Design World May 2018

www.designworldonline.com

May 2018

inside: Motion Control: Air apparent: benefits of air

motors for motion

p. 60

Internet of Things: Best practices for IIoT

security

p. 74

Electronics Better simulation brings

fewer surprises in HALT

p. 80

Linear actuators: smarter, more powerful page 66

MAY 2018 DW COVER_FINAL.indd 1

5/1/18 10:52 AM

THK EndlessProdAd_wIMTS(DW)_840-06205 GN-N Ad(MSD) 4/13/18 12:21 PM Page 1

Our wide range of products gives you maximum design freedom.

Booth 134514

September 10-15, 2018 McCormick Place, Chicago

THK 5-18 (Endless Products).indd 1

As the leader in linear motion, THK is dedicated to developing not just the best choices, but also the most choices in linear motion solutions. Our virtually limitless range of products includes linear motion guides, ball screws, actuators, specialty products and more - many featuring our patented Caged Technology.

To learn more, give us a call at 1-800-763-5459 or visit www.thk.com.

4/27/18 8:14 AM

Your Success is Our Success AutomationDirect is your trusted source for cost-effective control solutions

www.chemence.com

James Catlett

Chemence, the only industrial, consumer and medical cyanoacrylate manufacturer in the US, looks to AutomationDirect for their manufacturing and packaging control needs.

Plant Manager Chemence

“AutomationDirect’s low prices and free support keep us coming back. Their automation products are exactly what we need to get the job done and the new BRX PLC, with its motion capabilities and built-in analog, is perfect for our packaging lines.” - James Catlett At AutomationDirect, customer satisfaction is priority one and we are continually expanding our offering of practical, cost-effective industrial control products to meet a wide range of applications. The latest addition to our Do-more! family of programmable controllers is just another example. Starting at $199.00, the Do-more! BRX PLC platform is packed with features and has the tools you need to “get the job done” for less.

Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2016 AutomationDirect, Cumming, GA USA. All rights reserved.

AutomationDirect 5-18.indd 1

www.BRXPLC.com

1-800-633-0405

the #1 value in automation

4/27/18 8:15 AM

FREAK © Allied Electronics & Automation, 2018

Allied Electronics 2-18 - spread_DW.indd 2

4/27/18 8:12 AM

Automation & Control Freak?

Same here.

We carry more automation & control brand names than any other distributor in North America.

It’s true – we checked.

Get your A&C fill at Allied Electronics 2-18 - spread_DW.indd 3

alliedelec.com

1.800.433.5700 4/27/18 8:13 AM

NEW!

4 AXIS SERVO

I n s ights

from

2.25”

- brushed or bldc motors - 5 amps per axis - 16 analog inputs - 16 on/off drivers - home and limit in - live tech support - made in the USA See the

EZQUAD SERVO in action!

WWW.ALLMOTION.COM

(510) 471-4000 30097 Ahern Avenue Union City, CA 94587 Te c h n i c a l S u p p o r t

The coming power of AI Last month’s GPU Technology Conference was a fascinating insight into the power of artificial intelligence, and how it is being harnessed by software developers and engineers to break through old barriers in a bevy of industries, from autonomous vehicles to virtual reality to medicine.

Nvidia CEO Jensen Huang offered his insights on a variety of topics in his keynote address, and spoke about the era of supercharged computing, in which CPU growth has fallen below Moore’s Law in recent years—but GPU-accelerated computing is instead growing at a faster rate than what he called “the miracle of laws.”

“There’s a new law going on, a supercharged law,” he said, “and I think this is the future of computing.”

He showed examples of how AI is impacting the rendering of images in video games and film—and noted how computing power is still lagging behind on major science initiatives.

According to Huang, a Caltech-Oak Ridge National Laboratory project on reinventing the lithium-ion battery took 7 days on the Titan supercomputer. A Princeton-Oak Ridge study on mapping the Earth’s core took 17 days on Titan. An Illinois/NCSA study looking into the structure of HIV took 16 days on Blue Water. And an ETH Zürich/ MeteoSwiss look at cloud-resolving climate simulation took an amazing 840 days on Piz Daint. Soon, this technology will reduce those times to 1 day, he said, thanks to GPU-accelerated computing.

“There’s serious groundbreaking science to be done. We’re going to build an exascale computer, and these simulation times will be compressed down to one day … science needs supercharged computers.”

Among the corporate news releases that Huang discussed was a series of advances to the company’s deep learning computing platform, which delivers a 10x performance boost on deep learning workloads compared with the previous generation six months ago.

“The extraordinary advances of deep learning only hint at what is still to come,” said Huang. “Many of these advances stand on Nvidia’s deep learning platform, which has quickly become the world’s standard. We are dramatically enhancing our platform’s performance at a pace far exceeding Moore’s law, enabling breakthroughs that will help revolutionize healthcare, transportation, science exploration and countless other areas.” DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

(408) 460-1345

4 May 2018 www.designworldonline.com DESIGN WORLD

Insights 5-18_Vs3.LL.indd 4

4/27/18 9:01 AM

WATCH

SAFETY

https://exair.co/58_agv_ad

AIR GUNS POWERFUL

EFFICIENT

ERGONOMIC

OSHA COMPLIANT

EXAIR Safety Air Guns are reliable, durable and comfortable to use. Each model uses an engineered Air Nozzle to provide superior performance while using less compressed air and producing lower noise levels than typical air guns. Safe operation is assured by a design which prevents exiting airflow from being blocked. If saving energy and keeping personnel safe are important to you, contact EXAIR for the solution! To further enhance their performance, EXAIR Safety Air Guns can be upgraded with a chip shield and extension pipes.

Variable Flow, Trigger Control The new Compact Safety Air Gun effectively produces different force values with a variable flow trigger. These new safety air guns are easily configurable with EXAIR air nozzles, Extension Pipes and Chip Shields.

Industrial Duty, Versatile, Ergonomic and Reliable The Soft Grip Safety Air Gun is cast from aluminum with a comfortable four finger trigger to reduce fatigue over long periods.

A large variety of air nozzle options provide a solution for light to heavy duty blowoff applications.

High Performance, Rugged, Durable The Heavy Duty Safety Air Gun is the powerhouse you need for the harshest environments and stubborn blowoff applications.

It is outfitted with many of our most powerful nozzles to provide the highest force for your application.

https://exair.co/58_411 Manufacturing Intelligent Compressed Air Products Since 1983 11510 Goldcoast Drive, Cincinnati, OH 45249-1621 email: techelp@exair.comm . fax: (513) 671-3322

Exair 5-18 (NEW).indd 5

@exair

4/27/18 8:18 AM

Teschler on Topic

Who has smarter eighth graders?

Here are a couple of physics questions. How well do you suppose an average eighth grader would do at answering them?

There are two identical blocks of ice, one wrapped in newspaper. Which ice block will melt first and why?

An object has a density of 1.1 gm/ cm3. Would the object float in liquid X having a density of 1.3 gm/cm3, or liquid Y with 0.9 gm/cm3?

Actually, you don’t have to guess about eighth graders and their answers. These questions come from the Trends in International Mathematics and Science Study for eighth graders. The TIMSS is one of the international assessments of STEM skills that evokes a lot of hand wringing about U.S. education. Every year, the International Association for the Evaluation of Educational Achievement releases a few of the questions and statistics about who got them correct.

It turns out that 62% of South Korean eighth graders knew that the object would float in liquid X, the top score among countries. Only 43% of U.S. eighth graders knew the answer, but that was above the international

average of 31%. Interestingly, individual states can choose to have their scores computed separately. Kids in Massachusetts did slightly better than the Koreans while six other states did better than the U.S. average.

When it came to wrapping ice cubes in newspaper, 60% of Chinese eighth graders knew that newspaper would help prevent heat from reaching the ice. The international average was 35%, 31% for the U.S. The top scoring state was snowy Minnesota with 36%.

Before you panic about low U.S. test scores, consider the findings of researchers from Harvard and Boston College writing in a recent issue of Science Magazine. They say the rankings that come out of such international assessments as TIMSS or the Programme for International Student Assessment test (PISA) can be quite misleading.

One big problem is that those taking the tests probably don’t represent the average kid, particularly outside the U.S. For example, in less developed countries such as Turkey and Mexico, as many as 40% of 15-year-olds have already dropped out of school. In East Asia, a lot of students get private tutoring. South Korea is good example; About half

the Korean kids taking the PISA test in 2012 had tutoring that often focused on test preparation. So high scores by Korean kids may be an indicator that private tutoring works, rather than saying anything about the Korean educational system.

An even bigger variable is whether kids apply themselves when answering test questions. At least in the U.S., assessments like PISA or TIMSS don’t go on a kid’s academic record. Thus, they aren’t a factor in college admissions or in anything else that matters to the students taking the test. Time spent taking the PISA is little more than an excuse to avoid what otherwise might be time spent listening to a boring classroom lecture. In this scenario, U.S. kids probably can’t be faulted for not putting a lot of thought into their answers.

But the situation is different in East Asian cultures, the researchers note.

It’s plausible, they say, that East Asian kids score higher partly because they’re conditioned to take any test seriously, even one that’s unimportant.

All these imponderables are good reasons to be skeptical of educational rankings based on test results. They are also good to keep in mind the next time you hear politicians advocate expensive remedies for low U.S. test scores. DW

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

6

May 2018 www.designworldonline.com

Lee Teschler Column 5-18_Vs2_LT.indd 6

DESIGN WORLD

5/2/18 11:42 AM

Space Tight?

GO FLAT! Flat cables occupy just 50% the space of comparable round cables. For dense packaging, flat cables are the most space-efficient solution. Cicoil Flat Cable, with its thin profile and extreme flexibility is the ideal choice where space is tight.

u One Cable For Everything: Combine Power, Signal, and Tubing into a single flat cable for the smallest packaging density. u Standard or Custom: A wide variety of standard cables are available, and our engineers can design custom cables for any requirement or industry.

Learn How To GO FLAT at

cicoil.com

u Design Your Own: Our Online Configurator lets you design virtually any flat cable in minutes! You get an immediate drawing, and your custom cable is delivered in less than 2 weeks.

PHONE: 661.295.1295 Cicoil 5-18.indd 7 Cicoil_Tight-Space-FullPg_ad_DW.indd 1

4/27/18 10:05 8:17 AM 12/21/15 AM

Technology Forward Trends in additive manufacturing

indicate a strong and maturing industry At the 30th annual Additive Manufacturing Users Group Conference in St. Louis, Mo., Todd Grimm, President of T. A. Grimm, an additive manufacturing consulting and communications company, gave the keynote address, which included a look at trends in additive manufacturing that he has seen over the last year.

One of those trends is the need for more people skilled in working with additive technology. As additive grows, various industries in dental, medical, aerospace, automotive and others need more people who know how to design, operate, and take advantage of the benefits of additive technology. That’s good news for engineers and college students graduating soon.

Another trend is the continued growth and development of hardware for metal additive manufacturing.

China continues to develop additive manufacturing businesses and technologies. The Chinese government is investing billions and plans on being a major player in the additive industry.

The European additive conferences have seen a number of Chinese exhibitors, and you will see more of the coming into the U.S. UnionTech, Farsoon, and XDM are among the companies out of China exhibiting at the AMUG conference.

Another development is new and unique ways to build objects layerby-layer. The recent Evolve Additive Solutions is one example. GEFERTEC GmbH is another one, introducing its GTarc machines that manufacture metal parts cost-efficiently and at high production speed. Processes that explore further opportunities with building using Photopolymers are on the increase.

More additive technologies can be measured for Overall Equipment Effectiveness (OEE). Efforts are underway to prove that additive systems deliver ruggedness, effectiveness, and other equipment productivity measures in manufacturing situations. This is a key development in establishing greater acceptance of this technology on the manufacturing floor.

The quest for better prices is still focused on materials and continues. In addition, though, the price of additive systems is dropping a bit due to increasing purchases and efficiencies in building these systems. A number of additive systems today are about 20 to 30% lower than in previous years.

Plus, it’s a lower cost of entry for many innovators. Downward pricing pressure is coming.

There’s a trend of “me too,” in that some companies claim they can do it for less. While cost and speed are not the only criteria for purchasing additive systems, you will see more of this.

Development in software is a big trend this year. One development is “direct from CAD,” where designers no longer need to convert CAD files to a language for additive, such as STL. This is a big time saver. A number of companies are developing predictive software tools for additive. These tools can predict how the build will go, where support structures are needed, and simulate geometry reactions during a build. AI is being added in several design programs where the software creates the design based on engineer described parameters. This generative software will lead to greater use of additive technology because it takes advantage of additive’s ability to produce complex and custom designs.

Another software trend is workflow management software that directs the design to build process for additive. You will soon hear terms like blockchain being used.

Grimm also sees a trend of niche targeting for additive systems. General purpose additive machines will not be the wave of the future. Instead, the trend will be for additive systems targeted at specific industries.

Successes are already here with dental and medical.

There was plenty more from the AMUG conference. This industry is poised for its next level of growth and innovation. DW

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

8

May 2018 www.designworldonline.com

Leslie Column 5-18_Vs2.LL.indd 8

DESIGN WORLD

5/1/18 10:56 AM

Pressure Valve

Floating Gear

Oil Valve

ALL SPRINGS ARE NOT EQUALÂŽ Reduce spring height by 50% over ordinary coil springs while maintaining the same force and deflection. Standard parts available in stainless and carbon steel. Need custom? No problem.

We’ll provide you with the right spring, in the right material, for your application.

FREE SAMPLES: Call (866) 478-9757, or visit expert.smalley.com/DW/springs

Smalley 11-17 (new ad 11-17).indd 9

4/27/18 8:16 AM

Whether it’s a standard off-the-shelf cylinder or a cutting-edge custom assembly, Bimba is uniquely positioned to help with your motion control application. That means everything from simple, non-repairable products to the latest in precision mechatronics or end-of-arm tooling applications. If you’ve got an engineering challenge, Bimba has the solution. From innovative design to unparalleled customer service, it’s all about getting you the right solution at the right time.

© Copyright 2018 Bimba.

All rights reserved.

www.bimba.com BIM-11339 Bimba10 Resizes 2018_DW_WMTM_050118.indd 1 Bimba 5-18.indd

4/9/18 8:52 4/27/18 8:19 AM AM

Green Engineering

The U.K. looks at reducing packaging waste Miguel Campos is export sales manager for Advanta

According to the Waste and Resources Action Program (WRAP), food packaging waste in the U.K. accounts for more than 5.6 million tons of the total waste—and that’s just from the food and drink supply chain. Imagine what the rest of the world adds to that total. But what’s the alternative to plastic?

Aluminum packaging first appeared on the market in 1948 and saw a period of growth in popularity throughout the 1950s and 60s, when TV dinners began to revolutionize the food market. Most of the aluminum used in packaging is in the form of rolled products, which are used for flexible packaging like fine foils, or as rigid packaging like drinks cans and trays.

The strength, flexibility and ability to withstand extreme heat and cold are some of the key benefits for choosing aluminum over other packaging options.

Aluminum trays, for instance, can be molded in to nearly any shape or size.

This creates opportunities to develop visually appealing packaging that is capable of supporting the storage and cooking of even awkward or unusually

DESIGN WORLD

Green Engineering 5-18 Vs2.LL.indd 11

www.designworldonline.com

shaped. It also means that packaging can be adapted to meet the needs of any manufacturing process equipment, like conveyors or robotic arms.

Aluminum can resist temperatures of up to 400° C and be frozen at temperatures as low as -40° C. Throughout these extremes, the rigidity of the structure is not compromised, making it an ideal material for many products.

Another alternative that can produce a high-end look, while being environmentally conscious, is fiber pulp packaging. It is manufactured using 100% pre-consumed materials like cardboard and is often used for packaging premium food products.

Fiber pulp packaging is extremely May 2018

11

5/7/18 9:15 AM

Green Engineering Now is the time to provide consumers with sustainable, environmentally friendly packaging choices. popular in Nordic markets, where environmental and green cultures are well developed. However, as more customers adopt healthy, environmentally conscious lifestyles, many are willing to pay premium prices for sustainable packaging options.

Fiber pulp is also suitable for the ready meal or the ready-to-cook market as the material is cool to touch when taken out of the oven or microwave. It can also be formed into trays that have sealed compartments, meaning no cross contamination between meal components.

Now is the time to provide consumers with sustainable, environmentally friendly packaging choices. With reports from GLJ Recycling stating that every average household produces more than a ton of waste every yea—a figure that is increasing by 3% year-on-year—it means that in 25 years, the amount of waste produced will have doubled.

While consumers will undoubtedly start to look for eco-friendly packaging alternatives in the supermarket, the problem of plastic waste will continue if

manufacturers keep using it to package their products.

When you consider that some waste has limited use, and ultimately will end up in landfill for hundreds of years or make its way into our oceans, manufacturers must take ownership of sourcing recyclable packaging materials— and there are many available. DW

Advanta | advantapack.com

INJECTION MOLDING Faster Parts. Your Way.TM

Molds starting at $1,400 15 Days or Less For Molds.

5 Days or Less for Parts.

Custom Quick-Turn Manufacturing • Lifetime Mold Guarantee One-Stop-Shop • Production or Prototype Parts • Aggressive time-to-market with two facilities to serve you • Simple-to-complex part production • Offshore alternative • Serving 50+ industries

Very Competitive Pricing. Ask Us For A Quote Today.

586-598-4636 or sales@xcentricmold.com

ISO 9001:2015

DW_InjectionMolding_HalfPageHoriz.indd 1 Green Engineering 5-18 Vs2.LL.indd 12

24541 Maplehurst Drive | Clinton Township, MI 48036 586-598-4636 | www.xcentricmold.com

2/13/18 11:14 AM 5/7/18 9:49 AM

Discover ebm-papst.

Intelligent drive solutions for industry at discover.ebmpapst.com/drivetechnology

Simon Echle, Applications/Project Engineer at ebm-papst

At ebm-papst we aim to set a great deal in motion with efficient technologies – for example the goods in modern logistics centers.

We are in great demand by many fields of industry, because we develop not just the motor itself but complete drive systems.

You can’t see it. But you can feel it!

For more information, please contact: sales@us.ebmpapst.com

ebmpabst 5-18.indd 13

5/1/18 9:47 AM

Contents 5 • 2018

•

vol 13 no 5

•

designworldonline.com

Sensor www.sensortips.com

80 _ELECTRONICS

Air apparent: Benefits of air motors for motion

Better simulation brings fewer surprises in HALT

The electric motor may be the most common source of mechanical power in modern industrial environments, but that doesn’t make it the best setup for every application.

Sensor Tip cover 5-18_FINAL.indd 98

5/2/18 2:01 PM

98-105

60 _MOTION CONTROL

Selecting the right sensor for motion applications

| istockphoto.com

74

A Supplement to Design World - May 2018

Vibration simulation software has been optimized specifically to handle printed circuit boards.

86 _MEDICAL 66 _LINEAR MOTION Linear actuators: smarter, more powerful

Electromechanical actuators continue to advance with more integration as well as more powerful actuators able to compete with some fluid power mainstays.

When adhesives go wrong

Too often the adhesive selection for a medical device is left to the end of a project. It doesn’t help that there are so many adhesives as to make the choice overwhelming. With many potential negative outcomes, here are tips on making the right choice.

74 _INTERNET OF THINGS

92 _MECHANICAL

Best practices for IIoT security

Playtime is over: understanding internal clearance in ball bearings

A recent report from the Industrial Internet Consortium presents best practices that designers can use to increase security for their Industrial Internet of Things (IIoT) projects from the design stage up.

At first glance, ball bearings are relatively simple mechanisms.

However, an analysis of their internal geometries reveals that they are quite complex.

ON THE COVER SEZ electric cylinders from AMK Automation are linear drive systems where the rotor is pressed directly onto the screw, providing high rigidity. | Courtesy of AMK Automation

A | S | B | P| E

A | S | B | P| E

American Society of Business Publication Editors

American Society of Business Publication Editors

Fostering B2B editorial excellence

2018 Regional

May 2018 www.designworldonline.com

CONTENTS 5-18_Vs2.LL.indd 14

2018 Regional

PR INT

DESIGN

Revenue of over $3 million

Revenue of over $3 million

Award Winner

14

Fostering B2B editorial excellence

Award Winner

DESIGN WORLD

5/3/18 10:30 AM

180330_CYW_DW_US.indd 1 Digi-Key 5-18.indd 15

3/29/18 4/27/18 1:23 8:21 PM AM

Easy-to-Use

Instant Online Configurator.

5.18

• contents

(Results in 60 seconds or less)

departments 04 Insights 06 Teschler on Topic 08 Technology Forward Now you can configure Fabco-Air products anywhere.

On the shop floor. At the airport. At a remote job site. And you can do it with almost any device.

Even your smart phone!

The Fabco-Air configurator is the most comprehensive, user-friendly, and dynamic program in the industry.

It generates everything you need from one location.

1 1 Green Engineering 18 Design For Industry 32 Design Notes 46 Internet of Things

52

A few clicks instantly give you: • Product Part Numbers • List Prices • Lead Times • CAD Files • Seal Part No's & Prices • Repair Kit Part No's & Prices • Mounting Hardware • Accessories & Attachments • Switches/Sensors

CAE Solutions

106 Product World 112 Ad Index

Additionally, the program includes an unprecedented DECONSTRUCTION feature.

Simply input a valid Fabco-Air part number to display all relevant information.

DECONSTRUCTION can also be used to re-configure a basic part number for different mounting, stroke, added options, etc.

Try it out now at

www.FABCO-AIR.com Phone (352) 373-3578 • Fax (352) 375-8024 E-Mail service@fabco-air.com

16

CONTENTS 5-18_second page_Vs1.indd 16

May 2018

DESIGN WORLD

5/1/18 11:08 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

DESIGN & PRODUCTION SERVICES

EDITORIAL

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

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Production Associate Tracy Powers tpowers@wtwhmedia.com

DIGITAL MARKETING

Digital Marketing Director Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia Webinar Manager Lisa Rosen lrosen@wtwhmedia.com Digital Marketing Coordinator Aly Ryan aryan@wtwhmedia.com @wtwh_aly Leadlift Onboarding Specialist Mike Ulanski mulanski@wtwhmedia.com @wtwh_mike

DIGITAL MEDIA/WEB/ DEVELOPMENT

Events Manager Jen Kolasky jkolasky@wtwhmedia.com @wtwh_jen

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

Events Marketing Specialist Christina Lograsso clograsso@wtwhmedia.com @wtwh_christina

Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick

Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com

Videographer Manager John Hansel jhansel@wtwhmedia.com @wtwh_jhansel Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek

Customer Service Representative Stephanie Hulett shulett@wtwhmedia.com Digital Production Manager Reggie Hall rhall@wtwhmedia.com

FINANCE

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

2011 - 2017 2014 Winner

WTWH Media, LLC 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103 Ph: 888.543.2447 | FAX: 888.543.2447

Medical Design & OUTSOURCING

DESIGN WORLD

Staff page 5-18_Vs1.indd 17

www.designworldonline.com

May 2018

17

5/1/18 11:10 AM

Design for Industry Packaging

Robot saves space in rapid food packing

F

Fold it, seal it, tape it, box it, pick it, place it — automate it.

These are the separate processes that Finland-based Orfer Oy needed to automate to speed up its packaging operations.

However, automating these processes without expanding the factory floor space was no easy feat.

The company, that has recently opened its North American office in Toronto, innovates, engineers, and manufactures robotic material-handling systems for a range of industries.

For a new design of a fully automated packing machine targeted to the food and packaging industries, Orfer needed a robot that offered fast and accurate handling and that could easily integrate with a vision system to track and pick parts from a moving conveyor.

Orfer’s existing BoxCell system uses a Toshiba Machine TH650A SCARA robot from TM Robotics to pack products into plastic or cardboard boxes.

Orfer’s newest system — the ORFER BoxCellPlus — expands on the BoxCell packing cell with the ability to open flattened boxes, fold the flaps, and seal the bottom with tape and then fill the box with products — all in one space-saving, and fully automated packing cell.

However, before manufacturing this new product, the robot at the heart of the BoxCellPlus needed to be easy to use, flexible, and cost-effective, with high-quality components for reliability and low maintenance. For the design of the BoxCellPlus, Nigel Smith, CEO of TM Robotics, helped Orfer

18

define the robot specification based on the reach, payload, and cycle time requirements for food and packaging applications.

Smith assessed Orfer’s needs and ruled out a sixaxis or spider-style robot. “Packing is a classic pickand-place application,” he explained. “It doesn’t require the dexterity of a six-axis robot and needs a greater working envelope than a spider-style robot offers.” With this in mind, Orfer standardized on the Toshiba Machine TH650A high-speed SCARA robot for the BoxCellPlus.

“Toshiba Machine’s SCARA robots can reach as far as 1.2 meters, but the TH650A has a reach of 650 millimeters, which is closely equivalent to the length of the human arm,” Smith continued. “Many automated processes were originally designed for human workers, so consciously or not, this is a common specification, especially for packing and assembly applications.”

While Toshiba Machine SCARA robots can handle payloads of up to 20 kilograms, the TH650A payload of 10 kilograms suits food packaging. This allows a variety of products to be picked, while supporting a variety of tool configurations.

“A company that has multiple sizes of chicken products may need a gripper capable of picking up the

May 2018 www.designworldonline.com

DFI 5-18_Vs4.LL.indd 18

DESIGN WORLD

5/1/18 11:26 AM

one-, two-, or five-kilogram family pack,” said Orfer’s Mäkelä. “A single gripper for these products requires a number of components, all of which need to be considered when looking at the robot’s final payload. The 10-kilogram payload of the TH650A gives our engineers plenty of flexibility to design their end-of-arm tooling.”

Orfer also considered the Toshiba Machine THL series SCARA robots, which achieves its efficiency with smaller motors and lighter components in the arm construction. TM Robotics was able to help the company evaluate the two robots and make the best decision for the BoxCellPlus application. “The TH650A uses a larger motor and high-performance RF gears on joints one and two, which are the strongest, longest-lasting gears for a SCARA arm,” said Smith.

“This, along with its fast cycle time, made the TH650A a good choice for the high-speed, high-throughput demands of Orfer’s end-ofline packing application.”

Orfer’s designers chose the ceiling-mounted option for the TH650A robot so it could be placed above the conveyor rather than using the standard floor mounting to the side. This allowed them to minimize the overall size of the BoxCellPlus while maximizing the robot’s ability to access products coming down the moving conveyor and place them into the box. The smaller robot also helped make the system more cost-effective overall.

The TH650A robot’s ability to place parts accurately within 0.01 millimeters was enhanced with an extended Z shaft of 400 millimeters that enables parts to be placed deeper into the box. This accuracy and depth helps prevent product damage during packing, and provides consistent, high-quality output for customers.

Due to its modular structure and adjustable control system, the BoxCellPlus can be easily integrated into factory or warehouse management systems. As part of an automated packing system, the BoxCellPlus can be fed from conveyors from a weight-checker, labeling machine, or a vacuum packer. The robot also interfaces

DESIGN WORLD

DFI 5-18_Vs4.LL.indd 19

May 2018

19

5/1/18 11:27 AM

Design for Industry Packaging with leading vision systems, which can be used for inspection and to send coordinate data to the robot to pick parts from a moving conveyor.

Orfer is able to pass along the advantages of the Toshiba Machine robot in its new BoxCellPlus system, including faster, more accurate processing, smaller size, and lower cost.

“Our customers could use multiple machines to erect boxes and fill them, which could take up as much as 50 percent more space on the production floor,” said Mäkelä. “With the BoxCellPlus, both of those functions happen in a smaller space and at as much as 15 to 25 percent lower cost than using multiple machines.”

TM Robotics’ focus on customer support and design expertise helped Orfer optimize its new, highly integrated food-packaging system. “Our focus is on helping customers identify their most

TL Design Worls ad copy.pdf

1

1/25/18

important system requirements and meeting those with exactly the right robot,” said Smith. “In comparison to a six-axis robot with a cycle time of five seconds, the Toshiba Machine SCARA robot’s cycle time is approximately two seconds, which dramatically improved capacity. And it costs about 40 percent less than a spider robot.”

Automating several processes without expanding on floor space can be difficult, but with the correct combination of automation, like carefully chosen robotics and ceiling mounted options, the rewards can be excellent. DW

TM Robotics | www.tmrobotics.com

WHAT DO YOU THINK?

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

8:28 AM

Same Day Shipping on Thousands of Parts

CALL US TODAY!

FREE SAMPLES

C

M

Test Our Trims and Seals for Fit and Function

FREE CATALOG

Y

CM

MY

CY

Quickly View Our Most Popular Lines of Trims and Seals

CMY

DESIGN ASSISTANCE

K

Let Us Help you Find the Right Trim and Seal

IF YOU HAVE AN EDGE… WE HAVE A TRIM! 800-933-4915 HEADQUARTERS 6855 HERMOSA CIRCLE BUENA PARK, CALIFORNIA 90622

20

MIDWEST MANUFACTURING 1642 GATEWAY COURT ELKHART, INDIANA 46514

May 2018 www.designworldonline.com

DFI 5-18_Vs4.LL.indd 20

LOCAL: 714-562-0500 FAX: 714-562-0600

WWW.TRIMLOK.COM INFO@TRIMLOK.COM

DESIGN WORLD

5/1/18 11:28 AM

Packaging

RFID reader range is from millimeters to meters

Automotive and assembly and packaging applications often have a need for RFID readers where the read range will vary from a few millimeters to a meter based on the size of the product being manufactured.

The BIS VU-320 UHF reader adds Ultrahigh (UHF) capabilities to the BIS V multichannel processor, which can now accept readers in the Low (LF), High (HF), and Ultrahigh (UHF) Frequencies. All three frequencies can operate simultaneously.

These capabilities mean tags can be read at a range of 1 to 3 feet. The typical read range of LF and HF readers is just a few inches. With most UHF readers the read range can extend out to 20 feet or more, but that makes it difficult to single out one tag on a production line.

The VU-320 is built to withstand tough manufacturing environments with its IP67 rating. Four highly visible LEDs simplify the trouble shooting process, eliminating the need to access a webserver or PLC to determine if a tag is being read or if the antenna is sending a signal. Because the VU-320 is a part of the BIS V portfolio, it can communicate with Profibus, Profinet, Ethernet/IP, CC-Link, Ethercat and TCP/IP. A full line of mounting accessories and connection cables is available, as well.

The UHF Ultrahigh Frequency can read up to 50 tags at once.

DW

Balluff Inc. | www.balluff.com

DESIGN WORLD

DFI 5-18_Vs4.LL.indd 21

May 2018

21

5/1/18 11:28 AM

Design for Industry Packaging

Easy to lubricate bearings

L

Lubrication is a key factor in keeping packaging equipment operating. These Lubricating Stainless Steel and Self-Aligning Linear Ball Bearings pillow blocks and flange blocks feature a lubrication fitting and an alignment set screw. The self aligning linear bearings are modified by having an alignment flat ground on the bearings’ outer shell and drilling a hole through the outer shell. Lubricants can then be pumped directly inside of linear ball bearing races without having to remove the bearing from the shaft. The Pillow and Flange Blocks also have been designed to accommodate encapsulated ETX Scraper Seals that prevents contaminants from getting inside the bearing and retains the lubricant in the bearing.

These “New Design” pillow blocks are available in closed single and double bearing models for inch sized shafts from 0.5 in. up to 2.00 in. and the flange blocks are available in single and double bearing models for inch sized shafts from 0.5 in. to 1.25 in.

These pillow blocks are available in untreated aluminum or with a FDA/ USDA/3A-Dairy compliant corrosion resistant Electroless Nickel coating. When used with a FDA/USDA/3A-Dairy compliant lubricant, the pillow block and flange block bearing combinations suit: food processing, handling, and packing, bottling, pharmaceutical production and packaging, medical testing or patient handling, and other applications where there are corrosive or contaminating fluids (such as from fruit juices, biologics, and so on), or when cleaning with steam and/or caustic chemicals is required. DW LM76 | www.lm76.com

22

May 2018 www.designworldonline.com

DFI 5-18_Vs4.LL.indd 22

DESIGN WORLD

5/1/18 11:29 AM

THE FUTURE OF STEM IS AT SNHU

At SNHU, we’re building the next generation of designers, engineers, mathematicians, and leaders. With a combination of expert faculty, high-tech labs and simulators, exciting internship opportunities, and a dedication to career development that begins on day one, our programs put students on the path to future success.

Aeronautical Engineering | Air Traffic Management | Aviation Management | Computer Science | Construction Management Electrical and Computer Engineering | Game Art and Development | Game Programming and Development | Mechanical Engineering

We take pride in providing our students with the tools and experience they need to launch successful careers. It’s all part of our ongoing commitment to seeing our students achieve their education and career goals. Come see for yourself! Visit the SNHU campus today.

snhu.edu | admission@snhu.edu | 603-645-9611

Southern New Hampshire Univ 2-18.indd 23

5/1/18 9:48 AM

Design for Industry Packaging

Clutch/brakes deliver precise positioning with minimal maintenance

A

Applications with frequent start/stop cycles, such as indexing conveyors, rotary tables, batch feeders, rotary coal samplers, cutoff machines, often need motion control devices that allow high cycle rates to increase production. Posidyne clutch brakes feature oil shear technology for rapid and precise stopping, starting, speed change and positioning, without adjustment or maintenance. They offer cycle rates up to 300 cycles per minute. In addition, these brakes have a long service, often 5 to 10 times longer.

Designed with low inertia cycling components makes these clutch brakes efficient, requiring less motor horsepower to accelerate the load, and less torque to stop the load. Their

DFI 5-18_Vs4.LL.indd 24

5/7/18 10:07 AM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

totally enclosed design is impervious to dust, chips, chemicals, coolants, caustic wash down, weather. Posidyne clutch/brakes feature a multiple disc design that produces high torque from a small package. Re-circulating the fluid dissipates the heat of engagement, a common cause of downtime in many clutch/brake assemblies.

A simple actuation system allows torque in the clutch and brake to be precisely controlled. Adjustment for rapid or soft starts and stops is easy. Manifold mounted control valves reduce response times by eliminating hoses and fittings, and are recommended for high cycle applications.

By reducing the high starting inrush currents and the associated power factor imbalance in the motor these clutch/brakes can also reduce energy costs. The clutch brake can be actuated by air or hydraulic pressure for use in a plant or outside remote applications. The hydraulic actuation package includes a hydraulic pump, solenoid valve, regulators, and a filter. A heat exchanger can be added for additional cooling.

These units are explosion proof with the addition of an explosion proof actuation valve, or locating the valve in an explosion proof cabinet.

Multiple sizes are available to suit particular applications from ½ to 350 HP (99 lb-in. to 79,000 lb-in.) with cooling options, control logic and mounting arrangements to simplify and speed installation. DW

BEARLOK

SHOELOK

BEARLOK Shrink Disc

BEARHUG

CLAMPNUT

TANGENTLOK

PRECISION NUTS & WASHERS

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

ADAPTER SLEEVE ASSEMBLIES

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

Force Control Industries www.forcecontrol.com

NUTS & WASHERS

HARDENED TONGUE WASHERS

SPLIT COLLAR

RETHREADING DIES

ADJUSTABLE SPANNER WRENCH

BEARING ASSEMBLY SOCKET

W

HI

TT

WHAT DO YOU THINK?

ET

-H

IG

GI

NS US

A

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

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

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

or a good distributor.

DESIGN WORLD

DFI 5-18_Vs4.LL.indd 25

 

May 2018

25

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

5/1/18 11:30 AM

Design for Industry Material Handling

Augmented reality

can reduce needs for skilled maintenance

I

It can be tough to find qualified and skilled personal for maintenance needs. But TechSight, a real-time augmented reality system, can help that situation. This system enhances the capability of existing maintenance personnel. It can guide inexperienced on-site technicians through troubleshooting processes and reveal simple fixes like incorrect cabling or switch pressure settings. Developed by Honeywell Intelligrated, TechSight lets operators tap into expertise, while eliminating travel costs for emergency support.

TechSight can reduce repair time and minimize operational disruption in the event of an unplanned outage. The system leverages smart glasses and a videoconferencing platform to connect on-site technicians with remote Honeywell Intelligrated technical support experts for live service

instruction through two-way audio and visual communication.

Available to Honeywell Intelligrated Lifecycle Support Services customers, TechSight allows onsite technicians to share their vision, gestures and voice in real time. Connected, smart glasses enable technicians to receive visual aids like schematics and marked-up images to supplement verbal input, while leaving both hands free for safer, more efficient work. This expedites troubleshooting and resolution, while equipping on-site staff with the expert support to handle complex, non-routine issues that require specialized service prescriptions DW.

Honeywell | www.honeywell.com

May 2018 www.designworldonline.com 26

DFI 5-18_Vs4.LL.indd 26

DESIGN WORLD

5/1/18 11:30 AM

Material Handling

For motion control innovation, Solution City never sleeps.

For vision guided vehicles, software

drives efficiency Seegrid Supervisor is fleet

management software that helps increase overall material movement efficiency from self-driving vehicles in material handling. It helps users shift to automated, data-driven environments. The latest version adds three new features–Queues, Barcode Scanner support, and Caution Tape.

Seegrid Supervisor directs selfdriving vision guided vehicles (VGVs), tracking vehicles in real time and facilitating a connected, smart factory environment.

The Queues feature reduces wasted travel time of the VGV to help maximize productivity. When a VGV completes a job, Supervisor identifies the next available job and automatically dispatches the vehicle to execute its next task, reducing the amount of travel without payloads, known as deadheading.

In one example, VGVs no longer need to return to a taxi stand across the organization’s 500,000+ sq ft facility before being dispatched to the next assignment. The VGVs are assigned new tasks by Supervisor as soon as they become available, wherever they are in the building, which reduces wait time, mileage, and wasted energy.

Supervisor integrates with barcode scanners, allowing customers to direct the movement of materials transported by VGVs throughout their facilities.

Team members simply scan each payload and Supervisor understands the load type, automatically dispatching the vehicle to its destination. The Barcode Scanner integration streamlines the delivering process, eliminating the need for a team member to decide where the goods and vehicle should be sent.

Developed with an innovative automotive industry customer, Supervisor’s Barcode Scanner integration has increased efficiency in this customer’s parts-to-line application. Previously, team members in the warehouse loading station spent time telling each forklift driver where to stop and unload parts.

Now, they simply scan each payload and Supervisor tells the VGV where to drop off the materials among the 100+ work cells. This shaves minutes off each delivery, making a significant impact on operations.

When customers need to block off or restrict certain areas from VGV travel, Supervisor’s Caution Tape feature prevents VGVs from traveling down certain segments of the route network. When a VGV begins its route, Supervisor tells it to ignore any blocked segments. The VGVs intelligently work around the blocked area and continue on their routes. DW

Whatever keeps you up at night, we’ve got a solution—the largest selection of motors, pumps and air-moving devices available.

Plus, one-of-a-kind solutions ready to be custom-engineered for your precision industrial, commercial, combustion or transportation application.

If you can dream it, you’ll find it at Solution City. ametekdfs.com

Seegrid | www.seegrid.com 100 East Erie Street • Kent, OH 44240

DESIGN WORLD

DFI 5-18_Vs4.LL.indd 27

www.designworldonline.com

May 2018

27

© 2017 by AMETEK Inc. All rights reserved.

5/1/18 11:31 AM

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

How contextual HMI is replacing stationary HMI

Ed Nugent • COO • PcVue Inc.

S

Stationary Human Machine Interface (HMI) displays are being replaced by contextual HMI. Whether a single line display or a dedicated touch screen, stationary HMI are failing to meet mobile operators’ expectations. Today’s workers want information at their fingertips and they increasingly look to their mobile device to provide it.

The same is true for maintenance workers. Time is wasted when a maintenance engineer has to repeatedly move back and forth between a stationary HMI and the physical location where maintenance is performed. In many cases, the location where the work is to be done is actually on the opposite side of the equipment from the stationary operator HMI. This is the case during commissioning, troubleshooting repairs and during equipment changeover and startup.

Contextual HMI can provide a simple and elegant solution. On a mobile device it eliminates navigating a screen designed for a workstation on a much smaller screen, as is the case when using a web browser to display a workstation HMI.

May 2018 www.designworldonline.com 28

DFI 5-18_Vs4.LL.indd 28

DESIGN WORLD

5/1/18 11:31 AM

FREE BROCHURE AND CATALOG!

Contextual, in the case of HMI, means in the context of the worker’s location and work to be performed. If the contextual mobility server is aware of the location of the mobile device and has validated the user, it is able to push specific HMI components to the worker’s mobile device.

For security and safety reasons, the HMI must be automatically removed from the device when the worker moves away from physical proximity to the equipment being worked on.

To realize the benefit of contextual HMI, it is a matter of deploying a straightforward infrastructure. A contextual mobility infrastructure is centered on the smart mobile device. It takes advantage of standard indoor and outdoor geo-location technologies found on nearly all modern mobile devices to provide a dynamic and contextual HMI based on the worker’s proximity to a predefined geographical zone. A zone may be an entire facility, a room, or it may also be in the direct proximity of a specific piece of equipment.

Geo-tags such as Bluetooth Low Energy Beacons (iBeacons), Near Field Communications (NFC), and QR Codes are placed strategically in these geographic zones of control, known as geozones. A secure proximity services mobile app on the device receives the ID of the geo-tags in range of the device. If more than one is in range (i.e. two Bluetooth beacons are detected), the one with the stronger signal is used. This concept, known as geo-fencing, allows actions based on zones of control. The mobile app communicates with the contextual mobility server using a standard Internet Protocol (IP) connection such as Wi-Fi or cellular network. The contextual mobility server is responsible for evaluating and responding with the necessary information and controls pushed to the user’s mobile device automatically. The required information and control is evaluated based on the current geo-zone and as determined by the mobile worker’s login profile.

There can only be one supervisor of equipment so neither the mobile app nor the contextual mobility server communicates directly to the equipment. The supervisory system retains responsibility for communication with equipment or other assets that it supervises. The contextual mobility server must reflect the real-time status of the equipment variables or tags by using OPC or other real-time methods to synchronize with the supervisory equipment.

The cornerstone of the infrastructure is the contextual mobility server and its Contextual Logic Engine (CLE). The contextual mobility server maintains a database that associates geo-zones

DESIGN WORLD

DFI 5-18_Vs4.LL.indd 29

May 2018

29

YOUR STAMPING AND WASHER SPECIALIST

bokers.com

Call (888)-WASHERS 612-729-9365 sales@bokers.com

3D-PRINTED PROTOTYPES AVAILABLE BO-3055 2018 Combo Ad_IO-2354-DW-2.indd 1

Motor Feedback Systems for linear and rotative drives

10/9/17 9:18 AM

Absolute and incremental magnetic measurement ■ ■ ■ ■ ■

Contactless and completely wear-free and maintenance-free Extremely precise, even if the scale is covered with dirt Flexible dimensioning of measurement lengths and diameters Easy handling, high accuracy of position for highly dynamic processes Safety SIL2 certified (optional)

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

5/1/18 11:35 AM

Design for Industry

IS

material handling

O

0 90

1

ISO 13485

Tube bending

perfection in stainless Eagle has the expertise and the specialized machinery for bending tubing exactly to spec.

Call us for a quote !

Eagle Stainless

Tube & Fabrication, Inc. Franklin, Massachusetts

Phone (800) 528-8650

www.eagletube.com

and user profiles with information, equipment controls, actions and events.

The CLE determines the appropriate actions and triggers the distribution of information and control elements to the mobile worker. This includes additional resources (drawings, schematics, and so on) needed by the worker in the performance of their job.

Both operations and maintenance personnel now have the relevant HMI they need for situation awareness and intelligent control in their area of work responsibility. It is literally at their fingertips as it is pushed to their device automatically when the app and contextual mobility server detect that the device has entered a geo-zone. This eliminates requiring navigation designed for a computer monitor, when using the smaller mobile device screen. It provides improved performance and operational efficiency while also increasing safety.

The connected supervisory system is enhanced when augmented with contextual HMI capability. Knowing the location and routes of mobile workers provides the ability for control room assistance with efficiency, safety, and security issues. For example, the control room is now able to see where workers are or have been in order to recognize unauthorized access to restricted areas.

They can dispatch the nearest certified technician in the case of a maintenance emergency and assist with safe passage routes in the need for evacuation A private and secure internal messaging system is also an essential element of a contextual mobility infrastructure. It allows mobile workers to exchange information with each other and with the control room. This includes text, photos, videos and audio recordings.

Integrated messaging is preferable to alternatives, such as SMS (short message service), due to the fact the messages become a permanent part of the Operations & Maintenance (O&M) record.

A messaging system is particularly useful as an electronic notebook for shift handoff since messages can be directed to a group as well as individuals.

Deployment of a contextual mobility infrastructure includes ensuring that there is access to the network for the

30

May 2018

DFI 5-18_Vs4.LL.indd 30

mobile device in all work locations.

Design of the geo-zones and placement of the geo-tags is the next step. Finally, the configuration of a contextual mobility server is a matter of defining the content to be sent in each geo-zone and user profile.

While there is a cost associated with the deployment of a contextual mobility infrastructure, it is more than offset by the elimination of many, if not all, of the stationary HMIs and the increased efficiency of the O&M team. When you factor in the impact of improved safety and security, it is obvious why the trend is away from stationary HMI and toward contextual HMI. DW

PcVue Inc. | www.pcvuesolutions.com

WHAT DO YOU THINK?

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

www.designworldonline.com

DESIGN WORLD

5/1/18 11:36 AM

Safety

Safety based

communications protocol IS

Traditionally, safety devices are wired to separate safety inputs, which requires significantly more wiring and introduces more potential fault points. When wired in this series connection, customers lose the ability to distinguish information from each device.

The Allen-Bradley Guardmaster GuardLink safety system is a safety-based communications protocol that helps operators reduce and improve machine diagnostics and downtime while increasing productivity.

With GuardLink, safety devices are easily connected in series while providing access to individual device diagnostics. This system provides safety, diagnostics, remote reset and lock command over a single four-conductor cable with up to 32 devices per link. In addition, customers can reduce installation cost with up to 38% reduction in wiring.

The GuardLink technology integrates with Allen-Bradley Guardmaster safety relays and components, allowing users to access status information throughout their entire safety system. The connection of safety devices with smart taps enabled by GuardLink technology and standard cabling to a Guardmaster safety relay allows greater visibility into the system, down to individual guard doors and E-stops.

The GuardLink safety system integrates with the Logix platform with predetermined tag names in the Rockwell Software Studio 5000 application. Its simplified design and reduction in wires allows for simple plug-and-play installation. DWÂ

O

0 90

1

ISO 13485

Laser machining

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

Let us help !

Rockwell Automation www.rockwellautomation.com

Eagle Stainless

Tube & Fabrication, Inc. Franklin, Massachusetts

Phone (800) 528-8650

www.eagletube.com

DESIGN WORLD

DFI 5-18_Vs4.LL.indd 31

www.designworldonline.com 

May 2018

31

5/1/18 11:37 AM

Design Notes

Vesconite Hilube and Vesconite polymer rods.

True grit: polymer bushings help harsh

agricultural applications Edited by Mike Santora • Associate Editor

When an Australian agricultural equipment manufacturer wanted to upgrade its oil-impregnated nylon bushings, it chose to put Vesconite Hilube polymer bushings on the hydraulic tynes it manufactures for seeding machines. Vesconite Bearings, a South African self-lubricated polymer-bushing manufacturer, provides machining services and has the largest machine shop in the Free State, with 60 computer numerically controlled lathes, large conventional lathes, and machining centers.

32

May 2018 www.designworldonline.com

Design Notes 5-18_Vs4.indd 32

DESIGN WORLD

5/7/18 10:26 AM

TopBallUltDznWrld.pdf

1

1/4/18

11:46 AM

TOPBALL Ultimate ®

New, Unrivaled Self-Aligning Linear Ball Bushing

4 Times The Load 64 Times The Life* • Optimized load plates and outer cylinder plus more ball circuits.

C

• Improves performance of: Machinery and equipment for automation, optics and measuring.

* Compared to conventional ball bushing types

M

Y

CM

MY

CY

CMY

K

TOPBALL® Ultimate´s Advantages • Our raceways are ground not stamped - affording precision tolerances.

• Floating load plate adjusts clearance.

• Greater ball contact in ground circular arch triples load capacity.

• Each load plate is

• Light weight components for energy reduction.

• Floating raceway wiper seal allows unrestricted self-alignment.

• Load plate ends are thinner making center a fulcrum for self-alignment.

precision-ground and checked for consistency - unlike competitions’ stamped plates.

• Unibody construction for quieter operation.

Headquarters Toll Free: (800) 521-2045

Western Regional Offices Toll Free: (888) 562-4175

Eastern Regional Offices Toll Free: (800) 981-8190

www.nbcorporation.com

NB Corp 5-18.indd 33

5/1/18 10:19 AM

Design Notes Polymer bushings are often chosen by farmers and agricultural equipment manufacturers for being a selflubricating, wear resistant polymer for agricultural applications characterized by grit, mud, and water. With seeder tynes being the teeth that cut through the soil during seeding, their exposure to harsh wear conditions is significant. OptiAg Systems director Peter Hills explains that there are up to 80 or more hydraulic tynes on a seeding machine. These allow for seeds to be planted at the correct depth so that seeds have better access to moisture and nutrients.

Speaking about the introduction of Vesconite Hilube bushings to his tynes, Hills said, “As grain growers ourselves, we are looking for the best products. We want to provide our clients with the best possible product as well.”

OptiAg will be testing the lifespan of its new bushing selection as compared to the oil-impregnated nylon bushings and expects that, although there are higher upfront costs associated with the new bushings, the longer life, and the lower maintenance requirements, will show the bushings to be a superior component over time.

Vesconite Bearings’ factory in Virginia produces rods, hollow bar and wear plates for the agriculture and other industries, and also machines bushings and wear components to specification for the industry. DW

Vesconite Bearings www.vesconite.com

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

Custom Automation Equipment Our engineers utilize time tested platforms and new technologies to provide you the most cost-effective solution

www.arthurgrussell.com

34

May 2018 www.designworldonline.com

Design Notes 5-18_Vs3.indd 34

DESIGN WORLD

5/1/18 11:47 AM

™

dESIgN

SOLuTIONS

… for smt threaded standoffs

• Designed for Surface Mount use on PC Boards • Minimize PCB damage • Reduced scrap/handling • Faster board assembly • Manufactured with tin plate • Available in 2-56, 4-40 and 6-32 threads • Lengths from 1/16” up to 3/8” • Ideal for automated installations • Supplied on tape and reel with Kapton tape for easy pick up • Compatible with all reflow operations and vacuum and mechanical pick-&-place assembly systems

It’s what’s on the InsIde that counts ® E L E C T R O N I C S

www.keyelco.com

•

(516) 328-7500

C O R P.

•

(800) 221-5510

REquEST CaTaLOg M65

DW THiNKElectronics Abst+SMTStdoffs_5-18.indd 1 Keystone 5-18.indd 35

4/3/18 5/1/18 10:52 9:49 AM AM

Design Notes

Controlling motion in

a network-controlled band pass filter Shown here is the Network Managed Tunable RF Filter for military applications designed and manufactured by Telonic Berkeley Inc.

Terry Persun • AllMotion

Telonic Berkeley Inc. has been manufacturing bandpass filters for many years and is an ISO 9001:2008 Certified manufacturer. When they decided to design and manufacture their Network Managed Tunable RF Filter for military use, they needed a motion system that would offer the highest accuracy and reliability.

Bandpass filters are critical components in transmitters and receivers and are used to maintain a strong signal in a selected range of frequencies. For example, they are used in wireless transmitters and receivers to limit the bandwidth of the output signal of a transmitter to the band allocated for that transmission. The filter, then, prevents the transmitter from interfering with other stations. In a receiver, the bandpass filter

36

May 2018 www.designworldonline.com

Design Notes 5-18_Vs3.indd 36

DESIGN WORLD

5/1/18 11:48 AM

INNOVATE YOUR

SELF DRIVING HARDWARE

WITH MPD SOLUTIONS

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

M e

m o r y p

Memory Protection Device 5-18.indd 37

r o t e c t

i o n

d e v

i c e s . c o m

5/2/18 11:12 AM

Design Notes allows a chosen range of frequencies to be decoded while preventing unwanted frequencies from getting through. Therefore, in both transmit and receive modes of operation, a bandpass filter, providing the optimum bandwidth for the mode and speed of communication being used, maximizes the number of signals that can be transferred in a system while minimizing the interference among signals.

In operation, a bandpass filter optimizes the signal-to-noise ratio of the receiver.

Telonic Berkeley produces a line of tunable bandpass and bandstop filters which have set industry standards for performance, quality, and versatility. They offer the broadest tuning range available in the world, covering HF, VHF, UHF, L-Band, and S-Band. So, when it was time to design their new device, they came up with the concept, design, and development of the product.

The EZHR17EN was able to provide the precision needed for Telonic Berkeley’s latest product in their line of bandpass filters.

VIONiC™ digital encoder series Designed for the designer

The VIONiC digital incremental encoder series has been specifically designed with the machine builder in mind. Its enhanced ease of use, superior metrology capability and multiple configuration options all ensure optimal machine performance. VIONiC really has been designed for the designer.

For more information visit www.renishaw.com/vionic

Renishaw Inc. West Dundee, IL

Renishaw VIONIC advert 1216_USA.indd 1 Design Notes 5-18_Vs4.indd 38

www.renishaw.com

20/12/2016 16:01:46 5/2/18 11:27 AM

AN INDUSTRY FIRST FOR INDUSTRIAL ETHERNET. fido5000 makes it easy to incorporate a single Industrial Ethernet interface that supports multiple protocols for any Intelligent Factory application. Ready for tomorrow, fido5000 provides a clear path to TSN – to future-proof applications as protocols evolve in smart, connected Industry 4.0 environments.

#ADIahead

Analog Devices 3-18.indd 39 1 17ADI405_PRINT_DW.indd

fido5000 CHANGES THE GAME FOR INDUSTRIAL ETHERNET DESIGN.

FOR VIDEOS, TECHNICAL ARTICLES AND MORE INFORMATION ON THE FIDO REM SWITCH: analog.com/industrial-ethernet 5/1/18 2/2/18 10:17 11:20 AM AM

Design Notes

pharmacy endoscopic surgical devices non-invasive surgical devices orthopedic implants syringes devices IV bags lab automation dental

Quality components for long life In the medical industry, the ability to produce product faster with less down time is critical. PHD actuators offer the quality your manufacturing demands with rugged design, high precision, approved materials and fast delivery.

• Pneumatic & Electric Actuators • High-Precision Compact Designs • Unique Medical Solutions • FDA-Approved Materials • Fast Delivery

To learn more, visit phdinc.com/medad or call 1-800-624-8511 P.O. Box 9070 • Fort Wayne, IN 46899 USA

They decided for their network managed tunable RF filter to be controlled

by SNMP V1, V2C, and V3. SNMP (Simple Network Management Protocol) is an application layer protocol that exchanges management information between network devices. It is also the most widely accepted protocol to manage and monitor network elements. To maintain the quality and accuracies the company was accustomed to, they turned to a controller that was designed and manufactured

by AllMotion (Union City, CA). Telonic Berkeley had been using stepper motors for its other products and didn’t want to have to go with a servo motor to maintain precision. With the controller board, the company was able to use stepper motors like servo motors.

The EZHR17EN stepper motor controller boards are available to operate from an input voltage from 10- to 40-volts and draw only 2 amps of power. The controllers are compact at only 1.6 x 1.6-in. in size. They operate from a 1/64th step and are fully intelligent stepper motor controller+drivers designed to be bolted onto the back of the stepper motor they control. These controllers are suitable for applications like the network managed tunable RF filter. For ease of use, the EZHR17EN controllers use a single fourwire bus, containing two power wires and two communication wires (and can link up to 16 stepper motor controllers in a daisy chain if the application requires).

Commands are made via any serial terminal program or from the EZStepper Windows application. All controllers in the EZStepper line are capable of stand-alone operation with no connection to a PC. The device can be set to execute a preset string of commands upon power up. The commands include nested loops and execution halt pending a switch closure, which is useful in stand-alone applications of all types.

According to the Telonic Berkeley engineering team, the AllMotion controller board was able to provide the degree of movement from the stepper motor that was critical for the application. The tolerance requirement for the networkmanaged tunable RF filter was for a frequency range of ±1 MHz. The torque needed for the application was 33 in. lbs, while the accuracy is better than 1%.

40

Design Notes 5-18_Vs3.indd 40

May 2018

DESIGN WORLD

5/1/18 11:52 AM

HIGH PERFORMANCE. STANDARD. With products including linear guides, ball screws, actuators, robot modules and direct drive motors, NSK employs cutting-edge friction control technology and precision accuracy to ensure optimal movement and positioning.

For high loads and high speeds to special environment and compact design requirements, NSK consistently delivers reliable, smooth, and precise motion and control.

PRECISION PRODUCTS FOR LINEAR MOTION AND CONTROL

www.nskamericas.com

NSK Presicion 5-18.indd 41

5/1/18 10:18 AM

Design Notes

smallmachine

BIG RESULTS Real CNC

Through the use of the latest technologies including the EZHR stepper motor controller, Telonic Berkeley’s Network Controlled Band Pass Filter for Military Applications can be managed in real time from a central location or remotely using a cell phone app.

Users also obtain features such as remote monitoring and diagnostics and optional adjustable endpoint devices to match changing deployment needs.

The company’s tunable bandpass and bandstop filters are available in special tuning ranges and bandwidths, with special connectors. DW

AllMotion www.allmotion.com

for shops of all sizes

Tormach machine tools are fully capable of cutting aluminum, plastics, and steel, giving you the ability to bring all your prototyping and light manufacturing in-house.

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

Tormach Personal CNC mills are designed to be value driven to enable your ideas.

mill CNC g at in start

$ 4950

x

Functional prototypes without the wait

x

Iterate new ideas fast

x

Cut real metal

x

Plug in anywhere with 120 Vac

x

Compact footprint fits any space

TORMACH.COM 42

Design Notes 5-18_Vs3.indd 42

May 2017

DESIGN WORLD

5/1/18 11:53 AM

We believe in partnerships that produce high quality, cost-effective products that help you grow your business!

Why work with Maryland Precision Spring?

• • • • • •

Strategic partnership • Leverage spend with one supplier • Joint end-user calls Quality / Made in the USA DoD Certifications • DD 2345 and NN 801 Extensive inventory Same day and next day service Standard catalog pricing

• • •

Volume discounts/ rebates Quick quote turns Product support • Training • Engineering Support • Consignment • Blanket PO Management • Special Packaging

mw-ind.com Maryland Precision Spring • 8900 Kelso Drive • Baltimore, MD 21221 • P (410) 391-7400 • F (410) 687-9223 • mps_inquiries@mw-ind.com

Maryland Precision Spring_FINAL.indd 43

5/3/18 11:03 AM

Design Notes Edited by: Mike Santora • Associate Editor

Bringing a needed lift to the

industrial gantry market

As industrial activity continues to grow and diversify, so does demand for more efficient systems to enhance manufacturing processes. For example, to keep up with trends and steep competition, automakers must manage increasingly complex machining and assembly processes during powertrain production.

Gantry systems are among the more significant solutions for industrial manufacturers given the gantry’s pivotal role in material handling, assembly, sorting, inspection, packaging, palletizing and more.

Long recognized for meeting new requirements and specs in the industrial sector, one global gantry provider grew its portfolio with flexible, programmable logic controller (PLC)-based material handling systems in response to present demands.

The new systems rival existing ones, The SIMATIC S7-1516F CPU used expand capabilities, and cut the in the gantry is part of the advanced cost of ownership.

Harry Major Machine is a S7-1500 range of failsafe CPUs, offering global provider of industrial a new standard in PLC controllers. The production solutions and services controllers have seamless integration of for manufacturers in diverse SIMATIC controllers in the common, toindustries. They specialize in the tally integrated automation (TIA) portal design and manufacture of custom engineering framework allows for rapid automated parts handling systems, software development and deployment. industrial parts washers, assembly machines, and special machines for use in multiple industries. Harry Major Machine provides a range of robotic gantry systems that use the productivity of computer numerical control (CNC)-based overhead gantry robots in an array of production environments. Many gantry systems are CNC-based in performing motion control functions. While these systems are known for precision and allow all motion functions of a gantry to be manipulated, they are also more expensive to purchase, require higher levels of support from an

44

engineering and maintenance standpoint, and parts are costly as well.

With customer requirements evolving, Harry Major Machine was certain that a PLC-based gantry system would give manufacturers a viable alternative – as long as the whole package was desirable and cost-effective for its customers. Harry Major Machine’s intent for the new gantry was to provide a linear, XYZ-type gantry that is PLC-based instead of CNC-based.

They also wanted the gantry to perform industrial material handling with much greater flexibility at a lower cost.

May 2018 www.designworldonline.com

Design Notes 5-18_Vs4.indd 44

As part of its initiative, Harry Major Machine wanted to be able to demonstrate real and applicable examples to customers through product demonstrations and at industry trade shows, because nothing compares to seeing a new solution in action.

“We were expanding and improving our offerings and found that new technologies from Siemens would allow us to exceed our goal of providing a cost-effective and valuable solution for our customers,” said Frank Loria, vice president of Harry Major Machine. “While

DESIGN WORLD

5/7/18 10:49 AM

developing the new unit on our floor, Siemens came to us with advanced and relevant technologies, including total integrated diagnostics and safety. We chose these and other new Siemens technologies, which helped us deliver dramatic improvements.”

The Siemens engineering team went to Harry Major Machine to review the company’s mechanical designs, and based on their findings, developed a bill of materials (BOM) with recommended Siemens components. Siemens worked with Harry Major Machine to successfully integrate the new Siemens product lines.

Harry Major Machine introduced a new series of linear, PLC-based gantry systems for industrial material handling. The systems accommodate a more extensive range of applications, requirements, and specifications than similar XYZ gantry systems offered by other providers. There are five models in the Harry Major Machine series, with the model numbers representing each system’s lifting capacity in kilograms. They include the MGL-30, MGL-50, MGL-150, MGL-250, and MGL-500.

All plants have unique requirements for system performance and application complexity, and Harry Major Machine’s customers are no exception. The SIMATIC S7-1516F CPU used in the gantry is part of the advanced S7-1500 range of failsafe CPUs, offering a new standard in PLC controllers. The controllers have seamless integration of SIMATIC controllers in the common, totally integrated automation (TIA) portal engineering framework and allows for rapid software development and deployment, consistent data storage, the smart library concept and a uniform operating philosophy to simplify use of universal functions.

In the past, servo drives with PLC were too slow for industrial applications. With Siemens developments and technologies, that is no longer the case. The servo drive components in the gantry systems, combined with the advanced PLC, automation products, and control products, are more advanced, flexible and userfriendly than CNC-controlled motion systems, and allowed Harry Major Machine to exceed its goals.

On the scalability front, the company also wanted the ability for their new gantry systems to be cabled or cable-less. Using the same hardware design, the SIMATIC S7-1516F Controller will accommodate both options with integrated safety. Cable-less options can be achieved using optical, RCoax, SCALANCE Wifi or power bus communications, and by adding a module on each end of the machine. Nothing else has to change.

“Siemens assisted our engineering team from the design concept and prototype to design approval, and all the way through commissioning of the gantry system,” Loria said. “One major hurdle was setting the parameters of the servo drives.

During commissioning, the Siemens technical support team was able to resolve those issues, and they were helpful with many smaller issues as well.” DW

Siemens | siemens.com

Rod Ends and Spherical Bearings designed and manufactured to Aurora’s exacting standards for quality and durability.

Your Partner moving forward!

Registered and Certified to ISO_9001 and AS9100.

From economy commercial to aerospace approved, we’ve got it all!

R

Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538

complete library of CAD drawings and 3D models available at:

w w w. a u r o r a b e a r i n g . c o m

DESIGN WORLD

Design Notes 5-18_Vs4.indd 45

May 2018

45

5/7/18 10:47 AM

pla tfo rm

Provi des m

ch

dev.

IIoT

ea n d do c

g an

g

ing & eer n i g en

m en t nage

PLM =

c han

Testin g aut o m at io

a em

ion rat

ent

+

bo la

m age an

ALM

xCA Dc ol

ement nag

t

r fo

ma

nd

agement

com p l i anc e, s y st e

QA a

an Mm O B

t en um

d

e ev

nt me p o l

tm es

Sof tw ar e

Internet of Things

n,

ma de

agement conf i g man u rat nd i on

an d

Lionel Grealou Vice President PLM Services • Tata Technologies

T

The Industrial Internet of Things (IIoT) is the use of Internet of Things

(IoT) technologies in manufacturing. It incorporates machine learning and big data technology, harnessing ‘real-time’ sensor data, machine-to-machine (M2M) communication and automation technologies that have existed in industrial settings for years. By accessing a range of data repositories across the organization, IIoT can enable companies to pick up on inefficiencies and problems sooner, saving time and money and supporting business intelligence efforts, and create competitive advantage with enhanced products and services.

In manufacturing specifically, IIoT holds great potential for quality control, sustainable and green practices, supply chain traceability and efficiency.

New product features and the rise of embedded electronics, hardware and software, sensor and electrical technologies put a great deal of importance onto how ECAD and telematics data is managed – especially in collaboration with the more traditional mechanical and enterprise data which resides in Product Lifecycle

46

May 2018 www.designworldonline.com

Internet of Things_5-18_Vs.4.LL.indd 46

Management (PLM). This translates by a number of new technical and business requirements to enable manufacturers to create more competitive products, faster and with better quality and features: • The integration of software or Application Lifecycle Management (ALM) with the enterprise Bill of Materials (BoM), ECAD and MCAD data lifecycle is critical for full product configuration, from design to service and maintenance.

• The rising number of mobile and wireless features, such as embedded software upgrades, implies the need for greater end-to-end data traceability, security, regulation compliance and safety; for example, to support ‘real-time’ DESIGN WORLD

5/1/18 12:13 PM

external data feeds to products that are already in-use by end customers.

ALM versus PLM The software world is more complex than the mechanical world; it requires a more data integration, speed of processing, data volumes, cross-functional technical collaboration, as well as service to manufacturing and design cross-loop integration.

By design, PLM simply cannot manage such large amounts of data changes that propagate up to and until the end of service of products. PLM is an ecosystem that focuses on engineering changes pre-production and manufacturing changes during production or assembly.

It assumes less and less product design changes as products mature, while ALM supports continuous product changes even after it is released or in-service (after-sales).

ALM provides an integrated environment for software development, ensuring complete traceability across the entire application lifecycle, including QA and test management, testing automation, demand management, configuration and change management, DevOps, and linking tests to requirements.

ALM covers the entire software development lifecycle (SDLC) and much more across governance, development and operations.

Traditionally, PLM assumes that product attributes are defined and managed across its lifecycle, up to a maturity level that allows for its design to be frozen – i.e. under change management from the time that designers put their “pencil down.”

PLM provides a platform for BOM management, xCAD collaboration, change and document management, compliance, system engineering and development.

Broadly speaking, software developers don’t put their “pencil down” at the same time that other engineers do (…).

This implies that the sheer amount of change that manufacturing organizations are facing is continuing to increase, perhaps not so in the mechanical

DESIGN WORLD

Internet of Things_5-18_Vs.4.LL.indd 47

space, but rapidly in the software space and associated disciplines (hardware integration, electronics, sensors, etc.).

ALM-PLM Integration: the “xLM ecosystem” Both ALM and PLM enable software development teams to effectively manage project requirements and provide a means to carry out security testing transparently and with complete traceability. Integrating them as part of an “xLM ecosystem” enables teams to collaborate effectively while managing complexity, product quality and flawless deployment, considering that: • Robust data security and compliance are important success factors when implementing IIoT solutions.

• Development and continuous alignment of these requirements is also a critical success factor.

Traditionally, ALM and PLM used to be isolated disciplines, operating within the boundaries of their own “silos.”

Innovative products such as connected or autonomous products rely on IIoT and IoT technologies and create a need to break these boundaries as part of an “xLM ecosystem,” fundamentally reshaping the lifecycle management software industry. Integrating ALM and PLM provides opportunities for architecture and process alignment, software and hardware requirement integration, covering also electrical, mechanical, manufacturing and service BOM alignment, consistent defect and change management, as well as test strategy and result integration, traceability for compliance and service operations. DW

Adjustable handles, knobs, spring plungers, hand wheels, and standard machine elements.

Tata Technologies | www.tatatechnologies.com

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

www.designworldonline.com

May 2018

47

www.fixtureworks.net Fraser, Michigan 888.794.8687 5/7/18 4:33 PM

Internet of Things

Bidirectional serial/ Ethernet Modbus gateways

L

Line of STRIDE Modbus Gateways offers more connectivity choices for Modbus applications. Communication networks vary greatly from site to site and often change as technology advances. Converters and gateways provide connections between different protocols and standards that exist in the industrial automation field. STRIDE Modbus Gateways provide the bridge between Modbus RTU/ASCII (Serial) products and Modbus TCP (Ethernet) products.

STRIDE gateways convert bidirectionally between Modbus RTU or Modbus ASCII protocols and Modbus TCP. These compact gateways feature 1 or 2 10/100 Mbps Ethernet ports and 1, 2, or 4 industrial serial ports. The Ethernet ports each support up to 16 TCP devices, client or server. Serial ports each support up to 128 slave devices or 1 master device and provide

48

a high serial isolation voltage of 2kV. There is a DIP switch selectable termination resistor for the RS-485 mode.

STRIDE gateways feature metal housings, have a wide temperature range of -40 to +75 deg C and a Class 1 Div 2 Hazloc rating (UL61010). The three models of the STRIDE Modbus Gateway are priced from $185.00 and have a 5-year warranty. DW

AutomationDirect | www.automationdirect.com/modbus-gateways

May 2018 www.designworldonline.com

Internet of Things_5-18_Vs.4.LL.indd 48

DESIGN WORLD

5/7/18 10:55 AM

Simplify connecting traditional and emerging devices to cloud analytics The SmartServer IoT platform is an addition to the SmartServer family. This platform simplifies the process of connecting traditional and emerging industrial devices to cloud analytics and AI (Artificial Intelligence) applications.

It features modern web APIs (Application Programming Interfaces) and an IoT-friendly distributed intelligence architecture. The product supports popular IIoT (industrial IoT) protocols such as LonWorks, BACnet, Modbus and M-Bus along with IT-centric connectivity technologies such as Wi-Fi and Bluetooth. The IoT platform is up to ten times faster and has more than 50 times the memory of the previous generation platform (SmartServer 2). With its set of APIs, it enables developers to create solutions in days

DESIGN WORLD

Internet of Things_5-18_Vs.4.LL.indd 49

or weeks instead of months or years. SmartServer IoT will be available for sampling in Q2 2018 and ship in volume before the end of 2018.

The SmartServer IoT suits OEMs and system integrators in the IIoT space. Both will now be able to collect and analyze data from existing traditional control system installations running protocols such as LonWorks, BACnet or Modbus, as well as extend those installations with IT-centric solutions such as Wi-Fi. SmartServer IoT is open, programmable and extensible. DW

Echelon Corp. | www.echelon.com

www.designworldonline.com

May 2018

49

5/4/18 9:55 AM

Internet of Things News Multi-protocol network for real-time automation

S

Sercos International, provider of the Sercos automation bus, will show the Sercos TSN Demonstrator and an Industry 4.0 Demonstrator during Hanover Fair, in Hanover, Germany April 23-27, 2018.

The Sercos TSN Demonstrator shows the transmission of the Sercos III real-time protocol via IEEE 802.1 TSN (time-sensitive networks), illustrating the possibilities for providing a real-time and multi-protocol-capable network infrastructure based on TSN for automation technology. The demonstrator was developed at the Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) at the University of Stuttgart with the support of several industrial partners such as, Tenasys.

The demonstrator includes a TSN-based Sercos III SoftMaster with a Soft-CNC from Industrielle Steuerungstechnik (ISG), which communicates with Sercos III servo drives from Bosch Rexroth via TSN switches from Hirschmann Automation & Control. At the same time, video streams from a web cam are transmitted to a remote display over the TSN network infrastructure without hampering the characteristics and functionality of the Sercos real-time communication.

An Industry 4.0 Demonstrator highlights how process and device data are made available both locally via the real-time bus and remotely via OPC UA for a range of application scenarios in a uniform and cross-manufacturer manner. This makes data exchange between production machines and superior IT systems easier and also supports the requirements of Industry 4.0 regarding semantic interoperability.

The multi-protocol capability of Sercos makes various implementation options possible. One option is integration of the OPC UA server functionality into a machine control, where the control acts as a gateway in which the mapping of Sercos data and services is implemented. With Sercos III, it is also possible to integrate an OPC UA server directly into a Sercos drive, I/O station or sensor. In this case, the OPC protocol is routed directly to the relevant Sercos slave device. The gateway functionality of the control is thus reduced to the function of an Ethernet switch. Due to the Sercos transmission process (no tunneling!), the ability of an OPC client and an OPC UA server to communicate with each other is preserved even when Sercos real-time communication is not running.

A Sercos SoftMaster Demo scores points with an open “upward” and “downward” communication link. It is based on a Sercos III SoftMaster core, which was developed in cooperation with Bosch Rexroth and is available as open-source software.

With the Sercos III SoftMaster, a specific Sercos III FPGA or ASIC master component is not required. Instead, a standard

50

Ethernet controller is used and the Sercos III hardware functions are emulated in host-based driver software.

This implementation approach ensures adequate real-time behavior for a large number of applications.

The CPU load is significantly reduced using the SoftMaster in combination with the powerful Intel I210. Control manufacturers can use an industrial PC without special fieldbus hardware and without PCI slots to control a machine, saving cost and space and reducing development time. DW

Sercos International | www.sercos.com

May 2018 www.designworldonline.com

Internet of Things_5-18_Vs.4.LL.indd 50

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

DESIGN WORLD

5/1/18 12:14 PM

Opto 22 5-18.indd 51

5/1/18 10:20 AM

CAE Solutions

In IronCAD’s Catalog Browser, tabs are located at the bottom right of the screen, which allows for quick access to your most useful 3D models.

Can you find gold in IronCAD?

W

Phil Foley • Contributor

When reviewing new software, I’m always careful

not to trust my first impressions as they can prevent you from seeing important features and capabilities. With IronCAD this rule of thumb was important.

In reviewing IronCAD I was surprised at how cool and powerful it was. IronCAD reminds me of many cad packages. It feels like AutoCAD was out drinking with 3dsMax, and Inventor felt cheated on by AutoCAD so it started dating Rhino3D. Revit called IronCAD to get together, and while they were driving to the movies their car was hit by Sketchup. The surface models of the cars did a Fusion 360 and due to IronCAD’s Houdini driving they were fine. After the movie they got pizza and Draft Sight. Onshape walked in to the pizza joint and everyone else was jealous because Onshape was the only one that had web access.

For the record, I am wary of software packages that rename functions, sketch commands or features that are the cornerstone of computer aided design. An example of this is the Fillet command; in IronCAD it’s called Blend Edges.

As an engineer, when I see this I get a bit worried that the software is being developed by non-engineers. I love development and enjoy breaking paradigms within design of machines, products and robotics. However, there are some paradigms that should almost never change. I really can’t believe I said that! When companies compete to convert users

52

from one 3D package to the next its critical that the initial learning curve isn’t too steep. The quickest way to lose the attention of a new potential user is to rename items such as Fillet to something fluffy like Blend Edges.

One other feature I historically dislike has been drag and drop features; maybe because it reminds me of using TinkerCad. I feel TinkerCad is the annoying little brother of all the other parametric modelers. It’s like if AutoCAD and Inventor were going to the park to shoot hoop with their friends, Solidworks and Onshape, and Mom makes them take their annoying little brother, TinkerCad. That said, I’m glad I broke through the TinkerCad viewpoint and gave IronCAD Drag and Drop Modeling a try.

It’s a slight departure in my typical design flow, however, it was a great time saver and they may have converted me. If you give it a try I think you will incorporate this into your future workflows. I am looking forward to spending more time exploring IronCAD. But I think there is an identity crisis with IronCAD. I thought I was opening a modeling package specifically developed for mechanical engineers designing sheet metal parts, machines, and products, however, it’s so much more.

This package is extremely flexible for mechanical engineers, architects, game developers, animators and product rendering specialists.

Using IronCAD’s Catalog Browser, I opened every tab as if I were exploring a new frontier. The list of shipped catalogs

May 2018 www.designworldonline.com

CAE Solutions 5-18_Vs4.LL.indd 52

DESIGN WORLD

5/2/18 9:14 AM

Manufacturers of Power Transmission and Motion Control Components was expansive and fun to review. The tabs are located at the bottom right of the screen, which allows for quick access to your most useful 3D models.

I initially didn’t like the Selector Wheel because I was expecting different right click results, but continued to use it, and found it useful. This can be turned off and edited as well.

IronCAD puts out regular improvement updates, and they are free! There website is clean and organized showing summary updates and product offerings.

The Export options were not vast like Rhino3D, but they hit all the standards and a few surprises such as Visual Basic files, 3D PDFs and Raw Triangles. IronCAD has been built to be flexible and scalable. Add-Ons are available for several CAD packages such as CATIA, Solidworks, SolidEdge, Pro /E and Inventor. They also offer a Native CAD Translators that run alongside with IronCAD that I’m excited to check out.

The IronCAD package competes with all the heavy weights in the industry, however, their product offerings and price tags are the best in the industry. I looked up pricing as it’s not listed on the IronCAD site and here’s what I found.

One of my favorite features in IronCAD was the ability to Save All as External, which will create a new single file for each part within your design and locate in a selected directory. In the early days of parametric modeling this was a chore. However, today we see similar functions in Solidworks such as Pack-and-Go. I opened the Awards tab in the Catalog Browser, dragged in every model and then used the Save All as External, Selected the destination folder and presto!, it created a nice neat directory of every model.

Concentric Maxi Torque

Stock and Custom Keyless Hub-to-Shaft Connection System Email or call to get your CMT Stock Products Catalog Order today. Ships today!

To sum up my experience of IronCAD; it exceeded my expectations and left me wanting more. DW

IronCAD | www.ironcad.com

IronCAD Draft:...........................................$559 IronCAD Inovate:......................................$1,199 IronCAD Inovate/USB dongle:..........$1,395 IronCAD PRO XT:.......................................$615 IronCAD Translate Add-On:..............$659

Custom Synchronous Drives

Precise. Reliable. Cost Effective.

A key feature in IronCAD is the ability to Save All as External, which will create a new single file for each part within your design and locate it in a selected directory. In this example, using the Awards tab in the Catalog Browser, I dragged in every model and then used the Save All as External, Selected the destination folder it created a nice neat directory of every model.

Timing Pulley Stock

Guaranteed When You Need It. Custom Machine & Tool Co., Inc. (800)355-5949•sales@ cmtco.com www.cmtco.com Precise. Reliable. Trusted.

American Engineering • American Made

DESIGN WORLD

CAE Solutions 5-18_Vs4.LL.indd 53

www.designworldonline.com

May 2018

53

© 2017 Custom Machine & Tool Co., Inc.

5/2/18 9:14 AM

CAE Solutions

Maple 2018 offers better user experience

M

Maplesoft announced a major new release of its flagship product, Maple, the mathematical software that makes it easy to analyze, explore, visualize, and solve math problems. Maple 2018 includes substantial improvements to how customers interact with it. The release includes an extensive collection of improvements in advanced mathematics, visualization, specialized application areas, and more, which will be useful to the mathematicians, educators, engineers, and scientists who rely on these particular features.

CARLO GAVAZZI Automation Components

Innovative Automation Solutions CARLO GAVAZZI Automation Components SENSORS: Inductive and Capacitive Proximity Sensors • Photoelectric Sensors • Level Sensors • Ultrasonic Sensors • Magnetic Sensors • Limit Switches • Interlocks

SWITCHES: Solid State Relays • Contactors and Overloads • Soft Starters • Definite Purpose Contactors • Mini Circuit Breakers • Electromechanical Relays • Pilot Devices

CONTROLS: Energy Meters and Software • Current-, Voltage- and 3-Phase Monitors • Current Transformers • Transducers • Time Delay Relays • Digital Panel Meters

Whether it’s our industry leadingCARLO solid state relays and con- Contact us today, and one of our field sales representatives will GAVAZZI Automation Components tactors, our our vast range of sensors, motor controls, energy show you why we are one of the fastest growing automation USA Tel: 847.465.6100 Fax: 800.222.2659 meters and current-, voltage- andCanada 3-phase monitors, CARLO companies worldwide. We’ll even provide a free evaluation Tel: 888.575.2275 Fax: 905.542.2248 Tel and Fax:needs 55.5373.7042 GAVAZZI has the solution for your Mexico application sample to qualified OEMs. www.GavazziOnline.com • Info@CarloGavazzi.com twitter.com/CarloGavazziNA facebook.com/CarloGavazziNA

GavazziOnline.com • 847.465.6100 • Info@CarloGavazzi.com 54

Visit our website for downloadable data sheets, brochures and pricing: www.GavazziOnline.com

May 2018 www.designworldonline.com

CAE Solutions 5-18_Vs4.LL.indd 54

DESIGN WORLD

5/2/18 9:14 AM

People use Maple to do many different things, so the value of the improvements in any new release varies for each user. The improvements to Maple 2018 include:

• An intelligent Context Panel, which brings

• Significant enhancements to Maple’s code

editor, which makes writing, debugging, and maintaining Maple code and Maple-based applications easy and fast.

• Deeper integration of units into the

mathematics engine that simplifies units-based calculations.

• New options for protecting work from

modification or viewing, so customers can share their work while remaining in control of their content.

Maple 2018 also includes improvements that deepen its capabilities, as well as features that broaden its applicability. Core mathematical enhancements were made in integration, ordinary and partial differential equations, simplification, graph theory, and more. New abilities include computational geometry, support for performing computations involving thermochemical properties of chemical species, generating practice sheets for students that are graded by Maple automatically, and interpolating unstructured data. DW

I need a plastic molder with custom expertise and a large selection of catalog parts.

And they need to be fast and cost-effective.

For more than 65 years, Caplugs has been the leading technical expert in product protection, masking and molded components.

If one of our 15,000 catalog parts doesn’t fit your requirements, our team of design engineers will create a custom-designed solution for you.

You’ll enjoy peace of mind knowing that Caplugs can produce the parts you need — on time and on budget.

Our molding capabilities: • Injection Molding • Vinyl Dip Molding • Extrusion Molding

Maplesoft | www.maplesoft.com

• Rubber Molding • Vinyl Coating • Die-Cutting

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

DESIGN WORLD

May 2018

www.caplugs.com 1.888.CAPLUGS sales@caplugs.com 55 CAP66341 GeneralIndustrial_TwoThirdsPgAd_DW_mech.indd 1

CAE Solutions 5-18_Vs4.LL.indd 55

R ca of equ pl al es ug l c t s.c at fre om alo e s /f g p am re a p e- rts le sa a s m t pl es

together and enhances some of Maple’s Clickable Math tools, providing point-and-click access to a variety of mathematical operations.

4/9/18 2:55 PM

5/2/18 9:15 AM

CAE Solutions

Onshape delivers new Design Data Management 2.0

O

Onshape claims that its “Design Data Management 2.0” is a radically different approach that marks a new era in the way engineers manage design data. The new approach reworks how data are created, stored, shared, and managed. This approach eliminates the problems of old file-based data management and introduces new possibilities: • Virtual documents, not files • Secure Cloud workspace, not scattered copies • Parallel, not serial • Instant collaboration, not meetings • Immutable links, not brittle file references Search – Onshape stores all design data in a secure cloud workspace. Finding the data is quick using the integrated search tools with filters such as Name, Description, Part Number and Revision. Search results are scoped for users with restricted access permissions.

Versions & History – Onshape records every design change, with unlimited undo/redo and a complete history of who changed what and when. This process is automatic, so users will never lose data or work. When design milestones are reached, users can create immutable versions to bookmark progress.

56

May 2018 www.designworldonline.com

CAE Solutions 5-18_Vs4.LL.indd 56

DESIGN WORLD

5/2/18 9:17 AM

ca i r e m A 3 4. n i e d 9 a 1 m e c n Y i s R E V

Branch, Compare & Merge – Create branches in Onshape to explore multiple design alternatives in parallel. Compare any version or branch to see the differences visually and by feature definition, then merge the changes from one branch into another.

Share, Comment & Collaborate – Onshape enables realtime collaboration with simultaneous editing of parts and assemblies and commenting for design reviews. Documents are shared with edit or view-only permissions. Data never leaves Onshape, so Document permissions can just as easily be revoked.

Onshape is also announcing two new features: Release Management and Approval Workflow will help eliminate the headaches caused by creating and using formal product release processes.

• Formal Release Management – Onshape’s approval based release process provides a controlled release workflow fully integrated into the design experience.

Multiple approvers, notifications, automatic part numbering and error checking streamlines the release process and enforces company procedures.

• Release Workflows – Onshape’s Formal Release Management gives your company a formal approval release process without the typical downtime associated with checking files in or out. As an approver, you can easily approve or reject a Release candidate and it will automatically move to the next state in the workflow and notify the appropriate people.

Simultaneous Bill of Materials builds upon the existing Design Data Management 2.0 foundation to revolutionize part information tracking and sharing. Onshape lets users edit assemblies and Bills of Materials at the same time with complete associativity and without the need to create a drawing. DW

ENGINEERED SOLDER MATERIALS

Gold-Tin Solder • High-temperature • Strong • Reliable • Die-attach • Semiconductor-grade • Custom packaging Contact our engineers today: askus@indium.com

Onshape | www.onshape.com

Learn more: www.indium.com/america/DEWV ©2018 Indium Corporation

DESIGN WORLD

CAE Solutions 5-18_Vs4.LL.indd 57

May 2018

57

5/4/18 10:58 AM

CAE Solutions OnScale emerges from stealth

to unveil Cloud Solver Platform

O

OnScale recently released its a solver-as-a-

Same TechnologyDiverse Applications

service platform called OnScale Cloud. The platform addresses demand for computer-aided engineering (CAE) and cloud computing resources to solve engineering challenges in areas such as, Internet of Things (IoT), Industrial Internet of Things (IIoT), sensors, biomedical and smart car industries, according to Ian Campbell, OnScale’s chief

Self-clinching microPEM® Tackpin® Fastener

Self-clinching M10 stud

Our mission is to provide improved, dependable, cost effective, fastening solutions for thin sheet/panel applications in your current and next generation product designs.

For immediate design assistance email us techsupport@pemnet.com Free PEMSpec™ app now available

To install, simply: 1. Punch Hole 2. Insert Fastener 3. Press Into Place

102R ©2017

executive officer.

“The CAE/HPC space is ripe for disruption because yesterday’s systems are too expensive and cumbersome to solve tomorrow’s engineering problems,” Campbell said. “Our platform eliminates the risk associated with sequential trial-anderror physical prototyping, reduces design cycles from months to weeks or even days, and delivers unequaled computing performance that easily scales to meet ever-changing CAE workloads.”

The company initially targeting underserved market verticals, worth $4 billion, with heavy demand for advanced computer-aided engineering and high-performance computing (HPC), Campbell said.

OnScale will initially focus on the following market segments: • 5G – RF Filters and RF switches for 5G smartphones and base stations.

• IoT and IIoT – Microphone arrays for Alexa-style IoT devices, motion and gesture sensors, biometric and fingerprint sensors and industrial sensor systems.

• BioMed – Advanced therapies, targeted treatment planning and consumer ultrasound.

• Driverless Car Systems – Driverless car sensing technologies like 3D ultrasound for object classification, driver and passenger monitoring.

The company’s SaaS platform combines CAE multi-physics solvers with a scalable cloud HPC platform. OnScale gives individual engineers, small engineering design teams, and multinational engineering firms cost effective computational power, agility, and scalability through a pay-as-yougo subscription model, Campbell said.

OnScale charges engineers for actual solver time, measured in core-hours. For example, a solve that requires a 16-core HPC and 30 minutes to solve would consume eight core hours. Engineers can use as many HPC instances as they like to solve massive

Q a

W

For Fro hav

www.pemnet.com

58

May 2017

CAE Solutions 5-18_Vs4.LL.indd 58

DESIGN WORLD

5/2/18 9:19 AM

optimization studies in parallel. This means engineers who use OnScale Cloud and the companies they work for don’t buy new CAE software licenses, pay for maintenance and support, procure expensive HPC hardware, or wait for IT to deploy and maintain CAE systems, Campbell added.

OnScale Cloud is offered in three monthly subscriptions, all with a bundle of core-hours included, for discounted, ondemand pricing: Free: Any engineer can begin using OnScale for free and receive ten core-hours, per month without commitment. Ten corehours is sufficient to perform many simulations of simple devices. Additional on-demand core-hours can be purchased with a credit card for $10 per core-hour.

Professional: The Professional OnScale Cloud subscription is $300 per month and includes 50 core-hours, which opens up simulation of more complicated designs and parametric design studies. Additional on-demand core-hours can be purchased for $9 per core-hour at the Professional subscription level.

engineering team to optimize next-generation devices.

Additional on-demand core-hours can be purchased for $7 per core-hour at the Team subscription level.

In addition to these subscription levels, OnScale also provides discounts for annual subscriptions and flexible subscription programs for small, medium, and large enterprises, Campbell said.

“OnScale was built for engineers, by engineers,” he said.

“We’ve experienced the restrictive nature of legacy CAE tools ourselves, so we designed OnScale tools to help engineers at Fortune 100 companies and startups alike remove cost and compute constraints.”

In March, the company emerged from its stealth position and announced $3 million in strategic seed funding.

Campbell founded the company along with Robbie Banks, vice president of product development, and Gerry Harvey, vice president of engineering. OnScale is a spin-off of the company Thornton Tomasetti. DW

OnScale | onscale.com

Team: The Team OnScale Cloud subscription is $1,000 per month and includes 200 core-hours, enough for a small

Questions about encoders and motion control?

We’ve got your answers.

For almost 50 years, EPC has been providing encoder solutions for reliable motion feedback.

From industrial equipment to packaging to conveying – almost any kind of machinery – we have the encoder solution you need and the expertise to help you find it.

Expert Technical Support

Industry-Leading 3-Year Warranty

Highly-Configurable Encoders

Fast Lead Times

Call us today.

We’ll help you find the motion feedback solution you need.

1-800-366-5412 • www.encoder.com

CAE Solutions 5-18_Vs4.LL.indd 59

Configure Your Encoder in 3D Configure & download 3D files of encoders at encoder.com

5/2/18 9:19 AM

Huco’s Dynatork air motors are quiet and run at speeds from 0 to 800 rpm or more while delivering torque to 15 Nm without gearsets. The motor come in aluminum, stainless steel, and acetal versions.

Piston-type air motors from Huco Dynatork are also up to four times more energy efficient than vane-style air motors.

60

May 2018 www.designworldonline.com

Motion Control (Huco Dynatork)_ 5-18_Vs3.LL.indd 60

DESIGN WORLD

5/2/18 9:26 AM

M o t i o n

C o n t r o l

Air apparent: Benefits of air motors for motion

The electric motor may be the most common source of mechanical power in modern industrial environments, but that doesn’t make it the best setup for every application. Air motors are simple and won’t overheat if stopped under load … Plus they can be specified to meet motion requirements without necessitating complex controls.

David Lockett | Managing director at Huco Dynatork

Amid the buzz surrounding the Fourth Industrial Revolution and Industry 4.0, it’s easy to discount the effect of technologies that’ve powered earlier industrial transformations. Factories of the original Industrial Revolution were driven first by water and then by steam. Then they we driven by the Second Revolution and mass production — enabled by electricity (and especially the electric motor) to free industrial engineers from reliance on cumbersome line-shaft installations (and their factory ceilings full of belts) with controllable mechanical power delivered anywhere it was required.

Well, almost anywhere.

DESIGN WORLD

Motion Control (Huco Dynatork)_ 5-18_Vs3.LL.indd 61

www.designworldonline.com

May 2018

61

5/2/18 9:27 AM

M o t i o n

C o n t r o l

In these applications, industrial engineers must often adopt alternative technologies.

For example, in some cases they may install electric motors a safe distance away and then use shafts and mechanical-transmission components to feed power to where it is needed.

A list of the most common air motor applications includes paint mixers and agitators, paint shop automation drives, conveyor drives, winding and unwinding systems, oilfield down-well cable and hose reel tensioning, and back flush filter drives.

Food packaging machinery is also a common application where compact air motors can precisely start and stop rolls of printed plastic bags used to package meat, poultry, and cheese. Air motors also run axes in packaging machines that fill precision-metered quantities of sauces into pouches.

Huco Dynatork piston air motors often install in automotive paint lines. The air motors mount to the tops of paint-drum agitators to maintain constant agitatorblade rpm. That in turn makes for a better surface finish and lower running costs — as well as quieter operation.

62

Though electric motors remain the prime mover of choice in most industries, there are numerous applications for which electricmotor use is difficult, expensive, or even hazardous.

A simpler and safer alternative in many such applications is use of motors powered by compressed air. Air doesn’t ignite flammable atmospheres or contaminate most products. It’s easily distributed through low-cost pipework and in most production environments is already used and readily available. What’s more, air motors are often smaller than comparable electric motors, which is beneficial in compact machinery.

Typical air-motor installations include machines subject to humid or wet conditions that can cause corrosion in electric motors. Air motors also work when submerged .. and excel in harsh washdown environments, as they can withstand high-pressure water and cleaning solvents.

Air motors also withstand installation inside vibrating equipment. Still another application is in explosive atmospheres where sparks generated by motors (and their associated switchgear) present unacceptable risk of ignition.

May 2018 www.designworldonline.com

Motion Control (Huco Dynatork)_ 5-18_Vs3.LL.indd 62

Two air motor technologies Modern air motors are one of two technologies. The first — vane motors — operate like turbines with bladed wheels that spin in the flow of air induced by a pressure gradient between the motor housing’s inlet and outlet. Most vane motors run at high speed and produce low torque, especially when rotating more slowly than their design speed. That makes them most common in applications needing relatively narrow rpm ranges.

Much like a diesel or gas engine, piston air motors use reciprocating pistons to turn a central shaft. They generate maximum torque at startup so improve the performance of applications that necessitate frequent stops and starts — especially under load. In contrast, if a brake holds an ac or dc electric motor, that motor is at risk of quickly burning out. Under such braking, an air motor will simply stop and then seamlessly operate again upon brake release.

Efficiency of air motors Air motors are far less efficient than their electric counterparts. However, where air motors are indispensable, piston air motors offer higher efficiency than vane-type air motors. This is because they exhibit less leakage of air. Ultimately, the overall motor efficiency depends on the integrity of the air DESIGN WORLD

5/2/18 9:29 AM

supply from the compressor. Piston motors can consume as much as 80% less air than vane designs with similar power output.

Nearly instantaneous stop-startreverse also allows very accurate control of the rotary position of the shaft, which is suitable for indexing applications or other automation tasks where precision is required.

Huco supplies air motors to a major builder of automated paint-booth systems used by a global automotive manufacturer. The motor works on a vertically mounted drive system where it’s connected through a worm gearbox to drive a carousel that delivers paint-filled containers to a spraying robot. The systems builder uses air motors to get high torque instantly in stopstart-reverse conditions — even at speeds to 800 rpm. The air motors are also suitable here because sparks generated by electric motors would present significant risk of ignition in the potentially explosive paint-booth environment.

Air-motor installation considerations The top requirement for proper air motor operation is a steady supply of compressed air. A reliable compressor is often the optimal source, but the motors can also be run from compressed air cylinders. The air should be filtered through a standard in-line filter, and air pressure is typically between 4 and 6 bar. That said, some models can run with pressures down to 1 bar.

| istockphoto.com

Advancements in Reed Switch-Based Technology Madison Company has developed an advancement in proven reed switch-based technology that provides ultra-high resolution, very tight tolerances and consistent repeatable measurements in liquid level sensor designs.

Learn more about our capabilities at www.madisonco.com/custom.

• Innovative • Customized • Quality-Driven

Visit Us in Booth #1609 Sensors Expo & Conference

Let’s Discover Your Solution.

June 27 & 28, 2018 San Jose, CA

www.madisonco.com/custom 203-488-4477 Toll-free: 800-466-5383 info@madisonco.com

DESIGN WORLD

Motion Control (Huco Dynatork)_ 5-18_Vs3.LL.indd 63

www.designworldonline.com

May 2018

63

5/2/18 9:29 AM

M o t i o n

C o n t r o l

Air motors can operate with or without lubrication in the air. Tip: Applications that rely on cleanliness (such as paint sprayers) always need clean and unlubricated air.

The simplicity of air motors and their airsupply systems (compared to electric-drive equivalents) makes installation and maintenance easy. The motors are also lightweight and compact so it’s possible to lift and maneuver during routine maintenance. Connecting and disconnecting the air supply is straightforward.

Consider how some manufacturers’ air motors deliver speeds of 0 to more than 800 rpm and torque to 15 Nm without gears. Some motors come in aluminum, stainless steel, or acetal … with the latter two options suitable for harsh washdown environments (thanks to their high resistance to caustic acids and chlorinated sanitizers) — and acetal particularly suitable for use in food and beverage processing.

Because air motors don’t directly depend on electricity, they don’t generate electromagnetic fields when running. Special motors produced without magnetic components are used in a number of specialized applications, including MRI scanners, scientific equipment and military applications that must eliminate electromagnetic emissions.

In fact, even as a decades-proven technology, piston air motors satisfy Industry 4.0 automation needs — with high-accuracy controllability (using feedback from either pneumatic or electronic sensors) and so offer connectivity with today’s remote monitoring and controls. DW Huco Dynatork | www.huco.com

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

When second-best is just not good enough.

From design to delivery, you can count on us to give you the best gearmotor solution. When your product demands outstanding performance every time, contact Bodine. visit us at bodine-electric.com | info@bodine-electric.com

64

Motion Control (Huco Dynatork)_ 5-18_Vs3.LL.indd 64

May 2018

DESIGN WORLD

5/2/18 9:30 AM

HOW DOES A

CHECK VALVE WORK? WHEN YOU’RE CREATING A LOW PRESSURE, LOW FLOW APPLICATION, IT PAYS TO UNDERSTAND HOW CHECK VALVES WORK. WILL A CERTAIN STEP AFFECT YOUR DEVICE’S PERFORMANCE? IS THERE A PART IN THE OPERATION PROCESS THAT WILL BE CRITICAL TO YOUR APPLICATION?

ADD TO YOUR KNOW-HOW WATCH THE 1:40 MIN VIDEO OR DOWNLOAD WHITE PAPER AT SMARTPRODUCTS.COM/CHECK_VALVE_OPERATION.PHP Smart Products 5-18 (NEW).indd 65

5/1/18 10:21 AM

Linear actuators: smarter, more powerful Electromechanical actuators continue to evolve with more integration as well as more power, challenging some fluid power mainstays.

Putting together a linear motion system has never been easier, considering the options available to designers along with powerful new tools with which to design such systems. The availability of more integrated components and so-called smart actuators has a lot to do with this.

Along with the ongoing trends of integrating more components into single units, the force capabilities of actuators are getting better, gaining ground on fluid power technologies like hydraulics, in what is by now a familiar story. Hydraulic actuators are still at their best when it comes to high force capacity, but electromechanical actuators are catching up, primarily in the area of controllability.

The reality is that there is a wide range of linear actuator options to meet diverse application needs and design challenges. Here are some of the best recent examples.

Miles Budimir | Senior Editor

66

May 2018 www.designworldonline.com

Linear Motion 5-18_Vs4.LL.indd 66

DESIGN WORLD

5/2/18 9:31 AM

L i n e a r

M o t i o n

AMK Automation’s new SPINDASYN SEZ electric cylinder is a ready-toinstall linear drive motor system in which the rotor is pressed directly onto the screw. It also features the ability to set multiple travel profiles, especially useful for packaging applications.

DESIGN WORLD

Linear Motion 5-18_Vs4.LL.indd 67

www.designworldonline.com

May 2018

67

5/2/18 9:32 AM

L i n e a r

M o t i o n

Electrak HD electromechanical actuators from Thomson Industries handle loads of up to 16 kN (3,600 lb).

Programmable servo actuators Integrated actuators are far more commonplace today. Take for example a new 35-mm-diameter electric cylinder with a built-in controller from SMAC Corp. The company’s CBL35C can control force, position, and velocity and features simple installation.

The durable actuators boast a long life expectancy of over 100 million cycles.

With a 35 mm diameter and lengths from 135 to 217 mm, depending on stroke length needed, and peak force of 61 N and encoder resolution to 5 um, they’re suitable for applications with limited space but needing accurate control.

Many of these actuators like the CBL35C series enable the direct replacement of existing pneumatic cylinders and retrofits without any machine modifications required. Plus, a GUI lets users easily change product profiles and setup parameters on the fly, improving factory uptime.

Another innovation among electric cylinders comes from AMK Automation.

The company’s new SPINDASYN SEZ electric cylinder is a ready-to-install linear drive motor system in which the rotor is pressed directly onto the screw.

Featuring high and constant force, high precision and position accuracy and high energy efficiency, the closed-loop positioning and force control of the SEZ make it a suitable alternative to other linear technologies such as pneumatic or hydraulic cylinders, rack and belt drives and linear motors. With several options available for screw and strength length, motor type and acceleration, the SEZ provides high rigidity without additional wearing parts.

With the ability to set multiple travel profiles, the SEZ can be easily integrated into machine automation processes and applications such as tubular bag packaging, blister packaging, carton forming, pick and place as well as labeling, wrapping, and other packaging tasks.

High force hydraulics competitor As mentioned before, electromechanical actuators continue to offer higher force capacities, which make them attractive alternatives to some hydraulic actuators.

For instance, consider Tolomatic’s high force electric rod-style actuators, which now feature stroke lengths to 1.5 m (60 in.) They offer more flexibility for converting motion control applications with hydraulic or pneumatic cylinders to electric linear motion. Designed for high duty-cycle performance in demanding applications, the RSX, RSA and ERD electric rod-style product families use planetary roller screws for longer service life in a compact package compared to electric actuators using ball screw technology.

Specifically, the highest-force actuator, the RSX, is expanded to 1.5 m stroke length (from 600 mm). The RSA and ERD are expanded to 1.5 m and 1.2 m, respectively, from 450 mm.

Along with the ongoing trends of integrating more components into single units, the force capabilities of actuators are getting better, gaining ground on fluid power technologies like hydraulics.

68

May 2018 www.designworldonline.com

Linear Motion 5-18_Vs5.LL.indd 68

DESIGN WORLD

techno

6/4/18 11:37 AM

WELCOME to automation24.com Your online shop for automation technology

9 High-quality products 9 Competitive prices –

no minimum order quantity

9 Same day shipping 9 Excellent customer service

& technical support

High-quality products from well-known manufacturers:

We are happy to advise you personally! +1 800-250-6772 (free) +1 610-981-2900

Automation24_5-18.indd 69

mail@automation24.com

LIVECHAT www.automation24.com

...

LIVECHAT

Brandon Hobusch Technical support

5/1/18 10:22 AM

L i n e a r

M o t i o n

The Exlar GTX080 integrated motor/ actuator from Curtiss-Wright features continuous force ratings up to 5,680 N (1,277 lbf), suitable for replacing hydraulic actuators in some applications.

The RSX uses a tie-rod design, provides forces up to 133.5 kN (30,000 lbf) and is suitable for hydraulic replacement applications. The RSA HT is available in four sizes, with forces up to 58 kN (13,039 lbf) and is the most flexible product line for fluid power replacement. The ERD stainless steel, hygienic electric actuator, rated IP60k for applications in the food and beverage market, is available with forces up to 35 kN (7868 lbf).

Tolomatic’s IMA servo linear actuator and ServoWeld spotwelding servo actuator platforms are also available with roller screw configurations at various thrust ratings and stroke lengths.

The company’s roller screw actuator families are available with unique features to aid conversion of fluid power cylinders and maximize life, including easy re-lubrication and IP ratings from IP65 to IP69k.

Another example of roller screw technology with high force capacity comes from Curtiss-Wright’s Sensors & Controls Division. The company’s new Exlar GTX080 next-generation integrated motor/actuator features a number of design enhancements. Incorporating the company’s patented inverted roller screw technology, the GTX080’s high power density and compact form factor makes it a suitable replacement for hydraulic cylinders in some applications.

The GTX Series actuators offer the power, precision, and programmability of a servo system while minimizing the maintenance associated with hydraulics. With continuous force

70

May 2018 DESIGN WORLD

Linear Motion 5-18_Vs4.LL.indd 70

5/2/18 9:33 AM

ratings up to 5,680 N (1,277 lbf), speeds up to 4,200 rpm, and stroke lengths from 100 mm (4 in.) to 450 mm (18 in.), the actuators can be applied across a wide range of factory automation applications.

The high-capacity planetary roller screws offer up to 15 times the life and significantly higher shock load resistance than a comparably sized ball screw. They also feature IP65S environmental protection. As for integration with other systems, they easily integrate into most leading motion-control architectures.

Helping that are removable front seal bushings that simplify maintenance and re-greasing of the nut assembly to maximize actuator life.

Also, a modular design with bolt-on mounting hardware allows mounting style reconfiguration or replacement in the field using commonly available tools.

Other manufacturers are adding force capacity to their actuator lines as well. Case in point: Thomson Industries has extended the capability of its Electrak HD electromechanical linear actuator line to loads of up to 16 kN (3,600 lb.) It delivers heavy load handling capacity comparable to hydraulic actuators, but with greater controllability, smaller footprint and lower maintenance.

Smart electromechanical actuators accomplish all operation and control functions with onboard electronics, reducing actuator footprint as well as installation and maintenance costs. Electrak HD actuators connect to a power supply and PLC or other control source to bring the benefits of onboard electronics to high load applications for construction and agriculture, material handling, and factory automation.

Force and stroke lengths have been expanded from 10 kN (2,250 lb) to 16 kN and stroke lengths up to 500 mm (20 in.) The company claims that the minimum duty cycle of 25 % among stroke lengths up to 500 mm is the highest in the industry, assuring maximum continuity of operation with minimum current draw. For 16 kN loads at those stroke lengths, Thomson also offers speed options up to at least 5 mm/sec (0.197 in./sec.)

With enhanced functionality provided by an advanced onboard Electrak Modular Control System (EMCS) and its optional functions, the Electrak HD line offers a simpler method of control and communication, which reduces

Linear Motion when you need it

NOW!

It’s no secret that linear motion is in short supply these days. If your supplier can’t deliver, contact us….

We can help! Here’s how:

•

Ball and Crossed Roller Slides manufactured right here in the USA.

• •

Quick deliveries!

DESIGN WORLD

Linear Motion 5-18_Vs4.LL.indd 71

May 2018

Ball Slides

DL Linear Actuators Lead Screw/Ball Screw Driven

Standard Products or Custom Designed to meet your specific requirements.

800.245.5013

www.deltron.com • ISO 9001:2015

Non-Magnetic

Micrometer Positioning Stages Micrometer Driven Ball & Crossed Roller Stages

71

5/2/18 9:34 AM

L i n e a r

M o t i o n

operating costs, requires less space and simplifies setup and installation. Optional out-of-the-box J1939 CAN bus communication enables control and monitoring, while optional low-level switching, end-of-stroke indication output, choice of analog or digital feedback, and a customer control interface provide additional versatility.

Contributing to durability in high-load operations are environmental resistance ratings of IP69K static, IP67 static and IP66 dynamic. Even with high loads, the actuators will operate in temperatures ranging from -40 to +85 °C (-40 to +185 °F), can withstand salt spray for 500 hours, and are CE, RoHS and REACH (EU) compliant. DW SMAC Corp. | www.smac-mca.com Curtiss-Wright | www.curtisswright.com Thomson Industries | www.thomsonlinear.com AMK Automation | us.amk.systems Tolomatic | www.tolomatic.com

WHAT DO YOU THINK?

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

72

Linear Motion 5-18_Vs4.LL.indd 72

May 2018

DESIGN WORLD

5/2/18 9:35 AM

LEVEL UP to

Superior

Life, Precision, Lead Accuracy, and System Integration!

Innovative Anti-backlash Nut!

The NEW Standard for Accuracy and Life!

Patented Design

Lead accuracy at 2–3 times

delivers 2–4 times

the industry baseline

better performance than

PBC Linear Screw

achieved with German CNC

conventional designs

Roll Thread machinery and

as validated in

advanced process control

customer FDA testing.

and metrology.

Competitor X’s Screws

Pitting Fissures

Surface Roughness

Find out more about the benefits of an integrated system with Motor and Control technology

Request a FREE product sample at:

optimized for the most demanding linear applications at:

bit.ly/leadscrew-sample

pbclinear.com/Pages/New-Products

pbclinear.com 6402 Rockton Road, Roscoe, Illinois 61073, USA – 1-800-962-8979

PBC Linear (Level Up) 5-18.indd 73

5/1/18 10:23 AM

I n t e r n e t

o f

T h i n g s

Best practices for security

lloT

A recent report from the Industrial Internet Consortium presents best practices that designers can use to increase security for their Industrial Internet of Things (IIoT) projects from the design stage up.

Edited by Leslie Langnau | Managing Editor

The digital thread, where design and manufacturing components, equipment, and systems are connected through the Internet of Things (IoT), opens more opportunities for unsecured data. Many companies involved with the IoT and even the Industrial Internet of Things (IIoT) are taking data security seriously.

The result is the emergence of best practices design engineers can use to protect the data their designs collect.

Finally, data security is being treated seriously, especially as the problems of not securing data become more apparent. These problems include, but are not limited to, safety issues, equipment damage, poor quality that leads to customer dissatisfaction, poor product reliability, and possible legal liability. And, of course, any or all of these problems can contribute to lower profits.

74

May 2018

Internet of Things feature 5-18_Vs2.LL.indd 74

www.designworldonline.com

A recent report from the Industrial Internet Consortium discusses best practices designers can use to increase security from the design stage up. The practices primarily apply to new designs, as it can be difficult to modify existing components and equipment.

However, some of these practices can still be applied to legacy components and endpoints.

In some cases, designers may have to go through a network to ensure legacy endpoints are secured.

5/2/18 9:49 AM

| istockphoto.com

Security is not a stand-alone feature. It should be interwoven with other product features, such as safety, privacy, reliability and resilience, taking into account environmental disruptions, human errors, and system faults and attacks. Thus, most security solutions are devised iteratively to account for the impact of one choice over all the desired characteristics.

DESIGN WORLD

Internet of Things feature 5-18_Vs2.LL.indd 75

Designers can base security design decisions on the Industrial Internet Security Framework (IISF), which offers a secure design architecture format.

The following best practices tips are excerpted from the Endpoint Security Best Practices document from the Industrial Internet Consortium. The suggestions for the appropriate security levels were determined through risk modeling and threat analysis. www.designworldonline.com  

May 2018

75

5/2/18 9:50 AM

I n t e r n e t

o f

T h i n g s

The problems of not securing data include, but are not limited to, safety issues, equipment damage, poor quality that leads to customer dissatisfaction, poor product reliability, and possible legal liability.

Security Level Enhanced (SLE) defends against “sophisticated means with moderate resources.” This would be hackers exploiting known vulnerabilities in industrial control software or systems.

Security Level Critical (SLC) defends against attackers with more sophisticated means and resources, such as the ability to develop custom zero-day attacks.

Designers should perform a risk assessment to determine the appropriate level of security for each endpoint and their specific situation.

Security, all the way to the end According to the report Endpoint Security Best Practices, each endpoint contains a Root of Trust (RoT) feature that forms the basis for the endpoint’s security. The RoT provides security functions such as: endpoint identity cryptographically protected information about the devices hardware and software version, labeled as attestation.

· ·

Enhanced Endpoint Security

The stronger the RoT, the more secure a designer can make a device.

How the RoT is implemented, in software or hardware, affects its security strength. For critical security needs, the RoT should be implemented in hardware. The ways designers can use to protect against physical hardware tampering include use of a hardware security chip or an integrated hardware security block with tamper resistance.

Root of Trust

Endpoint identity

Endpoint configuration Secure and management communications

Secure Boot

Cryptographic services

The document defines three levels of security: basic, enhanced, and critical. The levels correspond to security levels 2, 3, and 4 as defined in IEC 62443 3-3 [IEC-62443-33], which is viewed as one of the more mature industrial guidance and compliance frameworks dating back to ISA99’s original work. Best practices for security levels 0 and 1 in IEC 62443-3-3 are not covered as they involve low security environments inappropriate for industrial internet environments. NIST SP 800-53r4 similarly defines three levels of security.

The basic level of security, known as Security Level Basic (SLB), protects against “intentional violation using simple means with low resources,” such as an ordinary virus.

76

Endpoint identity Endpoint identity is a fundamental building block essential for most other security measures.

Public Key Infrastructure (PKI) support is mandatory for basic, enhanced and critical security levels.

Open standard certificate management protocols, such as EST, automate the issuance, renewal, update, and revocation of endpoint certificates.

If designers use certificate chaining from the endpoint, they can smooth the transfer of ownership to an endpoint management system.

· · · ·

Achieving a secure boot Designers can put in firmware that ensures a secure boot. Such firmware will cryptographically protect bootstrap code during power on. For multi-stage booting, best practices include UEFI and U-Boot bootloaders using PKCS standards based on cryptographic key hashes.

These practices can extend security from bootstrap to the operating system startup, which can help prevent unauthorized firmware, bootloader, or boot image updates that occur wirelessly.

Cryptographic services Cryptography is a major best practice tool. But when using this tool across transport protocols (data-in-motion), storage (data-at-rest), and applications (data-in-use), be sure to protect confidentiality and integrity.

May 2018 www.designworldonline.com

Internet of Things feature 5-18_Vs3.LL.indd 76

DESIGN WORLD

5/2/18 9:58 AM

kelleramerica.com

digital pressure gauges

The LEO-3 combines a local digital display with high-accuracy process control instrumentation for easy installation into new and existing system designs. This loop-powered instrument includes 4-20mA output for pressure ranges up to 15,000 psi. Common side affects include increased versatility and decreased system downtime. Warning: In many cases, the desire to switch to all Keller instrumentation can occur as this indicates a high degree of customer satisfaction.

In such cases, contact Keller America at 877-253-5537 or email sales@kelleramerica.com for assistance.

KELLER 5-18.indd 77

5/1/18 10:24 AM

I n t e r n e t

o f

T h i n g s

Options here include: PKCS standards-based asymmetric and symmetric cipher suites, hashing functions, and random number generators NIST/FIPS standards-based validated cryptographic algorithm implementations Cryptographic algorithm agility with in-field upgrade capability, especially in light of the rise of quantum computing and the expected need to deploy post- quantum cryptography Dynamically deployed policy-based control of application use of crypto graphic functions based on permissible cipher algorithms and suites Interoperability of cryptographic key types and certificates across multi vendor systems as needed to enable secure communications within an ecosystem

·

Endpoint configuration and management dashboard

Critical Endpoint Security

·

Root of Trust

– Policy and activity

· ·

Security information and event management

Endpoint identity

·

Secure Boot

Flexibility By Design Linear Position Sensors With Attachment Options Novotechnik’s TEX Series has the mounting and connection configurations needed to be plug-in compatible with your existing or new application.

The TEX Series is designed for use in tough environments like industrial, off-road automotive and others.

• pivot head mount • snap clamps • rod end bearing

Cryptographic services

Configuring and managing the endpoint A key best practice is verifying remote or automated updates to firmware, the operating system, and applications without relying on blacklists and whitelists for scalability across the endpoints.

Recommendations are to use PKCS standards to encrypt data and certificate-based validation among the connecting parties for secure and confidential end-to-end content delivery. Remote attestation may be required to verify firmware and software integrity across platforms from endpoints to a cloud source.

Secure communications Another best practice is to use a secure end-to-end communications protocol stack.

The TEX Series is available in stroke lengths of 10 to 300 mm. Repeatability is better than 0.01 mm and the TEX Series has outstanding linearity – to 0.05%. A wide range of standard configurations for mounting are featured including:

• return spring • bolt through flanges • bushing mount

• zero backlash ball coupling • flange mount • cable and connector options

For complete information, visit www.novotechnik.com/tex Novotechnik U.S., Inc. 155 Northboro Road • Southborough, MA 01772 Telephone: 508-485-2244 Fax: 508-485-2430

Such a stack will provide:

· support for extensible authentication protocols with endpoint level non-repudiation or authentication support for cryptographically protected endpoint-to-cloud connectivity, when appropriate support for cryptographically protected endpoint-to-endpoint connectivity (for example based on standards based group key PKI for key lifecycle management) ensure trusted data transport based on secure public-private key pairs (PKI), and use of modern quantum resistant cipher suites

· · ·

78

May 2018

Internet of Things feature 5-18_Vs3.LL.indd 78

Secure communications

DESIGN WORLD

5/2/18 9:58 AM

·

manage a local endpoint firewall for network whitelisting and ingress/egress access controls leverage hardware for secure key store deliver interoperability across multi- vendor systems (based on relevant RFC specifications) offer complete suite of transport protocols relevant to the system (for example TLS, DTLS, SSH, IPsec, IKE, Wireless, GDOI) ensure compatibility with security mechanisms used by core connectivity protocols defined in the Industrial Internet Connectivity Framework [IIC-IICF2017] regardless of whether these mechanisms are implemented with open-source stacks or closed- source stacks.

· · · ·

Continuous monitoring Even with these best practices, systems must be installed that continually monitor endpoints in

real time. Designers can configure controls to detect and prevent unauthorized changes that alter the behavior of firmware, the operating system, or installed applications.

Designers can set up application-level controls to detect and prevent unauthorized activities, such as insecure ciphers or hash algorithms, that compromise data.

Better visibility To deliver better endpoint visibility to operators and administrators, designers can provide: remote policy management to define security controls policy orchestration across multiple endpoints for distribution event data that delivers context with totality, relevance, and timeliness for incident response

· · ·

use to measure and continually assess risks and handle security threats. Such logs should: offer policy based risk monitoring profiles distribute rules or manage behavioral analysis using open interfaces, data models or extensible formats (e.g.

REST APIs, JSON) across industry sectors trigger rules and feed behavioral analysis with contextual event related data log the generated events to services and data historians in extensible formats

· · · ·

For more detailed information on these best practices, the report, IIC Endpoint Security Best Practices is available from the Industrial Internet Consortium at www.iiconsortium.org DW

Event management Event logs are a valuable tool designers can

POWER TRANSMISSION-PART CONVEYING

PYRATHANE® BELTS With Lifetime Warranty Against Manufacturing Defects

LINE SHAFT CONVEYOR BELTS - Original Equipment & Connectable CUSTOM MADE IN INCH, METRIC & O-RING SIZES Round, Flat and Connectable Polyurethane Belts • Very Clean Operation • Eliminates Tensioning Devices • Exceptional Abrasion Resistance

SAMPLES AVAILABLE

40 Years of Innovation.

Winco.

Self-Adhesive Rulers JW Winco offers self-adhesive rulers in inch or metric sizes: ■ ■ ■ ■

Stainless Steel Transparent or Silver Plastic Vertically or Horizontally Arranged Figures Accessory: Indicator Arrows

Try our Pyrathane Belts

®

on your conveyor ...

the standard of the industry!

AN ISO 9001 CERTIFIED COMPANY

Explore our full line or contact us with your application requirements.

J.W. Winco, Inc. | Phone 800-877-8351 | Email sales@jwwinco.com

pyramidbelts.com • 641.792.2405 • sales@pyramidbelts.com

201702_Pyramid4x475_lineshaftR2.indd DESIGN WORLD 1

Internet of Things feature 5-18_Vs3.LL.indd 79

www.jwwinco.com

2/9/2017 10:43:58 AM www.designworldonline.com

May 2018

79

5/2/18 10:02 AM

E l e c t r o n i c s

Better simulation

brings fewer surprises in HALT

Vibration simulation software has been optimized specifically to handle printed circuit boards.

Craig Armenti Mentor Graphics a Siemens business Board Systems Div.

80

To get a feel for how vibration problems can affect product design, consider that the U.S. Air Force has estimated shock and vibration causes 20% of all mechanical failures in avionics. That level of failure is a problem for any kind of product, but it is particularly challenging for expensive equipment slotted to have a long lifetime. Military avionics, for example, is expected to last between 10 and 30 years.

Reliability has become important for most products regardless of how long they are supposed to last. Though cell phones only have a projected lifetime of 18 to 36 months, they still must work reliably over that time. Fortunately, engineers know the causes of shock and vibration failures in electronics. They arise primarily from broken component lead wires, cracked solder joints, cracking of component bodies, plated hole cracking, broken circuit traces, board delamination, and electrical shorting.

Mathematical relationships have been developed to relate fatigue life of various components to the dynamic displacement of the PCB on which they sit. Some of these

May 2018 www.designworldonline.com

Electronics 5-18_Vs3_LT(USE).indd 80

DESIGN WORLD

5/2/18 10:05 AM

View of a design after a vibration simulation. Special algorithms predict the probability of specific components failing because of tested vibration levels.

relationships are simple enough to have been developed into rules of thumb. For example, designers have long followed what’s called the octave rule which says the natural resonant frequency of the chassis should be at least one octave from the natural frequency of the PCB. Nevertheless, mathematical rules of thumb can only go so far.

Most design teams rely on physical testing to reveal such issues.

Physical vibration and acceleration testing, known as Highly

Accelerated Lifecycle Testing or HALT, provides a way to ensure the reliability of a product and identify potential failures caused by environmental factors. It takes place just before volume manufacturing and requires expert technicians. HALT testing involves applying a much higher fatigue than the actual product will undergo, thereby forcing failures and identifying weak spots as the product is rigorously tested. The process is, however, costly

A few screen grabs from an Xpedition simulation of a HALT test. After the simulation, the program lists the failed components. An advanced-view mode plots deformation intensity and stress intensity down to the lead level. In a deformed view mode, the board can be animated to view behavior under six-axis vibration in the predefined frequency range.

Post processor view of the board deformation. The software

Worst-case part deformation is called out in the post-processor

calls out failed parts.

simulation output.

DESIGN WORLD

Electronics 5-18_Vs3_LT(USE).indd 81

www.designworldonline.com

May 2018

81

5/2/18 10:05 AM

Acopian_EE_ad.indd 82

5/3/18 11:07 AM

E l e c t r o n i c s

and destructive, potentially requiring up to four months while averaging $30,000 (USD) or more for each design.

For military equipment, HALT takes place before qualification testing. Military products (as well as transportation and machinery) are built for high-reliability, and they must perform in the harshest of environments. So their HALT work tends to be severe, taking place in a range of environmental conditions.

A point to note is that there is no one set of HALT specifications for specific kinds of products. HALT procedures are defined depending on the stresses the specific product will see, how many samples are available, what circuits are active during the expected stresses, and so forth. HALT plans usually incorporate incremental temperature stress levels, fast thermal transitions, incremental vibrational stresses, and combinations of these conditions.

However, there are complicating factors: Results can vary depending on the test chamber, possibly concealing problems

that could lead to failures in the field.

Additionally, only a few samples typically go through HALT because of the expense.

Improving validation with simulation No wonder, then, there has been a move to develop simulators able to predict how PCBs and electronics will behave in vibration and acceleration. This software does not eliminate the need for HALT. But it can highlight potential problems on a layout, so design teams can reduce HALT expenses and let reliability specialists have more time to focus on tougher issues. Bridging the electrical and mechanical design disciplines, vibration and acceleration simulation can shorten design cycles and help boost product reliability.

During vibration and acceleration simulation, the software typically applies an acceleration load in all directions.

For efficiency, the analysis takes place concurrently with component placement.

The software streamlines simulation setup

by automatically reading the physical stackup and board materials along with the component weight and boundary conditions. The user need only define the sweep frequency and constraints or boundary conditions to use during simulation. Finally, the simulation lets the user directly view the harmonic frequencies and applied stress on all components that could potentially cause a failure.

As a best case, two options for quick design simulation are available within the layout domain: First, a vibration mode calculates relative stress and deformation values to pinpoint weak links in contact areas of component leads and pins. The results can later be translated into a probability of potential component failure.

Second, a constant acceleration mode provides a linear static analysis which applies a constant acceleration to the design. This analysis can find von-Mises stress, deformation, and safety factors, all of which can later be translated into pass/fail values for components.

H ARM O NIC SOLUT IONS

CBG

Benefits • Industry-leading lead times •

Direct dimensional replacement against industry standards

•

Standard and custom solutions

•

High efficiency, high ratio, low-to-zero backlash

HBC

CBC

RLC

CONFIGURE & DOWNLOAD YOUR MODEL AT ConeTools.com

+1.888.994.2663

1/2 PAGE AD Electronics 5-18_Vs3_LT(USE).indd 83

conedrive.com

5/2/18 10:12 AM

2 HOSES+ 1 COUPLING =

TOTAL HYDRAULIC HOSE SOLUTION

KURT HYDRAULICS

Now hydraulic system designers can handle the most common pressure ranges for their applications by selecting from just two different hose styles and a single coupling style from KURT HYDRAULICS. That really simplifies life for everyone, and reduces inventory.

For pressure ranges of 3,000 to 6,500 PSI, KURT TUFF™ and E-Z BEND™ hydraulic hose along with KURT W-Style couplings provide a Total Hydraulic Solution. Start simplifying your life today – call TOLL FREE 1-866-257-7995.

www.kurthydraulics.com

#7527 Kurt Hyd 2-18_FPW.indd Ad Two hose one84 coupling r6 FPW.indd 1 Kurt Hydraulics

4/18/17 1:21 PM 5/3/18 11:06 AM

E l e c t r o n i c s

Once failed parts have been identified, a post-processor interface that animates the model of the board can help determine the exact variables and factors causing the part failure. A simplified post-processor view can highlight problematic parts, so designers can note and correct potential component failures. This facility allows engineers or designers with no product reliability expertise to easily decipher fatigue and vibration issues.

An advanced view mode can let the product development team identify the direct cause of a failure. Besides letting the designer customize the visualization of the virtual prototype, the post processing utility provides a way to configure the deformation intensity of the critical areas so designers can directly view how the board will deform. The deformation of the board can be animated so designers can see how the board will bend and move during vibration analysis.

Physical vibration and acceleration testing, known as Highly Accelerated Lifecycle Testing or HALT, provides a way to ensure the reliability of a product and identify potential failures caused by environmental factors.

Typical cases A few examples show the kind of physical testing that simulation can eliminate or reduce. In one case, a company tests its products for transportation stress by shipping samples to multiple destinations around the world and then back. Products returned without problems are considered acceptable. If problems arise, the design is revised and the process of physical testing repeats.

To test for issues during use, another company secures its product to a warehouse floor and performs physical vibration analysis. This process is, of course, expensive, time consuming, and potentially destructive.

Another company that designs boards containing large connectors would run physical tests without the connector(s) in place to make room for the required test jigs. The inaccurate test environment gave rise to false positive results.

Virtual vibration and acceleration simulation can provide more reliable results than the physical tests these examples illustrate. Modern simulators incorporate an algorithm for failure prediction as well as a rapid and accurate fully automated finite elements analysis.

In essence, the simulator runs a virtual HALT sequence during the PCB layout stage. The simulation helps visualize and identify problematic parts, detect components on the threshold of failure that would be missed during physical testing, and analyze pin-level von-Mises stress and deformation to determine failure probability and safety factors. Additionally, designers can simulate all designs as opposed to just those that are high-risk.

All in all, the ability to run virtual simulation on every board while in the layout domain lets engineers and designers detect issues early in the product development process before the board goes to the manufacturer.

Though vibration simulation has long been available, it is only recently that versions of these simulators have been specifically optimized for use on PCB designs. In that regard, Mentor, a Siemens business, offers Xpedition Design for Reliability (DFR), the first PCB design-specific vibration and acceleration simulation package. It is specifically optimized for the PCB layout designer.

Its component modeling library includes over 4,000 unique 3D solid models used to create highly defined parts for simulation.

DESIGN WORLD

Electronics 5-18_Vs3_LT(USE).indd 85

www.designworldonline.com  

The 3D library allows users to easily match geometries to their 2D cell database.

Designers can assemble the part models on the board and automatically mesh them for performance analysis including any required stiffeners and mechanical parts.

Patented post-processor technology lets designers quickly see high-failureprobability components and analyze boundary conditions, material properties, and environment profiles. To simulate stresses, Xpedition applies a force vector to each component. That information is used to determine the stress applied to that particular component and to understand if there is a potential failure. Currently, this is an early on analysis looking for component failures. Designers can see the stress intensity and deformation of the entire board and any resulting failures due to placement.

When problems arise, the program lets designers easily move components around.

And though this may be the age of artificial intelligence, it is still the human operator who must see the results and identify a resolution. Xpedition (DFR) provides layered results to make the process easier and animations for visualization.

Finally, it is worth noting that Xpedition (DFR) employs a mesh size a factor of four to eight times higher than that of most ordinary mechanical analysis software. This is in the interest of accurate modeling and typically works best on systems containing 32 GB of RAM. DW References Mentor, a Siemens business, www.mentor.com Xpedition demo, https://www.mentor. com/pcb/multimedia/overview/ using-vibration-analysis-to-improvereliability-131dd9a5-c5db-4316-afffd3e4d0c4e5f5

May 2018

85

5/3/18 11:06 AM

When adhesives

go wrong

Too often the adhesive selection for a medical device is left to the end of a project. It doesn’t help that there are so many adhesives as to make the choice overwhelming. With many potential negative outcomes, here are tips on making the right choice.

Tony Kaufman | New Business Ventures, 3M’s Critical and Chronic Care Solutions Division Del R. Lawson, Ph.D., R&D | manager, 3M’s Critical and Chronic Care Solutions Division

86

May 2018

Medical (Adhesives) 5-18_Vs4.LL.indd 86

www.designworldonline.com

5/2/18 10:26 AM

M e d i c a l

If adhesive is an integral component in your medical device design, it needs to be thought about sooner rather than later. It’s often a factor left to consider at a point too late in the product development process – where changes in, say, device housing material or plans for final finishing processes would be too expensive or cumbersome to execute.

1

DESIGN WORLD

Medical (Adhesives) 5-18_Vs4.LL.indd 87

www.designworldonline.com

Too often adhesive selection is approached with the mindset “tape is tape.” Perhaps different kinds might be interchangeable in everyday life, but that’s a dangerous oversimplification when designing a product someone will eventually be wearing and perhaps depending on to make critical health decisions. An adhesive’s characteristics and how it interacts with other device materials directly impacts the integrity and success of a device, regardless of whether the adhesive is adhering device components together or sticking the device directly to skin.

So, what can happen when adhesives aren’t given careful consideration? Below are three levels of potential outcomes, progressing from bad to worse.

Level one: Manufacturing issues You’ve designed a device and the prototype looks, feels and even functions how it’s intended. You and your team are rightfully proud of what you’ve created and are excited to keep it moving forward. Next stop, the production floor.

Adhesives can cause manufacturing complications for a variety of reasons. For example, an adhesive that is too soft can gum up the equipment during production or converting (cutting to shape). Now a fast-paced assembly line is halted for cleaning, causing production delays that add unforeseen costs to the project. The choice of liner (the support film that is stripped away from the adhesive before application to the target substrate) is another potentially complicating factor, if the liner properties are not tuned to or consistent with the speed of production. If the liner release is too

May 2018

87

5/2/18 10:26 AM

M e d i c a l

Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone

silicone

36” X 36” sheets, gaskets, SEALS, die cut parts

Solid Silicone Silicone Sponge Silicone Foam Strip N’ Stick®

High Temperature FDA Approved Medical Grade Commerical Grade High Strength Thermally Conductive Sold by Lineal Yard Available with adhesive No minimum orders

800-461-4161 sales@cshyde.com www.cshyde.com

Too often adhesive selection is approached with the mindset “tape is tape.” Perhaps different kinds might be interchangeable in everyday life, but that’s a dangerous oversimplification when designing a product someone will eventually be wearing and perhaps depending on to make critical health decisions. high, the materials can break or fail during production. By working closely with your supplier early in the process, the adhesive and backing combinations can be formulated to work seamlessly for the performance of the device and optimized to match the speed and friction of manufacturing.

Adhesive issues can also show up after the final product has been made. For example, imagine you are making a sterile bandage or wound care dressing. The adhesive cut well and is sealed and packaged all in-line. However, the adhesive chosen may be soft and would therefore have a tendency to slightly ooze on the outer edges of the bandage or dressing. Upon opening the package, the bandage or dressing sticks to the packaging, which compromises the sterile delivery of the product. Not only is this an annoyance for the customer, it could also potentially compromise the safety of the product.

Adhesives, though seemingly a small component, can have an immense impact on keeping manufacturing on schedule and its associated costs in check.

2

Level two: Device and adhesive fails Even when the device is successfully manufactured, an incompatible adhesive can rear its ugly head. Let’s explore a few of the larger concerns.

Adhesives impact the device’s accuracy.

In stick-to-skin applications, accuracy

88

May 2018

Medical (Adhesives) 5-18_Vs4.LL.indd 88

largely has to do with keeping the device adhered to the user’s skin for a specific amount of time. If an insufficient adhesive is used, the device is more likely to prematurely fall off. In applications in which the adhesive is adhering components together, those individual components could move, or sheer in some cases, altering the device’s precision. The addition of an extended border, or “skirt,” around the perimeter of a device can help avoid movement, improving wear duration and stability. Devices, like cardiac monitors, rely on sticking to specific locations for accuracy and proper function of the device.

Another issue that can affect the integrity of a device is called de-bonding.

As an example, de-bonding can have a particularly detrimental effect in the case of flex circuits de-bonding from the printed circuit board. If the two are unable to stay connected, the device’s reliability comes into question. In some situations, conductive pressure sensitive adhesives (PSAs) can replace a solder connection, allowing for a quicker, more efficient conductive connection. However, if the wrong PSA is used, the connection can start to come apart, creating inconsistent or incomplete connections, which results in device reliability issues.

Adhesives also have the potential to combine with other device materials, such as plasticizers, if they’re incompatible.

Plasticizers are chemical compounds added to other plastic materials to create softer, more flexible features for the base

www.designworldonline.com

DESIGN WORLD

5/4/18 11:50 AM

material of the device. PVC and many rubber materials use plasticizers to change their properties. Although the initial bond to these materials is typically good, it is the adhesion over time that poses a concern.

The plasticizer can migrate from the device’s base material into the adhesive. Just like it does for the plastic or rubber material, the plasticizer softens the adhesive. This can create a very “gooey” situation, changing the properties of the adhesive and base material.

This is a particularly frustrating defect, as it is not often seen early in the evaluation of the device – it shows up over time. If you are using plasticizers in your device design, a knowledgeable adhesives supplier can help you identify adhesives that are more tolerant of these materials.

Another important note, specifically for lab-on-a-chip devices, is that the wrong adhesive choice can compromise the integrity of the bioassay that is being tested, rendering it useless. Adhesives can also have remnants in them from manufacturing, finishing or other processes that can interact with the assay, affecting the accuracy of its read.

3

Level three: Risk to user and their skin Skin cannot be treated like just any other substrate– it is a living organ. It’s one of our body’s best sensors – detecting subtle temperature shifts and letting us know when we are hot and cold – and we have to be careful with it. Skin also knows and can be impacted when an inappropriate adhesive is applied to it.

Some outcomes in this area are more annoying than catastrophic, like the adhesive leaving residue on skin or picking up lint.

These are more unsightly than the cause of real damage. But still – these annoyances don’t have to happen, and they shouldn’t.

On the other hand, some outcomes are more serious and can potentially result in harm to the user. Allergic reactions and medical adhesive-related skin injuries (MARSIs) are common adverse reactions to applying the wrong adhesive to skin.

Incomplete curing or finishing of an adhesive can result in residual contaminants

DESIGN WORLD

Medical (Adhesives) 5-18_Vs4.LL.indd 89

migrating into or onto the skin; these are common causes of allergic reactions. It’s also important to know which adhesives are meant for stick-to-skin applications.

MARSIs are most commonly caused by choosing an adhesive that’s inappropriate for the application. They can compromise the integrity of the wearer’s skin. Some common types of MARSI are skin irritations like folliculitis (small rash-like bumps on the skin’s surface that are a result of irritation of hair follicles) and maceration (whitened layer of skin caused by trapped moisture, essentially drowning the skin), which increase the vulnerability of the skin; tension injuries and blisters (typically caused by adhesives that are stretched when applied and create excess tension on the skin as the tape relaxes); skin tears or skin stripping (when the stratum corneum and the epidermis, the first two layers of the skin, pull apart from another during adhesive removal).

The biggest takeaway here, and why skin is so important to the success of a device, is that once the user experiences pain, they won’t want to use that device again or recommend it to others. And in a world where reviews can be proliferated quickly by word of click, an entire company can experience and be affected by the backlash.

Now even faster

PCB-POOL® NEW

Quick turns from 8 hours On time or FREE FREE Laser SMT Stencil with every order

Prevention A lot can go wrong with an inadequate adhesive selection. The good news is that they are largely preventable. In order to avoid these potentially costly and time consuming reworks, there are three key points to consider before starting the design process:

• The substrate it’ll stick to: There

are distinct differences in property characteristics between steel and skin.

Choose an adhesive that’s congruent with and friendly to the substrate to which it will stick.

• The environment in which it’ll live:

Let’s say you design a device that functions and stores perfectly in the cold Minnesotan climate, but the device will be shipped to and used in a humid South American country. Materials that

www.designworldonline.com

May 2018

89

sales@beta-layout.us Phone: 916 241 9062

www.pcb-pool.com 5/4/18 11:50 AM

M e d i c a l

hold up in one climate may not function as intended in another. For example, consider humidity levels when selecting an adhesive. If moisture needs to move through the device and adhesive, the adhesive needs to be breathable to avoid swelling.

• The length of its lifetime: A device’s

intended lifetime impacts the level of durability the device will need to withstand. If a stick-to-skin device needs to adhere for three days, pick an adhesive that’s capable of adhering for that duration, not longer. Over-designing by choosing the strongest adhesive possible is just as, or more so, dangerous than one meant to

adhere for a matter of hours (doing this may cause the device to prematurely fall off).

While not a comprehensive list, these considerations will get a project started down the right path. Additional projectspecific questions, which are tougher to answer and often neglected until problems arise, will also need to be addressed.

Even with so many potential negative outcomes, adhesives aren’t as fickle as they may seem. That being said, the plethora of adhesive options can make the choice seem overwhelming. For more help selecting the right adhesive for your next project, check out FindMyAdhesive.com, and

Let’s Talk about Mobility Solutions

answer a series of project-specific questions to identify a list of the most appropriate medical adhesive suggestions. DW 3M | www.3m.com

WHAT DO YOU THINK?

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

www.designworldonline.com

April 2018

inside: Motion Control: How to design gearmotors for extreme ambient conditions

p. 54

Linear Motion: Robot-transfer unit and other linear-transfer system considerations

p. 60

3D CAD: CFD helps sports fans keep cool

p. 72

Tubingversus hose in mobile machinery p. 66

APRIL DW COVER GATEFOLD 4-18_FINAL.indd 1

4/4/18 4:43 PM

Check out the digital edition!

Productivity and safety are two critical factors that need to be addressed when selecting the right mobility solution for your equipment. www.tente.com 90

T 859.586.5558

mobility@tente-us.com

May 2018 www.designworldonline.com

Medical (Adhesives) 5-18_Vs4.LL.indd 90

So much happens between issues of Design World that even another issue would not be enough to keep up.

That’s why it makes sense to visit designworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community. designworldonline.com

DESIGN WORLD

5/4/18 1:42 PM

Accumold 1-18_DW.indd 91

5/1/18 10:30 AM

M e c h a n i c a l

is over: Playtime understanding internal

clearance in ball bearings

At first glance, ball bearings are relatively simple mechanisms.

However, an analysis of their internal geometries reveals that they are quite complex.

T

AST Bearings

The ball to raceway conformity, the radial play, and the number of balls all impact the ability a ball bearing to support loads under a variety of conditions. Typically, ball and other rolling element bearings are designed and assembled with a slight amount of internal looseness between the rolling elements (balls), and the raceways. This looseness results in both radial play and axial play in the bearing.

By the nature of their design and construction, the internal geometry of needle, roller, and tapered roller bearings is different than that found in ball bearings. For example, tapered roller bearings are somewhat unique in that the clearance within the bearing is adjusted at the time of assembly. Radial play and running clearance are of primary importance on all rolling element bearings.

In this Technical Information Sheet (TIS), the discussion of contact angle, deflection, end play, and preload applies primarily to ball bearings.

Definition of radial play in a ball bearing Radial play, or internal clearance, is the internal radial looseness in a bearing and is the measured value of the total radial movement of the outer ring concerning the

92

May 2018 www.designworldonline.com

Mechanical 5-18_Vs.5.LL.indd 92

inner ring in a plane perpendicular to the bearing axis. Engineers assemble ball bearings to radial play values depending upon the desired range. The radial play is determined by the actual raceway diameters and ball diameter.

Radial play can be verified on assembled bearings using specially designed gages. When measuring the radial play, the bearing is subjected to a standard gage load to ensure full contact between all the bearing components. With miniature and thin section bearings under such a load, the measured value is larger than the stated value for radial play. This situation is due to elastic deformation. Engineers use compensation factors in these cases.

DESIGN WORLD

5/7/18 1:56 PM

THE ORIGINAL

VARIABLE VOLUME PUMP,

REINVENTED FOR SAVINGS.

We set the standard with the industry’s first precision variable volume pumps. Now, the same space-saving design and reliable performance are available at a fraction of the cost.

Our new LPD Series Precision Dispense Pumps offer unmatched reliability AND affordability, giving you exceptional total value.

Compact Design Maintenance-free Multiple Dispense Volumes Available Worldwide Engineering Support Give your device the benefit of our experience.

Contact The Lee Company or visit www.LeePumps.com

See us at MD&M East, Booth #950

Innovation in Miniature 2 Pettipaug Rd, Westbrook CT 06498-0424 860-399-6281 | 1-800-LEE PLUG | www.TheLeeCo.com

The Lee Company

LEE_Revised-OrigPump_DW_12-17.indd 1 The Lee Company 5-18 (MD&M East booth#950).indd 93

WESTBROOK•LONDON•PARIS•FRANKFURT•MILAN•STOCKHOLM

11/21/17 5/1/18 11:37 10:31 AM AM

M e c h a n i c a l

Definition of axial play in a ball bearing Axial, or end play, is the maximum relative axial movement of the inner ring concerning the outer ring. The end play is directly related to the radial play of the ball bearing. In most part numbering systems, axial play is usually not specified.

There is often confusion with “looseness” and precision level.

Radial play is specified independently of ABEC tolerance classes for rings. With ball bearings, in most cases, the internal looseness should be removed in the assembly process by applying an axial preload across the pair of bearings. This can be accomplished with shims, springs, take up nuts, or other assembly techniques. Axial preload is also an important design parameter that affects both performance and life. Preload is explained in further detail in a separate Technical Information Sheet (TIS).

Contact angle in a ball bearing When ball bearings are axially preloaded a contact angle is established. The contact angle is the angle between a plane perpendicular to the bearing axis and a line joining the two contact points between the ball and the inner and outer raceways.

The initial contact angle is the contact angle when the bearing is subjected to the minimal axial force or load necessary to remove the looseness resulting from the radial play. Additional applied axial loads will increase the contact angle further. The greater the value of radial play in the bearing, the greater the resulting contact angle will be.

In most bearing applications, radial play, from a functional point of view, is more critical than axial play. As a result, it has become the standard purchasing specification.

Radial Play, Radial Contact

General design considerations The selection of the radial play value in a specific bearing application is an important design consideration. As described previously, radial play directly affects the contact angle and axial, or end, play of the bearing. Also, in operation, it is an important factor that has a significant influence on other factors such as noise, vibration, heat, stress, deflection, load distribution and fatigue life.

life, lower torque, and less axial deflection. In a pure thrust situation, a 15° increase in contact angle can result in over a 70% reduction in contact stress (ballto-raceway).

When a ball bearing is subjected to pure radial loads (or radial load with low axial load), lower radial play is normally recommended. This distributes the load over a greater number of balls. However, particularly with miniature bearings, bearings with low radial play should not be subjected to interference fits. This can result in negative clearance and drastically reduce life.

Misalignment and positioning: Higher values of radial play allow for greater misalignment and should be selected in cases where there is a high degree of shaft deflection. It should be noted that although a ball bearing can compensate (around 1 or less), misalignment greatly reduces bearing life. However, in cases with light loads, the impact of minor misalignment may be tolerable.

Tighter values of radial play will control and restrict radial movement. When axial positioning must be controlled or end play of “zero” is desired, it is recommended that the end play be removed by applying axial preload via shims, washers, or other assembly methods. Duplex bearings should be considered as well. It is not advisable to use low values of radial play to control end play.

Temperature: When a high-temperature gradient exists between the inner and outer rings a looser radial play is recommended.

Fitting: A looser or greater value of radial play should be selected when the bearing is mounted using interference fits. The radial clearance in the bearing is reduced after mounting due to deformation of the inner or outer rings. Miniature bearings’ thin cross sections reduce radial play by approximately 80% of the actual amount of interference. The radial play after mounting is the primary design consideration. Therefore, a tolerance study of the mating components should be completed and compensation for the interference at maximum material condition must be made.

For maximum life, a positive clearance after mounting is desired.

Axial Play

Loading: When a ball bearing is subjected to thrust loading, a higher contact angle will result in reduced ball to raceway stresses.

Greater values of radial play result in higher values of contact angle. Under these conditions, this will provide longer bearing

94

May 2018 www.designworldonline.com

Mechanical 5-18_Vs.5.LL.indd 94

DESIGN WORLD

5/2/18 10:47 AM

June 17-20 | Boston, MA

ENGINEERING IN THE DIGITAL ERA See the future in action! Over 80 technical sessions, hands-on demos, and trainings on MBD, Additive Manufacturing, Robotics, Smart Connected Product Design & more.

At LiveWorx, fine tune your skill-set to uncover new business opportunities and anticipate future requirements.

VISIT WWW.LIVEWORX.COM TO LEARN MORE

LiveWorx 4-18.indd 95

5/1/18 10:32 AM

M e c h a n i c a l

Contact Angle

better products. better solutions.

Speed: As mentioned previously, high values of radial play result in high values of contact angle.

When a bearing is rotating, the set of balls (or ball complement) is rotating about the pitch circle of the bearing, each ball is rotating about its own axis, and gyratory moments are acting upon the balls.

The magnitude of the gyratory moment is related to the contact angle. As rotational speed increases, the gyratory forces acting on the balls increases and there is sliding action between the balls and the raceways. This slippage results in lubricant film failure, increased heat, and potentially premature failure. The balance between the benefits of contact angle reducing stress must be weighed against the potential for lubricant failure due to ball slippage.

Regardless of what makes your conveyor and robot unique mk can provide a standard or custom solution — that meets your needs and keeps your business moving.

   

Specifying radial play: It is not practical, or perhaps even possible, to produce a group of bearings that all have the same amount of radial play. This is because all of the features of the bearing components (inner ring raceway, outer ring raceway, and balls) that effect radial play have manufacturing tolerances associated with them. Manufacturers measure and sort the bearing rings and balls so that they can be “matched” during the assembly process to achieve a specific range of radial play for a group (or manufacturing lot) of bearings.

There are several ways to specify radial play.

Radial play specifications are usually manufacturer dependent. Complete part number descriptions are detailed in a separate Technical Information Sheet (TIS). AST specifies radial play as follows: Metric design ball bearings (miniature and instrument) with a bore diameter of less than 10 mm. DW

Aluminum framed conveyors Pallet-handling conveyor systems Stainless steel conveyors Extruded aluminum t-slot framing

AST Bearings | www.astbearings.com

www.mknorthamerica.com 96

Robot Report Feb 2018.indd 1 Mechanical 5-18_Vs.5.LL.indd 96

May 2018

DESIGN WORLD

1/9/2018 9:27:20 AM 5/2/18 10:47 AM

Behind the Scenes. Ahead of the Curve. Inside the Corner Office.

MINNESOTA

JUNE 4-5, 2018 INTERCONTINENTAL ST. PAUL St. Paul, MN

ENGINEERING THE FUTURE OF MEDTECH IN THE TWIN CITIES WORLD-CLASS EDUCATION AND EXCLUSIVE INSIGHTS FROM THE TOP MINDS IN MEDTECH

NEW TRACKS FOR 2018

This year’s DeviceTalks Minnesota will feature four tracks packed with expertly curated content created by the industry for the industry. Our ECO-SYSTEM track will focus on the issues impacting medtech companies across Minnesota; Our TECHNOLOGY track will drill down on the hottest new tech that is changing medtech: Our REGULATORY 201 and CLINICAL 201 tracks, hosted by Medical Alley, will focus on the most important trends in regulatory and clinical development.

KEYNOTE SPEAKERS

HOSTED BY

HEIDI DOHSE MICHAEL J. PEDERSON Google Abbott Tour de Heart Foundation

HON. MELVIN CARTER Mayor of St. Paul

JEFFREY BREWER Bigfoot Biomedical

Visit devicetalks.com for more information!

Save 10% with code DEVICE2018

presented by:

@DeviceTalks

Sponsorship opportunities are available for future DeviceTalks programs. For more information, contact Brian Johnson at brian@massdevice.com

DeviceTalks 97 DT 2018 full ad_5-18.indd page ad 5-18_Vs3.indd 1

5/7/18 5/7/18 9:43 9:10 AM AM

Sensor www.sensortips.com

A Supplement to Design World - May 2018

Selecting the right sensor for motion applications

Sensor Tip cover 5-18_FINAL.indd 98

5/2/18 2:01 PM

No place to replace a battery.

PROVEN

40 YEAR OPERATING

LIFE

*

Highly remote locations call for Tadiran batteries.

Battery replacement is costly and often dangerous work. Reduce the risk with Tadiran bobbin-type lithium thionyl chloride (LiSOCl2) batteries. With an annual self-discharge rate of just 0.7% per year, Tadiran LiSOCl2 batteries enable low power consuming wireless devices to operate for up to 40 years on a single battery, up to 4 times longer than the competition. Our 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.

ANNUAL SELF-DISCHARGE TADIRAN

COMPETITORS

0.7%

Up to 3%

Take no chances. Take Tadiran batteries that last a lifetime.

* 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.

Tadiran — IoT HB 04-18.indd 99

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

5/1/18 10:35 AM

S e n s o r

T i p s

The basics of transducers— and where they make the most sense

Edited by: Paul J. Heney • VP, Editorial Director

Transducers are devices that convert one form of energy (some physical quantity) into another. These physical quantities are converted to electrical signals in either analog or digital form and can be used to gain information about or control some process. Common types of transducers used in industrial applications can include sensors to measure temperature, pressure, force, strain, liquid levels and flow rates, among others.

Transducers for motion control can be any one of a number of sensors such as rotary or linear encoders or resolvers for position feedback, sensors such as tachometers for speed sensing, and even proximity switches to initiate or halt some machine action.

In motion control, the measured variable is typically position or speed. Depending on application specifics, the right transducer may be an encoder or a resolver or a simple potentiometer.

100

May 2018 www.designworldonline.com

TRANSDUCERS 5-18_Sensor Supplement_Vs2.LL.indd 100

DESIGN WORLD

5/2/18 11:04 AM

These area sensors from Micro Detectors are multi-beam, through-beam sensors with emitter and receiver elements used for detecting the presence of any object by sensing the light beam intensity returning from the receiver.

In brushless dc motors, for instance, Hall effect sensors are used in place of a mechanical commutator and brushes. Hall effect sensors are solid-state, magnetic field sensors. They work on the principle that when a conductor with current flowing through it is placed in a magnetic field, the magnetic field induces a transverse (or sideways) force on the charge carriers, which pushes them to the sides of the conductor—negative to one side and positive to

DESIGN WORLD

TRANSDUCERS 5-18_Sensor Supplement_Vs2.LL.indd 101

the other side. This buildup of charge on the sides of the conductor induces a voltage. This effect is referred to as the Hall effect, after its discoverer, Edwin Hall.

Hall effect sensors are the most common method of determining rotor position in brushless dc motors, due to their low cost and ease of use with the permanent magnets of the rotor. And since the commutation happens in 60-degree increments, highresolution sensing and output are unnecessary.

www.designworldonline.com  

May 2018

101

5/2/18 11:04 AM

Master Bond_Vs2_5-18_Sensor Tips Supp(float ad).indd 102

5/1/18 10:42 AM

SensorAd_DesignWorld5_18.qxp_Layout 1 4/9/18 5:07 PM Page 1

S e n s o r

Passive Component

T i p s

Picking the right transducer Before selecting a transducer for an application, consider a number of things including the desired variable to be measured, the required accuracy or resolution, the type of output, as well as any size or space restrictions, environmental factors, and product lifetime and cost.

For motion control applications, what type of motion is involved, rotary or linear? For instance, encoders or resolvers measure rotary position while a tachometer can provide speed data. For linear motion there are linear encoders using a variety of sensing technologies including optical, capacitive, inductive, and magnetic.

Consider the needed accuracy for the application.

This includes factors such as linearity, resolution, and repeatability. Generally speaking, the greater the accuracy, the more expensive the transducer. This is why knowing the needed accuracy can help in selecting the best type of transducer and lowering the design costs by not paying for more resolution than the application demands.

What is the required measuring range? For linear measurements, is the range on the order of nanometers, a few millimeters, or several feet? For rotary applications, if measured in degrees, is the angular distance more or less than 360 degrees? Is the type of encoder needed a single turn or multi-turn device?

What type of output is needed? Is it voltage or current?

Digital or analog? Many transducers are programmable through a simple data connection, such as a PC-to-USB link. Other interface options can include encoder-specific communication links like SSI (synchronous serial interface), BiSS (bi-directional serial/synchronous), or PROFINET.

Lastly, there may be other considerations such as any physical size or weight restrictions or special installation or mounting requirements. Environmental conditions are another important consideration. The transducer should be able to withstand the environmental conditions of the application. Some of the most common conditions to consider are EMI/RFI noise, shock and vibration disturbances, extreme heat or cold, and environmental contaminants such as dirt, dust, moisture, and corrosive chemicals. DW

Sensor Solutions Bus Bar with Integrated Current Sense Element

• High Precision Sensing by Kelvin Terminals • Custom Shapes and Forms Available

Battery Strap

• HS – Voltage Pins Available for Current Detecting • Bus Bar & Cable Attachment Configurations Available

Air Flow Sensors High Temperature

• SDT310 – Operational at +600°C • Low Thermal Time Constant of 3.2 seconds

Low Temperature

• SDT101 – Operational at +150°C & +300°C • Thermal Time Constant of 6 seconds

WHAT DO YOU THINK?

To learn more about KOA Speer’s sensor solutions, visit KOASpeer.com

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

DESIGN WORLD

TRANSDUCERS 5-18_Sensor Supplement_Vs2.LL.indd 103

May 2018

103

5/2/18 11:05 AM

SENSORS

KOA Speer Electronics Passive Component Sensor Solutions KOA Speer offers a wide range of passive component sensors to help your design make the leap from Concept to Reality. Our Bus Bar with an Integrated Current Sense Element provides precision sensing with Kelvin terminals and is available in custom sizes and shapes to satisfy your mechanical package requirements.

Batter Straps have been developed with voltage pins available for current detecting. Bus bar and cable attachment configurations can be included.

Air Flow Sensors are available for high temperature applications, operational at +600ºC with a low thermal constant of 3.2 seconds. Low temperature models for +150ºC and +300ºC applications have a thermal time constant of 6 seconds.

KOA Speer Electronics www.KOASpeer.com

KOA SPEER ELECTRONICS, INC.

SENSORS

Master Bond Inc.

104

Epoxy Meets Airbus Specifications for Flame Retardancy Master Bond EP93FRHT non-halogenated epoxy was developed for aircraft applications where stringent requirements for flame retardancy, smoke emission, and toxicity levels must be met.

This material has passed rigorous Airbus requirements including the following tests: • vertical ignition • optical density of smoke generated by solid materials • toxic gas analysis All three tests passed with flying colors, well under the permissible acceptable criteria.

Master Bond EP93FRHT is a two component epoxy that can be used as an adhesive, sealant and potting system. It is ideal for use in aircraft interior applications. To learn more about this specialty product, contact us today.

May 2018 www.designworldonline.com

Sensor Tips Supplement 5-18.indd 104

MASTER BOND INC. 154 Hobart Street Hackensack, NJ 07601-3922 main@masterbond.com Tel: +1-201-343-8983 Fax: +1-201-343-2132

DESIGN WORLD

5/2/18 11:08 AM

SENSORS

Tadiran Batteries TLI Series rechargeable Li-ion batteries deliver 20-year operating life Unlike consumer grade rechargeable Lithium-on (Li-ion) batteries that have a maximum operating life of 5 years and 500 full recharge cycles, industrial grade TLI Series Li-ion batteries can operate for up to 20 years and 5,000 full recharge cycles, making them ideal for long-term deployment in remote locations. These ruggedly constructed batteries can also handle extreme temperatures ranging from -40°C to 85°C, with storage up to 90°C. TLI Series batteries outperform consumer grade batteries by delivering the high pulses (5A for AA cell) required to power two-way wireless communications, making them ideal for powering IIoT-connected devices that utilize energy harvesting.

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

» A global educational engineering network. Connect, share and learn today. www.engineeringexchange.com

It’s not a web page, it’s an industry information site

designworldonline.com

DESIGN WORLD

Sensor Tips Supplement 5-18.indd 105

www.designworldonline.com

May 2018

105

5/2/18 11:08 AM

Product World Exoskeleton joint actuator Maxon maxonmotorusa.com This exoskeleton drive is for use in robotic limbs. It's complete joint actuation unit that consists of a pancake brushless dc motor with inertia optimized rotor. Also included is an internal high-resolution encoder, planetary gearhead with absolute encoder and a position controller with CAN and RS232 interface. Fitting absolute encoder directly at the joint rotation provides designers increased positioning accuracy. The unit delivers 54 Nm of continuous torque and 120 Nm on a 20% duty cycle and may be operated on supplies between 10 and 50 Vdc and the actuation speed is up to 22 rpm. Other features include: compact housing, integrated controller and reduced weight and cost and it is a suitable choice for use in hip and knee exoskeletons.

Fully Integrated Display

Data Image USA - www.dataimagelcd.com - 407.478.4064 heldred@dataimagelcd.com

106

May 2018 www.designworldonline.com

Product World 5-18_Vs5.LL.indd 106

DESIGN WORLD

5/2/18 11:38 AM

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

Couplings with hubs for k6 and j6 shafts Zero-Max zero-max.com

Ballscrews & Rollerscrews

ServoClass couplings in both Single and Double Flex models are now available with hubs for k6 and

Industrial Robots

j6 shafts. These couplings have torsional stiffness and are designed to handle high speed reversing loads and precise positioning requirements.

Linear Motors

The Single and Double Flex

ServoClass models handle bore diameters from 0.375 (10 mm) to 1.125-in. (30 mm). These couplings are lightweight with 304 stainless

Linear Actuators

steel disc packs, aluminum hubs, and center members. All models and sizes have clamp-style hubs with corrosion resistant socket head cap screws. All materials are RoHS compliant. ServoClass couplings provide zero-backlash, require no maintenance, and are quick and easy to install.

With the ability to mount on k6 and j6 shafts, these couplings are an acceptable

Linear Guideways

alternative to beam or bellow’s style couplings. They reduce shock loads and prevent positioning errors. When the application cycle becomes faster, they outperform beam couplings, which are subject to torsional wind up, and bellows couplings, which have a fragile design. There are nineteen sizes of standard off-the-shelf ServoClass couplings. These couplings are suitable for clean room applications in automation,

Linear Encoders / Positioning Measurement Systems

packaging, semi-conductor assembly, laboratory automation, medical equipment and for most products that use ball screws and servomotors.

AC Servo Motors

Hiwin D1 and D2 Servo Drives

For more information visit

www.hiwin.com

DESIGN WORLD

Product World 5-18_Vs5.LL.indd 107

www.designworldonline.com 

May 2018

107

5/2/18 11:38 AM

rethink the possibilities

TM

over 44 years of innovative excellence

Don’t stress

Central has your custom solution.

When designers can't find discrete semiconductors that can solve their problems, they turn to Central for the custom solutions they need. Central's robust services and capabilities offering is continuously expanding.

• Custom device configurations • Custom wafer metallization/diffusion TM • Multi-Discrete Modules combining multiple devices TM • Super Industrial solutions for extreme environments

For more information, call us at: 631.435.1110 or view solutions online: www.centralsemi.com/cdp35 diodes & rectifiers

bipolar transistors

Central Semiconductor Corp.

145 Adams Ave • Hauppauge, NY • 11788 • USA 631.435.1110 • www.centralsemi.com

Central SemiConductor 5-18.indd 108

MOSFETs & JFETs

protection devices

multi discrete modules (MDMs ) TM

thyristors

require a custom solution?

4/27/18 8:23 AM

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

Profile guide rail brakes Nexen nexengroup.com Profile guide rail brakes are now available in a wider range of sizes: 15 to 65 mm, and are WE Series Linear Guideway Wide Series Ball Type.

fully compatible with an even wider range of guide rail manufacturers including: THK, NSK, IKO, HIWIN, INA, SKF, Star, Bosch, Accu Tech and Schneeberger. As a result, they provide great first fit and suitable redundancy in a range of OEM and after market applications.

Profile Guide Rail Brakes provide fast engagement at 0.049 to 0.080 seconds, high static holding force to 2,600 N (585 lb) and can be combined to provide higher holding forces as needed. They also offer maintenance-free operation.

PG Series Linear Guideway Integrated Magnetic Encoder.

Key Bellevilles, Inc. LARGEST MANUFACTURER OF DISC SPRINGS IN THE WORLD Live Load with Belleville Disc Springs LARGEST STOCK OF STAINLESS STEEL AND INCONEL SPRINGS IN THE WORLD HIGH TEMPERATURE FLANGE BOLT

FREE ENGINEERING ASSISTANCE FLANGE BOLTING SERIES ON STOCK H-13, STAINLESS, INCONEL, AND TITANIUM

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

MANUFACTURED TO DIN AND NACE SPECS Metric and English sizes available

OUR PRICES ARE THE BEST ~ BUY DIRECT ~ Made in the U.S.A.

Immediate Delivery!

24-Hour Service 7 Days a Week!

Tel: 724-295-5111 Fax: 724-295-2570 Toll Free: Tel: 800-245-3600 Fax: 800-847-1672

Visit our Website: www.keybellevilles.com for a FREE Design CD-ROM

LIVE LOADING VALVE PACKING GLANDS

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

100 Key Lan e Leechbur g, PA 15656, U.S.A. Visit our Website a t: www,key bellevilles.com Email: sales@keybellevilles.com

DESIGN WORLD

Product World 5-18_Vs5.LL.indd 109

www.designworldonline.com 

May 2018

109

5/2/18 11:39 AM

Product World Integrated motor/actuator Curtiss-Wright curtisswright.com The Exlar GTX080 next-generation integrated motor/actuator’s design has substantial performance improvements over its predecessor. Incorporating a patented inverted roller screw technology, the GTX080’s high power density and compact form factor make it a suitable replacement for hydraulic cylinders.

The GTX Series actuators offer the power, precision, and

programmability of a servo system while minimizing the maintenance headaches and mess of hydraulics. With continuous force ratings up to 5680 N (1277 lbf), speeds up to 4200 rpm, and stroke lengths from 100 to 450 mm (18-in.), the GTX080 can be applied across a range of factory automation applications.

The GTX Series features include: • High capacity planetary roller screws offering up to 15X the life and significantly higher shock load resistance

SJ-Series of Preform Jumpers:

than a comparably sized ball screw

A Reliable, Affordable Solution for SMT Design Requirements

• IP65S (min.) environmental protection

The reliable SJ-Series from Components Corporation is the first true surface mount jumper developed specifically for SMT applications, offering strength and stability when mounted.

• Seamless integration into most leading motion

• Ultra-low profile with sufficient clearance for circuit paths.

control architectures • Removable front seal bushing greatly simplifies maintenance and re-greasing of nut assembly to maximize actuator life

• No insulation required.

• Available in 1206 and 0805 package sizes.

• RoHS/Reach/Conflict Materials compliant.

DESIGNED FOR VALUE. COMPONENTS

C CVALUED FOR PERFORMANCE. CORPORATION ®

cc

COMPONENTS CORPORATION

110

6 Kinsey Place, Denville, NJ 07834-2692 866-426-6726 www.componentscorp.com

May 2018 www.designworldonline.com

Product World 5-18_Vs5.LL.indd 110

DESIGN WORLD

5/2/18 11:41 AM

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

Biodegradable rail flank lubricating grease Klüber Lubrication klueber.com/us

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

Klüberrail AE 62-21 is an environmentally compatible and fully synthetic grease for stationary rail flank lubrication systems. Klüberrail AE 62-21 is an easily pumpable grease that adheres well to rails and flanks while reducing friction value. The special composition of the gray lubricating grease ensures rapid biodegradability acc.

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

to OECD 301 F as well as good wear protection for wheels and rails.

Klüberrail AE 62-21 is very adhesive and resistant to water, which largely prevents the

lubricant from being washed off by rain. Klüberrail AE 62-21 optimizes the friction value between wheel and rail, thus reducing both the stick-slip effect on curves and the generation of noise. The lubricant forms a lubricant depot on the rail flank which is picked up and distributed by the wheels of the train.

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

Failsafe force guided relays AutomationDirect automationdirect.com Dold force guided relays are electromechanical switching devices that offer safe operation through

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

mechanically linked contacts to ensure that all contacts move at the same time, and prevent movement if any contact is immobilized.

Dold force guided relays have at

least one NC contact set and one NO

AC Servo Motors.

contact set. Dold force guided relays are available with up to 6 poles in several NO/NC combinations with 5A contact rating and provide a large wire cross-section (12-24 AWG) to reduce thermal load on wires.

Mounting options include 35mm DIN rail mount integrated relay modules or

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

mounting socket with plug-in relay; the relays include diode protection and modules provide LED indication.

DESIGN WORLD

Product World 5-18_Vs5.LL.indd 111

www.designworldonline.com

May 2018

111

5/2/18 11:40 AM

Ad Index

SALES

Accumold ........................................................ 91

John Evans’ Sons, Inc. ...............................49

Acopian ............................................................ 82

Keller America Inc ......................................... 77

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

Key Bellevilles Inc. ...................................... 109

mcaruso@wtwhmedia.com 469.855.7344

Allied Electronics &

Keystone Electronics Corp. ...................... 35

Garrett Cona

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

Kurt Hydraulics ..............................................84

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

Madison Company ....................................... 63

Altech Corporation .................................. 19,21

Maryland Precision Spring ........................ 43

AMETEK DFS .................................................. 27

Master Bond ................................................ 106

Analog Devices, Inc. .................................... 39

Memory Protection Devices ..................... 37

Aurora Bearing Company ......................... 45

Metcase Enclosures ..................................... 17

Automation24, Inc. .......................................69

mk North America ........................................96

AutomationDirect ............................... 1, Insert

NB Corporation ............................................. 33

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

Novotechnik ................................................... 78

Beta Layout ....................................................89

NSK Precision ................................................. 41

Bimba ................................................................. 10

Opto 22 ............................................................. 51

Tom Lazar

Mike Caruso

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

Jessica East

jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

Michael Ference

mference@wtwhmedia.com 408.769.1188 @mrference

Michelle Flando

mflando@wtwhmedia.com 440.670.4772 @mflando

LEADERSHIP TEAM

Publisher Mike Emich

Bodine Electric Company ..........................64

PBC Linear ...................................................... 73

Boker’s Inc. ...................................................... 29

Penn Engineering ........................................ 58

Caplugs ............................................................ 55

PHD, Inc. ..........................................................40

Carlo Gavazzi ................................................. 54

PTC Liveworx ................................................. 95

Central Semiconductor Corp. ................ 108

Pyramid Incorporated ................................. 79

Cicoil .....................................................................7

Renishaw ........................................................ 38

CMT .................................................................. 53

Rotor Clip ......................................................... 72

Components Corporation .........................110

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

Cone Drive ...................................................... 83

SIKO Products ................................................ 29

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

CS Hyde Company .......................................88

Smalley Steel Ring ..........................................9

DATA IMAGE Corporation ........................ 106

Smart Products USA, Inc. .......................... 65

Neel Gleason

Del-tron ............................................................. 71

Southern New Hampshire

Digi-Key Electronics ...................................... 15

University ................................................. 23

Eagle Stainless Tube ............................. 30,31

Tensility International Corporation ........ 24

ebm-papst Inc. ............................................... 13

TENTE Casters ..............................................90

Elesa USA Corp. ............................................ 70

The Arthur G. Russell Co., Inc. ................. 34

Encoder Products Company .................... 59

The Lee Company ....................................... 93

EXAIR Corporation ..........................................5

THK Corporate ..............................................IFC

Fabco-Air .......................................................... 16

Tormach ........................................................... 42

Fixtureworks ................................................... 47

Trim Lok ............................................................ 20

HIWIN .................................................. 107,109,111

Whittet-Higgins ............................................ 25

Indium Corporation ...................................... 57

Xcentric Mold & Engineering ..................... 12

Mike Francesconi

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director

Marshall Matheson

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

J.W. Winco, Inc. .............................................. 79

Sensor Tips Supplement

FOLLOW US ON

Sensor www.sensortips.com

A Supplement to Design World - May 2018

KOA Speer Electronics, Inc. .......................... 103 Master Bond ...................................................... 102 Tadiran Batteries ............................................... 99

Selecting the right sensor for motion applications

Sensor Tip cover 5-18_FINAL.indd 98

5/2/18 2:01 PM

Follow the whole team on twitter @DesignWorld

DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2018 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Subscription Rates: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

Subscriber Services: To order a subscription or change your address, please email: designworld@omeda.com, or visit our web site at www.designworldonline.com DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Design World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

112

May 2018 www.designworldonline.com

AD INDEX_5-18_Vs1.indd 112

DESIGN WORLD

5/3/18 12:56 PM

2018 WINNER

Beckhoff 5-18.indd 1

5/1/18 10:33 AM

+

= $?

What’s the cost?

Actually, a single-worm gearmotor costs a lot more than just the gears and motor.

You must also add the dollars spent every year in wasted energy.

A premium efficient motor may yield 2-3% energy savings, but you still lose 50% or more through an inefficient worm gear.

Solution: Use a helical-bevel gearmotor from SEW-EURODRIVE and get 96% gear efficiency. It makes a lot of cents!

seweurodrive.com | 864-439-7537

SEW Eurodrive 5-18_BC.indd 1

4/27/18 8:22 AM