For visualization and monitoring, industrial Ethernet connects PC-based and embedded HMIs to controllers, and to each other. Itâ&#x20AC;&#x2122;s also used to connect HMIs to the Internet, and to upper level servers running historian, quality, manufacturing and other enterprise applications. All of these industrial Ethernet communications require two things: a physical connection or layer, and configuration based on the protocol. The physical connection defines the electrical, cable and connection requirements. The protocol configuration specifies the common language of the data in the communication messages.

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Start with the basics Industrial Ethernet cables are not created equal, so consider network speeds when designing and selecting cabling. Then, select the communication protocol to communicate between devices. Once you have determined protocols and network speed needs, you will face a choice of selecting a patch cable or crossover cable, and does it matter? In the commercial world, most devices can auto crossover (Auto-MDIX) and use crossover cabling, but not all industrial devices can. Thus, the recommendation is to use patch cables for connecting end devices such as PLCs and HMIs to Ethernet switches, and use crossover cables to connect end devices together directly without a switch.

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Switches are an important part of any Ethernet installation, and managed switches can often significantly improve performance of the network. (Source: AutomationDirect.com)

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I nd ust r ia l E t h e r n e t RJ-45 connectors are used for most Ethernet connections, but many devices use this same connector for RS-232. Carefully check the technical data of the device before plugging it in. With the connection understood, the question of shielded versus un-shielded often comes up in industrial Ethernet applications. It’s good design practice to use shielded cable when possible in industrial environments because electrical noise is often present from

For most industrial automation applications, the link speed is often 100 Mb, and it's not critical since most industrial protocols don't require anywhere near the full speed (bandwidth) available. However, the

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factor when looking at performance. motors, VFDs, welding and so on. It’s also good practice to use at least Cat5e, but Cat6 cable is the better way to go, especially for the higher gigabit speeds. The choice of cabling should be specified based on run distance, bandwidth and other requirements. Another requirement to consider for both performance and compatibility is communication speed, and half or full duplex capability. While duplex compatibility can

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techno

May 2016

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Table: Key points for applying Industrial Ethernet Understand the basics—get connected properly Unmanaged switches versus managed switches—pick proper hardware

Here are some of the key points when using industrial Ethernet.

Subnetting/Networking—proper configuration Remote Access—setup and the IoT connection

be overcome by using a managed switch— discussed in more detail later—performance is limited to the slowest device. For most industrial automation applications, the link speed is often 100 Mb, and it’s not critical since most industrial protocols don’t require anywhere near the full speed (bandwidth) available. However, the link speed is an additive factor when looking at performance. With half duplex devices, the device (node) can only transmit or receive data; it can’t do both simultaneously. Thus, its performance is slower than full duplex arrangements, which can do both. Plus, it is common to see half duplex devices drop packets under heavy load due to data collisions. Most devices (nodes) with a bandwidth of 100 Mb or more use full duplex. While this speeds data transmission, there can still be compatibility issues. Even though Device A has an Ethernet port and Device B has an Ethernet port, they may not be able to communicate with each other. Chances are, the devices are using more layers for communication than just Ethernet. They are probably using multiple layers based on the Open System Interconnection (OSI) model, which defines seven layers (Figure 1) for communication. Each layer used should be understood by both devices. With most operating systems, the lower OSI layers of physical medium data link with MAC address, network with IP address, and transport with TCP or UDP, and will be understood by both devices. More research is often needed to understand if some of the uppermost layers—such as the session, presentation and applications layers—are common to both devices.

The Open Systems Interconnection model is a common reference model showing how applications can communicate over a network.

Some examples of application layer protocols in industry are Modbus TCP, Ethernet/IP and Profinet. However, even with compatible layers, both networked devices must support protocol functions. Unmanaged versus managed switches Ethernet network topologies include the bus, ring and star. Bus and ring are similar to a daisy-chain connection where a single cable hops between each device. Bus topology is a bit obsolete, while the newer ring topology adds fault tolerance. However, most industrial Ethernet installations use star topology, with some ring connections to reduce cable run distances.

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With the star topology, a switch connects devices to a central access point. Ethernet switches come in both unmanaged and managed configurations. There are applications and situations that make sense for unmanaged switches, and there are others where a managed switch is a far better choice. When connecting a device to a switch, it automatically negotiates to an agreed upon speed and duplex mode. Auto negotiation can be tricky and will often fail. It is better to turn off auto negotiation, using a managed switch, and fix the speed and duplex to a known working setting for both sides. This can be particularly helpful when

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In du st r ia l E t h e r n e t

This Wireshark troubleshooting tool dashboard enables analysis of Ethernet data and detection of problems.

connecting together devices from different manufacturers. For a simple network with five or fewer devices in a relatively small area, an unmanaged switch will usually work, and it will always be less expensive than its managed equivalent. For larger applications with many devices from several manufacturers, consider a managed switch. Often these applications include extensive multicasting, using Ethernet/IP for example, and are spread out over a large area. A managed switch’s configuration and problem solving features will easily outweigh the cost premium over an unmanaged switch in most complex applications. IP addresses and MAC addresses are targeted at specific devices. But there are two other types of messages that are targeted at multiple devices: broadcasts and multicasts. It takes a router to stop broadcast messages, but managed switches can intelligently route multicast messages to the correct ports by using IGMP snooping. The switch will learn which ports should be receiving multicast messages (by “IGMP Join” messages) and only send messages to those ports, enhancing system performance. Managed switches can filter out multicast messages used in Ethernet/IP. Managed switches can also prevent the network from shutting down if someone

accidently loops the switches. If unmanaged switches are mistakenly connected together in a ring, a broadcast storm will occur and shut down the network. Managed switches prevent this by shutting down one path of the ring. If something happens to the working path, the switch changes over to the other path, which also provides a level of redundancy. Subnetting and networking The media access control (MAC) address is the “hard” physical address of a device. The address is set during manufacturing and should never change. Although there are exceptions to this, hard coding the MAC address was the original intent of the design. An Ethernet packet cannot enter a device without this address. However, it’s rare that a communication setup or configuration will need this address because another protocol, called address resolution protocol (ARP), usually automatically retrieves it and correlates it to an IP address. The IP address is the logical address of a device, used to identify an address and network of the specific device. An IP address, such as 192.168.070.001, includes two identifiers: the network address and the host address. The network address helps devices and routers determine where to send messages. The host address identifies the specific device on that network. The subnet

mask, such as 255.255.255.000, determines which part of an IP address is the network address and which part is the host address. The subnet mask determines the portion of the IP address that is network and host. Wherever there are 1s in the mask, the corresponding bit location of the IP address is part of the network address. Wherever there are 0s in the mask, the corresponding bit location of the IP address is part of the host address. The default gateway address and a router enable connections to other networks. A device can only send and receive Ethernet messages to other devices on its network as determined by the IP address and subnet mask. If a device needs to communicate with a device on another network, a router is required. To get the message to the other network, the device will send its message to the default gateway address, which is the IP address of the router. Local area network (LAN) and wide area network (WAN) definitions vary greatly, but in general LANs are networks encompassing switches and hubs. Once a network traverses across a router, these networks are encompassed within a WAN. Subnet specifics As noted above, IP addresses in conjunction with subnet masks logically separate networks into subnets that typically do the same kind of work. Subnets are separated by routers, and messages can traverse across these routers through the default gateway address (router address). If two devices are on the same LAN and need to communicate to each other, their subnets must be compatible and their host addresses unique. If not, they cannot communicate to each other without the help of a router. May 2016

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I nd ustrial E t h e r n e t To determine whether two devices can communicate to each other on a LAN without a router, apply the subnet mask of each device to its respective IP address to see if the resulting network addresses are the same. If they are, they should be able to communicate. This calculation can be done manually, but there are many website and mobile applications to assist. For example, at www.subnet-calculator.com, one can simply enter the IP address and subnet mask, and it will calculate the range of possible devices that can communicate to each other. Another concept called network class is included with this tool. The network class is determined by whether there are many subnets with relatively few devices (hosts) or fewer networks with many hosts, such as the Internet. For most private networks inside of a company, Class B or Class C will be the network class of choice. Remote access—routers and firewalls Remote access speeds are increasing, reducing the need to be on-site for many monitoring, adjustment and troubleshooting activities. However, accessing devices behind a router and firewall adds some complexities to how devices connect at a remote facility. NAT stands for Network Address Translation. The purpose of NAT is to allow a facility to give many devices access to the Internet without requiring a public IP address for each one as there is a cost associated with each required public IP address. The router/firewall will translate the IP addresses of outgoing and incoming messages to and from the Internet so that anyone outside of the company network will only see the public IP address. Port Forwarding is a feature of a router/firewall allowing messages coming from the Internet to go to a specific device on the inside of that network. Outgoing messages get handled automatically. The router keeps track of where a message originated from within the network by means of the port number, and matches up the response to the original message. But a router does not know where to send an incoming message simply by means of the IP address as the device originating the message does not know the internal IP addresses of all the devices. The port number is used for this purpose. The router has a configuration table that allows the user to determine the correct internal IP address by specifying the port number receiving the May 2016

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I nd ustrial E t h e r n e t message. But Port Forwarding is not the most secure method of allowing remote access because opening up a port can open up a door for other devices to come in and cause trouble. A VPN is a far more secure way to access devices remotely. A virtual private network (VPN) connects to a router/firewall with VPN server capability from a remote device that makes it look like they coexist on the same local network. A connection is established between the local and remote devices by means of a local VPN router, or through use of a VPN client software tool that runs on a PC or device. Once connected, the VPN server gives the remote device an IP address of the internal network, and the remote device can communicate to the devices on the internal network without routing. There are different ways to configure and connect a VPN, and these connections can be more complex and difficult to setup initially. But once this initial effort is completed, VPNs provide easier and more secure remote connectivity. Wireshark hunts down problems Much diagnostic information is available in a managed switch. Here’s how to access and make sense of this information. Port mirroring can be used to specify a port to send all of the messages from one or more devices. A PC running a free tool called Wireshark (www.wireshark. org) can be connected to this mirror port. Wireshark will grab and display all of the messages from those devices, which will show exactly what is occurring in the way of communications. This tool helps when connections and configurations are complete but problems still remain. Wireshark is an invaluable tool, and you don’t have to be a protocol expert to use it to solve most Ethernet issues. For more complex problems, you can take captures of the data, save it to a file, and send it to others who are protocol experts. It can save you hours and hours of troubleshooting time. DW AutomationDirect automationdirect.com

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F a s t e n i n g

J o i n i n g

Advanced epoxy

adhesives revolutionize structural bonding

Walter Brenner, PhD Founder Master Bond Inc.

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Structural polymers offer distinct advantages over traditional fastening methods. Here, we explore the cornerstones of successful structural bonding.

Structural bonding is defined as the process of joining parts together using an adhesive as opposed to conventional mechanical fasteners or assembly methods such as soldering, brazing or welding. Structural adhesives are substances capable of holding and bonding parts together by chemical and mechanical surface attachment forces. Structural adhesive bonding requires bonding agents that can transmit structural stresses without the loss of structural integrity. They accomplish this by transmitting stresses from one part to another evenly over the entire bonded area. This is in contrast to mechanical methods, such as screws, rivets and welding, where the structural strength is limited to the areas in contact with the fasteners or welds.

Structural epoxy advantages The main benefit of structural bonding by epoxy resin adhesive systems is that they can produce assemblies mechanically equivalent to or stronger than conventional metal-fastened parts at a lower cost and weight. Additionally, they offer outstanding corrosion resistance, even

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Fastening & Joining

PEM® VariMount™ Fastening System Ideal for fastening or bonding to assorted panel types

VariMountTM assembly is comprised of standard PEM nuts, studs and standoffs mounted permanently into a base plate--available with either steel or stainless steel base plates depending on the fastener selected. Key feature is the base plate’s radial holes which provide various mounting options.

Typical Mounting Methods

Careful planning is the key to successful bonding. An engineer must consider several factors to maximize the performance of structural polymers including: style of joint to be bonded surface preparation options for the substrates involved pros and cons of the various polymer chemistry options necessary performance properties of the adhesive curing requirements

Mounts On Or In:

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Features

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upon prolonged exposure to aggressive solvents, high temperatures and other hostile environments. Some additional advantages of structural adhesive bonding include: uniform stress distribution and larger stress- bearing area outstanding fatigue, mechanical shock and thermal shock resistance contiguous contact between substrates promotes improved load-bearing and sealing properties can bond dissimilar substrate materials, including metals, plastics, elastomers, ceramics, glass and wood can bond materials with different coefficients of thermal expansion, even when subjected to low or elevated temperatures smooth, contour-free surfaces, without external projections and gaps gap-filling capability reduces required tolerances minimized galvanic corrosion between dissimilar metal substrates can provide thermal and/or electrical insulation or conductivity wide service temperature range capability long-term durability

Take care with joint design A properly designed joint should enhance bond strength and minimize stress concentrations so the load is distributed over the entire area. Popular joints used in structural bonding applications include butt, scarf, lap and offset lap. Butt joints are used when stress concentrations are located along the bond line and when forces perpendicular to the bond are minimal. Scarf joints allow for an ample adhesive bond area, but parts joined in this way must maintain closer fits. Lap and offset joints are recommended for thin sections and rigid parts. In lap joints, the bonded parts are slightly offset causing peel and cleavage forces to develop when the joints are under load. These forces can be minimized by using the offset lap joint design instead. 90

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Joint design considerations

Proper surface preparation Surface preparation is critical in achieving high-strength structural bonds. To get the best adhesion, substrates must be properly prepared, cleaned and roughened. Substrates with oils, greases, dirt, moisture and other contaminants on their surfaces must be carefully cleaned prior to adhesive application. Certain forms of oxidation (notably loose rust) must be completely removed. Physical abrasive treatments and/or appropriate chemical cleaning are essential manufacturing steps to achieve the desired performance characteristics with most metallic substrates. Specially formulated primer coats are also useful in some applications. A great deal of R&D has been carried out to develop suitable pretreatments for metallic and nonmetallic substrates, so be sure to carefully follow the adhesive manufacturer’s specific recommendations to assure optimum results. For more information on common surface pretreatments, please see Table 1. Polymer types Structural adhesive bonding offers significant technical and economic advantages over mechanical fasteners, as well as joining techniques such as soldering, brazing or welding for many demanding assembly constructions. Due to their unmatched processing versatility, high strength, low weight, and wide service temperature capabilities (even when exposed to hostile environmental conditions), epoxy polymerbased resin systems have become the driving force for the growth of structural bonding. Their strength properties can be further improved by compounding with glass,

carbon or polyimide reinforcing fibers. Additionally, both thermally conductive and electrically conductive adhesive formulations are available and are widely used in the design of many electrical, mechanical and medical devices. Fiber reinforced epoxy resin composites can compete economically with steadily increasing success against conventional metal constructions, both on the basis of a more favorable strength-to-weight ratio and enhanced corrosion resistance over the service life of the assembly. Their industrial success is demonstrated by the fact that some 60% of today’s aerospace structures are manufactured with epoxy resin adhesive systems. The workhorses of the structural adhesives field are bisphenol A-type epoxy resins and amine-type hardeners. Epoxy resins and hardeners can be either liquid or solid, with liquids generally preferred. They are also available in supported and unsupported semi-cured films. A polymer’s overall performance profile and cure requirements are mainly determined by the choice of base resin and hardener.

Performance properties Structural epoxy adhesive systems feature the highest tensile strengths of all commercially available bonding agents. Resistance to moisture, fuels, oils, acids, bases and many other aggressive chemicals is of a very high order over a wide temperature range. They can safely be operated at service temperatures from as high as 300° C to cryogenic conditions. May 2016

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Given the intended uses of structural adhesives, joint design is as important as adhesive selection. Joint design requires selection of the correct style, proper surface preparation and use of careful applications and assembly procedures. Joint design should minimize stress concentrations by ensuring that the load is distributed over the entire bonded area. Some stresses, such as peel, cleavage and shear stresses, should be minimized. Most structural adhesives withstand tensile stress well, so joints should maximize this type of stress and minimize others. Joint style should serve to improve bond strength. Some joints used in structural applications include butt, scarf, lap and offset lap. Butt joints are used when stress forces are concentrated along the bond line and when force perpendicular to the bond is minimal. Scarf joints allow a large adhesive contact area, but parts joined in this way must maintain a close fit. Lap and offset lap joints are recommended for bonding thin cross-sectional, rigid parts. In lap joints, the bonded parts are slightly offset, thus peel and cleavage forces develop when the joints are under load. These forces can be minimized by using the offset lap joint. Surface preparation is critical. More often than not, surfaces are contaminated with oil, grease, dirt, moisture or other contaminants, so they must be cleaned before adhesive is applied. Certain forms of oxidation, such as the loose rust formed on iron, can contaminate adhesive. However, some metals, such as aluminum and copper, form oxide layers that cling tenaciously to the substrate and form a satisfactory surface for adhesives. Glass and some other substrates require special surface treatments to maintain good bonds. Failure to follow recommendations for adhesive application and processing is a major cause of bond failure. Often, cure temperatures may be raised and cure times shortened to get a faster cure. However, caution must be taken so that these adjustments do not result in weak bonds.

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Fastening & Joining Table 1. Common Pretreatments for Bonding and Assembling Structural Components Substrate

Recommended pretreatments

Aluminum & its alloys

Degrease and clean followed by rigorous abrasion or acid etching (96% sulfuric acid with sodium dichromate)

Chromium

Degrease and clean followed by rigorous abrasion or acid etching (37% hydrochloric acid and distilled water at 80° C)

Copper & its alloys

Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid-based solution)

Magnesium & its alloys

Degrease and clean followed by rigorous abrasion or acid etching (chromic acid solution)

Nickel & its alloys

Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid-based solution)

Stainless steel

Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid-based solution)

Titanium

Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid/60% hydrofluoric acid blend)

Zinc

Degrease and clean followed by rigorous abrasion or acid etching (37% hydrochloric acid and distilled water @ 20° C)

Acrylic plastics

Solvent clean and light abrasion, if possible

ABS plastics

Solvent clean and light abrasion, if possible

Acetal resins & copolymers

Solvent clean, acid etch (sulfuric acid-based solution); abrasion minimally effective

Ceramics

Solvent clean and abrasion, if possible

Diallylphthalates

Solvent clean and abrasion, if possible

Epoxy resins & epoxy phenolics

Solvent clean and abrasion, if possible

Fluoropolymers, e.g Teflon, Viton

Solvent clean, chemical etching required (Contact Master Bond for additional information)w

Polyamides (nylons)

Solvent clean, abrasion somewhat effective, chemical etching preferred (phenol-based solution)

Polyesters, thermoplastics (PET, PBT)

Solvent clean, possible abrasion or primers; plasma or corona treatments preferred

Polycarbonates

Solvent clean and light abrasion, if possible

Polyolefins

Solvent clean, abrasion minimally effective, flame treatments, chemical etching (sulfuric acid), corona treatment preferred

Polysulfones, polyether

Solvent clean and abrasion, if possible

Thermoplastic elastomers such as EPDM

Corona or plasma treatments, or special chemical etching

Carbon & carbon fibers

Solvent clean and abrasion, if possible

Silicones

Special primers

“The core properties of an epoxy system, including its mechanical strength, temperature resistance, electrical insulation and chemical resistance, are primarily determined by the chosen combination of resin and curing agent.”

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Their outstanding gap-filling properties make them especially advantageous in structural designs. Generally, only contact pressure is required during curing. When bonding dissimilar metals, the epoxy adhesive bond also functions as protection against galvanic corrosion. The core properties of an epoxy system, including its mechanical strength, temperature resistance, electrical insulation and chemical resistance, are primarily determined by the chosen combination of resin and curing agent. For example, one can choose a rubbermodified resin when formulating a toughened system with increased resistance to impact and thermal shock. Other materials such as fillers, reactive diluents and flexibilizers are then added to alter the system’s properties. For example, adding aluminum oxide will change an epoxy from a thermal insulator to a thermal conductor while maintaining its electrically insulative features. Adding silver, nickel or graphite instead will produce an electrically and thermally conductive system. Various reactive diluents can be added to reduce www.designworldonline.com

viscosity, increase impact strength, promote adhesion and increase the chemical resistance of the epoxy system. The vast number of resins, hardeners and additives available let the formulator tailor desirable processing and performance properties to an application’s requirements.

Types of cures The most widely used epoxy adhesives are one- and two-component liquids or pastes. The two-component systems may be cured at ambient temperatures or more quickly at higher temperatures. One-component formulations require elevated temperature cures. There are also specialty onecomponent epoxy systems that can be cured in seconds by exposure to UV light. Dual-cure systems that cure through exposure to UV light or heat are available for certain sensitive plastic substances, as well as for use in assemblies where the ingress of UV light in certain areas is limited.

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Conclusion As technology has advanced and assemblies have become smaller, traditional mechanical fastening methods have become increasingly difficult to use. For example, joining components that are small and thin, such as sheet metal less than 0.01 in. thick, proves problematic for traditional fastening methods. In addition, specialized methods such as welding, brazing and soldering require expensive skilled labor without yielding any clear advantage over adhesive bonding. The contiguous contact between substrates afforded through the use of adhesive bonding serves as a metaphor for the incredible attention that adhesive manufacturers bring to the needs of industry. When the needs of one industry are met through the creation of new bonding systems, many others reap the spoils as

well. For instance, the high-tech demands of aerospace and defense have lead to the development of lighter weight, high strength and heat resistant formulas that are now used in many other industries. DW

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E l e c t r o n i c s

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Hoverboards get their own UL standard Leland Teschler â&#x20AC;˘ Executive Editor

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here is a video on YouTube called “Fire exploding hoverboard caught on camera” that, as of this writing, has received 4,285,155 views in the three short months since it was first posted. At about the 1:58 mark, it shows a hoverboard suddenly start to smoke and within a few seconds, burst into flame.

Unfortunately, hoverboards are getting a reputation for being flaming conflagrations thanks to the lithium batteries they typically contain. Dozens of YouTube videos pop up under the search phrase “hoverboard fire,” and the U.S. Consumer Product Safety Commission is now investigating at least 40 reports of hoverboard fires across 19 states. Hoverboards have even been the subject of a skit on the widely watched TV humor show Saturday Night Live. Late last year, flaming hoverboards got the attention of engineers at Underwriters Laboratories. “We know that when there is a lot of lithium in the product, you really have to do your due diligence,” said Ibrahim Jilani, dusiness development manager for UL’s Energy and Power Technologies Div. A hoverboard These concerns led to the from HoverBoard launch of a new safety standard, Technologies. UL 2272, that applies specifically to hoverboards. HoverBoard co-founder The road to the new standard, officially titled Electrical Systems for Self-Balancing Scooters, started when Robert Bigler said the UL engineers purchased about a half-dozen hoverboards boards use a conservation from various sources and took them apart. “We consistentlithium-ion battery ly saw a few things,” said Jilani. “A lot of the hoverboards chemistry and used the UL mark in a way that was considered counterfeit. The boxes they came in typically lacked the name monitoring of each battery of a manufacturer so you couldn’t trace the product back cell to head off problems to who made it. These are signs of a gray market supply chronicled in hoverboards chain. We’ve seen problems like this in the past with consumer products such as Christmas tree lights, but those from other manufacturers don’t store a lot of energy as do hoverboards. The stored in YouTube videos. energy in a hoverboard can cause a fire at any moment.”

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An electric skateboard from Onewheel in action. Electric skateboards would fall under the new UL 2272 hoverboard standard.

“The biggest impact on hoverboard manufacturers is likely to be in battery technology,” Bigler thinks.

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The standard considers only the safety of the hoverboard electrical system, not factors such as whether riders can hurt themselves if they fall off. UL 2272 drew from previous work done on standards for light electric vehicle battery packs. For example, most of the construction criteria comes from UL 2271, which covers batteries for light electric vehicles. Under review The new standard published in January. Hoverboard makers can start evaluating their products for compliance and submit them to UL for certification. But the standard isn’t final. As part of its review process, UL convened a meeting of stake holders in March. There, suppliers and regulators and manufacturers whose products will be affected by the new standard discussed provisions of it. As part of the normal review process, these stake holders vote on whether the final standard should include specific provisions that UL initially outlined. One of the participants in the March meeting was Robert Bigler, co-founder of California-based HoverBoard Technologies and inventor of the single-wheeled HoverBoard. Bigler said he feared the worst going into the UL meeting: That the regulator was planning provisions that would make it all but impossible to sell anything that looked like a hoverboard in the U.S. “I was wrong,” he said. “UL took our input seriously.

The standard got edited as we spoke. UL was fair and even-handed about the whole thing. They took the attitude that they don’t want to make the standard unnecessarily burdensome.” Bigler thinks his own products won’t have any trouble meeting the new UL standard. The units most likely to encounter trouble with UL 2272, he thinks, are some of those coming into the U.S. from Asia. “By way of example, people will no longer be able to run wires willy nilly in the hoverboard. There are provisions in the standard to make sure there are no wiring pinch points,” he said. The biggest impact on hoverboard manufacturers is likely to be in battery technology, Bigler thinks. “Chinese manufacturers tend to use inexpensive and volatile battery chemistry having a failure mode that results in a fire. The flip side is that they can advertise a hoverboard with a long range,” he said. “This new standard gives manufacturers an incentive to use better batteries. Reputable companies are already using more stable battery chemistries that are inherently safe. But you might see the advertised ranges change on some products as a result of the new standard.” Bigler also figures other hoverboard manufacturers will have to adopt some of the

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Safety in lithium-ion batteries Many of the lithium-ion cells used in hoverboards contain cobalt cathodes. This lets them hold twice the energy of a nickel-based battery and four-times that of lead acid. To lengthen the time between recharges, battery manufacturers have, over the years, packed more active material into each cell and made the electrodes and separator thinner. Such measures have doubled the energy density of lithium-ion cells since they were introduced in 1991. The high energy density can potentially make cells more prone to defects. Manufacturing methods become more critical as cells grow denser. With a separator thickness on the order of 20 to 25 µm, any small intrusion of metallic dust particles can potentially destroy the cell. The worst case is where such microscopic metal particles lead to a dead short circuit within the cell. The complex assembly techniques involved in constructing high-energy batteries make it tough to eliminate all metallic dust. A resistive short will only bring an elevated self-discharge. This generates little heat because the discharging energy is low. But enough microscopic metal particles on one spot can lead to a major electrical short and a sizable current flowing between the positive and negative plates. This causes a temperature rise leading to a thermal runaway. Manufacturers of lithium-ion cells with cobalt cathodes say these batteries should stay below 130° C (265° F). At 150° C (302° F) the cells become thermally unstable and could end up going into a thermal runaway in which flaming gases vent. If this happens, the high heat of the failing cell can propagate to the next cell, causing a thermal domino effect. In some cases, the chain reaction can be such that each cell disintegrates at its own timetable. A pack can self destruct within seconds or roast for several hours as cells die one-by-one. 98

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To reduce the chance of such catastrophic difficulties, some lithium-ion cells use chemistries that are more stable. For example, some substitute manganese for cobalt cathode material. Manganese can sustain temperatures of 250° C (482° F) before becoming unstable. Manganese also has a low internal resistance and can deliver high current. However, a cell having a pure manganese cathode only provides about half the capacity of cobalt. So battery makers sometimes mix the materials as a compromise. Typical cathode materials are cobalt, nickel, manganese and iron phosphate. Though it has not made the same kind of headlines as thermal issues, cold-temperature charging is another safety concern. Consumer-grade lithium-ion batteries cannot charge below freezing. The sinister thing about a sub-freezing charge is that though the packs appear to be charging normally, metallic lithium plates on the anode. The plating is permanent. Repeated charging at low temperature can compromise the safety of the pack. A big shutdown Most major hoverboard makers in the U.S. go with more conservative lithium-ion chemistries, trading off range for a lesser chance of thermal runaway. Nevertheless, the new UL standard may affect how manufacturers build-in safeguards against abnormal battery conditions. Take as an example the handling of an overvoltage on a battery cell. The typical battery powered consumer appliance might just shut down if it senses this problem. But that’s not a practical solution for a hoverboard. “You can’t just shut the system down because that could throw the rider,” said Bigler. “The standard will likely compel hoverboard manufacturers to devise ways of slowing the board. We might have to trick the rider into slowing down. Board manufacturers might have to go through a redesign to accomplish this.” But battery issues might not be the main problem for hoverboard manufacturers, particularly those based outside the U.S. “There will be an impact on foreign hoverboard makers not so much because they have to design to spec, but because they’ll need a different kind of structure,” said Bigler. “When you are making hundreds of thousands of hoverboards a month, you are doing it in thousands of factories. You don’t have the connections to get this kind of certification done. The factories are beholden to those with western connections.” Hoverboard manufacturers that want to certify their products to the new standard can start submitting samples to UL for testing. UL’s Jilani said the certification process can take four to eight weeks in the absence of surprises. “But compliance doesn’t just involve testing,” he said. “Compliance with UL standards mean meeting construction require100

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UL drew on other standards for many of the provisions in the 2272 hoverboard standard. UL 2271, a safety standard for light electric vehicle batteries, provided many of the provisions on construction.

ments, labeling and marking requirements, user instruction elements, and other factors. So it isn’t just testing.” Meanwhile, the 2272 standard continues to undergo refinement. It will eventually be put through the ANSI accreditation process to establish it as an American National Standard. It will go through a similar process in Canada. Also the ASTM standard for pocket bikes and e-scooters will reference UL 2272 for electric system safety. The upshot: Hoverboard difficulties of a different type. “I think there will be a lot of counterfeit UL marks on hoverboards,” speculates Bigler. DW HoverBoard Technologies hoverboard.com Underwriters Laboratories UL.com

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Solving tougher in sensing requirements industrial applications

Manufacturers are tackling more difficult—and unique—design problems with the newest generation of sensors. Randy Frank • Contributing Editor Getting serious consideration for a design-in involves meeting all of the required specifications. This is true for all applications. However, industrial is one marketplace where the specifications can be classified into usual (or typical or standard) and unusual or tough (or unique) requirements. The usual specs are satisfied by many suppliers and many products. The tough ones require special design considerations by the supplier to satisfy specific application issues and/or survive in a harsh application environment.

Recognizing and addressing tough requirements For All Sensors, a supplier of pressure sensors, unusual application requirements were historically addressed with unique electronic performance. This changed with the introduction of the SPM 401 series of stainless-steel media-isolated and CPM 602 series of ceramic sensors.

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Sensors The sensor families address similar markets but have different strengths. Both are radical departures from the design capabilities of the company’s previous pressure sensors. The need for the media-isolated families came from an annual customer satisfaction survey. “In the past few years, customers have indicated that they would like All Sensors to offer media-isolated pressure sensors and we decided to take on this challenge,” said Han Mai of the All Sensors marketing department. Complementing the electrical capability of its existing microelectromechanical system (MEMS) sensors, the media-isolated SPM 401 series can address pressure ratings as low as 1.5 psi and typically require half of the current of competitive products for high output. The pressure spikes that can occur in applications involving pumps require high burst pressure capabilities. For this reason, All Sensors’ design has a rating that is typically twice the capability of comparable units. With stainless steel providing the media isolation and oil providing a transfer media to apply pressure to the MEMS sensor, these three differentiating capabilities are still available in the SPM 401 products. The stainless-steel design does add cost to the sensor. Ceramics sensors address media compatibly with a lower cost approach and can handle much higher pressures. In some environments, a ceramic design has a significant advantage, providing higher mechanical stress capability compared to the thin stainless-steel membrane that can be destroyed or deformed by poking it with an object, such as a screwdriver. So processes that require a high mechanical stability typically dictate a ceramic sensor design. “The SPM 401 series specifically allows All Sensors to address medical devices, HVAC controls, ship and marine

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systems and environmental engineering in the lower pressure range from 1.5 to 100 psi,” said Jason Paiva, product manager for media-isolated sensors at All Sensors. “The CPM 602 series covers applications for automotive, medical devices, marine systems, and plant and mechanical engineering and allows us to have a higher pressure range of 30 to 6,000 psi.” All Sensors plans on introducing more products for both series later this year.

new IMB inductive sensor from SICK was made specifically for two extremely harsh environments: machine tooling and outdoor applications. “A long life expectancy with a reliable output is required in these working conditions and can be achieved with the IMB’s IP69K stainless-steel housing, −40 to 100° C extended temperature range, and 150 g shock and vibration rating,” said Jill Oertel, product manager at SICK. The durability that results from the Environment issues design of the IMB inductive sensor saves Other types of sensors also need to survive costs and time by reducing the risk of harsh environments. For example, the DON-201501-DesignWorld Qtr pg_Qtr pg 12/8/14 machine 10:04 AMdowntime. Page 1

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Se nso rs Figure 4. TE Connectivity’s HLIR 750 series LVDT Position Sensors, constructed entirely of stainless steel with a hermetically-sealed sensor body, achieve a CSA intrinsically safe rating.

environments damage low-cost plastic sensors leading to machine downtime. Banner’s M18-4 photoelectric sensors are designed to provide long term and reliable sensing performance in harsh industrial applications with enhanced chemical and washdown resistance.” For harsh industrial environments where abrasive chemicals and ingress fluid are present, the M18-4 self-contained photoelectric sensors have an IP69Krated, 316 stainless steel housing. In addition to their mechanical ruggedness, the sensors have circuitry that provides resistance to fluorescent light and a high level of crosstalk avoidance. Some applications require an intrinsically safe sensor. For example, TE Connectivity’s recently introduced HLIR 750 series Intrinsically Safe, 4-to-20mA LVDT Position Sensors provide reliable contactless position measurement for critical applications in gas turbines for fuel valve position feedback, vane pitch servo controls, governor controls and generator shell expansion measurements. The HLIR 750 series sensors have built-in electronics that allow them to operate without the need for external signal conditioning. This simplifies the installation and flexibility in connections with the outside world. But the key parameter is the safety rating. “Units are Class I Division 1 Intrinsically Safe, Exia approved for use in areas where an intrinsically safe sensor is required,” said Karmjit Sidhu, TE Connectivity, director of Business Development, Oil & Gas, Power Generation and Marine Applications.

Difficult specifications Not all tough requirements are harsh. Low operating current and low power supply voltage levels are critical in some applications such as portable robotics, motor controls and automation. To meet these demanding requirements, Micro Oscillator Inc. designed its LPS series of inductive proximity sensors. “We are currently working with several utility meter suppliers to provide longer battery life in wireless connectivity applications,” said Fred Mirow, CEO of Micro Oscillator Inc. “The ability of our product to operate directly at the battery voltage while consuming just a few micro amps of current in these applications is paramount.”

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Sens o r s

Figure 6. Autodesk’s SeeControl provides users guidance for matching sensors with controllers in harsh applications such as aircraft deicing.

Figure 5. Micro Oscillator’s LPS proximity sensors address the tough specification of long battery life.

Sensors 5-16_Vs5.MD.indd 108

The LPS series uses the company’s patented LS1500 IC to perform at the industry’s lowest operating current (4 µA) level and lowest power supply voltage levels (2.5 to 27 V). Some applications involve tough specifications in harsh environments. For example, Autodesk’s SeeControl offers a cloud service for collecting data from sensors and microcontrollers designed into industrial products. “We do everything in the cloud that’s required to connect to the machine, gather the data, analyze it and then present that

information to the person that is using the machine,” said Bryan Kester, head of IoT at Autodesk. In addition to collecting data from the machine, Autodesk has accumulated data about both the sensors and the communication modules themselves. “Over time we are going to be gathering a lot of data about how various sensors and devices that collect all the data and how they actually perform in different environments,” said Kester. With this knowledge, Autodesk can recommend sensors to match the data

4/28/16 5:11 PM

Tested and Proven 138 million cycles Figure 7. Designed specifically for improved survivability in harsh, remote liquid level applications such as flood sensing, Senix sensors are built using stainless steel, epoxy potting, and potted in cables to achieve IP68, NEMA-4X ratings. Source: Senix and University of Iowa / Iowa Flood Information System.

Extreme environments For tough requirements it is hard to beat a sensing application that has to cope with remotely measuring water level and withstand lightning strikes. “Senix customers are installing remote water level sensors where thousands of lightning strikes a year are common. Nothing stops a direct strike, but 7-kV surge protection allows sensors to survive transients from nearby strikes,” said Doug Boehm, who has been designing industrial sensors for more than 30 years and is Senix’s founder and CTO. The ToughSonic Remote 14 sensors use ultrasonic sound waves to provide high reliability and fast, non-contact measurements at distances up to

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14 ft (4.3 m). Longer range ToughSonic Remote 30 and 50 sensors that can handle distances up to 50 ft (15.2 m) will be available this year.

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collecting and communicating board. “We have a customer now who is designing a private, commercial fuel pumping station,” said Kester. “They are designing a fleet of sensors to gather the data from the fuel pumps.” Instead of searching for and experimenting with combinations of products that can be intrinsically safe, Autodesk has a curated library for harsh or dangerous environments. “We have a list of pre-approved devices and sensors that can talk to those devices that work with our platform that the customer can pick right off the shelf,” said Kester.

Tackling unusual requirements While the unusual application requirements can vary extensively, meeting them not only provides the company who is willing to go outside of the industry comfort zone of usual specifications the potential of a greater market share, it also means bringing advanced technology, safety and durability to more users. DW All Sensors allSensors.com

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Miniature ball bearings are high precision devices compared to many mechanical parts. Good performance will therefore require treatment that takes into account their characteristics and operating environment. Handle with care. Literally. Just because bearings are built to last doesnâ&#x20AC;&#x2122;t mean theyâ&#x20AC;&#x2122;re made for mistreatment. A high percentage of bearing problems, including failures, are the result of improper handling procedures. The following information represents the results of some common case studies. Particle contamination

The performance of miniature precision ball bearings is critically affected by minute particle contamination. Avoid exposing the bearing to any environment where particles may be presentd. Shields and seals are used to prevent contaminants from reaching the inside of the bearing. However, after assembly, there is still a small gap between the shield and the inner ring. This gap may permit particle entry.

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The performance of miniature precision ball bearings is critically affected by minute particle contamination. Avoiding exposing the bearing to any environment where particles may be present is highly recommended. A few procedural guidelines to consider:

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with the cleaning agent. The liquid agent itself could leak into the bearing, carrying particles with it. • When applying a lubricant to the outer circumference of a bearing, make sure the lubricant is not contaminated. Contamination might inadvertently be transferred into the bearing. • Never use an applicator that will leave contaminants on or near the bearings. A cotton swab, for instance, may leave small fibrous particles behind. A mechanical dispenser or a clean room type of applicator is recommended. • Do not handle bearings in a place where they could be directly exposed to outside air. Airborne contaminants include dust, dirt and humidity.

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Rust contamination

Because many bearings are metallic products, they rust easily. Their treatment requires certain precautions. When handling bearings, use finger caps, tweezers or gloves that do not generate cotton fibers. When using unprotected fingers to handle a bearing, first make sure they are clean and free from perspiration and dust. Apply a quality mineral oil to the fingertips before touching the bearing; do not use hand cream, as it may induce rust. Additionally, if a shaft is dirty on the surface, rust may gather between the shaft and the bearing after they are fitted. It is important to make sure that the shaft is free from finger prints, perspiration, dust and dirt. Smaller details involve avoiding the storage of bearings near air conditioners and direct sunlight. Bearings may rust when

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Shock Forces

effectively bus-capable.

Bearings are easily affected by shock forces. Depending on the size of the bearing, a shock force from a 100-g weight at 4 mm away could May 2016

are built to perform in the toughest

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M e c h a n i c a l cause brinelling. Brinelling could also occur when bearings are automatically press-fitted to a rotor shaft, if the shaft and bearing bore are not kept accurately in line. A typical example of shock causing brinelling is when motors are placed on a conveyor belt. As the motors move through the conveyor, the movement causes the motors to hit the iron plate underneath the conveyor, resulting in shock which causes brinelling to the bearing. Holes made to the iron plate prevent this type of shock force to be generated. Mounting precision bearings

When bearings are mounted incorrectly, the balls will cause brinelling on the raceway and undermine bearing performance and life. Brinelling, (dents and abrasions to the raceway) as small as 0.1 Âľm in depth will have an adverse effect on acoustic noise levels

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Shields and seals are used to prevent contaminants from reaching the inside of the bearing. However, after assembly, there is still a small gap between the shield and the inner ring. This gap may permit particle entry.

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Your Global Automation Partner

M e c h a n i c a l as well as causing increased torque levels. Several general rules apply to mounting bearings. When assembling a bearing with its shaft or housing, it is critical that no force be applied to the balls. When mounting a bearing to a shaft, always press the inner ring. When mounting a bearing into a housing, press the outer ring. It is also important to never apply force to the outer ring when mounting a shaft, or to the inner ring when mounting into a housing; never apply a shock load in either case. When manually fitting a shaft into a bearing through its bore, do not force the shaft as it may cause brinelling to the bearing.

Varnish applied to a motor winding may also cause bearings to rust when the acid generated by varnish gas is absorbed into the grease of the bearing.

Application Environment

The environment in which bearings are used will largely determine their life. Chlorine gas, ozone and other chemicals will shorten bearing life, as the grease will become contaminated relatively quickly. Generally, grease life will fail by half with every 10 to 15º C that the ambient temperature increases. Therefore, it is critical to select the correct lubricant for the anticipated operating temperature. DW

NMB nmbtc.com Content edited from materials supplied by NMB Technologies Corp.

WARNING

Not suitable for repairing flimsy connectors (or your reputation).

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Rugged, reliable industrial automation products from Turck are built to perform in the toughest conditions, and our engineered solutions are customized to meet your application challenges. Cheap knockoffs can’t compare. Turck works!

After gluing a bearing to a housing using a guide through the bearing bore, take the guide out carefully. When motors are being assembled, be aware that bearings may be attracted by the magnet and could slip from your fingers. To avoid this, hold the motor shaft in your palm, and cautiously insert the rotor. For automated assembly, use an air cylinder, and steadily operate the assembly.

Overmolded Deutsch Connectors Designed for longevity in demanding environments where shock, vibration, cold, moisture and oils can affect performance.

May 2016

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Inside: 120 Advances in additve manufacturing 126 3D printed end-of-arm tooling lightens load on robotic packaging line

A supplement of Design World â&#x20AC;˘ May 2016

132 Metal additive manufacturing enables lean, green heat exchanger

3D printing

a better car 136

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Advances in

additive manufacturing As the media hype around 3D printing/additive manufacturing (3DP/AM) winds down, researchers and developers in this industry stay focused on business.

Leslie Langnau • Managing Editor

If you follow the Gartner hype curve, we are probably now in the trough of disillusionment. Some startups are no longer around. Investors have been short-selling the public stocks. News seems to have slowed. The excitement appears to have diminished. Except for metal AM— that area is still experiencing some media hype. The situation, however, is not at all bad. While investors are making shortsided decisions on 3D printing public stocks, more companies are entering the 3DP/AM industry. Such as Trumpf, with its TruPrint 1000 laser cladding system, and Toshiba, noted Todd Grimm, founder and president of T. A. Grimm & Associates, at his keynote at the AMUG 2016 Conference. As the hype and the buzz die down, many companies and researchers in this field are busy developing improvements and new technologies. As Grimm noted, advances in technology won’t be rolling off every month or week, but they will be happening. “We can get back to sanity,” he said. “This is the era where practicality reigns.”

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

» Stratasys Direct Manufacturing

(SDM) is partnering with DSM’s

Somos, which doubles SDM’s

stereolithography production

capacity. May 2016

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Software controlled chemical reactions Better living through chemistry is a phrase that could be applied to the company Carbon. The founders’ goal is to make real final parts through a form of digital light processing. Parts so good, they rival conventional injection-molded parts. Joe DeSimone, co-founder and CEO, wants to deliver an alternative technology to injection molding, through the additive process often known as 3D printing. Although DeSimone uses the term “grow” rather than 3D print. Build speed is a key differentiator of Carbon’s technology from other additive technologies. In typical UV stereolighography approaches, a build » XJet created a unique method of additive printing by taking stochastic metal- tray dips into a vat of photo-reactive nanoparticles and engulfing them in a proprietary liquid, forming drops. These drops are then jetted in a high-temperature build chamber, evaporating the liquid and leaving resin where a UV light cures that the metal particle material to adhere to the layer beneath it. one layer. Then the tray dips into the resin again and another layer is cured onto the previous layer, and so on. to do more, and do more with more One drawback of this trough, DeSimone figured out how to eliminate types of parts,” Grimm continued. however, is that it may require more the dips, shaving a lot of build time off Several companies recently effort to make a business case for the entire process. Depending on the have or will be introducing new buying a 3DP/AM machine for your part, the speed improvement is 100 additive approaches and equipment, department. Conversations on just fold or more. including a number of 2D printing how to make your case were frequent The ability to skip the dips is the companies moving into 3D printing, at the AMUG Conference. “You will molecular science part of Carbon’s such as Canon, Richo, Fuji and need lots of information to navigate process. The printer injects oxygen at Epson; not a development you would the AM landscape over the next few a key point in the build, which inhibits see if this industry was in trouble. years to create a deliberate, thoughtthe resin from curing too quickly. A lot of development and out strategy of how this technology This curing delay delivers parts with research that came about because can work for you,” added Grimm smooth features, on par with injection of the earlier hype is delivering these All the previous attention from the molding. Plus, without layers, the risk imaginative processes. And more is hype did help catalyze innovations of fractures along the build layers is coming. Said Grimm, between 2016 and ideas for many, who are working reduced or eliminated entirely, so parts and 2026, we will see a number on realizing them now. It will take are inherently stronger than through of new ways to additively make time to finalize these ideas. But in other 3DP processes. The controlled products side by side with traditional five or so years, major introductions curing also makes it seem as if the part manufacturing. We’ve only seen the will emerge. “We will see better tools, is “growing” out of the printer. As with tip of what is possible in additive more applications, more innovation, any additive process, you can make manufacturing. and some disruption. We will be able 122

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Additive

Additive Manufacturing

any geometry you like. This oxygen injection process is controlled through software, which is another key part of the process. The oxygen is injected into a hardware part called the Window, located at the bottom of the build interface. The software monitors and manages this build zone where light, oxygen and other factors are tracked. The software calculates all the parameters needed to ensure a proper build. All Carbon printers are internet connected. This approach is an interesting use of the Internet of Things. Users can combine Carbon resins in many ways; the data from such a build goes back to Carbon, where they are

added to the software database and updated code generated as needed. In this way, users are partners of Carbon, helping explore and expand this additive process. Post processing involves a solvent wash to eliminate residual resin or some supports. The next step is the part is based to install specific mechanical properties. The resultant parts can be machined and cut. Some parts will behave like real rubbers. Third party users can design resins for the printer. The build data will go back to the software and be incorporated into future software upgrades. A good number of UV active resins can be injected with

oxygen and made compatible with this process.

A safer metal additive 3D printing system Another new method to additively build parts discussed at the recent AMUG Conference was NanoParticle Jetting from XJet. XJet takes stochastic metal-nanoparticles and engulfs them in a proprietary liquid, forming drops. These drops are then jetted in a pattern to build parts. The build chamber is heated to an extremely high temperature so that when the drop touches the build tray, the carrier material holding the metal particles in suspension evaporates while the metal

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consolidate multiple parts in one assembly.

Also known as 3D printing, this technology is

Additive manufacturing is also complementary

not constrained by traditional manufacturing

to conventional machining technologies, and

design rules. Create complex geometries such

directly contributes to reduced lead times,

as conformal cooling channels for tooling

tooling costs and material waste.

■

No requirement for tooling.

■

Increased design freedom—complex geometries and hidden features.

■

Rapid design iterations right up to manufacture.

Renishaw.com/additive

Renishaw Inc Hoffman Estates, IL www.renishaw.com

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Additive Manufacturing

particle material adheres to the layer beneath it. The result is strong binding of the metal with virtually the same metallurgy as traditionally-made metal parts. The metal part will undergo an easy sintering process, with the supports removed simply and with almost no manual intervention. According to Dror Danai, CBO at XJet, because the metal particles and liquid are delivered in cartridges, you are not handling metal powders, making this a safe approach to build with metals. The XJet printer has 24 print heads, a total of 512 standard inkjet nozzles, each of which can jet 18,000 drops/sec for a total of 221 million drops/sec in a build. The size of the metal particles delivers fine detail to the part. You can build thin layers and walls, which will have smooth surfaces. You can build parts of any geometry. If support is needed, the print heads jet either suspended metal or support material. You remove the support material when done. XJet plans to have a machine at the upcoming RAPID show.

Materials It looks like development in UV curable materials, such as those used in Stereolithography (SL) 3D printers, is resurging.

Stratasys Direct Manufacturing, an indirect subsidiary of Stratasys, Ltd., and one of the larger providers of additive and conventional manufacturing services in North America, is partnering with DSM’s Somos, one of the larger developers of 3D printing materials. According to Stratasys Direct Manufacturing, the move doubles its SL production capacity, allowing the company to deliver large projects more rapidly, and accelerate material development. Stratasys Direct Manufacturing will apply 25 years of experience in SL from legacy companies Solid Concepts and Harvest Technologies, collaborating with the Somos development team to beta test new Somos materials. The agreement gives customers more choice and greater control over which materials to use for their SL projects. Somos materials available now at Stratasys Direct Manufacturing include: Somos NeXt, Somos ProtoGen 18420, Somos WaterClear Ultra 10122 and Somos WaterShed XC 11122. 3D Systems returned to the AMUG conference after several years’ absence. It brought the ProJet MJP 2500 series,

» Build speed is a key differentiator of

Carbon’s technology from other additive technologies. Depending on the part, the speed improvement is 100 fold or more. The printer injects oxygen at a key point in the build, which inhibits the resin from curing too quickly, speeding up the build process.

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» The EOS M 100 system is geared for entry into additive manufacturing. Its small build volume is based on a round build platform with a diameter of 100 mm. For example, the system can produce approximately 70 dental crowns and bridges in three hours.

which is the latest addition to its MultiJet Printing (MJP) line. The ProJet MJP 2500 series offers simple, clean operation and easy post-processing. It uses the new MJP EasyClean System, offering hands-off, chemical-free finishing without the need for waterlines or special disposal considerations. In conjunction with 3D Systems’ exclusive non-toxic, melt away wax supports, the EasyClean System delivers simple post-processing with no damage to delicate feature details. “We have been impressed with the results from the ProJet MJP 2500,” said Haleigh Doremus, rapid prototyping manager at Nike, a 3D Systems beta tester. “It complements our current technologies and processes and allows us to print complex geometries that were previously impossible on other printers in this class. The consistency of parts and hands-off postprocessing it provides gives us time to accomplish more in a day.” Engineered to deliver detailed, true-to-CAD parts, the ProJet MJP 2500 series features two models: the MJP 2500 and the MJP 2500 Plus. Each printer in the series is compatible with VisiJet M2 materials in durable white and black plastic. These materials deliver parts with a surface finish that looks and feels like injection-molded plastic and enables rigorous testing and functional use.

The ProJet MJP 2500 Plus offers additional material capability with rigid clear plastic as well as flexible elastomeric black and elastomeric natural, each newly developed for printing rubber-like parts that provide pliability, strength and full elastic recovery. For functional prototyping, rapid tooling and design communication, the 2500 series can print 790 DPI in Z, or more than half-a-billion droplets of material for every cubic inch printed. The series also includes 3D Systems’ 3DSPRINT software, enabling quick printability checks, file repair, build time and material estimation, optimal part positioning, and print queue management, all from one integrated platform. n MPF

3D Systems 3Dsystems.com Carbon carbon3d.com DSM/Somos dsm.com Stratasys Direct Manufacturing stratasysdirect.com XJet XJet.com

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

Dprinted 3end-of-arm tooling It’s a typical scenario: a customer needs “one tool, that doesn’t weigh a lot, and we want it now.” Here’s how

Edited by: Leslie Langnau • Managing Editor

3D printing helped the

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New robots for a pick-n-pack line were already on order. A major American food producer’s equipment supplier, Langen Group, began designing the end-of-arm tool that would let the robots pick up wrapped, stacked crackers and place them into cardboard boxes. Then the engineers ran into a challenge. Without upsetting the center of gravity of the robots as they move at maximum speed, the end-of-arm tool plus the weight of the product it lifts could not measure more than 2 kg. The largest load of crackers on the line was 1.5 kg for a 10-pack. That meant the end-of-arm tool had to weigh less than 500 g.

design team deliver.

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The finished assembly attached to one of the packaging line’s robots. Compared to similar machined designs, the laser-sintered version uses less air but has far greater picking power.

www.makepartsfast.com

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» A worker removes the laser-sintered part from the powder bed. Multiple parts or a complete assembly can be built in a single job, and only light finishing is required before being used for production.

» The bottom of the gripper cup Langen Group, a global supplier of product handling and packaging equipment, turned to Anubis 3D (a division of Anubis Manufacturing Consultants Corporation based in Mississauga, ON) for support. “Meeting these requirements would have been impossible with aluminum and sheet metal,” said Tharwat Fouad, president, Anubis. “To handle a heavier metal tool meant ordering larger robots, which would be more expensive—and they were also under extreme time constraints.” Furthermore, the tool needed to be quick-release, quick-connect, so operators could change from one size to another without bolts and nuts. “In all, there were two completely different configurations [with] different shapes, and three box sizes consisting of two small boxes at a time and one large box,” said Fouad. “They wanted a single tool that could handle it all, weigh no more than half

showing the Swiss cheese pattern of channels leading to the vacuum hole at the top of the workpiece. Making these holes with conventional machining would have been impossible, but was easy to accomplish with additive manufacturing.

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a kilo, and they wanted it as soon as possible.” Additive manufacturing provides the best solution Fouad knew exactly the technology that would provide the best solution: additive manufacturing (AM). His Anubis 3D division specializes in low-volume production of parts that are either too expensive, too complex, or outright impossible to make through conventional manufacturing techniques. Fouad and his team first spent nine months studying the market, evaluating which manufacturing technology would best serve their customers. “We found that most of the manufacturers that bought into plastics-based AM did it for prototyping,” he said. “But our reasons were completely different. We envisioned a number of opportunities for functional, end-use

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» Tharwat Fouad

components, and felt AM was the best technology for such applications.” Once Fouad decided on AM, he performed a detailed analysis of the types of equipment available before deciding on a FORMIGA P 100 system from EOS. The system uses a 30-W CO2 laser paired with precision optics to quickly and accurately “grow” parts measuring up to 200 × 250 × 330 mm (7.9 × 9.8 × 12 in.) and layer thicknesses between 0.06 and 0.1 mm (0.0023 to 0.0039 in.). Equally important to Fouad’s vision of end-use products was material selection—EOS powderbed laser-sintering technology uses engineering-grade polyamides, polystyrenes, thermoplastic elastomers and polyaryletherketones. “The system gives us the ability to build a virtually endless array of parts, using materials that are widely accepted in the industry,” Fouad said. The benefits of laser sintering quickly became clear. One of Anubis’ first successes was an end-of-arm tool for a blow molding application, which Fouad said inspired his team and opened their minds to what’s

“Most users that bought into plastics-based AM did it for prototyping. We envisioned a number of opportunities for functional, end-use components.” possible with plastic laser-sintering technology. They’ve since designed similar tools for injection molding and bottle packaging customers, as well as various brackets and supports. As a result, Fouad purchased two additional systems from EOS, including an EOSINT P 395, and is looking at a fourth. Lighter, yet more powerful, components In the case of the job for Langen Group, instead of a more traditional metal vacuum plate and shroud

holding a pair of finished vacuum grippers for Langen Group. After a light bead blasting, the parts were dyed per customer specifications and assembled with the mounting pieces.

(which would have taken months to design and manufacture), Anubis designed a lighter, streamlined set of components with 4x the gripping force of legacy vacuum grippers. It took only a week to additively manufacture, assemble and test the new tool. The material used for the main vacuum part was nylon 12 (PA 2200 material from EOS), chosen for its flexibility, ability to sustain crash loads, and because it is FDA-approved for food contact. The wall thickness of the vacuum cup was between 2 and 3.5 mm and varied from section to section. The parts were designed specifically for AM with the help of a software program that optimizes the design of structures “organically,” following the lines of the geometry and adjusting the thickness as needed for strength and/or flexibility. Finite Element Analysis (FEA) is built into the optimization to analyze stresses and strains on the structure. “The creative part designs that AM allows still have to be fully functional,” said Fouad. “Many of the plastic products we make at Anubis replace aluminum and other metals, so care must be taken to assure structural integrity.” May 2016

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Anubis loaded the material properties and vacuum requirements into the software, then used those calculations to determine how many and what size holes should be placed in the vacuum cup. The holes, laid out in a Swiss cheese pattern of channels leading to the primary vacuum hole at the top of the workpiece, create a superior grip on the cracker stacks. “The options we looked at were whether to have fewer, but larger, holes—or more, smaller ones,” said Fouad. First they duplicated the traditional aluminum plate hole layout using nylon 12 in the EOSINT P 395 system and tested the gripping power of the result. Then, to further increase the grip, the Anubis team created a new design with profiled holes and channels that could not have been manufactured conventionally. A larger number of these custom, smaller holes supplied a much stronger grip. Digital data from the final design guided the laser to melt the nylon and grow the parts in the EOSINT P 395. “The efficiency of the new hole profile enabled the redesigned gripper to suction so well you could actually hang on it with your own weight,” said Fouad. “Our customer had never seen that level of performance before.” The vacuum grippers were delivered to Langen Group and installed on the new robots at the food producer’s plant. “To A dual-box version of the completed vacuum assembly, shown attached to a robot. design and produce tooling capable of picking what we wanted, while still staying within the

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Additive Manufacturing pay load constraints of the robot, would have been impossible before,” said Langen Group Engineering Manager Robert Husnik. “Due to the freedom provided by plastics lasersintering, we can now do the impossible.” The additive manufacturing advantage Achievements such as this are becoming the norm in the additive world. Laser sintering has the ability to create organic shapes unimaginable with conventional manufacturing techniques. Complex internal structures, smooth curves and geometries, undercuts and features that would be out of the reach of traditional tools—all this and more is achievable when parts are built one layer at a time. “I tell people that, unlike traditional manufacturing, complexity is free with additive processes,” Fouad said. “A designer can come up with all sorts of wild ideas and no one will complain. You can reduce part weight, maintain strength, and deliver nice looking products with greater functionality in less time and at lower cost. It’s a real manufacturing shift.” The biggest challenge to AM acceptance is changing decades-old ways of thinking, Fouad said. “The conversion from metal to plastic is possible, especially when it’s done scientifically. You need to focus on part geometry, and throw out traditional concerns over part complexity. Laser sintering has no such constraints. Companies afraid of change often contact us only when they’ve run out of options. However, there are many times when laser-sintered parts are a better alternative to CNC, one that can reduce costs and deliver a better end product, and do so without investments in tooling.” n MPF

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Metal additive manufacturing

enables lean, green heat exchanger

Leslie Langnau • Managing Editor

The University of Maryland’s Center for Environmental Energy Engineering (CEEE) sums up its quest to deliver innovative approaches to energy conversion in two words: lean and green.

CEEE is working with Oak Ridge National Laboratory to develop the

next generation of miniaturized air-to-refrigerant heat exchanges for HVAC and refrigeration applications. For this project, funded by the U.S. Department of Energy’s Building Technologies Office, only one type of manufacturing could satisfy CEEE’s lean and green mandates: additive manufacturing. They turned to 3D System’s Quickparts service, which offers direct metal printing (DMP). Greater efficiency in less time CEEE provides innovative solutions and technology transfer to meet industrial research and development challenges. Sponsors are leading industrial companies and government agencies that pool research funds to augment direct support from the University of Maryland.

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» CEEE and Quickparts optimized the design of the original heat exchanger (on left) so that it could be made as a single part (on right). The design kept secondary finishing to a minimum. The best way to make such a design is with additive manufacturing.

Quickparts is a leading provider of unique, custom-designed parts, offering instant online quoting, expertise in 3D design and printing, and proven manufacturing services support. CEEE and Quickparts teamed to increase the efficiency of a 1-kW heat exchanger by 20% while reducing weight and size. The manufacturing cycle for the heat exchanger was reduced from months to weeks.

complex technically with small feature sizes and extremely thin material thicknesses.” That’s where the unique capabilities of direct metal printing (additive manufacturing) come into play. With additive manufacturing, complexity is free—it costs no more to create a highly complex design than it does a more simplistic one. 3D Systems’ ProX DMP 320 system enabled CEEE to prototype its heat Making it manufacturable exchanger with non-conventional, On a global scale, heat exchange is a variable shapes that are not possible multi-billion-dollar industry touching to manufacture using traditional everything from consumer goods to forming techniques such as extrusion automotive and aerospace engineering. or stamping. CEEE’s extensive experimental “DMP allowed us to manufacture and theoretical research has led to highly unusual tube shapes in the automated design algorithms for form of a hollow droplet to carry the creating unique shapes for tubes and refrigerant,” said Aute. fins used in heat exchangers. The goal Quickparts provided input into is to reach an optimal air-side thermal the design of the heat exchanger to resistance and minimize the size ensure that it could be manufactured and weight of the heat exchangers. efficiently. But, these innovative designs “The ProX DMP 320 allows us require new ways of manufacturing, to deliver open-channel diameters according to Vikrant Aute, director of and feature sizes as small as 250 CEEE’s Modeling and Optimization µm in a reliable and repetitive way,” Consortium. said Jonathan Cornelus, business “Most of these designs are simply development manager at Quickparts. not economically manufacturable “High pressure and leak-tight today,” said Aute. “They are too exchanger walls can be built as thin as 134

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200 µm, which is a true game-changer for heat-exchanger applications.” Better design in one part Working together, CEEE and Quickparts optimized the heatexchanger design so it could be printed as a single part that requires minimal secondary finishing operations. Manufacturing can be completed in weeks instead of months, enabling CEEE to test designs much earlier and more often during the research program. The one-part design also helps ensure greater reliability. “With conventional manufacturing technologies, assembly by brazing extremely thin tubes to a manifold is a painstaking operation with low reliability when it comes to leakages under high-pressure conditions,” said Aute. “With additive manufacturing, no assembly is required since the part is produced in one continuous operation, no matter how complex the parts or how delicate the features.” Besides the ability to handle complex parts at no extra cost, the ProX DMP 320 offers other advantages that fit into CEEE’s lean and green scenario. Preset build parameters, developed by 3D Systems based on the outcome

4/28/16 1:41 PM

10618_

Additive M a n u f a c t u r i n g of nearly half-a-million builds, provide predictable and repeatable print quality for almost any geometry. A new architecture simplifies setup and delivers the versatility to produce all types of part geometries in titanium, stainless steel or nickel super alloy. Titanium was chosen for the CEEE heat exchanger project, based on its lack of porosity and the ability to provide extremely thin, but strong, walls. Exchangeable manufacturing modules for the ProX DMP 320 system reduce downtime when moving among different part materials, and a controlled vacuum build chamber ensures that every part is printed with proven material properties, density and chemical purity. The small portion of non-printed material can be completely recycled, saving money and providing environmental benefits.

CEEE performed extensive testing on the new heat exchanger design, using infrared cameras to verify that heat was dispersed uniformly over the exchanger and that all the narrow, droplet-shaped exchanger channels were open and functioning fully. Results showed that the DMPmanufactured heat exchanger performed as expected. Adding mean to lean and green The unique capabilities of direct metal 3D printers, such as the ProX line, is rapidly turning additive manufacturing systems from experimental prototyping tools into mainstream production assets for manufacturers worldwide. “We are witnessing new applications and massive improvements for existing projects in

upper-end aerospace and industrial equipment markets, especially in cases where reduced space, low weight and high efficiency are critical concerns,” said Quickparts’ Cornelus. “CEEE’s heat-exchanger application exemplifies the importance of additive manufacturing in the lean manufacturing space for creating low-volume, highcomplexity metal components. These parts are now performing critical functions under challenging conditions such as continuous stress, high pressure, repeated use and extreme temperatures.” n MPF 3D Systems 3dsystems.com

The event of the year for anyone involved in 3D manufacturing SME’s RAPID event plays a vital role defining additive manufacturing. It is the event to see the latest innovations, network with industry experts, and explore the unlimited possibilities of how additive manufacturing can advance your business. No other event provides such a comprehensive display of 3D technology, expertise, and innovation in one place. Why go anywhere else? It’s all at RAPID 2016.

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

3D printing a better car

Edited by Leslie Langnau â&#x20AC;˘ Managing Editor

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anufacturers must

integrate an increasing number of concepts and energy storage systems into vehicle structures. Future vehicle bodies will be lighter, which will require more flexible design. As the number of vehicle varieties increases, designers must develop adaptable bodywork concepts that are economical to manufacture. Additive manufacturing can help with these new approaches.

One example of how additive manufacturing enables

flexible design is the EDAG “Light Cocoon” concept car. The car was unveiled in March 2015 at the Geneva Motor Show and in September 2015 at the International Motor Show (IAA) in Frankfurt. The car is intended to polarize opinions among designers and break open existing thought patterns in vehicle design. The bodywork of the compact sports car embraces bionic patterns and translates them into a lightweight structure. The outer skin is made from weatherproof textile material. EDAG Engineering (Wiesbaden, DE), Laser Zentrum Nord (Hamburg, DE), Concept Laser (Lichtenfels, DE), and the BLM Group (Cantù, IT) created the optimized frame. It was produced by hybrid manufacturing to highlight an adaptable bodywork concept that can be manufactured flexibly and delivered to make the increasing range of different vehicles manageable thanks to the large number of different drives and load stages.

The “EDAG Light Cocoon” concept car is a functionally integrated lightweight vehicle structure that can be made in a flexible manner. The space-frame concept was produced by hybrid additive manufacturing processes to highlight a new way in which an adaptable and flexible production concept can be implemented to produce bodywork nodes suitable for different load stages. Image courtesy: EDAG Engineering

www.makepartsfast.com

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Additive Manufacturing

The NextGen space-frame nodes can be configured to be functionally integrated thanks to additive manufacturing. Images courtesy: EDAG Engineering

Playing a coordinating role, EDAG Engineering devised and optimized the space-frame concept, while Laser Zentrum Nord did the laser welding. The BLM Group undertook the 3D bending and laser cutting, and Concept Laser performed the additive manufacturing of the nodes. These additively manufactured bodywork nodes are combined in the frame. They can be configured to be flexible and multifunctional so that, for example, different versions of a vehicle can be produced “on demand” without additional tooling, equipment and startup costs. Steel profiles are used as connecting elements. They too can easily be adapted on an individual basis to the specified load levels using different wall thicknesses and geometries. They are cut to the appropriate shape and length using 3D bending and 2D and 3D laser cutting processes. The design of the space-frame nodes prevents them from be manufactured by conventional steel casting. So the team used an X line 1000R LaserCUSING machine from Concept Laser, which has the appropriate build envelope (630 × 400 × 500 mm3) for such projects and operates with a 1-kW laser. Both the nodes and the profiles can be adapted to new geometries and load requirements without any additional outlay. The basic idea is to have a node/profile design which can be customized to reflect what the particular model requires. By employing processes, which do not involve much use of apparatus or tools, it will be possible in the future to manufacture all bodywork versions economically and with the greatest possible flexibility. n MPF Concept Laser concept-laser.de/en

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Sensor www.sensortips.com

A Supplement to Design World - May 2016

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Background

suppressing sensors

In a sample application, product presence needs to be verified—objects in a blister pack—before the sealing process occurs. The product and blister pack material can be various colors and textures, and in some cases, they will be close to the same color as the product. A properly specified sensor will therefore have a small, focused light beam—and a visible beam is preferred for ease of setup. Regardless, the product needs to be verified without sensing the package from above, because of machine compactness, making the background suppression sensor the ultimate solution. Background suppression sensors are becoming more popular because of their ability to ignore backgrounds, thus preventing false triggering. These sensors excel in applications where the background would possibly change: for instance, people walking behind a conveyor in light-colored clothing. Also, they are perfect for error proofing parts to ensure O-rings or other parts are in position. Background suppression is a variation of the diffuse sensing mode that uses the triangulation principal.

When light emitted from the sensor strikes the target, it will be reflected back to the receiver at some angle. The closer the target to the receiver, the greater the angle; likewise, the farther the target is from the sensor, the smaller the angle. Unlike the standard diffuse sensor, which depends on the amount of light reflected back to the receiver, these sensors also depend on the angle of the light striking the sensor to activate the output. Adjustable background suppression sensors are available either with a mechanical or electronic adjustment, each with their advantages. The sensors use more sophisticated electronics and therefore are more expensive than their standard diffuse mode counterparts. Background suppression sensors also have a shorter sensing range than diffuse sensors.

Background colors and movement may cause issues if you don’t properly select your sensor.

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....................... ............. ..... Even though background suppression sensors may be more expensive and complex, they can provide solutions to complex applications or applications that have pushed diffuse sensors to their limit. These sensors are especially suited for error proofing applications.

Mechanical adjustment background suppression features better optics, sharper cutoff range, and is stable through temperature range. But it cannot withstand high vibrations and requires larger housings.

Advantages of background suppression sensors include: • less sensitive to target color • ignores reflective backgrounds • detects small objects • precise and repeatable • single device to be installed There are several application considerations that you should keep in mind: • higher costs than standard diffuse sensors • typically have a shorter sensing range than standard diffuse sensors • may have a minimum sensing range (blind spot) • the light spot should be smaller than the object being detected; if the target is smaller than the light spot, the sensor may detect the background because the light beam passes around the target (this is referred to as the cross- eyed effect) • if the background is highly reflective, for instance a mirror or reflector, too much light may be returned to the receiver (referred to as the blinding effect; to correct this issue, tilt the sensor approximately 5° • when using a fixed background suppression sensor (no adjustment for sensing distance), the sensor should be adjusted for the background, and not the object • it is best if the target moves either toward or perpendicular to the sensor face. DW

Electronic adjustment background suppression features smaller housings and is better in high vibration situations. However, it can be more expensive.

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sensor tips

Understanding IP Ratings for LVDT linear position sensors

IP (ingress protection) ratings classify the level that a sensor is protected against infiltration by foreign materials such as dust and water. The first digit of the IP rating indicates the protection level against solids entering a sensor while the second one notes moisture resistance (Table 1). While a zero designates that there is no protection at all, higher numbers identify more stringent defense against elements invading a sensor while operating in a specific environment. LVDT linear position sensors are typically rated between IP61 and IP69. While dust-tight in virtually all configurations (hence the constant use of the number 6 as the first digit of the IP rating) LVDT sensors have different levels of water ingress protection, based on construction. For example, some LVDT position sensors are built with limited coil protection, while others are protected with varnish or epoxies. Hermetically sealed LVDTs are welded closed so nothing can intrude the sensor. Each

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type of LVDT construction bears a different IP rating and may vary by manufacturer. Below are IP ratings for some common LVDTs. Non-hermetically sealed LVDTs (IP61 rating) The external sealing of non-hermetically sealed LVDT linear position sensors may meet IEC standard IP61. As these sensors are protected from dust ingress and condensation, they are suitable for use in the following applications: • dry environments with limited dust/dirt exposure • laboratory testing, indoor applications • precision gaging • dial indicator replacement • robot actuator position feedback When coils are completely encapsulated in epoxy, the nonhermetically sealed LVDT position sensors increase their rating to IP64, making them suitable for use in environments where heavy humidity may occur.

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Tadiran batteries make your devices run for their livesâ&#x20AC;Ś

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40 YEAR OPERATING

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And keep keep them them running running until until 2056. 2055. And The battery of the future is here today. Tadiran bobbin-type lithium thionyl chloride (LiSOCL2) batteries feature an annual self-discharge rate of just 0.7% per year: so energy efficient that they allow low power consuming wireless devices to operate for up to 40 years on a single battery. No one else even comes close. Tadiran lithium batteries also feature the highest capacity, highest energy density, and widest temperature range of any lithium cell, plus a glass-to-metal hermetic seal for added ruggedness and reliability in extreme environments. For a battery that lasts as long as your device, run with Tadiran.

Tadiran Batteries 2001 Marcus Ave. Suite 125E Lake Success, NY 11042 1-800-537-1368 516-621-4980 www.tadiranbat.com

* Tadiran LiSOCL2 batteries feature the lowest annual self-discharge rate of any competitive battery, less than 1% per year, enabling these batteries to operate over 40 years depending on device operating usage. However, this is not an expressed or implied warranty, as each application differs in terms of annual energy consumption and/or operating environment.

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sensor tips

Table 1: Key to second digit IP ratings IP second digit

Level of water ingress protection

None

Dripping water

Dripping water when tilted up to 15°

Spraying water

Splashing water

Jetting water

Powerful water jets

Temporary water immersion

Continuous water immersion

Hermetically-sealed LVDTs (IP68 rating) Constructed entirely of stainless steel, hermeticallysealed LVDT position sensors may incorporate coil windings that are sealed against hostile environments to IEC standard IP68. In addition to being protected from total dust ingress, these sensors can be rated for long-term water immersion up to a specified pressure without water ingress. Recommended applications for IP-68 rated LVDTs include: • outdoor structural monitoring • applications with dust, dirt, grease, humidity • heavy industrial • valve position All sensors rated by manufacturers to achieve IP68 may not be the same but must exceed IP67 ratings. For example, IP68 sensors from TE Connectivity are sealed through welding, with all wetted parts constructed of metal with the exception of the connector. The sensors themselves can be submerged in water or other fluids up to 1,000 psi when not operational. However, they cannot operate while submerged because water could intrude into the mating plug and cause a short.

Supreme 3HTND-2DA Ideal for die attach applications

One part compound

No mixing/freezing needed

Recommended applications: • seawater or fresh water • dam/bridge structural monitoring • choke/Christmas tree valve position monitoring • subsea extensometers • mooring Cables • ROV actuator/latch position feedback

Ideal dispensing profile

No tailing or bleed out

TE Connectivity te.com/usa-en/products/sensors.html

www.masterbond.com

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Submersible LVDTs (IP68) Submersible LVDTs may be rated at IP68 with appropriate Seacon-Branter mating connector. The connector and mating plug can be rated for pressures up to 5,000 psi or higher. Typically, these units are designed with a 20-year life for use in critical applications where access to the unit for replacement or repair is very costly.

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SENSORS

Pepperl+Fuchs Discover the R2000 Detection Unmatched Precision 360° Performance Advanced Intuitive Control The new generation of photoelectric sensors combines standard sensors with the latest measuring techniques. Equipped with innovative Pulse Ranging Technology (PRT), the R2000 2D laser scanners provide reliable and extremely precise measuring results— with a gapless all-around vision of 360°. One series, two versions: • R2000 Detection - laser scanner for demanding field monitoring applications • R2000 UHD (Ultra High Density) - laser scanner for complex measuring tasks and navigation With 250,000 scan points per second, the R2000 UHD works at the highest performance level. The Detection model uses a razorsharp, 2D scan plane to detect objects only a few millimeters above a surface. Tel. +1 330 486-0001 E-mail: fa-info@us.pepperl-fuchs.com www.pepperl-fuchs.us/r2000

Suco Pressure Transducers and Pressure Switches Fifty years ago Suco developed its first mechanical pressure switch. Today the company sets benchmarks in the industry and offers a complete line of pressure monitoring devices. Their product portfolio includes mechanical pressure and vacuum switches, electronic pressure switches and transducers and transmitters. Suco pressure switches are produced to operate in harsh operational conditions in mobile equipment, off-highway, material handling and industrial applications. They are designed to withstand pressure spikes, prolonged exposure to continual pulsation, shocks and vibrations. Suco offers a groundbreaking line of pressure Transducers and Transmitters with Silicon-on-Sapphire technology. Silicon-on-Sapphire has been approved for decades in the oil, gas, and defense industry. Suco Technologies makes this high end technology affordable now for off-highway and industrial application. Silicon-on-Sapphire has the ability to operate at extreme temperatures and has outstanding long term stability.

Suco Technologies, Inc 6560 W. Rogers Circle #22 Boca Raton, FL 33487 Phone: 561-989-8499 Fax: 561-989-8816 Email: info@suco-tech.com www.suco-tech.com

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SENSORS

Master Bond Inc. One Component Epoxy Adhesive Has Ultra Low Thermal Resistance and Meets NASA Low Outgassing Specifications Master Bond Supreme 18TC is a single component epoxy adhesive that contains a blend of special thermally conductive fillers. This smooth paste system can be applied in bond lines as thin as 10-15 microns. It offers an exceptionally low thermal resistance of 5-7 x 10-6 K•m2/W and a thermal conductivity of 22-25 BTU•in/ft2•hr•°F [3.17-3.61 W/(m·K)]. Supreme 18TC passes NASA low outgassing tests and offers outstanding heat transfer capabilities. Supreme 18TC maintains high bond strength properties over the wide temperature range of 4K to +400°F. It bonds well to a wide variety of substrates including metals, composites, ceramics and plastics. This compound offers a tensile lap shear strength of 2,200-2,400 psi, a tensile strength of 6,000-7,000 psi, a t-peel strength of 5-10 pli and a compressive strength of 22,000-24,000 psi. Supreme 18TC features a low shrinkage upon curing, a low CTE and a high degree of dimensional stability. It can be used in applications in the aerospace, electronic, optical, specialty OEM and cryogenic industries.

Contact: Master Bond 154 Hobart Street Hackensack, NJ 07601 +1 201-343-8983 www.masterbond.com

Visit www.SensorTips.com for the latest technical news and developments about sensor technologies. Find technical articles, selection tips, new product developments and more on most sensor technologies, including motion, vision, level, position, pressure, speed, temperature and more.

Sensor

www.sensortips.com

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Produ ct Wo rl d Data recorder DTS dtsweb.com With a footprint of only 26 × 46 mm, SLICE NANO IEPE can be embedded in almost any test article. SLICE withstands impacts up to 500 g, meets MIL-STD-810-E, and does it all on standard batteries. The data recorder is used in a variety of critical test applications for automotive, aerospace, military, and sports and safety equipment. Configurable from 3 channels to 24 per stack, SLICE can be daisy-chained for large test set-ups. It records samples from 10 to 500,000 sps/channel, and data direct-writes to 16 GB flash memory. In addition to supporting IEPE (piezoelectric) sensors, SLICE also works with bridge, MEMS, strain, load and temperature sensors.

The Standard in High-Performance Linear Motion Just Got Better Aerotech’s new and improved PRO-Series stages

• Performance specifications improved by as much as 98% • New linear-motor stage sizes – PRO115LM and PRO190LM • Linear motor stages now with an absolute encoder option • Ball-screw stages now available with a linear encoder option • Direct mounting to English or metric optical tables

Proven linear motor and ball-screw positioning stages now with new sizes, features, and improved performance. Call or email an Aerotech Applications Engineer today to discuss your requirements, or go to aerotech.com to request a quote. Ph: 412-963-7470 • Email: sales@aerotech.com • www.aerotech.com

Dedicated to the Science of Motion

WORLD HEADQUARTERS: USA THE AMERICAS • EUROPE & MIDDLE EAST • ASIA-PACIFIC

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Prod uc t World Pressure wash hose and couplings Kurt Hydraulics kurthydraulics.com The pressure wash hose is available in two

CUSTOM ENGINEERED SPINDLE / SLIDE COMBINATIONS DESIGNED & MANUFACTURED TO YOUR SPECIFICATIONS

types of tubing both made from water resistant synthetic rubber and either reinforced with one or two high tensile steel wire braid. The tubing is covered with black or non-marking blue coating that is abrasion, ozone and weather resistant. Kurt Hydraulics offers their K2 Couplings for pressure wash applications in sizes 4 to 10. These couplings feature reduced size Bite-Wire shell for good compact hose fit. This line of hose and couplings feature an operating temperature range from −40 to 300° F.

www.setco.com/customize Let Us Help You 1-800-543-0470 148

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

Pushbuttons EAO eao.com

Ballscrews & Rollerscrews

Series 82 anti-vandal pushbuttons feature IK10 shock protection and IP67 sealing. Reliable operation continues even amongst extreme temperature fluctuations from −30 to 70° C (−22 to 158° F) and humidity up to 85%. Other features include: 16, 19 and 22.5 mm diameter mounting hole sizes; momentary or maintained switch action, the capability to handle up to 5 A/250 Vac; and sunlight readable LED illumination in either attractive dot or ring style

Industrial Robots

versions.

Linear Motors

Linear Slides and Cam Roller Linear Guide Rail System Components

Linear Actuators

Linear Guideways

Linear Encoders / Positioning Measurement Systems

J.W. Winco, Inc. offers high quality, heavy duty linear slides and telescopic linear slides, along with cam roller linear guide rail systems components, suitable for every application. Explore our full line at www.jwwinco.com or contact us with your requirements.

AC Servo Motors

2815 S. Calhoun Road New Berlin, WI 53151 Phone: 800-877-8351 Fax: 800-472-0670 Sales@jwwinco.com

Hiwin D1 and D2 Servo Drives

For more information visit

www.hiwin.com

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Prod uc t World Two-component epoxy Master Bond masterbond.com Supreme 45HTQ-4 is serviceable from −100 to 450° F and is capable of withstanding rigorous thermal cycling. This compound offers high tensile lap shear, compressive and tensile strength of 1,400 to 1,600 psi; 24,000 to 26,000 psi; and 8,000 to 9,000 psi, respectively. Supreme 45HTQ-4 also retains its strength at elevated temperatures. It is a dimensionally stable system with low shrinkage upon curing. Additionally, this epoxy has a dielectric constant at 60 Hz of 4.6 and a volume resistivity exceeding 1014 ohm-cm. It has a mix ratio of 100:30 by weight and a thixotropic paste consistency and features a long pot life of more than 12 hours at room temperature for a 100-g batch.

Precision Cycloidal Reduction Gears The Spinea TwinSpin cycloidal reduction unit is ideal for precise rotary positioning where high torque density and system rigidity is required.

Screw Jack Lifting Systems Whether one jack or a complete multi-jack system, the Zimm series offers all the connecting, drive, and safety components from a single source. Download the App Guide Today!

Miniature Series

• 1/2 to 100 Ton • Complete Systems

Standard Series

Flange Series

• 10 Sizes 50-300mm

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• High Torsional Stiffness Phone: 630-980-1133 Web: www.diequa.com

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• Standing & Rotating

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

groov expansion Opto 22 opto22.com The groov 3.1 update adds WE Series Linear Guideway Wide Series Ball Type.

integrated image management, new image uses, and new on-screen and project options. Graphics features added include a new Image Indicator gadget that uses multiple images to indicate states or ranges of values. Another new feature is applying images to button gadgets, typically used for on/off or start/stop controls, while new page navigation links let you create custom navigation controls anywhere on the groov page. A new Image Library in groov 3.1 manages all the graphics used in a groov project for easy uploading, accessing and handling.

PG Series Linear Guideway Integrated Magnetic Encoder.

Encapsulated dc-to-dc converters AutomationDirect automationdirect.com The Rhino PSE series of dc-to-dc converters offers a compact, steady power source for

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

equipment exposed to harsh conditions. Ultra-wide input voltage ranges of 9.5 to 36 Vdc and 18 to 75 Vdc allow these models to operate from all popular dc supply voltage systems while supplying output voltages in the 5.1 to 48 Vdc range. Remote on/ off control, input polarity protection, and overload protection make them extremely rugged and versatile; and they offer easy installation with chassis or DIN rail mounting options.

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

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Prod uc t World Portable display for inductive probes Hexagon Manufacturing Intelligence hexagonmi.com Due to its special hemispherical form of the analog scale with 200 segments, the TESA TWIN-T10 allows for a clear analog and numeric reading of form variations. This portable display for inductive probes offers ease of operation for its users, as well as a clear and immediate graphical display of data. It also offers an exceptional operational time of more than 340 hours with standard AA batteries, so it can be used efficiently without the need to recharge frequently.

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Indexing table ETEL etel.ch LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

The RTMBi family consists of indexing tables with five different active lengths to match torque and size with specific application requirements, providing peak torque up to 197 Nm, continuous torque up to 36.4 Nm, and top speeds of 1,200 rpm.

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

All RTMBi tables have an optimized 166-mm outer diameter and a 25-mm hollow shaft. The tables offer 15% improved continuous torque, 20% reduction in inertia, 10% improved peak torque and 600 Vdc compatibility compared to previous models. They also offer an improvement of accuracy (±20 arcsec), unidirectional repeatability (±2 arcsec) and bi-directional repeatability (±3 arcsec).

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

Cartridge Check Valves

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

Designed for Installation into Plastics • 100% Performance Tested • Simple Press-In Installation • Wide Range of Cracking Pressures • 2.5, 5.5, and 8 mm Sizes • All Stainless Steel

AC Servo Motors.

For more information, contact The Lee Company

Innovation in Miniature

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The Lee Company 2 Pettipaug Road Westbrook, CT 06498 USA Tel: 860-399-6281 shanleyg@theleeco.com www.leeimh.com

May 2016

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

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Prod uc t World Seal-less water circulation pump AMETEK ametek.com

Personal CNC Prototyping - Product Design - R&D - Engineering

Circulation Pump incorporates a brushless dc motor with a 40,000-hour design life and a quiet-running, wet-rotor design. The pump’s wet rotor design circulates cooling water

Eisertech, a medical device company in San Diego, CA, designs and manufactures spinal implants and surgical instruments with the help of their Tormach PCNC 1100. What started out as garage shop prototypes has grown into a successful medical device product line.

around the motor’s rotor to provide thermal management and lubrication of the bearing system. Its electromagnetically coupled design has no wet seal to wear out or replace. The pump also features CAN interface, protection from over temperature, current overload, locked rotor, reversed polarity and transient

To read more about this story, and to see what others are doing with their PCNC mills, visit www.tormach.com/design. PCNC 1100 Series 3

The ROTRON SLP 2418 Seal-Less Water

voltage spikes. It weighs only 6.7 lb and can handle operating fluids from −40 to 95° C.

Titanium bone screws and surgical spinal implants manufactured by Eisertech LLC.

PCNC 770 Series 3 PCNC mills shown here with optional stand and accessories.

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Safety relays Phoenix Contact phoenixcontact.com PSRmini safety relays come in two form factors: slim and compact. The 6-mm slim relay variants have one or two normallyopen safety-rated contacts, and the 12mm compact variants have up to three normally-open safety-rated contacts. The safety relays switch loads up to 6 A and are compatible with a variety of signaling devices, such as emergency stop equipment, safety-door switches and light grids. The list of approvals, including PLe according to EN ISO 13849, and SIL 3 according to IEC 61508/61511, makes them suitable for many mechanical engineering and process industry applications.

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SALES

A d In dex Accu-Mold LLC .................................................................114 ACE Controls ..................................................................... 40 Aerotech ..........................................................................147 All Motion .............................................................................6 Allied Electronics, Inc. ...................................................7,86 AMETEK DFS ......................................................................35 AMETEK PMC .....................................................................21 Anderson Metals Corp ................................................... 107 Aurora Bearing Co. ............................................................72 AutomationDirect .............................................................13 Baldor Electric Co. ........................................................... 28 Balluff ............................................................................... 49 Baumer LTD .......................................................................39 Beckhoff Automation ...................................................... 84 Bimba Manufacturing Company ...................Inside gate,3 Bison Gear & Engineering Corp. .....................................IBC Bodine Electric Co ........................................................... 80 BOKER’S Inc. .....................................................................18 Braxton Manufacturing, Co. Inc. .....................................54 Caplugs ..............................................................................57 Carlo Gavazzi ....................................................................29 CS Hyde .............................................................................12 Delta Computer Systems ................................................ 53 Del-Tron Precision, Inc. .....................................................64 DIEQUA Corportion ....................................................44,150 Digi-Key Electronics .........................................................17 Donwell Company ......................................................... 105 Dunkermotoren, part of Ametek ....................................61 Eagle Stainless Tube & Design .................................26,27 Elesa USA Corporation .................................................... 56 Encoder Products Co. ...................................................... 46 eplan ................................................................................. 34 EXAIR Corporation ..............................................................5 EZAutomation .....................................................................1 FABCO-AIR, Inc................................................................ 106 Fixtureworks .....................................................................72 Groschopp .........................................................................82 Harmonic Drive .............................................................. 103 Haydon Kerk .....................................................................69 Helical Products Company ................................................9 HELUKABEL USA ...............................................................25 Hitachi Cable America ......................................................33 HIWIN ................................................................149,151,153 igus ................................................................................. 109 Interpower .......................................................................113 ITT Enidine Inc. .............................................................. 108

J.W. Winco, Inc. .............................................................. 149 KB Electronics ............................................................... 104 Keystone Electronics Corp. ............................................19 Master Bond ................................................................... 105 maxon precision motors, inc. .........................................63 Memory Protection Devices, Inc. ....................................97 MICROMO .........................................................................116 Moog Components Group ................................................41 MW Industries .............................................................36,37 NB Corporation ................................................................ 30 Nippon Pulse Americas, Inc. ............................................74 Novotechnik ......................................................................75 NSK Precision ...................................................................45 NTE Electronics ............................................................... 98 Ondrives.US Corp. .............................................................71 OPTO 22 .............................................................................55 Parker Hannifin ..........................................................22,23 PBC Linear .........................................................................47 Peninsular Cylinder ....................................................... 152 Penn Engineering ............................................................ 90 Pepperl + Fuchs ............................................................. 100 PHD Inc. .............................................................................87 Pilz Automation Safety ..................................................101 Proto Labs, Inc. .................................................................15 R + W ..................................................................................85 Ringfeder Corp. ................................................................ 93 Rittal .............................................................................50,51 Rotor Clip Company, Inc. .................................................77 SAB North America ...........................................................43 Schneider Electric (IMS Group) ..................................... 99 Setco ............................................................................... 148 SEW Eurodrive ..................................................................BC SIKO Products, Inc. ...........................................................18 Smalley Steel Ring Company ..........................................10 Sunstone Circuits ...........................................................112 The Lee Company .......................................................... 153 Therm Omega Tech ...........................................................65 THK America, Inc. ............................................................IFC Tolomatic, Inc. ...................................................................73 Tompkins Industries ........................................................76 Tormach .......................................................................... 154 TRIM-LOK, Inc. .................................................................. 42 Turck-USA ................................................................. 115,117 US Tsubaki ...................................................................... 155 Whittet-Higgins Co. ...........................................................31 Zero-Max, Inc. ......................................................................2

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Inside: 120 Advances in additve manufacturing 126 3D printed end-of-arm tooling lightens load on robotic packaging line

A supplement of Design World • May 2016

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132 Metal additive manufacturing enables lean, green heat exchanger

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Proto Labs, Inc..................................................118 Renishaw Inc. .................................................. 123 solidThinking, Inc. ...........................................131 SME - RAPID 2016 - 3D Technology Event .....135

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