DESIGN WORLD MAY 2019 by WTWH Media LLC

www.designworldonline.com

May 2019

inside: MOTION CONTROL: Selecting the best

servomotors with integrated drives

p. 118

MEDICAL: 8 medical device design

specifications

p. 132

INTERNET OF

THINGS:

Improving IIoT implementation

p. 148

A look into factor 1 proximity sensors page 110

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Built a few miles from its current headquarters, the plant represents a 250-million-euro investment for the company, as well as a bold step forward toward the future of Industry 4.0. Uwe Schard, Managing Director of IT and Industry Business Units for Rittal, explained that the company purchased more land in the area in 2015, due to the disappearance of some automobile manufacturing. The decision was made to combine a new factory with a global logistics center and innovation center — providing some simpler material flow issues. But what really impressed me was the forethought in developing this new facility. Rittal’s management decided that they needed to build a new state-of-the-art digital factory before their current headquarters plant began to fall behind technologically. This wasn’t a crisis decision — this was a planned way to stay ahead of the competition for years to come. Schard said that setup possibilities for the new factory were simulated over the course of about 3,000 hours (135 days’ worth of computer time!). Engineers optimized every area from the decoupling sections to the paint shop — something that really wouldn’t have been possible to do on a piece of paper. “So, you have your ideas, you analyze your process, and you get a layout — but you have to simulate this all, because you’ve got to get the best output, in the most efficient manner,” he said. “We had 17 weeks where computers were just simulating, simulating.” “The plant is to be fully aligned with efficient Industry 4.0 principles,” said Prof. Friedhelm Loh, CEO of the Friedhelm Loh Group, Rittal’s parent company. “The new manufacturing site will also safeguard future competitiveness for our customers and our own business. The total investment of 250 million euros is a positive statement in terms of the regional economy and the 290 jobs at our Haiger plant. We have quite consciously decided to proactively shape the future with the local people who made us what we are today.” The new factory is comprised of roughly 260,000 sq-ft of floor space, and houses more than 100 high-tech machines. The plant will manufacture 9,000 AX compact and KX small enclosures daily, processing approximately 35,000 metric tons of steel each year. Equipment here is highly automated, producing individual work pieces and assemblies efficiently. In the past, individual steps such as cutting to size, edging, welding and painting were transactional, sequential and independent of one another. Now, all workers, machines and materials are more integrated into the manufacturing execution system. At the end of the process, the individual assemblies are automatically merged and a QR code is applied. The machines and handling systems communicate with each other and with higherlevel control systems via Industry 4.0-capable networks. Materials and components are moved by 20 automated guided vehicles. Packaging, marking and transfer to the distribution center are also performed automatically. And knowledge-based learning systems will enable predictive maintenance, preventing faults from occurring and minimizing downtime. The Haiger facility is an interesting pilot for real-world implementation of Industry 4.0 — and Rittal says it will act as a role model for the company’s international operations. DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

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Teschler on Topic Get ready for engineers who earn their degrees online Long ago, the engineering magazine that employed me explored the idea of working with local universities on an educational program. Our concept involved instructing engineers on newly emerging technologies, but without requiring them to actually sit in a classroom. This was long before the days of the internet. What we suggested was novel for its time and would have exposed the school to a large group of new potential students. But the concept went over like a lead balloon with the colleges we approached. The reason why became evident quickly: The schools had physical buildings. Any idea that didn’t involve putting people in them was a nonstarter. I was reminded of this little fiasco recently when I ran across an article in The Economist magazine that, shocker, found universities tend to resist online learning. This reality elicited handwringing on the part of Economist editors because online teaching could drastically cut education costs. And in the age of undergraduates sometimes carrying six-figure student loans, there is little question that higher education costs desperately need trimming. Readers for whom

undergrad tuition is a distant memory might gain illumination on the subject from the results of a study done by the online publication Business Insider. BI calculated the cost of the credit hours (not including fees, room and board) needed to graduate from some of the most expensive U.S. universities. Here are a few highlights: U. of Chicago, $188,556 for four years; Dartmouth, $187,0523; New York University, $174, 984; USC, $182,408; Columbia University, $213,520. Of course, tuition at many state universities are less stratospheric. To pick one example, four years of tuition at the University of Nebraska-Lincoln runs about $31,000 for in-state students, about $97,000 for out-ofstaters. (Though engineering students at UN-L pay more.) Online courses are a way to potentially make even UN-L-type fees much cheaper. And the evidence is that students learn as much doing online coursework they would sitting in a conventional class. That was one conclusion of a study by the nonprofit educational organization Ithaka Harbors Inc. Its researchers examined several courses where students spent more than half their time working with programmed learning software rather than sitting through lectures. It turned out students learned as much this way as in conventional classes but with

educational costs cut by more than 50% in some cases. Another study by the Center for Academic Transformation at Rensselaer Polytechnic Institute reached similar conclusions. It looked at 30 institutions that employed some kind of online learning and found they had reduced costs by an average of 40% with no discernable drop in student performance. Despite such documentation, it’s likely that the first institutions to fully embrace online learning will be those on the educational fringe. For a hint at what might be possible, consider a non-profit American-accredited online institution called University of the People. You can get a four-year BS degree in computer science there for a mere $4,060. And those for whom that figure is unaffordable can get scholarships. There are logistical hurdles to overcome before U of P-style education costs can go mainstream – one big one is that the institution’s faculty consist of academics who volunteer their time. And it’s not clear how courses that require lab work can go online. Nevertheless, don’t be surprised if the engineers you work with in coming years have done most of their coursework from a laptop in their bedroom. DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW_LeeTeschler

May 2019 www.designworldonline.com

Lee Teschler Column 5-19_V3_LT.LL.indd 6

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Technology Forward

To 3D print or buy? A criticism often made against 3D printing / additive manufacturing is why make it if you can buy it at your local Home Depot, Lowes, or other store? It’s a question I’ve often entertained. From a pragmatic level, it would appear that simply buying a common, easy to procure part would be faster, easier, and probably less expensive that to 3D print it.

But is that always true? Mark Bashor, a manufacturing engineer with GoEngineer, makes a compelling argument for making versus buying. Bashor was responding to a comment that one should always buy, if you can, rather than make, because it “will be cheaper when compared to the total cost of 3D printing it on a commercial grade system.” But Bashor has had different experiences. His approach is to consider each buy versus make situation on the unique merits. For Bashor, the general rule of buying when you can does not always hold up. Bashor cited an example of a time when he was facing a tight customer deadline. He was going to backfill a printed prototype with epoxy but he did not have a strong enough stirring tool to mix the epoxy. He had to get the prototype to the customer by the end of the day, and he had other obligations that limited how much time he could spend on this prototype. But he found an idle 3D printer, and quickly worked up a stir tool on

a CAD program. Then sent the file to that printer. The 3D printer took about an hour and seven minutes to print two stirrers for his mixer. It would have taken him longer to leave the office, drive to the local hardware store, buy the right stirrer and return to the office. So in this example, the 3D printer saved time. Now what about cost? Bashor reports that total material cost was less than $11. Even here, the 3D printed solution was at least equivalent to a purchased solution. Thus, just because you can buy your part locally, it does not mean that is the fastest, least expensive choice. One of the more interesting aspects to 3D printing is how it breaks traditional rules or commonly held assumptions. It can offer unique solutions, if users are willing to explore. Some days, it might be more efficient to buy. Some days, it might be more efficient to make. To have the perspective that one route is always the best route is to lose an opportunity, especially when there’s a game-changing tool like 3D printing around. DW

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

May 2019 www.designworldonline.com

Tech Forward 5-19_Vs3.LL.indd 8

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Green Engineering Paul J. Heney

• VP, Editorial Director

A conceptual view of a transistor device that controls photoluminescence (red cone) emitted by a hybrid perovskite crystal (red box) that is excited by a blue laser beam after voltage is applied to an electrode (the gate).

Exotic crystal semiconductor may

lead to better solar cells Scientists have found a new way to control light emitted by exotic crystal semiconductors, and this finding might lead to more efficient solar cells as well as other advances in electronics, according to a Rutgers-led study in the journal Materials Today. The discovery involves crystals called hybrid perovskites, which consist of interlocking organic and inorganic materials that have shown great promise for use in solar cells. The finding could also lead to novel electronic displays, sensors and other devices activated by light and bring increased efficiency at a lower cost to manufacturing of optoelectronics, which harness light. The team found a new way to control light (known as photoluminescence) emitted when perovskites are excited by a laser. The intensity of light emitted by a hybrid perovskite crystal can be increased by up to 100 times, simply by adjusting voltage applied to an electrode on the crystal surface. “To the best of our knowledge, this is the first time that the photoluminescence of a material has been reversibly controlled to such a wide degree with voltage,” said senior author Vitaly Podzorov, a professor in the Department of Physics and Astronomy in the School of Arts and Sciences at Rutgers University–New Brunswick. “Previously, to change the intensity of photoluminescence, you had to change the temperature or apply enormous pressure to a crystal, which was cumbersome and costly. We can do it simply within a small electronic device at room temperature.”

DESIGN WORLD

Green Engineering 5-19_Vs2.LL.indd 11

Semiconductors like these perovskites have properties that lie between those of the metals that conduct electricity and non-conducting insulators. Their conductivity can be tuned in a very wide range, making them indispensable for all modern electronics. “All the wonderful modern electronic gadgets and technologies we enjoy today, be it a smartphone, a memory stick, powerful telecommunications and the internet, high-resolution cameras or supercomputers, have become possible largely due to the decades of painstaking research in semiconductor physics,” Podzorov said. Understanding photoluminescence is important for designing devices that control, generate or detect light, including solar cells, LED lights and light sensors. The scientists discovered that defects in crystals reduce the emission of light and applying voltage restores the intensity of photoluminescence. Hybrid perovskites are more efficient — and much easier and cheaper to make — than standard commercial siliconbased solar cells, and the study could help lead to their widespread use, Podzorov said. An important next step would be to investigate different types of perovskite materials, which may lead to better and more efficient materials in which photoluminescence can be controlled in a wider range of intensities or with smaller voltage. DW

www.designworldonline.com

May 2019

5/2/19 9:39 AM

Contents 5 • 2019

•

vol 14 no 5

•

designworldonline.com

INSIDE:

A Supplement to Design World - May 2019 www.designworldonline.com

• The Robotics Summit 2019 takes a close look at mobile robots ............................62 • What Amazon’s acquisition of Canvas Technology means for mobile robots ..........66 • Augmenting SLAM technology with deep learning ............................................71 • Expert roundtable: mobile robotics challenges and opportunities .........................82 • Integrating AI with fleet management software advances collaboration for autonomous mobile robots ............................88 • How 5G will impact mobile robots ...............95

Mobile robotics matures

118

60-108 ROBOT REPORT COVER_5-19_Vs3.indd 60

140 _3D PRINTING

Selecting the best servomotors with integrated drives

How to select the right 3D printer

Although new distributed servo drive systems promise incredible performance, engineers should consider cabling, form factor, and safety integration before standardizing on a platform.

How to improve ball screw rigidity

Ball screw rigidity depends not only on the screw shaft and ball nut, but also on the thrust bearings and on the ball nut and bearing housings.

A look into factor 1 proximity sensors

148 _INTERNET OF THINGS

ON THE COVER

Inductive proximity sensors are suitable for many applications. Selecting models with factor 1 capability makes them even easier to employ.

No matter the purpose, selecting the right adhesive for the right application plays a direct role in a medical device’s overall success and ability to fulfill its intended purpose.

| courtesy of AutomationDirect.

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

2019

140 May 2019 www.designworldonline.com

CONTENTS 5-19_Vs4.LL.indd 12

5/6/19 11:11 AM

The IIoT provides many benefits to machine builders and their customers, but new solutions are needed to reduce complexity and expense while maintaining a high level of security.

8 medical device design specifications questions

Sensor Tip cover 5-19_FINAL.indd 109

109-116

Improving IIoT implementation

132 _MEDICAL

A Supplement to Design World - May 2019

Factors of cost, quality, function and material requirements help narrow the field.

126 _LINEAR MOTION

5/3/19 10:25 AM

Sensor www.sensortips.com

118 _MOTION CONTROL

page 76

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Machine Tool Components

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• contents departments 04 Insights 06 Teschler on Topic

Spring Plungers

08 Technology Forward 11 Green Engineering 18 MC2 School

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20 Design For Industry 30 Design Notes

Workholding Grippers

CAE Solutions

Internet of Things

155 Product World

Fixturing Accessories

160 Ad Index

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

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May 2019

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w w w. d e s i g nw o r l d o n l i n e . c o m / M C 2

Hot off the digital press:

MC² online reference covering linear systems

MC2 is a new online reference series for design engineers needing

information about motion components and systems. Curated by Design World’s editorial team, each installment is a digital content hub with comprehensive background information, current trends, typical and emerging applications, and FAQs on one motion technology.

May 2019 installment:

Linear guides and slide systems We invite you access and bookmark the first MC2 at

Lisa Eitel

Paul Heney

www.designworldonline.com/MC2.

Recall that linear-motion supports take the form of guide rails, slides, and ways … and include profile rails, linear bearings, guide wheels, slides, and plain-bearing systems that bear load while employing either sliding or rolling to allow translational motion. Typical designs pair rail or shaft with mating carriages or runner blocks. At www.designworldonline.com/linearmotion-control-classroom, you’ll find resources on linear guides and slides to help you choose from the vast array of these linear systems … and satisfy requirements for loading, stroke, speed, accuracy, and design life. Also check out the references on preloading considerations and marketspecific topics … including machine-tool applications and semiconductor manufacturing, where rolling linear guides abound; advanced medical applications, where square rails are common; and simpler machine axes, where forgiving slide designs maintain machine-build ruggedness. n

Danielle Collins

Miles Budimir

The MC2 online reference series also includes sizing and selection videos.

May 2019 www.designworldonline.com

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Round shaft or profiled rail? How to choose Choosing the wrong linear motion system can be a costly mistake — resulting in design or structural changes, poor machine performance, or oversized components of unnecessarily high cost. Although both round shafts and profiled rails may appear to be suitable options for most applications, there are typically a few criteria that dictate which technology is more appropriate. n Read this piece and the following articles at designworldonline.com/linear-motion-control-classroom.

Common applications for linear rails Linear rails are the backbone of many industrial applications, providing low-friction guidance and high stiffness for loads that can range from just a few grams to thousands of kilograms. Their range of sizes, accuracy classes, and preloads make linear rails suitable for virtually any performance requirement.

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Design for Industry Material Handling

Multiple options for moving product

Corners, turns, lifts, and various load sizes demand a flexible handling system. The 2200 Series Precision Move

Pallet Systems come with heavy load corners, tight turn corners, low-profile lift and locates, elevators, and more. The heavy load corner design allows the conveyor to carry pallet loads up to 70 lb around 90° or 180° corners for loop capacity for larger, heavier pallets. Additionally, pallets can be accumulated in the corner. Pallet widths have also been expanded to 640 x 640 mm to handle heavier loads. The tight transfer 180° corner creates a loop with only 135 mm between main run conveyors. This option uses the Dorner Pin Tracking system that eliminates the need for other transfer devices while maintaining pallet orientation through the loop. The low-profile lift and locate is for operator stations, as the feature lifts the pallet off the conveyor and locates it within +/- 0.015 in. The compact and safe device protrudes beyond the main conveyor only 1 in., saving space for operators or other equipment.

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A versatile addition is the Precision Move elevator, which uses dual-sided timing belt conveyor technology to raise and lower pallets for over/under pallet applications. Dual sided support delivers transport for wider pallet applications. Elevators can transport heights from 18 in. to 120 in. top of belt. DW

Dorner Mfg. Corp. www.dornerconveyors.com

DESIGN WORLD

5/3/19 9:43 AM

Material Handling

Increase productivity of conveying systems

Fulfillment and distribution centers are turning to intralogistics to optimize, integrate, automate, and manage the logistical flow of goods. One component particularly suited to intralogistics is the LOGIDRIVE. The LOGIDRIVE includes integrated drive technologies for manufacturing and warehousing: high efficiency gearboxes; IE4 permanent magnet synchronous motors; and decentralized variable frequency drives (VFDs). The VFDs and IE4 motors support large speed ranges through gearboxes to deliver automation for stacker cranes, automated guided vehicles, chain conveyors and roller conveyors. These VFDs operate with all common field bus networks, offer free PLC integration, and provide simple commissioning with plug-in parameter boxes or through NORDCON, a free programming software tool. Efficient operation at partial load and low speeds make LOGIDRIVE suitable for high-volume warehousing, manufacturing and packaging systems. DW

NORD | www.nord.com/cms/us

DESIGN WORLD

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Design for Industry Robots

ProfiNet cable moves with the robot

As companies install more automated equipment in industrial applications,

network protocols are shifting away from ProfiBus to ProfiNet, a protocol that can handle the increased data transmission rates required for operational efficiency in real-time.

Another reason for the shift to ProfiNet involves the dynamic requirements, such as

acceleration and speed, which have increased and created more mechanical stress and electromagnetic interference in automation equipment, especially robots. ProfiNet standards for automation have usually been divided into three classifications: • Type A, a solid conductor for fixed installation • Type B, stranded conductor for some movement or areas exposed to vibrations • Type C, stranded conductors for continuous-flex/permanently moving applications (such as drag chains)

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A new classification has been added, Type R, designated for robotic applications. The HELUKAT PROFINET Type R Torsion cable is rated Category 5e and offers solid transmission characteristics in EMI-heavy environments due to its double-shielding design that is suited for robotic applications that undergo continuous torsion loads. It has been tested to withstand more than five million torsion cycles under loads of +/-180°/m, and more than five million flexing cycles in a drag chain at acceleration rates of two Gs (20 m/s²) and a maximum speed of 11 mph (300 m/min). It can be used in environments that vary in temperature between -40°F and +176°F (-40°C to +80°C). The PUR jacket is flame retardant and halogen free according to IEC 60332-1-2 and 60745-1, respectively. Additionally, the cable is UL recognized under AWM Style 21161 80°C, and meets the standards according to ISO/IEC 11801 and EN 50173. DW

Helukabel USA Inc. | www.helukabel.com

DESIGN WORLD

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May 2019

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Design for Industry Aerospace

Custom 3-D woven joints saves steps in airframe subassemblies

Bally Ribbon Mills (BRM) has perfected the science and art of 3-D continuous weaving. The company’s Advanced Products Group has developed technologies to fabricate 3-D woven structures such as “Pi – π,” double “T,” “H,” and other complex net shapes. These complex woven structures are used primarily in aerospace applications, often in airframe structural components and subassemblies including stiffeners and joints. They are custom made to fit the application. The process consists of film infusion where a frozen sheet or film of resin is infused onto the custom 3-D woven joint, saving customers the trouble of infusing the resin themselves upon delivery of the joint. BRM uses the film infusion process to infuse a variety of resins to complex 3-D woven shapes. The company ships the 3-D woven joints as pre-made assemblies, saving processing steps that require time, work, and specialized machinery. BRM’s film infusion capability also allows them to control more steps of the 3-D woven joint assembly manufacturing process, ensuring consistent quality control. DW

Bally Ribbon Mills | www.ballyribbon.com

May 2019 www.designworldonline.com

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5/3/19 9:48 AM

Packaging

Vision sensor targets error proofing

Packaging applications have little room for error. To help ensure product is in the right place at the right time, packaging developers lead on vision. Designed for error proofing, identification, general inspection and robot guidance, BOA Spot XL vision sensors come with integrated LED lighting, lens cover and easy-to-use application software. Robust embedded vision tools include positioning, part locating, pattern matching, measuring, feature or defect detection and identifying, including automatic reading of characters (OCR) based on a pre-trained AI (Artificial Intelligence) inference network. Additional features include extensive image preprocessors and calibration for image correction and system coordinate mapping. Inspections using BOA Spot XL vision sensors can be triggered by parts in motion or from a PLC. Compatible protocols, such as Ethernet/IP and PROFINET, provide standard languages for communicating with 3rd party equipment or the factory enterprise. Thru- and surface-mounting options and a slim form factor enable these sensors to fit in tight places. DW

Teledyne DALSA | www.teledynedalsa.com/en/home/

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Design for Industry Safety

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools BEARLOK

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These speed safety relays provide overspeed, under speed and/or standstill detection for single- or three-phase motors by monitoring either external proximity sensors mounted on a rotating element of the motor or load, the frequency of the motor power signal or the remanence voltage (back EMF) of the motor signal. â&#x20AC;¢ Dold UH6932 speed monitor relay modules have 2 PNP or NPN sensor inputs and 2 N.O. positively driven and 2 semiconductor monitoring outputs. W

â&#x20AC;¢ Dold UH6937 frequency monitoring relay modules require no external sensors and provide 2 N.O. positively driven and 2 semiconductor outputs for monitoring. DW

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Design for Industry Material Handling

Additive manufacturing

enables robot shuttle system to use smaller motors A frequent goal in any design is find ways to save on weight and power needs. The engineers at Bastion Solutions, a Toyota Advanced Logistics company, were looking for a way to develop a more efficient robotic material handling system. They turned to additive manufacturing to build fingers, joints, and elbows for their Bastian Solutions Shuttle System. Because the additively made parts were built from polymers, the robotic handler was more dexterous and had lower power requirements for operatation. Thus, the engineers could choose a smaller motor than one they would have needed for metal versions of these parts.

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The engineers at Bastian Solutions worked with Fast Radius, a provider of additive manufacturing solutions, to implement additive design and manufacturing into the Shuttle System. The additive parts for the product are made at Fast Radius’ Chicago headquarters. Forty-five percent of the final buildof-material (BOM) for the arm will be produced using additive manufacturing. A portion of the Shuttle System’s parts and prototypes, including the durable polymer joints for the robotic arm, were made with HP 3D printers using Multi Jet Fusion industrial-grade technology. Additional parts, including the proprietary fingers/gripper for the robotic arm were developed using Carbon’s Digital Light Synthesis (DLS) technology and unique materials, notably EPU 40.

Said Ron Daggett, Vice President of Technology and R&D, Bastian Solutions, “The additive manufacturing process will enable us to customize each robot picker to fit a customer’s particular warehouse environment.” Noted Lou Rassey, Chief Executive Officer, Fast Radius, “The nature of additive manufacturing enabled us to create and test over a thousand prototype parts for Bastian Solutions in under 20 months until we arrived at just the right ones for this unique piece of equipment.” The Carbon DLS technology and EPU 40 resin made it possible for Fast Radius to manufacture a texture on the robot’s finger that allows the robot to

pick up any part, of any size. This couldn’t have been achieved using traditional manufacturing methods and is an example of what kind of innovation is possible with digital manufacturing. DW

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Design Notes Kempelen’s Owls, a new public art project that features two 10-ft owls, will open later this year in Austin, Texas

Slewing rings help interactive sculpture move

Edited by Mike Santora • Associate Editor

In 2019, a new public project will be coming to Austin, Texas. The interactive sculpture, Kempelen’s Owls, will feature two Texas great-horned owls, each standing 10-ft tall and perched atop dodecahedrons. What makes Kempelen’s Owls unique is a hidden mechanism that will allow visitors to secretly turn the heads of the birds. “The mechanism is hidden in plain sight and readily accessible,’’ said Dan Sternof Beyer, Founder and Creative Director of New American Public Art (NAPA), a multi-disciplinary studio that conceptualizes, designs, fabricates and installs interactive projects. The critical component that allows the head of the owl to spin is a slewing ring manufactured by igus. The PRT-01-300 ring is lubrication free, and has a high load capacity and wear resistance. “The bearing that spins the head of the owl is one of the most important pieces of the project, physically and conceptually,’’ Sternof Beyer said.

May 2019 www.designworldonline.com

Design Notes 5-19_Vs3.LL.indd 30

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5/3/19 9:53 AM

STANDARD AND CUSTOM MOTION CONTROL PRODUCTS FOR DRUG DELIVERY & LIQUID HANDLING The challenge, Sternof Beyer said, was finding a bearing that could meet all the requirements needed for this application. “For this bearing, we needed a particular set of qualities,’’ he said. “We needed a bearing that was very wide to allow for mechanical and lighting elements to pass through it. This bearing needed to support a large axial and dynamic range to be as safe in public as possible. It also needed to be as maintenance free as possible while being subjected to an outdoor environment. The demanding list of qualities rules out 90% of the bearings in the market.” The sliding surface of the slewing rings is made with iglide J material, which is characterized by chemical resistance, vibration dampening, and low moisture absorption. The ring has an axial static load of 27,000 newtons and an axial dynamic load of 7,000 newtons. “The large outside diameter (450 millimeters) allows for less cantilevered sculptural material and the large inside diameter (430 millimeters) allows us to pass through fiber optic cable, which light the owls’ eyes at night,’’ Sternof Beyer said. “The axial and dynamic range are more than enough for the weight of the owl head, but also gives us assurance if the public decides to pull on the head.” These slewing ring bearings are used in an assortment of industrial applications. They have been used in a handling system for a semiconductor carrier, a self-rotating light, an automatic welding plant, and a machine tool control panel. They are also used in a variety of industries, such as medical, packaging, food processing, solar, seating and material handling. The team designing the sculpture began by 3D scanning a stuffed owl from the University of Texas. “The biggest challenge was attempting to reach the perfection of the digital model, considering the real-world tolerances and fabrication constraints,’’ Sternof Beyer said. NAPA was accepted as an artist in residence at the Autodesk BUILD Each owl includes a Space in Boston, where it was able to use the most advanced fabrication slewing ring with a large techniques to achieve the detail and outside and inside diameter, tolerance required for the project. which was critical to the Its team made prototypes using 3D construction of the interactive

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Design Notes 5-19_Vs3.LL.indd 31

May 2019

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Design Notes

The slewing ring enables the head of the owl to rotate and is activated with a hidden mechanism that will allow visitors to secretly turn the heads of the birds.

printing, laser cut wood and plastic, and even large-scale plain carbon steel. Each sculpture is comprised of more than 3,000 individual pieces. “The prototype process was invaluable,’’ Sternof Beyer said. “It allowed us to fail early.” Unlike many complex engineering projects, Kempelen’s Owls will be open sourced. When the project is complete, anyone will be able to download the fully engineered model and see all the technical data, materials and engineering solutions the NAPA team employed. “It would make us very happy if this work became a well-known library of creative solutions, one that can be referenced and leveraged for years to come,’’ Sternof Beyer said. DW

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Design Notes 5-19_Vs3.LL.indd 32

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Discover ebm-papst drive solutions. Intelligent drive solutions for industry. At ebm-papst we aim to set a great deal in motion with efficient technologies â&#x20AC;&#x201C; 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 canâ&#x20AC;&#x2122;t see it. But you can feel it! Contact sales@us.ebmpapst.com for more info. Brushless DC motor ECI80 with planetary gearbox Optimax 63

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Design Notes

How rapid prototyping aids linear

motion design

Edited by Mike Santora • Associate Editor

During the analysis process, the Lin Engineering team selected which components were critical to most design needs to make selection easy, quick, and repeatable in a production setting — benefitting the manufacturer and customer.

Rapid prototyping is often thought to be about building plastic parts for use inside your system, or perhaps as an enclosure or mounting component. But there are other ways to use rapid prototyping to advance your design engineering capabilities — in this case, linear motion design. We don’t have to cover the many benefits of using rapid prototyped parts during the earliest stages of product design. Speed to market seems like enough. But, in the case of linear motion component production, having precisely the right part for your application is even more critical. We’re talking about saving money by eliminating over-design, but we’re also talking about footprint, specifications, and long life. To explore this concept of rapid prototyping for linear motion devices, we’ll cover two things: what modular component designs can do for fast customization, and how an online configurator can focus your idea quickly before making a final

May 2019 www.designworldonline.com

Design Notes 5-19_Vs3.LL.indd 34

DESIGN WORLD

5/3/19 9:57 AM

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selection. Both of these explorations will reduce time to market and minimize cost escalations from unnecessary customization. Whenever a customer wanted something different than what was offered in a general catalog—often to make them more competitive in cost or capabilities— they had to go through each specification, select what they want, and then wait between six and eight weeks to receive a prototype linear motion device. But they often needed the prototype much faster than that so that they could evaluate their choice and make additional adjustments if needed. There was no offthe-shelf answer. This method often came at a high cost. On a manufacturer’s side, the questions were how to shrink the lead-time without having to stock a lot of inventory (with incremental adjustments to standard products). They also had to account for how to provide customization—even in small increments— to help satisfy what was determined to be between 50 and 70% of the customers who needed a custom prototype. Such a product line would have to be highly flexible and quickly delivered. These same prototypes would then have to be able to go into production with no lag in delivery. Some manufacturers are looking at ways to get the most flexibility out of their linear motion products by stocking components properly and in such a way as to make as many selections as possible within the shortest amount of time. Modular product structures are not new, but when you’re talking about a complex product like a linear drive, there are many components to consider. The more components, the more complex a design can get, and the more difficult it is to discuss and select the right product for a particular application. This situation is why using a catalog to make a selection can get complicated. If an engineer is looking at the multitude of specifications without a full understanding of which ones are critical and which are not, the selection process becomes overwhelming. At this point, many engineers default to over specifying parts, driving up costs, and having to adjust product footprints. In the production of linear drives, the essential components include the motor, the lead screws appropriate to each motor (to eliminate mistakes in configurations that won’t work), nut sizes, and finishes. With a variety of each of these components, narrowing down what will work together and what an engineer might need for a specific application could become a nightmare. Nonetheless, by understanding common requirements like required force, speed, available power, and current draw, they could help to make the right selection of components.

DESIGN WORLD

Design Notes 5-19_Vs3.LL.indd 35

May 2019

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Design Notes Engineers are doing more and more of their selections online, which means that companies must be more accessible. Most companies have uploaded their catalogs. However, with only an online catalog, engineers often had to talk with the manufacturer once they were close to making a decision. This usually means speaking with a sales person who would steer them toward a product that might not suit their application. Thus, customization can come with a high price tag. The online catalog approach ignores the fact that many engineers want to play around with the parts for a while before asking an expert at all. An online configurator removes the sales pressure and allows the engineer to better understand what they need as a final product. Lin Engineering offers the Rapid Prototype Configurator to address

these needs of the engineer. Using the configurator, an engineer doesnâ&#x20AC;&#x2122;t have to talk with a salesperson until they have nailed down their needs. The configurator operates with a 10% safety buffer on product selection so prototyped products can be easily configured, selected, delivered, and installed without worrying that the component might not work properly. Engineers can play with the prototype, consider their specific application needs, and continue to hone their design â&#x20AC;&#x201D; even if they feel they need more customization. The prototype parts, configured from hundreds of combinations of products, are deliverable in roughly three weeks. And for designs that require faster deliveries, a one-week option is available with minimal rush fees. Ultimately, what a manufacturer needs is to provide services to engineers

focused on their needs and not just the products the manufacturer wishes to sell. If a manufacturer can help an engineer get close to their product needs quickly, without sales pressure; allow them to incorporate those changes right away, to evaluate their specific requirements; and do these things using modular designs, which minimizes potential flaws; then products can be designed and delivered efficiently. DW

Lin Engineering | www.linengineering.com

Fitting. The Vlier name has been synonymous with quality, value, service and selection for more than 75 years. That proven and trusted product innovation created Knurled Ball Plungers and Press-Fit Plungers. Both offer quick installation without the use of threads, locking elements or bonding agents for a secure fit.

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1902144_KnurledPressFitAd.indd 2 Design Notes 5-19_Vs3.LL.indd 36

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OPTO 22_ 5-19.indd 37

5/2/19 9:29 AM

The Evolution of Brewery Hoses

Design Notes

Dimensionally modified sliding bearings help solve frictional issue Edited by Mike Santora • Associate Editor By changing the thickness correlated to the theoretical calculation and practical examination, the Technymon team produced 50 sliding bearings with new radial clearance. These sliding bearings were then identified and numbered.

T422LH Series

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A company recently contacted Technymon GBT to resolve a frictional issue occurring on a sliding bearing (MU material). Initially, the company identified excessive friction and wear on approximately 10% of the assembled components, which was detected in the field during operation at the OEM end. The company was unable to analyze the root cause instantly. In the meantime, to deliver acceptable components to OEM, the company started to segregate the acceptable and unacceptable assembled components. This approach resulted in delay and stoppage in their assembly line, which further resulted in an increase in their processing and operating costs. The Technymon team was tasked with identifying the real root cause.

360 E. State Parkway | Schaumburg, IL 60173-5335 (847) 755-0360 E-Mail: sales@kuriyama.com www.kuriyama.com

Design Notes 5-19_Vs3.LL.indd 38

The technical team began by analyzing 50 assemblies provided by the company. They disassembled the sliding bearings and viewed them under the microscope. The excessive wear in about 10% of the inspected sliding bearings was seen on the PTFE layer, with this excessive wear reaching up to the intermediate layer of bronze. The team discovered the reason for excessive wear on the PTFE surface was due to extreme contact pressure and flash temperature. The actual contact pressure was exceeding the PTFE layer material bearing limits, leading to a plastic deformation of the bronze surface under the PTFE layer.

May 2019

www.designworldonline.com

DESIGN WORLD

5/6/19 11:02 AM

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Design Notes Scoring and bronze debris could be seen. The metallic bronze debris was causing deep scratches and the PTFE layer was getting destroyed. The deep scratches and excessive wear indicated that failure was originating during the sliding bearing mounting process because of the excessive outer diameter and roughness of the mounting pin. At this point, the team asked the company to elaborate on their mounting process and to share mounting components designs. After having a detailed discussion and analysis, the technical team was convinced that all operators at the company end were using the acceptable mounting procedures and mounting components. After investigating all factors, the technical team determined that the problem was related to the assembly tolerance and fits. As such, the technical team measured the sliding bearings available in the company and Technymon GBT stock. Sliding bearings available in stock were meeting the tolerance and specifications completely. Also, 50 pieces of the company’s shafts and housings were taken and analyzed with the statistical variation. Each parent component was examined and data recorded to include Cp and Cpk results. Every possible assembly scenario was considered to find the root cause.

What stood out the most? The company was encountering the problem only in 10% of the assemblies. After detailed theoretical calculations and practical examination, the problem was identified: the excessive wear was occurring when the shaft’s dimensional tolerance reached the high end of the tolerance limit and the housings, together with sliding bearings, were at the low end of the tolerance limit. In this operating scenario, excessive friction was generated and then converted into the temperature rise of the sliding bearing during actual operation. A thermal expansion on the shaft’s outer diameter was observed, which further converted the clearance fit into transition fit. As a result, the sliding bearing was experiencing the excessive contact pressure and, therefore, the excessive wear. After identifying the issue, the technical team advised the company that the issue could be resolved by changing the sliding bearing’s internal clearance or shaft outer diameter. By changing the thickness correlated to the theoretical calculation and practical examination, 50 sliding bearings were produced with new radial clearance. These sliding bearings were identified and numbered. Before assembly of these dimensionally modified sliding bearings,

the company’s components (i.e., housings and shafts) were also measured and numbered. The information was recorded to provide a statistical process control, with proper Cp and Cpk values. Additionally, these assemblies were tracked. Initial operational movement and testing on the customer end indicated the presence of radial clearance fit between the shaft outer diameter and sliding bearing internal diameter. Over the next several weeks, the company monitored the assemblies’ performance and recorded results. Ultimately, the data proved that the modified assemblies’ higher radial clearance eliminated the excessive friction and wear. With the root cause and solution identified, the sliding bearing thickness was changed. Both parties were then able to update the sliding bearing drawing to procure the dimensionally modified sliding bearings for all future supplies. DW

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CAE Solutions ANSYS Cloud: Direct cloud HPC access through ANSYS Mechanical, ANSYS Fluent Bruce Jenkins | Ora Research

“Engineering simulation has long been constrained

by fixed computing resources available on a desktop or cluster,” observes industry leader ANSYS. “Today, however, cloud computing can deliver the on-demand, highperformance computing (HPC) capacity required for faster high-fidelity results offering greater performance insight. To leverage the combined benefits of cloud computing and best-in-class engineering simulation, ANSYS is partnering with Microsoft Azure to create a secure cloud solution: ANSYS Cloud.”

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Within ANSYS Mechanical and ANSYS Fluent, the company says its users can “easily access HPC in the cloud directly— without the need for any additional setup. Access the hardware and software you need, when you need it—pay only for what you use.”

Capabilities Built-in cloud HPC access—ANSYS Cloud delivers easy access to on-demand HPC resources from within your ANSYS environment. Using your ANSYS tools, prepare your simulation models on your desktop. Simply select a pre-configured hardware, then submit your jobs directly to the cloud. You won’t have to wait in HPC cluster queues or reduce your model size to fit desktop constraints. Job progress may be monitored from your desktop or through a web-based cloud portal. The ANSYS Cloud is optimized for ANSYS solvers. Choose from a set of pre-defined hardware configurations depending on the needs of your model. Ready-to-use cloud service—Mechanical and Fluent users can “easily access ANSYS Cloud without involving their information technology (IT) teams. Without the need for complex software installations or cloud-side setups, users are free to focus on solving their engineering problems. And, without having to build in-house solutions or rely on third-party vendors, businesses can avoid costly upfront investment and delays.” ANSYS Cloud is a “ready-to-use solution that is ANSYStested and certified, and fully-supported by ANSYS HPC and solver experts.”

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“Completely secure workflows”—ANSYS Cloud provides a “highly robust and completely secure environment for running simulations in the cloud. At the Azure data centers, where simulations are run and data are stored, access is strictly controlled. The solution combines Microsoft Azure’s best practices with custom encryption for added security.” Both data at rest and in motion are encrypted. Leveraging Azure Virtual Networks, ANSYS Cloud offers a “separate, secure network architecture for each customer: only you can access your data.” The complete system architecture has undergone comprehensive testing, including detailed penetration testing, ANSYS says. Because new security threats continuously emerge, the solution’s security is regularly audited by a third party. “Economical on-demand pricing”—Payper-use access to both cloud hardware and ANSYS software is available on Microsoft Azure and enabled through ANSYS Elastic Licensing. Rather than locking into a longer-term lease, users purchase a pool of ANSYS Elastic Units (AEU) based on their short-term cloud-computing needs. How this works: “Using your existing licenses, prepare your model using your on-premise hardware. When you submit your simulation job for analysis in the cloud, use your pool of AEUs.” AEUs are consumed at a specified hourly rate that varies with the choice of hardware configuration and solver type (i.e., Mechanical or Fluent). For example, a Mechanical simulation on a small hardware configuration (1 node, 12 cores)

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May 2019

5/7/19 1:08 PM

CAE Solutions will consume 13 AEUs/hour, whereas the same simulation on a medium configuration (3 nodes, 36 cores) will consume 18 AEUs/hour. Your pool of AEUs (shared with other users in your organization) is charged based on your cloud runtime (in fractions of an hour). Consumption of AEUs may be tracked using the cloud portal, which is accessed via a desktop or mobile web browser. “With this combination of traditional licensing (leased and paid-up for steady workflows) and pay-per-use licensing (for in-cloud, flexible capacity),” ANSYS says, “you can optimize your company’s investment in simulation.” Remote job monitoring Easily monitor the progress of your simulation from within the desktop

installation of Mechanical and Fluent or from a web-based cloud portal. Job monitoring tools provide full access to the solver transcript, a graphical view of convergence parameters and real-time access to debug information when help is needed. You can also view a summary of your simulation jobs via a web-based cloud portal, which can be accessed from your desktop or mobile device. Using the cloud portal, you can track total consumption of AEUs and even share your simulation jobs with your peers and ANSYS support.

transferring only requested information to you for 3D rendering in your web browser,” ANSYS says. This approach “avoids heavy network usage and eliminates the latency typical of virtual desktop approaches. The performance is unmatched for all-size models.” Users can plot scalar and vector fields and visualize results on existing parts, planes, isosurfaces and isovolumes. When needed, “download the data to your desktop for detailed postprocessing using your familiar desktop applications.” DW

Cloud-based 3D results visualization With ANSYS Cloud, users can review and validate the results of their simulations while their data are in the cloud. “Innovative post-processing technology leaves the heavy data in the cloud,

ANSYS, Inc. www.ansys.com Microsoft Azure www.azure.microsoft.com

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CAE Solutions NEWS

Khronos Group releases provisional standard for AR and VR devices

The Khronos Group of Beaverton, Ore., an open consortium of leading hardware and software companies that come together to create advanced acceleration standards, has released the OpenXR 0.90 provisional specification. OpenXR is a unifying, royalty-free, open standard that provides high-performance access to augmented reality (AR) and virtual reality (VR)— collectively known as XR—platforms and devices. The Khronos OpenXR working group was formed in The OpenXR 0.90 provisional release specifies a cross-platform early 2017 with the support and participation of leading application programming interface (API) that enables XR XR companies. Throughout the development of the hardware platform vendors to expose the functionality of their specification, multiple Khronos members have been runtime systems. By accessing a common set of objects and developing independent implementations to ensure a robust functions corresponding to application lifecycle, rendering, and complete specification. Many of these implementations tracking, frame timing, and input, which are frustratingly are becoming available for developers to evaluate including different across existing vendor-specific APIs, software the Monado OpenXR open source implementation from developers can run their applications across multiple XR systems Collabora, and the OpenXR runtime for Windows mixed with minimal porting effort—significantly reducing industry reality headsets from Microsoft. Also, the Unreal Engine fragmentation, said Brent Insko, lead VR architect at Intel and from Epic plans to continue to support OpenXR. the OpenXR working group chair.

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For An Angle Sensor That Works Around Your Application… “OpenXR seeks to simplify AR/VR software development, enabling applications to reach a wider array of hardware platforms without having to port or re-write their code and subsequently allowing platform vendors supporting OpenXR access to more applications,” Insko said “The OpenXR provisional specification—together with the runtimes publicly available at launch and coming in the next few weeks—will enable hands-on, cross-platform testing by application and engine developers. Philippe Kalaf, chief executive officer at Collabora said his company was dedicated to royalty-free open standards and open source technologies. He also spoke about Monado, an open-source implementation of the OpenXR spec. “Monado is an open-source project and codebase to harness and focus wider community effort around XR technologies,” he said. “Collabora plans to provide the technical foundation and industry leadership to accelerate the development and deployment of XR technologies on Linux while providing XR device vendors the choice to use and contribute to a Linuxbased platform for their XR products.” Microsoft also offered feedback on the new standard. “Microsoft believes that for mixed reality to thrive, it must be open for everyone: open stores, open browsers and open developer platforms. We’re dedicated to supporting the launch of OpenXR this year on Windows Mixed Reality and HoloLens 2,” said Alex Kipman, technical fellow at Microsoft. The Khronos Group is an open industry consortium of over 140 leading hardware and software companies creating advanced, royalty-free, acceleration standards for 3D graphics, augmented and virtual reality, vision and machine learning. Khronos standards include Vulkan, OpenGL, OpenGL ES, OpenGL SC, WebGL, SPIR-V, OpenCL, SYCL, OpenVX, NNEF, COLLADA, OpenXR and glTF. Khronos members are enabled to contribute to the development of Khronos specifications and to vote at various stages before public deployment. They are able to accelerate the delivery of their platforms and applications through early access to specification drafts. DW

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Go Touchless.

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CAE Solutions NEWS

OnScale raises $10 million from Intel Capital and Gradient Ventures

OnScale, a developer of Cloud-enabled engineering simulation software, announced $10M in Series A funding led by Intel Capital and Gradient Ventures, Googleâ&#x20AC;&#x2122;s AI-focused venture capital fund. Additional investors include Thornton Tomasetti, Stage 2 Capital, Cultivation Capital, and CampbellKlein. OnScale will use the new investment to drive global expansion, respond to increasing demand, and accelerate development of its Computer-Aided Engineering (CAE) solutions for complex, real-world engineering applications. OnScale CAE tools are based on proprietary multiphysics solvers developed and validated for more than 30 years by one of the largest engineering consulting firms in the world for DARPA, the U.S. Department of Defense (DOD), and large commercial customers. The CAE solvers were architected for highly parallel mainframe computers to handle very large engineering simulation problems and suit modern cloud-based computing. DW

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May 2019 www.designworldonline.com

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Internet of Things

The case for Industry 4.0 in manufacturing Richard Chamberlain of Bosch Rexroth

Thanks to Industry 4.0, predictive maintenance is becoming more popular in reducing the risk of downtime. Based on condition monitoring, essential components are fitted with sensors, each programmed with upper and lower limit values for the sensor signals and alarms based on the operating instructions and experience of past values. In practice, the data deliver insights into machine health and enable manufacturers to make better-informed decisions around when to replace the components of vital machinery â&#x20AC;&#x201C; and avoid complete machine failure. The latest technologies shift the function of equipment maintenance into an anticipatory approach. However, simply installing the means through which big data can be collected is not enough; engineers must combine the power of digital solutions with that of human intelligence. Placing data at the heart Relying on data alone for answers will not deliver predictive maintenance functions. Data must be combined with intelligence, human intelligence. To render the data harnessed through a network of sensors useful, it must be visualized, evaluated and acted upon. One way of doing this is through ActiveCockpit, a tool developed by Bosch Rexroth that makes it simple to collect, process and visualize the relevant data of a manufacturing facility. By translating complex data collected from machinery through sensors and presenting it in user-friendly visuals in real-time, operators can make faster and more accurate decisions. Once installed, this means systems and processes can be adjusted inline with findings to achieve immediate tangible results. To make that happen, algorithms and mathematical models are constantly at play behind the scenes. These are not only written to make the best use of big data, but are combined with huge computing power to enable software to use the data for itself, connecting patterns, pathways and predictions to be visualized for operators. Once acted upon, changes can be evaluated to facilitate continuous improvement through machine learning.

May 2019 www.designworldonline.com

Internet of Things_5-19_Vs3.LL.indd 52

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Standard Parts. Winco. Ball Lock Pins JW Winco offers ball lock pins with a wide range of types, functions, dimensions and accessories: Proactive maintenance in the era of Industry 4.0 So as technology evolves to capitalize on the presence of big data and support manufacturers, the primary drivers to implement Industry 4.0 developments remain the same: to reduce costs, elevate levels of quality and increase output. On the factory floor – where components are fully networked and connected to give greater control and visibility of performance – that can translate into a health index program for predictive maintenance. In essence, that allows components to be replaced at the most optimal time, taking into account factors such as asset health, as well as the impact on the broader connected factory, so a smooth and efficient flow of operations is always maintained. One key advantage of this approach is the accuracy of fault finding and prediction capability. Statistically, in a given case, detecting a fault by chance carries a probability of just 13%, a figure that increases to 43% with expert human monitoring. Couple that with machine learning, however, and fault detection accelerates to 95%. The ODiN system from Rexroth, which uses self-learning algorithms and predictive maintenance software, is a system able to deliver a health index of connected machinery. Providing an indication of machine condition, manufacturers are equipped with the insights they need to maintain consistant levels of productivity and reduce the occurrence of unexpected downtime. Taking a big picture approach To maximize the impact of these digital solutions, it is critical for engineers to precisely plan how Industry 4.0 is to be incorporated into their facility. Here, whether they choose to take an incremental approach or opt for a complete digital overhaul, it is important to remember that digital technologies are highly scalable and can match even the most complex of production environments. Even legacy machinery, which is perhaps most prone to high component wear or unexpected breakdowns, can be brought in line with the digital future by adapting equipment to accommodate intelligent sensors, controls and drives to form the basis for comprehensive predictive analysis. Once connected to an end-to-end system, the process of proactive maintenance through machine learning is aided. As data harnessing and visualization drive software to become smarter and factories more intelligent, it also facilitates a proactive approach to maintenance, helping operations to run more efficiently to deliver more consistent levels of quality and output –maximizing profitability and competitiveness in today’s ever-changing global market. DW

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Internet of Things

What engineers really think of digital twin technology

One of the bigger developments in technology has been that

of digital twins. A digital twin is a virtual replica of a physical system, process or product. The technology essentially provides a real-time look at how a physical asset is performing.

Manufacturing, automotive, and construction industries are adopting digital twins. Organizations in these industries use digital twin technology to evaluate the performance of given physical assets and then identify where improvements can be made to reach better outcomes. Digital marketing specialists Reboot Online analyzed the latest findings from research facilities provider ‘Catapult,’ who surveyed engineers from a range of disciplines to better understand the components they believe are the most necessary for digital twin technology to function effectively. Reboot Online found that a ‘physical asset’ (71%) is the component engineers think is the most necessary for a digital twin. Thereafter, 52% of the experts view a ‘live data set’ as an essential feature. 45% also believe an ‘offline data set’ is an important component for the technology. Interestingly, with a digital twin being a pairing of the virtual and physical worlds, just 45% of engineers rate ‘3D representation’ as a must have variable for the technology. On a similar note, 31% state ‘2D graphic representation’ is needed for a digital twin to work properly. Only 39% place ‘trend analysis of historical data’ as a vital attribute for a digital twin. Even less feel ‘prediction of future events’ (32%) is a critical aspect that can push the technology to achieve objectives. Reboot Online also wanted to identify the stages in the product life cycle that can gain the greatest value from the integration and use of digital twins. A majority of engineers believe that ‘maintenance, repair and operations’ (77%) is the stage in the product life cycle where digital twin technology adds the

May 2019 www.designworldonline.com

Internet of Things_5-19_Vs3.LL.indd 54

greatest value. Thereafter, engineers view ‘manufacturing’ (70%) as the next most likely process to benefit from the use of digital twin technology. 62% of engineers think digital twin technology can be harnessed during the ‘simulation’ of a model that predicts the current and future behavior of a given physical asset. Slightly below, 60% feel digital twin technology can be highly practical for ‘quality control’ testing. Interestingly, 59% consider a digital twin to be impactful in the ‘design’ phase of a product/system. ‘Finance and procurement’ (13%) is the step in the product life cycle that engineers think will be able to capitalize the least from the capabilities of digital twin technology. Just above, only 19% of engineers place ‘sales and marketing’ as a key operation which can experience significant gains from deploying digital twins. DW

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Internet of Things

For wireless access applications

The ARS-7131-AC series is for industrial and enterprise wireless access applications. Embedded with the Qualcomm Atheros QCA9892 chipset, it boasts network robustness, stability, and a wide network coverage with a very low voltage input of 9 Vdc to a high voltage output of 48 Vdc. Based on IEEE 802.11 a/b/g/n/ac, the access point supports high-speed data transmission of up to 867 Mbps. The ARS-7131-AC series handles many routing functions usually found on advanced devices such as VPN and firewalls. The device can be used as an access point, WDS Station, transparent bridge, or repeater, which makes it suitable for a variety of wireless applications. These units also allow the user to position the wireless antennas in a better signal-broadcasting location for improved wireless coverage and signal strength or add external antennas in an optimal location. DW Antaira Technologies | www.antaira.com

For Absolute Feedback, we’ve got your solution EPC’s Absolute Encoders offer: • 16 bits resolution for single turn, and 43 bits resolution for multi-turn • SSI, CANopen, or EtherCAT communication protocols • Electronic cam switches on CANopen and EtherCAT models • Maintenance-free and environmentally-friendly magnetic design • Energy harvesting magnetic multi-turn technology • No gears or batteries

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NEWS Siemens and SAS partner to deliver AI-embedded IoT analytics for edge and cloud

Precision Welding For Critical Plastic Components

Siemens Digital Industries Software and SAS announced a partnership that will help companies create new IoT edge and cloud-enabled solutions by applying SAS and open source streaming analytics through Siemens’ MindSphere. Users gain access SAS predictive analytics in MindSphere, which can accelerate the adoption of machine learning (ML) and artificial intelligence (AI) in Internet of Things (IoT) environments. Siemens and SAS will collaborate with customers and, beginning with streaming analytics, enable near-real-time embedded AI for IoT devices at the edge. The partners expect the solutions to be generally available later this year. By intuitively applying AI and operationalizing its potential at scale, the partnership can drive an end-to-end solution framework for customers. Companies currently using both SAS and MindSphere will be able to port and deploy previously developed SAS models natively into MindSphere while new users will gain access to analytics capabilities. Siemens’ MindSphere is the cloud-based, open IoT operating system that connects real

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The Branson GSX Ultrasonic Welding Platform meets the growing demand for the assembly of smaller and more complex plastic components. Precise welds are achieved utilizing an advanced electro-mechanical actuation system that provides unprecedented control and position accuracy, while applying an industry low trigger force. The Branson GSX can also weld across multiple parameters, monitored in real-time to ensure quality. This is possible with a wide range of input materials and first class repeatability, across multiple Branson GSX welders.

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INSIDE:

A Supplement to Design World - May 2019 www.designworldonline.com

• The Robotics Summit 2019 takes a close look at mobile robots .............................62 • What Amazon’s acquisition of Canvas Technology means for mobile robots ...........66 • Augmenting SLAM technology with deep learning .............................................71 • Expert roundtable: mobile robotics challenges and opportunities ..........................82 • Integrating AI with fleet management software advances collaboration for autonomous mobile robots .............................88 • How 5G will impact mobile robots ................95

Mobile robotics matures

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The Robot Report

june 5-6, 2019

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Robotics Summit & Expo 2019 takes a close look at mobile robots Engineers can learn about recent developments in mobile robot technology from speakers, exhibitors, and peers at this conference in Boston in June.

Eugene Demaitre • senior editor The Robot Report

| Humatics

Last year’s Robotics Summit & Expo was a rare opportunity to see Boston Dynamics CEO Mark Raibert describe his company’s groundbreaking work on mobile robots. Attendees at this year’s event will have the opportunity to learn from more robotics experts. Robotics developers, suppliers, and users can attend keynotes, sessions, and panels on everything from sensing and machine learning to safety and commercialization. Here’s a preview of some of the programming at the summit, which will be held on June 5-6, 2019, at the Seaport World Trade Center in Boston.

Sessions to see at the Robotics Summit Deepu Talla, vice president and general manager of autonomous machines at NVIDIA, will discuss various types of robots and emerging applications in his opening keynote on “Bringing AI-Powered Robots to Life” on Wednesday, June 5. In “The Growing Pains of AGV Navigation,” David Mindell, CEO of Humatics, will explain how there is no “one size fits all” solution for automated guided vehicles

May 2019

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The Robot Report

More about mobility

The expo hall will include several companies supporting mobile robots, including Harmonic Drive, Humatics, IDS Imaging, Kollmorgen, and Sick, as well as AMR provider Waypoint Robotics

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(AGVs) and Industry 4.0. In this session in the “Systems, Design, and Development” track, Mindell will look at how new sensors and microlocation technologies are affecting mobile robots. One way in which autonomous mobile robots can deliver value to users is from the data that they collect. Tim Rowland, CEO of Jabil unit Badger Technologies, will explain “The Cerebral Side of Robotics,” as data analysis becomes just as important to the connected enterprise as materials handling. What is “sole agent syndrome,” and what can mobile robot designers do about it? In his session on “Machine Learning for Human-like Behavior,” Russell Toris, director of robotics at Fetch Robotics, will show the dangers of over-optimization and the best techniques for getting robots to move smoothly and efficiently. Current industrial robot safety standards are mature, but they are not enough to support certain types of robots, according to Joe Gelzhiser, safety application specialist supervisor at Sick. In “Navigating Mobile Robotics With 2-D Safety Lidar,” he will examine the proper application of such technology for “safe detection of persons.” VSLAM, or vision-based simultaneous localization and mapping, has matured, enabling robotics developers to improve visual positioning for robots. In his session, Dominick Vanthienen, vice president of technology innovation at Intermodalics, will talk about how VSLAM can help robots be more aware of their surroundings. He will also discuss problems that still need to be solved.

www.designworldonline.com

As with many technologies, the U.S. Department of Defense has been an initial supporter of much mobile robot research and development. In “Transitioning From Defense to Commercial Markets,” Parag Batavia, president of the Neya Systems Division at Applied Research Associates, will explain how government funding can help robotics startups on the road to commercialization. In his Day 2 keynote, Henrik Christensen, the Qualcomm chancellor’s chair of robot systems at the University of California, San Diego, and leader of the U.S. National Robotics Roadmap, will discuss R&D challenges and emerging use cases for robots of all kinds. In “Service Robots for Commercial Spaces: The Path From Autonomous to Intelligent Robots,” attendees can learn how mobile service robots are gaining new levels of autonomy. Marcio Macedo, co-founder and vice president of product and marketing at Ava Robotics, will describe how AI and the cloud are helping robots to function better in human environments.

Expo shines spotlight on components, suppliers The expo hall will include several companies supporting mobile robots, including Harmonic Drive, Humatics, IDS Imaging, Kollmorgen, and Sick, as well as AMR provider Waypoint Robotics. Robotics innovators, investors, and adopters can also participate in networking events, the AWS RoboMaker Immersion Day (on June 4), the Future of Mechatronics and Robotics Engineering Workshop, and the MassRobotics career fair. RR To learn more about and register for the Robotics Summit & Expo 2019, visit the website: https://www.roboticssummit.com/

May 2019

5/3/19 3:11 PM

The Robot Report

What

Amazonâ&#x20AC;&#x2122;s

acquisition of

Canvas Technology

means for mobile robots Amazonâ&#x20AC;&#x2122;s latest robotics purchase demonstrates the importance of safe navigation for developers and users of supply chain automation.

Eugene Demaitre â&#x20AC;˘ senior editor The Robot Report

The number of autonomous mobile robot providers has grown in the past few years, as e-commerce order fulfillment and other warehouse operations benefit from improving navigation and safety systems. Amazon.com Inc. last month acquired Canvas Technology Inc. for an unspecified amount. How will this affect the development and demand for autonomous mobile robots? When Amazon acquired Kiva Systems Inc. for $775 million in 2012, it took one of the early leaders in mobile robots for logistics off the market. It rebranded North Reading, Mass.-based Kiva as Amazon Robotics. The online retailer had rolled out more than 100,000 robots internally by 2017. As a result, the so-called Amazon effect prompted other startups to develop and offer automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) to retailers and third-party logistics (3PL) companies. Many of them, such as Canvas Technology, were at Automate and ProMat 2019 in Chicago in April.

May 2019 www.designworldonline.com

Amazon_Robot Report_Vs3.LL.indd 66

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| Canvas Technology

Goods to people and robots with people Amazon uses more than just the Kiva robots, which bring shelves of goods to human pickers. The choreographed movement of multiple robots takes place on purpose-built warehouse floors. Amazon recently added safety vests to warehouse worker gear, so Canvas Technology’s systems could help Amazon in existing and smaller facilities. In January, Amazon signed a seven-year commercial agreement with Balyo, a French company working on navigation modules to automate pallet jacks, tractors, and lift trucks. Amazon could acquire as much as a third of Balyo’s capital. Boulder, Colo.-based Canvas Technology previously raised seed round investment from Visionnaire Ventures in 2015 and 2016 and $15 million in Series A funding from Playground Global in late 2017. AME Cloud Ventures, Morado Ventures, and Xplorer Capital have also participated. Canvas’ staff includes Kiva Systems alumni.

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“This acquisition makes a perfect addition to the Amazon portfolio,” said Mike Oitzman, managing editor at The Mobile Robot Guide. “The Canvas Technology solution will augment the person-to-goods workflow in Amazon warehouses.” Amazon’s purchase of Canvas Technology is part of a wave of recent transactions around mobile robots. In March 2019, there was approximately $183 million in investments in lidar and mobile robot companies. In February, Amazon participated in a $530 million Series B round for Aurora, which is developing self-driving technology. Canvas Technology uses “spatial AI” to enable mobile robots to navigate safely around people in dynamic environments. It claimed that its combination of sensors and simultaneous localization and mapping (SLAM) software can enable AMRs to

Amount Unspecified acquisition $530M Series B investment Up to $346M operate without relying on a prior map. The robots can continuously update a shared map, according to the company. Canvas said its 3-D cameras and navigation technology can be applied to autonomous indoor and outdoor systems, and the Canvas Autonomous Cart is used in warehouses and factories. Amazon could also apply Canvas’ safety systems to its Scout delivery robots, which are in trials in Washington state, and its Vesta home robot project. Amazon responded to a request for comments with the following statement: “We are inspired by Canvas Technology’s innovations and share a common vision for a future where people work alongside robotics to further improve safety and the workplace experience. We look forward to working with Canvas Technology’s fantastic team to keep inventing for customers.” RR

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Augmenting SLAM with deep learning By Andrew Davison • co-founder • SLAMcore

Some elements of the Spatial AI real-time computation graph. | SLAMcore

Simultaneous localization and mapping (SLAM) is the computational problem of constructing or updating a map of an unknown environment while simultaneously keeping track of a robot’s location within it. SLAM is being gradually developed towards Spatial AI, the common sense spatial reasoning that will enable robots and other artificial devices to operate in general ways in their environments. This will enable robots to not just localize and build geometric maps, but actually interact intelligently with scenes and objects.

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The three levels of SLAM, according to SLAMcore. | SLAMcore

Enabling semantic meaning A key technology that is helping this progress is deep learning, which has enabled many recent breakthroughs in computer vision and other areas of AI. In the context of Spatial AI, deep learning has most obviously had a big impact on bringing semantic meaning to geometric maps of the world. Convolutional neural networks (CNNs) trained to semantically segment images or volumes have been used in research systems to label geometric reconstructions in a dense, elementby-element manner. Networks like Mask-RCNN, which detect precise object instances in images, have been demonstrated in systems that reconstruct explicit maps of static or moving 3D objects.

Deep learning vs. estimation In these approaches, the divide between deep learning methods for semantics and hand-designed estimation methods for geometrical estimation is clear. More remarkable, at least to those of us from an estimation background, has been the emergence of learning techniques that now offer promising solutions to geometrical estimation problems. Networks can be trained to predict robust frame-to-frame visual odometry; dense optical flow prediction; or depth prediction from a single image. When compared to hand-designed methods for the same tasks, these methods are strong on robustness, since they will always make predictions that are DESIGN WORLD

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similar to real scenarios present in their training data. But designed methods still often have advantages in flexibility in a range of unforeseen scenarios, and in final accuracy due to the use of precise iterative optimization.

Building in the right assumptions

The role of modular design

• Basic geometry of 3D transformation as a camera sees the world from different views • Physics of how objects fall and interact • The simple fact that the natural world is made up of separable objects at all • Environments are made up of many objects in configurations with a typical range of variability over time which can be estimated and mapped.

It is clear that Spatial AI will make increasingly strong use of deep learning methods, but an excellent question is whether we will eventually deploy systems where a single deep network trained end to end implements the whole of Spatial AI. While this is possible in principle, we believe that this is a very longterm path and that there is much more potential in the coming years to consider systems with modular combinations of designed and learned techniques. There is an almost continuous sliding scale of possible ways to formulate such modular systems. The end-to-end learning approach is ‘pure’ in the sense that it makes minimum assumptions about the representation and computation that the system needs to complete its tasks. Deep learning is free to discover such representations as it sees fit. Every piece of design which goes into a module of the system or the ways in which modules are connected reduces that freedom. However, modular design can make the learning process tractable and flexible, and dramatically reduce the need for training data. www.designworldonline.com

There are certain characteristics of the real world that Spatial AI systems must work in that seem so elementary that it is unnecessary to spend training capacity on learning them. These could include:

By building these and other assumptions into modular estimation frameworks that still have significant deep learning capacity in the areas of both semantics and geometrical estimation, we believe that we can make rapid progress towards highly capable and adaptable Spatial AI systems. Modular systems have the further key advantage over purely learned methods that they can be inspected, debugged and controlled by their human users, which is key to the reliability and safety of products. We still believe fundamentally in Spatial AI as a SLAM problem, and that a recognizable mapping capability will be the key to enabling robots and other intelligent devices to perform complicated, multi-stage tasks in their environments. RR May 2019

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Mobile robot

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from Automate/ProMat 2019 Incremental improvements, big new models took a spin in Chicago.

CHICAGO -- Attendees at Automate and ProMat 2019 here last month saw numerous autonomous mobile robots, automated guided vehicles, and accessories. From robots that can take shoeboxes from shelves to platforms for pick-and-place and machine-tending operations, suppliers started to fulfill the promise of mobile manipulation.

Eugene Demaitre • senior editor The Robot Report

Even as the sizes and types of mobile robots have grown for the supply chain and manufacturing industries, this year was one of incremental improvements rather than rapid innovation, according to analysts, engineers, and exhibitors at the show. Still, there were some significant mobile robotics trends and new models worth noting. Mobile robots can reduce infrastructure reliance A major driver for the growth in mobile robots is the need for greater flexibility in factories and warehouses. From autonomous forklifts and tote conveyors to heavy-lift platforms, mobile robots can enable users to work with existing, non-standardized facilities. They can also help avoid the costs of bolted-down infrastructure such as stationary conveyors, multi-layer racks, and positioning systems.

May 2019 www.designworldonline.com

AMR Trends_Robot Report_Vs3.LL.indd 76

“In Asia in particular, companies don’t want to invest in more infrastructure,” said Jurgen von Hollen, president of collaborative robot leader Universal Robots. “We need to serve customer requirements.” Cobots and AMRs were two of the best-represented types of robots in McCormick Place. More than 50 mobile robot vendors had booths at Automate/ ProMat 2019, observed Mike Oitzman, founder of Mobile Robot Guide. While there were still plenty of automated guided vehicles (AGVs), particularly at ProMat, several suppliers touted the more advanced navigation and obstacle avoidance of autonomous mobile robots (AMRs). Mobile carts for e-commerce order fulfillment were joined by a new wave of accessories. For instance, 6 River DESIGN WORLD

5/3/19 1:14 PM

Systems added Mobile Sort to its product line. The system combines machine learning with mobile sort stations and 6RS’s Chuck mobile robots. The company also featured demonstrations in which attendees could race with the robots. ROEQ, a partner of Mobile Industrial Robots (MiR), showed off its TR500 roller for the MiR500. “We are designed for the 10 standard pallet sizes in the U.S.,” said Peder Grejsen, technical sales manager at ROEQ. “Our nonskid rollers are collaborative and safe.” Another MiR partner, Nord Modules, displayed its modular system for lifting and loading payloads onto MiR’s mobile robots. Relative newcomers to the U.S. market for AMRs included GreyOrange and Geek+. On the navigation side, Humatics and Vecna Robotics’ partnership and

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Amazon’s recent acquisition of Canvas Technology are examples of how companies are collaborating to improve and spread their offerings. “We’ve worked directly with Vecna and MiR, and our APIs [application programming interfaces] are simple and can provide 2cm [0.78 in.] precision,” said Sean Lorenz, director of product marketing at Humatics. “GPS fails in urban canyons, and we can help mobile robots and cranes in noisy environments.”

6 River Systems’ Mobile Sort includes sort stations and its Chuck mobile robots. | 6 River Systems

Bases get bigger Several mobile robot vendors displayed larger platforms at Automate/ProMat 2019, including Clearpath Robotics, Fetch Robotics, MiR, and Waypoint Robotics. These larger robots are a far cry from the carts that follow (or lead) warehouse workers. Not only are they able to move www.designworldonline.com

May 2019

5/3/19 1:15 PM

The Robot Report More new mobile robots Geek+ self-driving forklift The new Geek+ Autonomous Forklift features SLAM navigation and is capable of automated storage and retrieval. Its sensors detect goods on the shelves, locate pallet slots and carry goods to the appointed area.

Brain Corp. autonomous cart Brain Corp debuted AutoDelivery, a proof-of-concept autonomous delivery robot designed to work in retail stores, warehouses, and factories. Brain Corp isn’t providing the hardware, but will partner with manufacturers to turn their tugs into autonomous robots by retrofitting BrainOS into the product.

autonomously through more dynamic environments, thanks to cheaper lidar and more sophisticated software, but they can also serve as mounts for multiple collaborative robot arms. Some are big enough to carry a car chassis, leading to visions of more flexible manufacturing. Imagine, instead of a car moving down an assembly line to be worked on by single-purpose machines, a swarm of robots moving around the vehicle. Such heavy AMRs could also be useful in construction and agriculture, growing applications for robotics.

Waypoint Robotics MAV3K MAV3K (pronounced Māy-vick) carries up to 3,000 lb. and has omnidirectional mobility. It weighs 1,000 lb. and complies with safety standards being developed at the Robotic Industries Association. It includes three layers of security measures: decelerate to slow, decelerate to zero, and safety stop.

Imagine, instead of a car moving down an assembly line to be worked on by singlepurpose machines, a swarm of robots moving around the vehicle. Such heavy AMRs could also be useful in construction and agriculture, growing applications for robotics. 78

May 2019 www.designworldonline.com

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Mobile manipulation arrives The combination of mobile and cobots seems obvious, but the challenges of power, safety, and precision have taken time to overcome. Several mobile manipulators were demonstrated at Automate/ProMat 2019, but there have been relatively few use cases so far. As part of its “smart production” demonstration at Automate (which it also showed the week before at Hannover Messe), Stäubli International showed its HelMo mobile robot, which carried a cobot arm. “Our smart production cell is ideal for small-batch manufacturing,” said Sebastien Schmitt, North American division manager at Stäubli. KUKA’s KMR iiwa is a cobot mounted on a mobile robot, using SLAM (simultaneous localization and mapping). “We have experience in missioncritical markets such as satellite manufacturing and life sciences,” said Michka Tosan, a sales application engineer at KUKA Robotics. “The mobile shop floor will drive down ergonomic costs.”

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IAM Robotics last month demonstrated expanded capabilities for its Swift mobile picking robot, as well as Bolt, its new tote-transport robot. Coming to the U.S. is Magazino’s Toru robot, which is designed specifically for picking and placing shoeboxes on shelves. It’s able to do so from the lowest shelves and from beneath other boxes, explained Florian Wahl, public relations manager. In Europe, returns are usually free within two weeks, so goods there have a 40% return rate, he said. Magazino is expanding its mobile manipulation with

Soto, which has a bigger gondola for totes. One of the flashier debuts of the past week was Boston Dynamics’ Handle robot, a wheeled, ostrich-like mobile manipulator for reaching and moving large boxes. While mobile version wasn’t at the show, the company did have demonstrations of the industrial arm and suction grippers. On a larger scale, Honeywell Intelligrated, which recently partnered with Fetch Robotics, introduced its robotic unloader, which can operated autonomously to empty a truck. RR

IAM Robotics’ Swift has been redesigned for a smoother lift and to exchange totes with its Bolt mobile robot. | IAM Robotics

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The Robot Report

Expert roundtable:

mobile robotics challenges and opportunities A3 chats with leading mobile robot providers about the differences between AMRs and AGVs, addressing customer concerns, and novel applications.

By Jeff Burnstein • president •

Association for Advancing Automation

The market for autonomous mobile robots continues to thrive, with Technavio predicting a 24% compound annual growth rate for 2018 to 2022. New players continue to enter the fray, and innovative applications and proven use in large fleets are contributing to these vendors’ success. To better understand the growth, the challenges, and the opportunities of autonomous mobile robots (AMRs), the Association for Advancing Automation (A3) turned to several market leaders. This excerpted virtual roundtable discussion includes Jeff Christensen, vice president of product at Seegrid; Ed Mullen, vice president of sales, Americas at Mobile Industrial Robots (MiR); Matthew Trowbridge, vice president of marketing at OMRON Automation Americas; and Jason Walker, CEO of Waypoint Robotics. How do you help your customers weigh the pros and cons of AMRs with respect to other material transport options such as automated guided vehicles (AGVs), pallet trucks, conveyor systems, etc.? Jeff Christensen, Seegrid: The key to automation decisions is not just thinking about what you need today, but also considering what you will need tomorrow. Selecting technologies that will adapt with your material flow over time is crucial to supporting long-term efficiencies.

May 2019 www.designworldonline.com

A3 Roundtable_Robot Report_Vs3.LL.indd 82

As an example, traditional infrastructure-based AGVs—those that need wires in the ground, tape, laser reflectors, or other physical infrastructure to navigate—require costly installation of permanent landmarks, which adds rigidity to a facility’s processes. No one can predict all of the things they’re going to need down the road, so it’s important to future-proof your system by incorporating technologies that are adaptable to unforeseen changes so that your infrastructure will not be a bottleneck to productivity. AMRs like Seegrid’s self-driving vehicles use camera-based vision guidance for navigation, making them highly adaptable to changing needs and allowing customers to instantaneously redeploy a vehicle to perform a different function, shift, or even to an entirely new facility.

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5/3/19 1:17 PM

| Waypoint Robotics

Ed Mullen, MiR: There are several aspects that customers need to take into consideration when choosing their system: which material handling processes they want to automate, what distances materials should be transported, the environment they drive in, if there should be any integration to communications systems such as ERP, etc. In respect to the other material transport options, AMRs are the new, flexible, and user-friendly alternative to systems that have been existing for years and that in many cases cannot live up to the requirements of companies today. What we see in general is that companies are looking into how they can automate their material handling which is non-value-adding, but they have been missing a logistics system that can fit into their setup. Companies today are facing shrinking product lifecycles with frequently changing customer demands, so they need agile production and factory layouts that can easily be changed.

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AGVs and conveyor systems are not flexible at all, but AMRs only require simple changes in their internal map, which make them the perfect match for agile companies. Matthew Trowbridge, OMRON Automation Americas: AGVs, pallet trucks, and conveyor systems are the technologies we are trying to replace, as they are cumbersome, heavy, and stationary. Our mobile robots run off of enterprise software packages, which can coordinate up to 100 mobile robots in a single facility. Additional enterprise software packages are available to increase the mobile robot fleet size. They are completely autonomous and need no other guidance system, which saves businesses money by not requiring the installation of predefined routes. Jason Walker, Waypoint Robotics: We encourage our customers to think about the more difficult-toquantify aspects of the ROI calculation in addition to the measurable ones when adopting AMRs. Examples include higher job satisfaction when workers can focus on valuable tasks they are proud

www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

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The Robot Report The market for autonomous

Seegrid GT10 Series 6 vision-guided tow tractor. | Seegrid

mobile robots continues to thrive, with Technavio predicting a 24% compound annual growth rate for 2018 to 2022.

of, more energy at the end of the day, and a longer, more productive career. These benefits make it easier to attract and retain talent in a competitive job market. What are customersâ&#x20AC;&#x2122; main concerns in implementing mobile robots and how are you addressing those concerns? Christensen, Seegrid: The unknowns of new robotic technology can sometimes create concerns for companies regarding workplace safety. However, these concerns are often misplaced on automationâ&#x20AC;&#x201D;whereas the real danger is inherent in the tasks and jobs these technologies perform.

Our self-driving AMRs are proven to make workplaces safer and reduce the number of human-involved accidents over time. By removing human involvement from dangerous tasks, it reduces the chance they will be injured on the job and allows them to take on higher-level roles in the organization. Mullen, MiR: Our robots are collaborative and completely safe, but customers are not used to this technology, and as our robots are transporting materials up to 500 kg among people that are walking around without any safety measures, safety is definitely a topic that comes up. Companies need to be absolutely sure that our robots are actually safe. At MiR, our robots speak for themselves, and an onsite demo can help customers understand the navigation and collaborative aspect of our robots. Our robots are loaded with safety features, and we live up to the relevant safety standards â&#x20AC;&#x201C; safety is our main priority. Trowbridge, OMRON Automation Americas: Much like the challenges any newer technology faces, we are overcoming the initial thought process of what it is, how much it costs, how it can be used, and the return on investment. We want to have these conversations with people. Most customers find that the return on investment for mobile robots like ours can be as soon as six months or less, with the longest we have seen hit only two years.

Safety is a key consideration for AMRs. | Seegrid

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Walker, Waypoint Robotics: Customers are challenged with the risk of effort and expense in changing processes, the loss of productivity while making the change, and not feeling confident that the robots are going to work as promised. Another risk is negative perception of the workforce.

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−

WORKING TOGETHER AS EQUALS.

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The Robot Report

MiR mobile robot with a UR cobot arm and Robotiq gripper. | MiR

Applications for AMRs will increase over time, says Ed Mullen. | MiR

Mullen, MiR: We see many innovative solutions. There is a big focus on adding mobility to more industrial robots, and many customers and integrators are working on solutions with collaborative robot arms on top of the MiR robots. What are some of the most innovative ways you’ve seen mobile robots implemented? Christensen, Seegrid: First, let’s debunk the myth that being innovative with mobile robots has to be complex and expensive. One of the real benefits of automated technology is that it can be leveraged effectively at both small and large scales. If you’re a regional supplier and thinking about how to operationalize a mobile robot for your warehouse, it is most effective when done incrementally, starting with a few vehicles that can lighten the load on your workforce. For larger operations who have implemented and realized the effects of automation on a micro level, the addition of each new machine gives rise to interoperability benefits that come as a result of having a fleet of automated technologies self-coordinating movement and maximizing productivity. We see many fully automated solutions, for example, where our robots serve as the flexible link between production lines or fixed conveyors, and our robots can take an elevator and open doors and lift entire shelves.

Trowbridge, OMRON Automation Americas: One of our favorite uses we have seen has been in hotels. The robots can sync up to function with the elevators, effectively enabling them to go in and out of the elevators to deliver items to proper rooms and return to their starting destination for the next delivery. With the technology being so new, customers are finding new ways to capitalize on the vast capabilities of the mobile robots. Walker, Waypoint Robotics: Feeding and watering crickets in an industrial cricket farm. RR

OMRON’s AMRs can be used in a variety of environments. | OMRON

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WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

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The Robot Report

Integrating

with fleet management software advances collaboration for

autonomous mobile robots Developers and users of mobile robots can gain new levels of efficiency and safety with AI. Ed Mullen â&#x20AC;˘ Mobile Industrial Robots

May 2019 www.designworldonline.com

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Manufacturers today are recognizing the significant benefits that autonomous mobile robots can offer. AMRs can automate repetitive and injury-prone material transportation without requiring expensive and disruptive reconfiguring of their infrastructure. Conventional logistics solutions like forklifts and conveyor belts -- as well as traditional automated guided vehicles -- haven’t allowed this level of flexibility or adaptability. Manufacturers and logistics companies trying to accommodate ever-changing customer demands will have difficulty if they rely solely on AGVs and other solutions.

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As a result, manufacturers satisfied with one mobile robot have started to implement multiple AMRs in hopes of expanding them to internal logistics applications they hadn’t realized could benefit from their use. To facilitate the process, they are using fleet management software, which offers centralized control of the robots from a single station. The most advanced tools are able to eliminate any bottlenecks and downtime with 24/7 mobile robot operation. Once an AMR is programmed, the fleet management system manages the priorities and selects the most suitable robot to the operation that needs to be carried out, based on position, availability, and top module.

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5/3/19 1:20 PM

The Robot Report

Today, mobile robots use sensors and software both for control (to define where and how the robot should move) and perception (to allow the robot to understand and react to its surroundings).

The system also monitors robot battery levels and automatically manages recharging. In addition, it can control the robotsâ&#x20AC;&#x2122; traffic patterns by coordinating critical zones with multiple robot intersections. Sounds smart, right? These robots and the fleet management software that manage them are becoming even smarter with new artificial intelligence capabilities, coupled with strategically placed cameras that function as an extended set of sensors. Today, mobile robots use sensors and software both for control (to define where and how the robot should move) and perception (to allow the robot to understand and react to its surroundings). Data comes from integrated laser scanners, 3D cameras, accelerometers, gyroscopes, wheel encoders, and more to produce the most efficient decisions for each situation. These technologies give AMRs many of the capabilities similar to those being developed for automobiles. Mobile robots are able to dynamically navigate using the most efficient routes, have environmental awareness so they can avoid obstacles or people in their paths, and can automatically charge when needed.

How AI is changing the game Without AI, however, the robots react the same way to all moving obstacles, slowing and attempting to navigate around the person or object if possible, or stopping or backing up if there is no safe way to maneuver around it. The AMRâ&#x20AC;&#x2122;s standard approach is appropriate for many situations, but just as AI is powering new capabilities for self-driving cars and intelligent drones, it is also poised to dramatically change robotics. AI for collaborative robots today is focused primarily on machine learning and vision systems, which are dramatically extending earlier sensorbased capabilities. In addition, AMRs are benefiting from advances such as smaller and more powerful sensors, cloud computing with broadband wireless communications, and new AI-focused processor architectures. These advances are widely available at lower costs, making it easier than ever to pull data from a robotâ&#x20AC;&#x2122;s immediate, extended, and anticipated environment as well as internal conditions. Using these capabilities, fleets of robots are able to learn while they are online, like a group of online students, and then perform without constant

| MiR

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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.

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The Robot Report Mobile robot market growing While estimates vary on the value of the global market for mobile robots, industry associations and analyst firms agree it will continue to grow. This is largely driven by the need for speedy e-commerce order fulfillment, the demand for more flexible operations in existing warehouses without adding new infrastructure, and improvements in sensors and software. “Advancements in machine vision, simultaneous localization and mapping (SLAM), swarm intelligence, and sensor fusion are making it possible for mobile robots to operate in unstructured environments such as the factory warehouse and the assembly area,” said Lian Jye Su, principal analyst at ABI Research. “These technologies are being supported by many cameras and sensors, such as lidar and radar. Moving forward, the robots can benefit from the integration of deep-learning algorithms with sensor fusion and swarm intelligence.” The autonomous mobile robot market will experience a 24% compound annual growth rate (CAGR) between 2018 and 2022, predicts Technavio. Transparency Market Research expects the market to grow from $8.58 billion in 2017 at a CAGR of 15.6% to $30.96 billion by 2025. Similarly, BIS Research projects a CAGR of 19.67% between 2018 and 2023, with the mobile market reaching $9.9 billion in 2023. These numbers vary depending on whether defense robots, aerial drones, or other subcategories are included, but industrial platforms are still significant.

access to online content. Low-power, AIcapable devices, and efficient machine learning techniques support new robotic systems with low latency and fast reaction times, high autonomy, and low power consumption—all key elements for success. AI improves AMR path planning, environmental interaction The new AI capabilities in mobile robots help maintain the robots’ safety protocols and drive improved efficiency in path planning and environmental interaction. With MiR’s MiRFleet, for example, new advanced learning algorithms are implemented in the robot’s software as well as in remote, connected cameras that can be mounted in high-traffic areas or in the paths of fork trucks or other automated vehicles. The cameras are equipped with small, efficient embedded computers that can process anonymized data and run sophisticated analysis software to identify whether objects in the area are humans, forklifts, or other mobile devices, such as AGVs. The cameras then feed this information to the robot, extending the robot’s understanding of its surroundings so it can adapt its behavior appropriately, even before it enters an area. The AI-capable network helps the robot avoid high-traffic areas during specific times, such as when goods are regularly delivered and transferred by fork truck, or when large crowds of workers are

Other factors that could increase mobile robot adoption include the rise of mobile manipulation, a trend toward reshoring production in reaction to trade and labor concerns, and the proliferation of providers. Where is mobile robot demand the strongest? “North America is currently dominating the global mobile robot market,” said Rahul Papney, an analyst at BIS Research. “However, the geographical analysis of this market unveils a great potential for the growth in the Asia-Pacific region.”

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present, such as during breaks or shift changes. For example, the robots will continue driving as usual if they detect a person but will park if they detect an AGV so the AGV can drive by. The robot can also predict blocked areas or highly trafficked areas in advance and re-route instead of entering the blocked area and then rerouting. While the robots’ built-in safety mechanisms will stop it from colliding with an object, person, or vehicle in its path, other vehicles like forklifts may not have those capabilities, leaving the risk of one of them running into the robot. With the AI-powered AMRs able to detect high-traffic areas before they arrive and identify other vehicles and behave appropriately to decrease the risk of collision, they are improving their own behavior and adapting to other vehicles’ limitations. With these smarter and more collaborative mobile robots, manufacturers should find it even easier to optimize the transportation of all types of materials as they strive to succeed on a global scale. RR

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About the author: Ed Mullen is the vice president of sales in the Americas at Mobile Industrial Robots. The Danish manufacturer of collaborative autonomous mobile robots recently launched its MiR1000, along with the industry’s first AI-based navigation capabilities for its entire fleet of mobile robots. For more information, visit https://www.mobileindustrial-robots.com.

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The Robot Report

How

will impact 5G mobile robots The robotics industry could be a major beneficiary of 5G, the fifth generation of wireless communication. If 5G meets its advertised median speeds of 1 Gbps, 5G will have a speed 20 times faster than 4G. Combine that increased speed with lower latency (about 1ms) and next-generation, 5G-powered robots should be more reliable and efficient. The consensus is 5G will help robots take better advantage of compute resources, enabling robots to process more data in real-time, learn new skills, and better communicate with other robots and humans. 5G will also reduce the cost of robots by offloading Steve Crowe • Editor some of the processing responsibilities to the cloud. The Robot Report “Higher bandwidth and lower latency enable advances in computer vision, edge computing capabilities, better localization, and other types of technologies that have been restricted by a wired connection or pared down based on their usage,” Joshua Ness, senior manager of 5G Labs at Verizon, recently told The Robot Report. “If you can run localized computer vision algorithms so cameraand sensor-enabled robots can better understand what they see and make better decisions, that’s a big benefit to industry.” Carriers didn’t play much of a role in the development of new technologies with 4G. Ness said carrieres don’t want to make that same mistake again with 5G. “Nobody could have predicted the technologies, industries, and economies that were born out of 4G, which was an incremental upgrade from 3G,” he said. “That pales in comparison to the leap in connectivity to what 5G represents.”

The Robot Report asked leading robotics companies how they see 5G impacting autonomous mobile robots. Here’s what they had to say. Smaller size, smarter fleets Ava Robotics, a Cambridge, Mass.-based spinoff of iRobot, showed a telepresence robot and a customer service robot prototype at the recent Verizon 5G Challenge Demo Day. Marcio Macedo, co-founder and vice president of product and marketing at Ava Robotics, said 5G could help lower the overall cost of commercial robots. “With the robots doing no processing and just transferring the data and receiving commands, you could offload a lot of computing to the cloud,” he said. “We’re talking an order of magnitude reduction in what the robot needs to do.” “In robotics, you create this vicious circle once you set the requirements,” Macedo added. “The weight drives the motor, the motor drives consumption, which drives the battery, which increases

Above: An intimate crowd watches a demo about how 5G could improve robotic manipulation during Verizon’s demo during Verizon’s 5G Demo Day. | MassRobotics

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5G could make it easier to deploy fleets of mobile robots, including Ava Robotics’ telepresence robots. | Ava Robotics

The Robot Report 5G Robotics Challenge

the weight. Breaking that cycle and cutting by an order of magnitude allows us to get to a price point that is significantly lower than commercial robots are today.” Macedo said 5G will also make it easier to deploy fleets of robots. With 5G, one network can control multiple robots. It makes it easier for robots to share knowledge and navigate on each other’s awareness of the space. Fleets of robots could potentially share collision avoidance data without having to go to the map, he said. If one robot learns about obstacles, the other robots can path plan. It’s easier to do that if the processing is all together instead of processing on each of the different robots.

To discover more ways 5G-powered robots can disrupt industry, Verizon and the Mass Tech Leadership Council, in partnership with Ericsson, held a 5G Robotics Challenge in the greater Boston area. After a slew of submissions, the challenge was narrowed down to winners from Northeastern University and the University of Massachusetts, Lowell, as well as four startups: Ava Robotics, GreenSight Agronomics, RealBotics and Southie Autonomy. The winning teams each received $30,000 to create insights, develop new use cases, and conceive innovative products that will advance the robotics industry by leveraging the speed, bandwidth, and latency benefits of 5G.

Dynamic obstacle avoidance Team Microgrid from UMass Lowell used two LiDAR sensors, four infrared sensors, and GPU on the edge to demonstrate dynamic obstacle detection and avoidance with a small mobile platform. Jumping in front of the robot and having it stop would not have been possible with 4G, the team said.

The teams had 12 weeks to create solutions in three key areas: industrial automation, collaborative robotics, and warehouse automation. The challenge ended with a Demo Day in late April at the Verizon 5G Cambridge Lab.

Enabling tele-operation RealBotics is using tele-operation and virtual reality to enable people to learn how to use complex robots, said Chris Quick, founder and CEO of the Pittsburgh-based company. “We’re going from the camera and the computer on the edge to user via 5G for low latency and back to the device,” he said.

They had access to dedicated 5G networks at Verizon’s 5G Cambridge Lab and 5G Waltham Lab, as well as 5G training and mentorship from Verizon and Ericsson. Waypoint Robotics also created a mobile manipulation platform for the teams to use. The system included Waypoint’s flagship Vector autonomous mobile robot and its quick-swappable UR5 payload.

Waypoint Robotics provided a mobile manipulation platform for Verizon’s 5G Challenge, combining its flagship Vector autonomous mobile robot and quickswappable UR5 payload. | Waypoint Robotics

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Infrastructure within warehouse Melonee Wise, co-founder and CEO of Fetch Robotics, a California-based logistics robotics company, said 5G is a great solution to use within the four walls of a warehouse. “If you have a customer without Wi-FI and want to get wireless set up very quickly, 5G is potentially a great solution for that,” she said. “You put up a 5G antenna in the building, all the robots have 5G modems and it’s a quick way to stand up Wi-Fi infrastructure.” “But it’s not clear to me how you’d move large amounts of data around. If you have one or two robots in a location, you can go straight to the cellular towers. If you have hundreds of

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robots in one location, you might not want to be throwing that kind of data of cellular towers.” Outdoor robots to benefit most Sean Lorenz, director of marketing at Humatics, which is working on microlocation technology for a variety of robots, said 5G will be more valuable once outdoor mobile robots become more commonplace. “Wi-Fi works pretty well for those in a factory,” he said. “Until more real-time data is pushed off the robot and into the cloud or a fog infrastructure, 5G doesn’t have much value. Customers won’t put mission-critical apps on 5G given the maturity of the tech. Several 5G providers have talked about private 5G networks, which would appeal to some customers.” “But as mobile robots move outdoors, such as ports, we’re seeing rail-mounted gantries and AGVs,” said Lorenz. “On the consumer/business side, you’re seeing food and package-delivery robots. You’ll see a point were 5G will be more ubiquitous, and that’s what we’re pretty excited about.” Of course, 5G-enabled robots won’t happen overnight. “To productize a robot that takes advantage of 5G requires a different processor,” Macedo said. “It requires less batteries on board to make the robots lighter. It’ll take time for 5G to be available and for robotics companies to truly redesign the products for 5G.” “A lot of teams said that what they’re trying to do -- in terms of increasing capacity from more sensors or improving the customer experience -- wasn’t possible before 5G,” said Taru Jain, product development lead for the 5G ecosystem at Verizon. RR

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CGI Inc. Advanced Products for Robotics and Automation At CGI we serve a wide array of industries including medical, robotics, aerospace, defense, semiconductor, industrial automation, motion control, and many others. Our core business is manufacturing precision motion control solutions. CGI’s diverse customer base and wide range of applications have earned us a reputation for quality, reliability, and flexibility. One of the distinct competitive advantages we are able to provide our customers is an engineering team that is knowledgeable and easy to work with. CGI is certified to ISO9001 and ISO13485 quality management systems. In addition, we are FDA and AS9100 compliant. Our unique quality control environment is weaved into the fabric of our manufacturing facility. We work daily with customers who demand both precision and rapid turnarounds.

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CS HYDE COMPANY Eliminating friction unleashes a Gantry robots full potential Applying UHMW tape is a performance upgrade to all robotic rail systems. UHMW or (Ultra-high-molecularweight polyethylene) is an abrasion resistant material with anti friction performance similar to PTFE. This plastic can be used on conveyor or guide rail systems across many industries. This tape is extremely abrasion and impact resistant which enables it to withstand the repeatability of robotic gantry systems. Its low friction non stick surface allows gantry robots to slide across rail systems freely. Eliminate drag and protect your rails from potential wear and tear. UHMW Tape is available in slit to width rolls, sheets, strips, or custom die cut parts. UHMW is supplied in sheet stock for mechanical fastening or tape with a PSA adhesive for easy

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Robotics Robotics 100

FESTO Corporation Festo Motion Control Package Simplifies Gantry Design and Install The Festo Motion Control Package (FMCP) is a readyto-use control system that handles coordinated motion up to six axes—providing an integrated robotic solution for Festo handling systems. Configure Cartesian motion applications using function blocks and without writing a single line of code. The FMCP is prewired and preconfigured according to your unique job requirements, enabling you to initiate production changeovers—including load size, speed or number of cycles—from a PLC interface. FMCP Highlights • UL enclosure • Heavy-duty connectors • Plug and play motion controller • Ideal for pick and place applications • Easy integration with any Ethernet-based protocol • No specialized programming knowledge required

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GAM The New Gearbox Standard in Robots Our new robotic gearbox offers a unique level of precision, lifetime and energy efficiency unseen from other gearboxes suppliers. Our planetary technology is based on a unique patented gear profile that remains backlash free at ≤0.1 arcmin for the lifetime of the gearbox. Our high tilting rigidity and 95% efficiency, allow us to achieve an impressive life of 20,000 hours, unheard of in today’s robotic gearboxes. We have 7 sizes up to 7000Nm with many versions available from sub-assembly to right angle in both shaft and hollow configurations. These features set this gearbox apart from all others in the market today!

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Harmonic Drive Customizable supermini actuator Small enough to fit inside the finger of a robotic hand, these ultra-compact servo actuators utilize zero backlash Harmonic Drive® precision gears, a brushless servo motor and an incremental encoder. RSF supermini actuators are available in 2 sizes with ratios 30:1, 50:1 and 100:1. Peak torque .13~1.4 Nm, max speed 100~333 rpm. RSF Supermini actuators are remarkably reliable. Known for our expert engineering and manufacturing, Harmonic Drive® products are relied upon every day throughout the robotics industry. 247 Lynnfield Street Peabody, MA 01960 United States www.harmonicdrive.net

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Honeywell Intelligrated Advanced robotics for the DC Unmatched integration experience and domain expertise uniquely position Honeywell Intelligrated to bring the benefits of smart robotics to your distribution center. From sorter induction and unloading to picking and depalletizing, Honeywell Robotics has a broad portfolio of patented robotic innovations and constantly develops new solutions. The Honeywell Universal Robotic Control (HURC) unleashes the power of artificial intelligence and the latest robotic controls software to enable new applications and continuous optimization. The highperformance platform enables machine learning across applications, enabling faster perception and more effective action. This allows Honeywell Intelligrated to provide meaningful performance advantages and

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igus Customize low-cost robotic joints and complete arm assemblies The new robolink designer is an online configurator tool from igus® that allows users to quickly and easily configure individual robotic systems. With the tool, users can select robolink components individually and configure a robotic arm step by step. They can also configure the length of the arm to match the dimensions a specific work environment, as well as simulate motion of the robot through rotating its joints. Furthermore, a parts lists can be saved for future reference, and a quote can be requested for the configured system. The digital design tool uses an intuitive CAD interface suitable for both desktops and tablets.

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Kollmorgen KBM™ Series Frameless Motors The KBM™ Series is designed to be directly embedded in a machine. With a vast selection of standard motors—plus Kollmorgen’s ability to create optimized modifications—design engineers can choose the exact-fit motor that yields the highest performance in the most compact space. • • • • • • • •

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LAPP LAPP ÖLFLEX ROBOT cables Engineered for Demanding Robotic Environments Harsh industrial conditions require robust cables to maintain operations and maximize productivity. LAPP’s ÖLFLEX® ROBOT F1 and 900 cables are engineered to provide superior signal and power connections for demanding manufacturing applications including multi-axis articulated robots with twisting and bending motion, and automated material handing equipment. ÖLFLEX® ROBOT F1 / F1 (C): UL AWM approvals for USA and Canada ÖLFLEX® ROBOT 900 P / 900 DP: multi-conductor control and signal monitoring cables Specially formulated polyurethane jackets for protection against plant environments. F1 (C) and DP have tinned copper spiral shield to suppress EMI. Unshielded cables have a maximum twist of ± 360°.

Corporate Headquarters 29 Hanover Road Florham Park, NJ 07932 Toll Free: 1-800-774-3539 Tel: 973-660-9700 Fax: 973-660-9330 www.lappusa.com Email: sales(at)lappusa.com

maxon precision motors High Performance Motion Controllers

maxon’s EPOS4 series offer a reliable and extremely versatile platform of high-performance motion controllers. It addresses the needs of system integrators and fulfills the requirements of a variety of applications, such as industrial automation, apparatus engineering, and robotics. These positioning controllers are scalable and consistently support a uniform set of functionalities and connection options. Modularity with different designs (module, compact, or encased version) ensures optimal integration in a wide variety of applications. The controllers offer excellent dynamic properties, control quality, and power density while requiring only minimal installation space. In addition, their automatic controller setting makes them ideally suited for easy control of both brushless (BLDC) and

maxon precision motors, inc. 125 Dever Drive

brushed DC motors.

Taunton, MA 02780

Learn more about the maxon solutions and visit epos.maxonmotorusa.com

Phone: 508.677.0520 www.maxonmotorusa.com info@maxonmotorusa.com

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MICROMO Power in New Dimensions: New BXT Flat Brushless Motor New winding technology, optimized design, & impressive performance make the new FAULHABER BXT Flat Brushless DC Motor Series ideal for applications in robotics, exoskeletons, & automation. The external rotor BXT motors are designed for continuous output power up to 100 W, and deliver torques up to 134 mNm. • Flat design for space-critical applications • Outstanding ratio of torque to weight & size • Available in 22mm, 32mm, 42mm diameter • Available with or without housing • Matching encoders, gearheads & controls available Since 1961, MICROMO has been the micro DC motor

MICROMO

expert, serving OEM engineers to deliver outstanding service

14881 Evergreen Ave Clearwater, FL 33762 USA

and the highest quality products. As the exclusive provider for FAULHABER micro motion products to North America, MICROMO

www.micromo.com

Mitsubishi Electric FR Series Next Generation, High Performance Industrial Robots Integrate Seamlessly with iQ Platform Controllers for Advanced Cooperative Functions “FA-IT Integration Functions” with the full line of Mitsubishi Electric FA products such as PLCs, motion controllers, VFDs, HMIs, and CNC, as well as MES/SCADA packages provide a level of performance, functionality and ease of use unparalleled in the industry. In addition, the open platform architecture OS enables integration with 3rd party devices normally difficult or impossible to use on closed platforms. With such flexibility, capability and performance, increases to both productivity and maintainability can be achieved, resulting in a lower TCO (Total Cost of Ownership). • With an extensive selection of arm sizes, configurations, protection ratings,

Website: us.MitsubishiElectric.com/fa/en Address: 500 Corporate Woods Pkwy Vernon Hills, IL 60061 Phone: 847.478.2100

backed with “Next-Generation” features, and options, the MELFA FR-Series line of robots are ready to handle all of your automation needs. Vertically articulated, horizontally articulated SCARA, ceiling mounted horizontal type, and dual arm high precision for micro-assembly • Industry’s best initial warranty - 3 year on-site for most models

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Phone: (800) 807-9166

creates value through advanced design and engineering services.

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Robotics Robotics

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mk North America Enhance Your Automation with Pallet-Handling Conveyors Pallet-handling conveyors utilize pallets to transport workpieces asynchronously between stations. Pallets range in size from 10x10 inches to 48x48 inches, and are capable of carrying loads of nearly 1,000 lbs. Pallet-handling Conveyor Benefits Are Delivered By: • Continuously moving materials from point to point • Handling every item in the same fashion with no variance • Removing production inefficiencies and wasteful delay by streamlining and standardizing the movement of material • Consistent material handling routines, ultimately reduces work in process and allows greater throughput • Eliminating bottlenecks and operations that require labor but, do not add value

Contact info: mk North America, Inc.

• Easily adapt to changing demands and production requirements

Website: www.mknorthamerica.com

• Efficiently handle changes to work flow by adding in new stops, locates or transfer components

Phone: 860.769.5500 Email: info@mknorthamerica.com

New England Wire Technologies Advancing innovation for over 100 years Why accept a standard product for your custom application? NEWT is committed to being the premier manufacturer of choice for customers requiring specialty wire, cable and extruded tubing to meet existing and emerging worldwide markets. Our custom products and solutions are not only engineered to the exacting specifications of our customers, but designed to perform under the harsh conditions of today’s advanced manufacturing processes. Cables we specialize in are LITZ, multi-conductor cables, hybrid configurations, coaxial, twin axial, miniature and micro-miniature coaxial cables, ultra flexible, high flex life, low/high temperature cables, braids, and a variety of proprietary cable designs. Contact us today and let us help you dream beyond today’s technology and achieve the impossible.

NEW ENGLAND WIRE T E C H N O LO G I E S

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Contact info: New England Wire Technologies www.newenglandwire.com 603.838.6624

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NSK Precision For Maintenance Free Operation Choose NSK Â K1TM Lubrication Unit NSKâ&#x20AC;&#x2122;s K1TM is a uniquely designed system that not only lubricates but also helps minimize contamination. K1 material composition consists of 70% mineral

oil

and 30% polyolefin resin which ensures long-term, maintenancefree operation even under tough lubrication environments. K1TM offers no maintenance for up to 5 years or 10,000 km operational distance. K1 is ideal for environments where the lubricant is hard to replace or is easily washed away. Available in ball screws, linear guides, monocarriers and tough carriers. NSK Americas www.nskamericas.com

Posital-Fraba Upgrade Your Motor Feedback with POSITAL ABSOLUTE Kit Encoders POSITAL ABSOLUTE Kit Encoders offer a great upgrade path for the traditional incremental kit encoders used for servomotors. Compact, rugged and cost effective, they provide accurate position feedback for precision motion control in robots, production machinery, autonomous vehicles and other motion and position control application. They can also be used to provide closed-loop feedback control for stepper motors. Rotational resolution is up to 17-bit (one part in 130,000) with a multi-turn range of

POSITAL-FRABA Inc.

more than 8 million revolutions.

1800 East State Street, Suite 148 Hamilton, NJ 08609

Standardized compact form factors make POSITAL absolute kit encoder a straightforward replacement for US Digital or Broadcom incremental kit encoders in existing machinery or in new designs.

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USA Website: www.posital.com Email: info@fraba.com Phone: +1 609.750.8705

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Robotics RoRobotics

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Renishaw Inc. QUANTiC™ Encoder series Our QUANTiC encoder series features exceptionally wide installation and operating tolerance, in addition to enhanced diagnostics compatibility. QUANTiC read heads incorporate our wellestablished filtering optics that averages the contributions from many scale periods and effectively filter out on-periodic features such a dirt. Also, featuring a third layer of signal filtering from a new detector design, which helps to eliminate non-harmonic signal frequencies that can occur due to contamination on the scale. These signal conditioning features combine to ensure low Sub-Divisional Error (SDE) and minimal signal variation over contamination. QUANTiC encoders will help to increase the throughput of high-volume production lines and offer potentially significant time and cost savings for OEM customers.

Contact Info: 1001 Wesemann Drive West Dundee IL 60118 Website: www.renishaw.com Phone: 847.286.9953

•

Email: usa@renishaw.com

ROLLON Extend Your Robot With A Seventh Axis Adding a seventh linear axis to a robotic system provides all the benefits of six-axes plus another degree of freedom for maneuverability during complex tasks. This flexibility lets designers of a pick-and-place system, for instance, “shuttle” a robot — or multiple robots — and parts back and forth along a rail. A seventh axis provides a host of advantages, including: • Extended operating area. Multiple robots or heavy loads can travel over long distances and to several workstations. • Greater robotic output. An additional linear axis expands the work envelope to the point that companies can use smaller, less- expensive robots to perform the same amount of work as larger robots. • Flexibility. Seventh-axis robot systems can accommodate lightweight or heavy loads, even at high speeds. • Efficiency gains. More machines and processes can be serviced with one robot. • Reduced capital costs. The combination of increased range of motion, greater output from smaller, more economical robots and the ability to service more workstations means greater cost savings for automated operations.

Contact info: Rollon Corporation 101 Bilby Rd. Hackettstown, NJ 07840 www.rollon.com Phone: 973.300.5492

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SICK, Inc. The Safety Laser Scanner for Outdoor Automation SICK has developed the world’s first safety laser scanner for outdoor use – the outdoorScan3. Certified in accordance with ISO 13849 and IEC 62998 for protecting people indoors and outdoors, it facilitates simple and safe outdoor automation in entirely new dimensions. Your benefits • High productivity due to safe human-machine cooperation in outdoor areas • Incredibly durable, even in harsh weather conditions, with outdoor safeHDDM® scanning technology • Flexibility for safe, customized automation processes with field range of 4 meters and up to 128 freely configurable fields • Precise localization due to highly precise measurement data • Continuous material flow due to intralogistics process between buildings • Safe networking with Flexi Soft safety controller

May 2019 www.designworldonline.com

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SICK, Inc. 6900 West 110th St. Minneapolis, MN 55438 USA www.sick.com info@sick.com

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Sensor www.sensortips.com

A Supplement to Design World - May 2019

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S e n s o r

T i p s

A look into factor 1

proximity sensors

Inductive proximity sensors are suitable for many applications. Selecting models with factor 1 capability makes them even easier to employ for sensing targets of varying metals.

Andrew Waugh â&#x20AC;˘ AutomationDirect Figures, all courtesy of AutomationDirect

Almost all forms of machine and equipment automation rely on accurate presence sensing of physical elements. Proximity sensors, also known as prox sensors or prox switches, are a great way to achieve this in many applications. Their non-contact operation makes them long-lasting, and their solid-state nature makes them very reliable. Proximity sensors can therefore improve the overall ruggedness and reliability of almost any automated sensing system. Inductive proximity sensors are specifically designed to sense ferrous metals, while capacitive sensors can detect metallic and non-metallic targets. Inductive technology is preferred for many machine sensing applications for several reasons. Metals are prevalent, rugged, cost-effective and easy to use as targets on machines. Because inductive sensors inherently cannot see other materials, they are not easy fooled by stray materials, dust, water or other environmental elements.

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Figure 1. Inductive proximity sensors are compact and reliable, providing a suitable way to sense the presence or absence of metal for automation applications.

As with any other automation element, some consideration is needed to select the right sensor for the application. This includes the desired form factor, the expected sensing distance and the target material. One downside of standard proximity sensors is the sensitivity of a given model when used on varying metal target materials, particularly ferrous and non-ferrous types. This leads to the need for specifying multiple models to meet the requirements of different applications. A special class of inductive proximity sensors featuring correction factor 1 address this issue by providing a constant

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sensing range without adjustment regardless of the target metal. Weâ&#x20AC;&#x2122;ll examine some proximity sensor considerations and show how factor 1 sensors can help with automation sensing needs. Limitations of standard inductive proximity sensors For sensing the presence or absence of metals, inductive proximity sensors are the devices of choice (Figure 1). Traditional versions of these sensors generate and sense electromagnetic fields using a single ferrite core and coil.

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Figure 2. Standard proximity sensors are available in a variety of diameters and sensing distances, but each must be carefully matched to the application.

When a metallic object moves into and interacts with this field, the switch operates to indicate its presence. Proximity sensors react to different metals at different distances, making the range dependent on the object material. A nominal target is generally considered to be mild steel, so the correction factor in this case is 1 (or k-factor = 1, sometimes shortened to K1). Other metals with little or no ferrous content will exhibit a reduction in sensing distance, and each sensor manufacturer will provide data sheets indicating the k-factor for certain materials. For instance, a certain proximity switch might be specified as offering a 3-mm sensing distance with a k-factor of 0.5 when the target is aluminum. Therefore, the effective sensing distance in this case would actually be 1.5 mm. In order to meet various end user needs, proximity sensors are available in a cylindrical form factor varying from 3-mm diameter up to 30-mm diameter. Generally speaking, the larger the diameter the greater the sensing distance. In addition, within any given size there may be standard (1X), extended (2X), triple (3X) and even some quadruple (4X) sensing distance variants (Figure 2). So,

Mastering challenges. Opening communication channels. Redefining flexibility. R10x and R20x Series

All photoelectric sensing modes in standard housing styles for maximum flexibility and more integration possibilities Simple installation and setup with one user interface for all housing styles and sensing modes IO-Link and Smart Sensor Profile in every sensor: standardized communication down to the sensor level as the basis for Sensorik4.0 ÂŽ

www.pepperl-fuchs.com/pr-rx

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Passive Component

there are many options, but the sensing range in relation to the correction factor must be evaluated for every location. Other considerations may be applicable to all forms of proximity sensors. For instance, if a sensor will be installed in flush-mount or metal location, it will need to be rated for that service so the mount will not affect its performance. Accommodating a sensing distance that varies under differing conditions is not ideal. For end users with diverse sensing needs, it means more types of devices will need to be specified and stocked, and also requires various installation clearances to achieve proper sensing. Factor 1 prox sensors provide a solution to this problem in a cost-effective manner. Factor 1 sensors address issues A suitable inductive proximity sensor would have the same range and sensitivity for metal targets of any type. Common industrial targets other than mild steel could be stainless steel, aluminum, copper, brass and more. Ideally, no adjustments or special accommodations would be required to use this sensor throughout a machine. In practice, this has been achieved with updated technology that can deliver proximity sensors with a k-factor of 1 for all metals. Various approaches enable factor 1 sensors to achieve better sensitivity, while adding discretion to sense the presence of varying metal materials. The result of this technology is a constant sensing range for all types of target metals. This greatly simplifies the design, application, commissioning and stocking of proximity sensors. Factor 1 inductive proximity sensors deliver many benefits over traditional technology, making them the right choice for many new and retrofit applications, especially since they carry little or no cost premium. The most basic advantage is the improved sensing range for all metals, not just steel. This means the sensor can be mounted with increased clearance from moving parts, minimizing the chance of damage. Their greater sensitivity also ensures less fine-tuning adjustment is needed to sense challenging metal targets. For production applications where product changeovers involve different metals that must be sensed, factor 1 technology is an obvious choice. But even on machinery and equipment where few changeovers are expected, it is often possible that targets of various metal types will need to be sensed. Because factor 1 sensors are more adaptable, design effort is saved — as there is less demand to select among multiple devices for an application. This allows the machine builder to source the required sensors earlier in the design process, and then quickly move on to the next challenge. New design work benefits from factor 1 sensors because engineers can focus on standardizing for consistency, and this also results in fewer parts needing to be stocked. For all the noted reasons, these improved sensors are also appropriate for retrofit applications as long as mounting, sensing distance and electrical compatibility are confirmed. For new and DESIGN WORLD

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May 2019

Sensor Solutions Bus Bar with Integrated Current Sense Element

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

Battery Strap

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

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

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existing applications, the best reason for using standard prox sensors it to match existing in-service equipment or stocked items. Regardless of the sensor type selected, it must be rated for the environmental conditions. Factor 1 sensors are readily available in stainless steel versions rated up to IP69K for high pressure and temperature washdown, so it is likely a version will be available to fit most applications.

Figure 3. K1 proximity sensors provide consistent sensing ranges for many metal target materials — and good value when evaluating cost versus sensing distance.

NASA LOW OUTGASSING APPROVED Per ASTM E595 standards

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Design considerations Although K1 sensors should be able to detect all metals at the same distance, it is important to assess each real-world application (Figure 3). The case where a sensor position is fixed (and various types of metal targets are passing by) it is very specific and not necessarily prevalent in the industry. However, capability does demonstrate product versatility for cases where the designer is using a single K1 sensor model to replace several varying instances on a machine or system, thus reducing the maintenance stock. The greatest benefit of K1 sensors revolves around the cost versus distance evaluation. Sensors increase in cost as the sensing range increases, within a given housing size and material type. Looking at a typical 12mm flush sensor, for example, the standard sensing range is 2mm, extended is 4mm, triple sensing is 6mm and quad sensing is a whopping 8mm of range. As the range doubles so, in general, does the cost. If the application is to sense stainless steel, then the associated correction factor causes the range to be reduced by 30%. This results in spending more money to obtain a triple sensing model to effectively deliver extended sensing range. K1 sensors can cost around the same as extended sensing proxes and still deliver that same range on any metal. By using K1 sensors, not only can designers obtain a better cost-torange value, they can also reduce the variety of maintenance parts and future-proof design installations from any changes to the target material. One ruler? Inductive proximity sensors are a mainstay for sensing metal presence in all forms of industrial and machinery automation due to their superior durability and reliability. However, traditional sensors have been somewhat application-specific, requiring substantial design effort to select the right sensor. Factor 1 sensors use dedicated sensor and receiver coils to overcome this deficiency and are therefore able to sense varying metal targets with a constant range and sensitivity. Not only does this make factor 1 sensors more adaptable for new applications, it also allows them to be retrofitted into existing systems. This flexibility reduces the design effort and allows users to minimize the number of sensor parts in stock. Because all of these benefits are available at little or no cost difference, the choice is clear to move forward with factor 1 inductive proximity sensors in most applications. DW

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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. Battery 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

SENSORS

KOA SPEER ELECTRONICS, INC.

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

MASTER BOND 154 Hobart Street Hackensack, NJ 07601-3922 +1-201-343-8983

www.masterbond.com main@masterbond.com

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SENSORS

Pepperl+Fuchs, Inc. R10x/R20x Series Photoelectric Sensors—Flexibility Redefined R10x/R20x series photoelectric sensors combine several photoelectric families of sensors with efficient technologies in five standard housing styles. With one user interface for all housing styles and sensing modes, the sensors minimize complexity by providing easy installation and setup. This all-round solution can be adapted to the requirements of any installation. Pepperl+Fuchs’ photoelectric sensors deliver absolute reliability and accuracy with eye-safe DuraBeam laser technology and proven Multi Pixel Technology. Continuous communication via IO-Link and Smart Sensor Profiles provides versatility and ensures that the intelligence of the sensors is used to the fullest. Experience more flexibility and enhanced integration possibilities with Pepperl+Fuchs’ R10x/R20x photoelectric sensor series.

Pepperl+Fuchs, Inc. 1600 Enterprise Parkway Twinsburg, OH 44087 330-425-3555 www.pepperl-fuchs.com

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

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S U M M I T

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M o t i o n

C o n t r o l

Selecting the best servomotors with integrated drives Although new distributed servo drive systems promise incredible performance, engineers should consider cabling, form factor, and safety integration before standardizing on a platform. Matt Prellwitz Drive Technology Application Specialist Beckhoff Automation

Servomotors with integrated drives were groundbreaking technology when they hit the market, but their full potential has rarely been reached. These servomotors are supposed to reduce footprint and commissioning time while increasing safety and performance. Unfortunately, due to design shortcomings, few have lived up to all of the promises.

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Distributed servo drive systems using an IP 65-rated distribution module can support even the most demanding topologies.

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â&#x20AC;&#x192;

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M o t i o n

C o n t r o l

Integrating the drive at the rear of the servomotor and using one-cable technology (OCT) are two key factors for minimizing a footprint on new designs or retrofits.

Beyond torque and speed specifications, other important factors to consider when selecting an integrated servo system include the drive’s cabling, form factor, and safety features.

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Given that motion control architectures are complex and costly to replace, it’s important to understand what differentiates a high quality servo system from the rest. Beyond torque and speed specifications, other important factors include the drive’s cabling, form factor, and safety features. These factors affect performance and reliability, so it’s important to weigh all options when standardizing on a solution.

Daisy chained vs. distributed servo drive systems When only one motor is necessary, a servomotor with integrated drive technology greatly simplifies installation. The engineer easily connects the unit to power and industrial Ethernet communication, such as EtherCAT. However, most factory settings require a more complex topology with servomotors spread across different machines and lines. In these cases, engineers must decide between a cascaded or distributed system. A cascaded system daisy chains the servomotors together. The first unit connects directly to power and the I/O terminals in the control panel, then shares with subsequent units. However,

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this presents a major downside, as the approach introduces a number of potential failure points. If a single error occurs in one motor, power cable or Ethernet cable, the entire motion control architecture could grind to a halt. On the other hand, a modern distributed servo drive system uses a distribution module to manage multiple servomotors, which can have a protection rating of IP 65 or a similar value. The machine mounted distribution module connects power and communication between the control cabinet and distributed servo drives via a single coupling module, which supports cascaded architectures while limiting points of failure. This approach ensures that if one cable is damaged, it usually doesn’t stop operations across the system as happens in alternative platforms. Further simplifying cabling issues, a one-cable technology (OCT) connection can provide power and industrial Ethernet communication for high-performance servo drives. This one-cable solution reduces both commissioning time and machine footprint, which is incredibly important DESIGN WORLD

5/3/19 4:08 PM

BASIC WHEEL PLATE

WE’RE MORE THAN 4 We invented the DualVee® guide wheel over 50 years ago in carbon steel and in only four sizes as a problem solver for harsh, debris-laden environments. It’s 2019. Now we have LoPro® Linear Actuators, which are now available as part of the QuickShip Program. The Bishop-Wisecarver QuickShip Program guarantees belt-driven LoPro® Linear Actuators with qualifying configurations to be on their way to you within 7 days of order placement. LoPro® Linear Actuators excel in high speed, long length and dirty environments. Its low profile is accomplished by mounting two lengths of hardened steel track to milled anodized aluminum substrate. The wheel plate incorporates four DualVee® guide wheels that accommodate axial loads ranging from 200 to 3,500 lbs., while also performing a natural wiping action when mated with the track for dust and debris that is in the environment.

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M o t i o n

Manufacturers of Power Transmission and Motion Control Components

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C o n t r o l

Distributed servo drive systems should reduce footprint requirements for new machines and maintain the same mounting plate and rectangular shape of previous models to support successful retrofits of legacy equipment and minimize any impact on mechanical designs. in any manufacturing environment. Combining OCT with a distributed servo drive system can provide the cleanest and most efficient motion control solution.

Top- or side-mounted integrated drives vs. back-mounted Form factor is key for servomotors with integrated drives, since combining both devices into a single functioning unit is more difficult than it sounds. Distributed servo drive systems should reduce footprint requirements for new machines and maintain the same mounting plate and rectangular shape of previous models to support successful retrofits of legacy equipment and minimize any impact on mechanical designs. Some manufacturers have struggled to successfully embed the drive in the best location on the servomotor. Many current models typically stack the drive on the top or side of the motor, and this significantly alters form factor, resulting in more mechanical changes and a larger footprint. The drive most logically fits at the rear of the motor, but the majority of manufacturers that have attempted to integrate it in this location could not solve heat dissipation issues created by the convergence of motor and drive technology. By approaching the design challenge differently, a few have succeeded in integrating the drive at the rear of the servomotor while slightly lengthening the form factor compared to servomotor-only models. Many companies have incorporated the drive at the rear of the

motor without heat dissipation issues, but reaching the high performance typical of standard servomotors has presented difficulties. A key factor for maintaining output and form factor has been new heat dissipation methods. Previously, these units would attempt to force all heat through the back of the motor and, therefore, through the integrated drive. However, Beckhoff Automation has devised an innovative heat dissipation method that efficiently releases heat through the sides of the motor housing down the entire length of the shaft, rather than entirely through the drive at the rear. A careful redesign of motor windings in these units makes this possible. As a result, users can select distributed servo drive systems that retain a small footprint without overheating and are optimal for both new installations and retrofits.

IGBTs vs. MOSFETs Another way to improve heat dissipation and form factor in distributed servo systems is through the selection of semiconductors for drive electronics. While most integrated motor and drive models use IGBTs, the most successful and compact servo drive systems more often incorporate MOSFETs, which produce less heat. IGBTs have been on the market for many years and have proven to be successful in the field. However, recent updates to the design of MOSFETs have made them the better switching option for

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M o t i o n

C o n t r o l

motion control systems for a few key reasons. Many differences and similarities exist between the two, and although IGBTs may be preferable in certain architectures, they are less desirable in these types of servo drive systems. As a bipolar device, IGBTs are able to handle high voltage and current. As a fieldeffect transistor, MOSFETs support higher current with fewer switching losses even when hundreds of milliamps are switched to double-digit amps or when small voltages are switched to thousands of volts. In general, IGBTs also require a larger amount of supporting components, including fans, heatsinks and additional wiring. This means that the benefits gained through higher voltage and current come with a sacrifice in terms of footprint and price. MOSFETs provide high performance operation at a lower temperature and with fewer components, which makes them the preferred semiconductor type for these distributed motion control architectures.

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Separated vs. integrated safety In any manufacturing environment, safety is always a top concern. Most servomotors with integrated drives use a separate, standalone safety system. This is more expensive and less efficient because it requires dedicated wiring and frequently a separate software platform and network. However, newer servomotors with integrated drives can provide integrated STO and SS1 safety functions by default in every unit. These should also interface with safety I/O terminals on the same EtherCAT industrial Ethernet network. Each of these differences in features and design may seem minor when considered separately, but together they can mean servomotors with integrated drives that improve — or seriously degrade — a motion control architecture depending on which path one chooses. Always consider the unique form factor, mounting considerations, cabling and safety requirements of each solution to choose the best distributed servo drive system for the application. DW

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L i n e a r

M o t i o n

. y t i d i g i r t s o o b p l e h s canHow to improve

ball screw rigidity

Ball screw rigidity depends not only on the screw shaft and ball nut, but also on the thrust bearings and on the ball nut and bearing housings.

The default method for increasing ball screw rigidity is to increase the preload of the ball nut. However, the ball nut is one of the most rigid components in the ball screw assembly … so increasing ball nut rigidity has little effect on the overall system rigidity The only exception is when upgrading from a ball nut with no preload to one that is preloaded. What’s more, higher preload causes higher frictional torque, which means more heat is generated and more

torque is required to drive the screw.

A double ball nut is somewhat more rigid than a

single nut, but again, the effect is minimal due to the nut’s already high rigidity relative to the other components. A double ball nut has higher rigidity than a single nut, but the overall effect on the ball screw system’s rigidity is relatively small.

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Nuts can help boost rigidity.

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L i n e a r

M o t i o n

In a fixed-fixed end bearing arrangement, the maximum unsupported length is 1/2 the length of the screw (La=Lb).

Fixed-free arrangements provide the least rigidity.

. y t i d i g i r t s o o b p l e h s can Floating-floating support includes a simple radial bearing at each end.

A fixed-floating arrangement has bearings at both ball screw ends, but a thrust bearing only at one.

A fixed-fixed arrangement provides maximum rigidity.

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L i n e a r

Ball screw rigidity is calculated:

1 1 1 1 1 R tot = R s + R N + R B + R N Where: Rtot = Rigidity of the screw system (N/μm) RS = Rigidity of the screw shaft (N/μm) RN = Rigidity of the ball nut (N/μm) RB = Rigidity of the support bearings (N/μm) RH = Rigidity of the ball nut and bearing housings (N/μm)

The limiting factor for rigidity in a ball screw assembly is typically the screw shaft. The rigidity of the screw shaft depends on its modulus of elasticity, diameter (which determines its crosssectional area), and unsupported length. The screw’s modulus of elasticity is dependent on the material (typically steel), and its diameter is primarily determined by the required thrust force and speed. The unsupported length of the screw shaft is determined by the stroke and the end-bearing arrangement.

L La

M o t i o n

The unsupported length of the screw shaft depends on the stroke and endbearing arrangement. The fixed-fixed end bearing arrangement provides the highest rigidity, while fixed-free is the least rigid arrangement.

Fixed-fixed arrangements have the shortest Fixed-fixed arrangements have the shortest unsupported lengths. unsupported lengths.

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M o t i o n

While the screw’s material and diameter are generally set by the application, the end bearing arrangement (and hence, its influence on unsupported length) is chosen based on factors such as speed, buckling load, and rigidity. There are four common end bearing combinations for ball screw assemblies. From most to least rigid, they are fixed-fixed, fixedfloating, floating-floating, and fixed-free. A fixed end uses an angular contact thrust bearing, for support against both radial and axial loads, while a floating end uses a simple radial bearing, with no support for axial loads. A free end has no bearing support. Using the stiffest bearing arrangement – fixed-fixed – increases the rigidity of the screw shaft by four times compared to the least rigid arrangement of fixed-free. This is due to two design advantages. First, using angular thrust bearings on both ends allows forces to be transmitted through the screw on both sides of the ball nut. In addition, with thrust bearings on both ends, the maximum distance between the ball nut and either one of the fixed bearings occurs when the nut is at the middle of the stroke, which means the unsupported length is one-half the length of the screw. Another effective method to increase ball screw rigidity is to change the way the assembly operates: hold the screw stationary and rotate the ball nut. In a rotating nut design, because the screw itself does not rotate, there is no need for support bearings on the ends of the screw shaft. Instead, the ball nut is supported by a large angular contact thrust bearing. The screw shaft is rigidly mounted at both ends, which allows torsional moments to be transmitted to the mounts at each end of the screw. While a rotating nut assembly is very rigid, its construction can pose dimensional problems and interference issues for applications that were designed with standard rotating screw assemblies in mind. DW

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medical device design

Specifications Questions

Tony Kaufman New Business Ventures in 3Mâ&#x20AC;&#x2122;s Medical Materials & Technologies Del R. Lawson, Ph.D. R&D manager in 3Mâ&#x20AC;&#x2122;s Medical Solutions Division

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No matter the purpose, selecting the right adhesive for the right application plays a direct role in a

M e d i c a l

medical device’s overall success and ability to fulfill its intended purpose.

Designing a successful wearable device is challenging – that’s no secret. With a myriad of device components, materials and functions, everything must be perfectly orchestrated for the device to function as intended.

One simple way to help avoid pitfalls is to select the optimal adhesive

for your project. Adhesives can solve several design challenges, ranging from helping a device stick to skin for its planned duration to effectively adhering device components together. No matter the purpose, selecting the right adhesive for the right application plays a direct role in the device’s overall success and its ability to fulfill its intended purpose.

Adhesive selection isn’t always as straightforward as it may seem,

however. From characteristics of skin to manufacturing processes, there are many contributing factors to an adhesive’s success in a device design. For best results, consider the following questions at the outset of your design process.

What material is the device? Letting your adhesive supplier know what materials will be used in the device will help ensure compatibility between the adhesive and other materials. Some popular materials are polycarbonates, acrylics, polyolefin and silicone rubber, but not all are compatible with every adhesive. For instance, silicone rubber is often used for its flexibility, but it’s tough to stick to; this can limit your adhesive options and cause other design compromises. Another potentially tricky design element that can jeopardize compatibility between adhesive and other materials is

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An experienced adhesive supplier will be able to provide counsel and work with you to find the bestsuited adhesive and material combination for your device.

plasticizer. Used to create softer, more flexible features for a device’s base material, these chemical compounds can also change other materials’ properties. While initial adhesion to altered base materials is typically good, plasticizer can migrate from there into the adhesive and soften it. An experienced adhesive supplier will be able to provide counsel and work with you to find the best-suited adhesive and material combination for your device.

What does the adhesive need to stick to? Which adhesive is best suited for your application hinges, in part, on what it needs to stick to. Adhesives that need to stick your device

to skin will require different features than ones that need to adhere device components together. Sticking to skin requires knowledge of skin’s unique characteristics as a living, breathing organ that needs to expel moisture and move. Adhesives used on skin must be breathable, conformable and gentle upon removal. They must also take into account hair growth, age of the wearer and their activity levels, among other factors. Adhering device components together, however, is all about strength and friction. Ask yourself, what will hold my device together to keep its parts from shifting and rubbing against each other?

What’s the intended wear time? It can be easy to assume the strongest adhesive is the best option because it’ll maximize wear time. However, this logic is flawed and potentially problematic, particularly if the adhesive is used to stick to skin. Some devices only need to stay adhered for a few days, so using an adhesive that’s at its peak strength when the device needs to be removed could cause the top layers of skin to strip off. Longerterm wear devices, such as those in the two week or more timeframe, do require a strong adhesive, but one that’s gentle and breathable to keep skin healthy. It’s important to be aware that adhesives adhere in different ways over specific amounts of time. Keep this in mind when discussing the best options with your material supplier.

4 Tools like FindMyAdhesive.com can answer project-specific questions to identify a list of the most appropriate medical adhesive suggestions.

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Where on the body will the device be placed? Skin is made up of three layers – the epidermis, dermis and subcutis – and skin has different thicknesses throughout the body. The epidermis and dermis, for example, are thickest on the palms and feet, but thinnest on the eyelid. Skin thickness also plays a role in how sensitive the skin is to stimuli. What does that have to do with designing a wearable medical device? DESIGN WORLD

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Thinner and/or highly sensitive skin will be less tolerant of a device covering it or an adhesive sticking to it. This consideration adds criteria that adhesive and other materials must meet to design a device that will fulfill its intended purpose.

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How old is the intended user? Age also influences skin characteristics. Babies’ skin, for example, is fragile and thin because it’s less developed. Adolescent skin increases oil and sweat production, whereas healthy, young adult skin is at its most durable. As skin ages, it loses hyaluronic acid making it stiffer, drier, less elastic and more fragile. Not every adhesive will work in all stages of life. Some will be too strong and others, not breathable enough.

What conditions will the device be exposed to? Materials that perform as intended in a dry, mild climate may not in one that’s wet and humid. The same can be said for adhesives and moisture – an adhesive may perform best when its substrate is dry, but once the end-user starts sweating or producing oil, issues can occur. An adhesive’s moisture-vapor transmission rate (MVTR) can help predict how an adhesive will act in high-moisture environments. However, MVTRs typically reported aren’t applicable for adhesives used beneath most wearables. Devices are often occlusive, preventing moisture from evaporating directly through the adhesive in the z-direction. Adhesives with nonwoven backings, which allow some x-y transmission of moisture beneath the device, can perform better than their film-backed counterparts.

What sterilization methods will the device be exposed to? Oftentimes an afterthought until the device is nearly finished, sterilization methods can alter the device’s material

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Connectivity for all dimensions Robust connectors from the FINEPITCH series The new FINEPITCH board-to-board connector series provides shielded and unshielded solutions for signal and data transmission, allowing the connection of individual PCBs with different orientations, stack heights, and numbers of positions. With compact 0.8 and 1.27 mm centerline spacings, it’s just another way Phoenix Contact inspires innovation — now throughout all dimensions. For additional information visit, www.phoenixcontact.com/BTBFINEPITCH

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properties. Three commonly used device sterilization methods are ethylene oxide, e-beam and gamma radiation. The latter two are radiation-based. Telling your adhesive supplier what type of sterilization method the device will undergo can help them test how the adhesive will react to your desired sterilization method before you get too far into the device’s development.

How will the device be manufactured? Not every adhesive is compatible with every manufacturing process. Some adhesives are too soft and will gum up equipment. Other adhesives are unable to withstand the speed and friction of certain processes, and some won’t bond at the performance level needed. It’s a good idea to run experiments with the selected adhesive and converting partners on pilot or full-scale process equipment, where possible, to avoid potential redesigns, delays and cost overruns. While not an exhaustive list, these questions will help ensure the adhesive selection process is heading down the right path. DW

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Del R. Lawson, Ph.D received his BS in Chemistry from California State University at Fresno, and his PhD in Chemistry from Texas A&M University. Dr. Lawson has over 25 years of experience at 3M in laboratory management, strategic product platform creation, and Lean Six Sigma operations. His experience has involved new technology creation in advanced analytics and sensors, biotechnology solutions, and medical adhesives. Dr. Lawson currently leads new product development and commercialization efforts in 3M’s Medical Solutions Division. Tony Kaufman received his BS in Biological Systems

Engineering from the University of Nebraska-Lincoln. He currently leads the New Business Ventures for 3M’s Medical Materials & Technologies Business. With over 20 years of medical device experience at 3M, he leverages his manufacturing, product development, and business knowledge to bring 3M Science & Technologies to help other device manufacturers deliver life changing devices to the medical industry.

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Quality – The standard of something as measured against other things of similar kind, the degree of excellence of something. At Fabco, our machine centers makes Quality parts for pneumatic cylinders. Every item Fabco manufactures reﬂects the highest standards of quality. Working in unison, our team takes every measure necessary to assure our parts adhere to these standards. Only after they have passed our critical quality checks at every step of their production will they be deemed ready for our customers. If quality and reliably high performance in your pneumatic automation applications matter to you as much as they do to us, then Fabco’s pneumatic cylinders are your only choice. Technical support Ph: (352) 373-3578 Fx: (352) 375-8024 service@fabco-air.com Fabco-Air, Inc. 3716 N.E. 49th Avenue Gainesville, FL 32609-1699 www.fabco-air.com

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•• ••

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P R I N T I N G

How to select Factors of cost, quality, function and material requirements help narrow the field.

The V650 Flex stereolithography 3D printer, from Stratasys, has a build

volume of 20” W x 20” D x 23” H.The laser-based system cures resin material at 1000 ips.

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the right 3D printer

Phil Hutchinson | element14 community

The 3D printing process offers electronic engineers a great way to speed up innovation. Early adopters such as the aerospace and defense industries have long used 3D printing for rapid concept modeling, component prototyping and the production of end products, without the constant retooling of manufacturing lines. Though the technology has been around for nearly three decades, recent advances have made 3D printers a much more attractive investment. Three-D printers are now more affordable than ever, and some entry-level printers cost below $200. Options have multiplied as the number of 3D printer manufacturers nearly tripled between 2014 to 2018 to about 120 today. In addition, the quality and speed of print has improved, and a wide variety of 3D-printable materials are available. We are

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•• ••

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P R I N T I N G

Additive manufacturing comes to the circuit board Three-D-printing isn’t just for mechanical parts. There are machines on the market able to produce sophisticated printed circuit boards having multiple layers, complete with passive components

Nano Dimension’s 3D printer handles

sophisticated PCB designs with its ability to do 3.5-mil trace widths and a similar pitch. The Dragonfly also has a big print bed, 20×20 cm., or almost eight inches on a side.

fabbed with the same conductive inks and dielectrics used to make circuit traces. Most additive machines aimed at PCB work use ink jetting to lay down PCB traces and other features. The print heads squirt out ink in the usual fashion, but the ink is engineered to have either conductive or electrical dielectric properties. Deposited inks typically undergo a curing step consisting of a heat treatment, usually on the bed of the printer. Many machines are able to produce boards on what might be called flimsy substrates such as coated paper or thin plastic. So the heat during the curing process must be kept relatively low, typically lower than the heat deflection point for common plastics. Some additive machines aimed at electronics fab more than just the PCB. The Squink by BotFactory is a combo PCB printer/pick-andplace machine for surface-mounted components. After finishing PCB traces, the machine picks components from a tray, corrects alignment and rotation, and uses on-board computer vision to place components in the correct spot. Each component is picked from a tray, not a rail, to keep the setup simple. The Squink uses a single tool head for both circuit printing and SMD placement. The first head deposits the conductive ink on the PCB. The operator then swaps the conductive ink cartridge for a conductive glue dispenser. Once the glue is in place, a vacuum pick-up assembly gets swapped in to pick-and-place components. Rather than using ink jets, the V-One from Voltera extrudes paste through a nozzle. It can deposit 8-mil traces with a pin-to-pin pitch of 0.8 mm on a print area of 5.5 x 4 in. The V-One has a single print head. So the process of printing a board involves plugging in the ink cartridge containing conductive ink, laying down traces, swapping out the cartridge for one containing dielectric, then dispensing an insulating layer. A third cartridge can be swapped in to dispense solder paste. The solder paste module can work on boards made with traditional etching methods, and these boards can be reflow soldered on the (continued on page 145)

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also beginning to see the emergence of 3D-printed circuitry. According to an Ernst and Young study, the printing of electronics could lower prototyping time by 63%. It makes sense for many engineers to utilize a 3D printing service rather than purchasing a 3D printer outright. But regardless of how they engage with 3D printing, engineers should carefully assess costs, quality, functions and material requirements to ensure they use the best 3D printer for their needs. The first step to choosing the right 3D printer is understanding which kind of 3D printing technology to use. Two of the more prominent types are Fused Filament Fabrication (FFF) – also known as Filament Deposition Manufacturing (FDM) or Molten Polymer Deposition (MPD) – and

Optomec print heads, called Aerosol Jets, create a tightly focused beam of ink by first atomizing the ink supply into a mist, then surrounding it with inert gas. This sheath gas speeds up the flow of the atomized ink as it traverses between the head and the substrate and behaves as a focusing mechanism. These print nozzles deliver ten-micron-diameter collimated streams of atomized ink.

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Stereolithography (SL), which uses laser or Digital Light Processing (DLP) resin printers. FFF printers use a filament of thermoplastic material fed through a heated moving head that extrudes layer after layer of plastic on a moving base that lowers with each layer deposited. It is the kind of technology most commonly used in desktop 3D printers and consequently, FFF tends to be affordable, easy to use, and relatively speedy. On the downside, FFF printers can print less accurately than other types of 3D printers, possibly an issue for projects that demand tight tolerances. FFF printers also tend to require more tuning and maintenance to keep them operating properly and the technology is sensitive to changes in temperature.

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A point to note with respect to accuracy is that many 3D printer makers don’t publish accuracy figures for their machines. The reason is that several operational factors can affect realized accuracy including the mechanics of the printer, the specific material being printed, and the process parameters used during the printing (such as the thickness of each layer, temperature, whether printers that extrude material do so within an inert gas environment, and so forth). That said, published reports put the accuracy of FFF printers at greater than ±0.5 mm. SL printers (often referred to as resin printers) use a light-emitting device (laser or DLP) to fuse together the part from a tank of liquid photo-polymerizing resin or a bed of powder. A laser beam sweeps the surface of the material to trace out the 3D design provided by the computer model, with the part progressively lowered while a blade recoats the top of the structure with resin. It is also possible to print objects bottom up via a vat with a transparent bottom. Here the laser is beamed up through the bottom of the vat while the part is raised. This approach is typical of desktop SL devices. Stereolithography’s big advantage is its greater precision and higher levels of detail making it a better choice for projects requiring more complex geometries and smoother, more realistic finishes. (Published reports put the best-case dimensional accuracy of industrial SL machines at ±0.01 mm, ±0.10 mm for desktop models.) SL printers are also well suited to smaller projects and large projects that require high definition. And while FFF printers are generally fast, SL printers are faster. But these advantages come at a price. SL printers cost significantly more (typically in the $1,000 - $10,000 range), and there are also fewer materials available. Products produced with thermoplastic resin or powder materials as well tend to be fragile. Materials are another important consideration when selecting a 3D printer. The variety of materials for 3D printing vary widely, even spanning into the edible (including chocolate, sugar and pancake batter) and construction-grade (as with houses 3D printed with extruded concrete). Engineers will need to assess more conventional materials for their designs. Polylactic acid or polylactide (PLA) : For FFF printers, polylactic acid or polylactide (PLA) is one of the most widely used thermoplastic materials as it is biodegradable and derived from natural resources such as corn and sugarcane. It is a good candidate for rapid prototyping ideas where form and aesthetics are the most important considerations. PLA also has a tensile strength high enough to make it resistant to warping. (Typical tensile strength at 73°F is 129 k to 529k psi per the ASTM D638 test method.) DESIGN WORLD

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Carbon delivers an unusual variation of stereolithography (SL). Through chemistry, the Carbon CLIP process delays the cure of a part just long enough to eliminate the typical stair-step effect common with SL parts and speed up the build process.

Acrylonitrile butadiene styrene (ABS) is another widely used thermoplastic polymer for FFF printers. ABS printed products tend to have good flex strength (average is about 10 k psi) and superior mechanical properties, making ABS a good candidate if breakage is a concern. It’s also suited for high heat applications as its structural integrity holds up with rising temperatures. (Deflection temperature can exceed 220°F.) Polyethylene terephthalate (PETG) is a candidate for food-safe applications. It’s often used to make water bottles, food containers and similar plastic products as it doesn’t absorb water. It has strong mechanical properties (tensile strength can average around 5.6 k psi) but can be challenging for beginners to use because it’s finicky with regard to process temperature and often requires a lot of fine-tuning of the extruding nozzle. Nylon: For applications that require even greater strength and durability than ABS, nylon is a popular choice. Nylon is strong and quite flexible, making it well suited for moving, high impact, or abrasive part applications. Its strength stems in part from its high melting temperature, but nylon can be toxic in its melted state. Nylon is also not well suited for applications where moisture or humidity are involved. Thermoplastic elastomer (TPE) is a favorite material when flexibility matters. Similar to rubber, TPE results in more elastic and stretchable products, but its softness and elasticity put significant limits the breadth of applications it’s suitable for.

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Materials for resin- or powder-fusing SL printers are usually bought with a more focused application in mind, which impact what resins and powders should be used. These materials and printers tend to be higher-end than consumer-level 3D technologies. There are five basic types of resin – standard (for lower-budget projects), grey (for smoother finishes), mammoth (for large-sized prints), transparent (for transparent surfaces), and high-detail resin (for more complicated geometries). Polymer powders are used in laser sintering, where a high-power laser fuses the tiny particles of the polymer together to form the 3D object. Powders are candidates for projects that require a higher-performing plastic, are metal impregnated, or require the flexibility of rubber with the strength of plastic. Additional considerations Infill is important material consideration and serves as the “filler” of the empty spaces within a 3D printed model. Infill produces a repetitive structure (like a honeycomb) whose pattern and density affects the model strength and weight - without it, many models would be too fragile. Because infill comes in many sizes and patterns, engineers must determine the right combination for their model - the higher the density, the heavier and stronger the print. Similarly, some 3D models need a support structure within empty spaces that must be removed after printing completes. Two types of plastics are commonly used as support material: polyvinyl alcohol (PVA) and high-impact polystyrene (HIPS). PVA is water soluble and relatively easy to remove, though it’s sensitivity to temperature and humidity can make it chemically unstable if not stored and handled correctly, causing the extruder to jam. HIPS doesn’t suffer www.designworldonline.com

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(continued from page 142) print bed thanks to the 550-W heater it contains. A machine from Nano Dimension aims at more sophisticated PCB designs with its ability to do 3.5-mil trace widths and a similar pitch. The Dragonfly also has a big print bed, 20×20 cm., or almost eight inches on a side. Another high-end additive machine comes from Optomec. Its print heads are offered in the form of print engine assemblies. The assemblies can be built into conventional automation equipment such as CNC positioners or specialpurpose motion control systems. Several print engines can be combined to print simultaneously as for mass production settings. The Optomec print heads differ from those used for conventional ink jetting. Ordinary ink jets depend on gravity to bring ink drops to a substrate. The drops spread out or widen as they fly from the nozzle to the substrate. In contrast, Optomec print heads, called Aerosol Jets, create a more tightly focused beam of ink by first atomizing the ink supply into a mist, then surrounding it with inert gas. This socalled sheath gas both speeds up the flow of the atomized ink as it traverses between the head and the substrate and behaves as a focusing mechanism. The result: From print nozzles having 100-micron diameters come ten-micron-diameter collimated streams of atomized ink. The print engines can create features as small as 10 microns wide and make deposits with thicknesses measured in nanometers. Conversely, the same print head can make features that are several millimeters wide and several microns thick. And features at both extremes can be printed in the same pass.

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from this problem, but it is not as easy to remove and requires the use of limonene, which is found in household cleaners and food flavoring products. Engineers also should consider the model support structure and overhangs. Many models need a support structure on which to extrude the model layer by layer. These support structures can affect the look and surface of the finished model, often leaving rough areas and blemishes requiring removal via surface finishing. The presence of a support is important because it impacts the model’s stability and material costs. A model having an overhang (or bridge) with nothing supporting it may need a support structure but perhaps not if the overhang tilts at a 45° angle or less. For a bridge, the rule of thumb is anything less than 5 mm long probably won’t require a support structure.

A Fused Deposition Modeling (FDM) 3D printer, the F120 from Stratasys, makes it

easy for small to medium size design firms to afford technology that’s reliable, repeatable, and industrial grade. This 3D printer supports everything from rapid prototyping and tooling to full manufacturing.

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Preparation of the model for printing requires choosing the right slicer: the software which generates the instructions the printer follows. The slicer translates the CAD drawing into geometric printable code, essentially slicing the 3D model into the individual thin layers that the printer extrudes as the model takes shape. Hundreds of slicing software programs are available, many of them free. In making a choice, engineers should consider which operating system the package supports, supported file formats (e.g. STL, OBJ, X3D or 3MF), integration with CAD software, cloud- or desktop-based, 3D printer compatibility, open source vs. proprietary, infill options and support control. So which 3D printer is right for you? Document the factors of cost, quality, functionality and material requirements to narrow the field and ensure the right selection. DW

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Improving IIoT implementation The IIoT provides many benefits to machine builders and their customers, but new solutions are needed to reduce complexity and expense while maintaining a high level of security.

Like many OEM machine and equipment builders, a California-based oven manufacturer needed to implement an industrial internet of things (IIoT) solution to meet customer demands, improve remote monitoring, and remain competitive in the marketplace.

Benson Hougland | Opto 22

The OEM builds ovens used in a variety of industrial and commercial applications, and it wants to differentiate its ovens from those of its competitors to increase sales. Feedback from customers points to three ways to improve upon its established offerings: • Make it easier for customers to integrate the oven with the other process control systems in their plants • Add human-machine interface (HMI) options so customers can more easily monitor and control oven operation • Reduce customer costs, especially for operation and maintenance Initial investigation showed that achieving these goals promised to be difficult due to a number of challenges.

OEM Challenges The OEM considered ways to simplify integration between their oven automation systems and the leading process control systems found in their customers’ plants. These larger on-site process control systems typically control the entire plant or facility and must interface to the OEM’s ovens. 148

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One method was to develop drivers for intersystem communications, but because the process control systems already in service are proprietary, a custom driver would have to be developed separately for each. Since the company’s ovens are used with many types of process control systems, a one-at-a-time approach would be required. Driver development would be resource intensive and require extensive time from the OEM’s programmers, and it would not be cost effective. This approach would also present future maintenance issues because many different versions of custom driver software would have to be supported, with each version requiring review and possible updates to keep up with changes to the corresponding process control system. DESIGN WORLD

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Integration with existing HMIs would run up against the same problem. The OEM’s engineers considered other options for an HMI, including an improved interface on the oven itself and even a mobile app. These ideas sounded possible but expensive to develop and maintain. Reducing customer costs seemed even more difficult. All of the OEM engineers’ ideas depended on getting the data they needed in a timely manner. If they could get operational data from ovens installed at their customer locations, they could analyze the information to improve oven efficiency. These www.designworldonline.com

The first of what are anticipated to be many EPIC devices on the industrial automation market comes from Opto 22. Their EPIC device was released in May 2018, and quarterly software updates since then have added significant features. This EPIC device features a built-in HMI, sufficient for many OEM applications. Figures, all courtesy of Opto 22

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Traditional methods of exchanging data between field devices and cloudbased or on-premises applications require many components and steps.

data could also be used to reduce customer costs by providing a new level of service. For example, the OEM could track burner ignitors, anticipate failures and contact the customer in advance to avoid unplanned downtime. Scheduled maintenance would likely be reduced as well, replaced by preventive maintenance — and even predictive maintenance — to determine the likelihood of failures before they might occur. The OEM knew its customers would appreciate these cost reductions and new services, but its engineers would have to gain access to the customer’s network to get oven control system data from each site. This would require the customer’s IT department to open incoming network ports in their corporate firewalls and allow the OEM to extract the data. IT personnel would never (and shouldn’t) allow such a potential breach to their network security.

An edge programmable industrial controller can be used to replace multiple hardware and software middleware components when transferring data from the field to cloud and on-premises applications.

How could the OEM redesign their ovens’ automation systems to meet their customers’ wishes and differentiate their products in the market, without spending so much time and money, along with creating major security risks?

IIoT Issues The challenges faced by this OEM are common to many IIoT implementations and involve three main issues: complexity, security and expense. Many IIoT or dataintensive automation applications end up

being far more complex with more security risks than initially anticipated. The result is that the final cost and human resources required are more than many companies can afford. Getting data from the edge of the network — from the sensors and actuators in factories, commercial buildings and remote sites — to the databases and people who need to use that data can be daunting. Bi-directional communication for control can be even tougher. Most industrial automation systems and components use protocols and networks proprietary or specific to automation, such as EtherNet/IP, Modbus, Profibus, serial, OPC or others. But commercial computers and mobile devices use standard Ethernet or wireless networks and open protocols and standards like TCP/IP, HTTP/HTTPS, JSON and RESTful APIs. Translating data between these disparate industrial and commercial systems, and then moving it where it’s needed, involves a lot of expense and middleware: computers,

EPIC devices can be employed to securely exchange data between an OEM’s headquarters and its customers’ sites.

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gateways, drivers, parsers, custom software, licenses and other addons. As soon as data moves outside the immediate network or off premises — for use in the company computer network, remote locations or on a tablet or smartphone connected to the internet — middleware requirements increase and security concerns balloon. A typical architecture to enable these communications requires many components and significant configuration and programming.

Addressing challenges and issues Control system engineers are familiar with programmable logic controllers (PLCs) and programmable automation controllers (PACs). Both have been used and improved over many years, incorporating capabilities formerly found only in proprietary SCADA systems, adding communications with Microsoft Windows-based HMIs, running on standard Ethernet networks and so on. But for IIoT and other challenging applications, more is often needed from automation systems. For these and future applications, a new approach is needed to simplify connections and communication—a new product that does much more than a PLC or even a PAC. What’s needed is a class of automation products that shrinks or eliminates the middleware and lets users move data from where it’s produced to where it needs to be in fewer steps. This new type of controller can be referred to as an edge programmable industrial controller (EPIC). Let’s look at each part of the EPIC acronym to more precisely define this type of controller. An EPIC system Edge: All data acquisition starts at the edge because that’s where data are produced. A manufacturing line or shipping department in a factory, refrigerated rooms or barcoded containers in a warehouse, pumps and pipes and storage tanks at remote sites—all are at the edge of the network, and all have data that can be used to improve processes and increase profits. It’s best to collect and process these data directly at the source to ensure accuracy, perform preprocessing and prepare it for transmission. An EPIC device sits at the edge and connects directly to sensors and actuators through its I/O, the inputs and outputs that gather sensor data and send control commands. It can also connect to existing PLCs, HMIs and other control system components to gather data and issue commands. An EPIC device installed at the edge of a network actively works on the data as well by filtering out anomalies, by labeling, by storing and by transmitting only by exception to reduce unnecessary volume, and by converting values from one protocol to another. This data preprocessing makes operations, enterprise and business cloud applications more efficient. Because it is the single source of truth for data, an EPIC device can also securely share the data with software and equipment including other control systems, building management systems, databases, cloud services and others.

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Programmable: An EPIC device is not a PLC, a

PAC or a PC, but like them it must be programmed for control. An EPIC device provides programming options, some of which reflect traditional automation tools, and others that come from the PC and internet world. Typical options include programming with familiar automation tools like flowcharting, scripting or any IEC 61131-3 compliant language, including: • Function Block Diagram • Structured Text • Sequential Function Charts • Ladder Diagram Users more familiar with non-automation languages can gain access to an EPIC’s open-source operating system and create custom programs in languages such as C/C++, Java, Python and others. An EPIC device does not limit programming options like PLCs and PACs or force one to learn a new programming language. It instead lets users leverage what they already know to create control, data exchange and HMI programs more quickly. Industrial: Controllers often have to operate in

difficult environmental locations. One problem with using PCs in industrial automation is that an off-the-shelf PC cannot be trusted to stand up to harsh environments. In contrast, EPIC devices incorporate real-world automation experience and are built to withstand tough conditions. Industrial-grade components like solid-state drives are designed for long life. UL hazardous locations approval and ATEX compliance are usually standard. Operating temperature ranges are wide, for example, -20 to 70 °C. EPIC I/O should be hot swappable, with stainlesssteel chassis in different sizes to fit enclosures or machine designs, and with options for DIN-rail or panel mounting. Controller: At heart, an EPIC device is a realtime industrial controller designed to run control applications. Programmed with standard automation tools like flowcharting, structured text and even traditional ladder logic, an EPIC fills the role of a PLC or PAC in a control system. Typically, I/O modules will offer multiple channels, with isolated channels available. Analog and discrete I/O should be available to accept a variety of signals, with each channel usually software configurable. Because EPICs are typically designed by control engineers, they often include features that simplify

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commissioning and troubleshooting, such as: • A built-in touchscreen, usable with a finger, a stylus or while wearing gloves • A web-based system management application to configure I/O and networking on the touchscreen in the field, or using a computer or mobile device • I/O module specs and wiring diagrams viewable in the field, on the device • Spring-clamp terminals and integrated, covered wireways to accommodate a variety of wire sizes • LEDs on each I/O module that indicate module health and discrete channel status

OEM Solution Returning to the oven manufacturer challenges discussed earlier, here’s how they could use an EPIC to address their issues. The EPIC can be wired directly to sensors and actuators in the oven to provide control, monitoring, data processing, communication

Implementations of the Internet of Things deliver the most value when they distribute information through the internet. and visualization in a single unit. For control programming, the OEM can use a flowcharting language, one of the CODESYS IEC 61131-3 compliant languages (like ladder diagram or function block diagram) or Secure Shell access (SSH) for creating a custom program running on the Linux OS.

from the data source or subscriber to the broker. Once initiated, data can flow in both directions. Most company firewalls allow outbound communications, so there’s no need to open ports in firewalls. Security is maintained and IT involvement is reduced. EPIC devices can provide real-time control for all kinds of traditional automation applications, and also handle IIoT and databased tasks. These devices offer a simple, secure, maintainable and cost-effective solution for IIoT data communication by flattening the architecture required to transfer data from the field to a cloud-based or an on-premises application. DW

For an improved HMI experience, the OEM has choices: • On smaller ovens, the EPIC’s built-in touchscreen can provide local visualization. • On larger ovens, an industrial monitor can be added and plugged into the EPIC’s HDMI port. • For all ovens, the OEM can build a secure Opto22 | www.opto22.com web-based HMI for use on computers and mobile devices. This HMI can be used by customers and also by the OEM.

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Because the EPIC’s system management software is web-based, the OEM can apply software updates and manage the oven from their location instead of traveling to the customer’s site. Perhaps the greatest advantage of an EPIC device for the OEM, however, is the ability to get the data needed from their ovens at customer sites, without causing security issues for their customers. In addition to the usual request/response method for data communication, an EPIC offers another method: publish/subscribe. Publish/subscribe, or pub/sub, works by setting up a central broker, either on premises or in the cloud. The broker handles all data communications. Each data source sends data to the broker only when it changes using report by exception. Equipment and software that need data subscribe to only the data they need, and they receive it from the broker only when it changes. Most important from a security standpoint, all communications are initiated outbound

DESIGN WORLD

5/3/19 4:34 PM

Product World Electro-magnetic brakes Miki Pulley mikipulley-us.com

Ballscrews & Rollerscrews

These spring-applied Electro-Magnetic Brakes safely hold a static position without the need for external power. The BXR-LE brake series is a power-off, engaged brake design. When the stator is energized,

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the brake is disengaged allowing free rotation. When no current is applied, compression springs halt the brake rotor thereby stopping the input shaft rotation. This is feature helps prevent rotation during power failure events. Now there are six total size configurations in the BXR-LE series to choose from, all of which are designed for smaller machine and robotic applications, where cantilevered loads can negatively impact operation.

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Of particular importance — these brakes have a slim design and high holding torque in

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The DCL series is a low voltage, brushless motor control that operates in the 12-48 Vdc power bandwidth, up to 30 amps peak (1 minute) or 15 amps continuously. The design of the DCL removes many of the trim pots and jumpers associated with typical motor controls, reducing costs on hardware and setup.

The DCL drive can easily be customized for specific OEM applications and motors. For users

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who wish to modify calibration in the field, the DCL uses programmer board CPC300-1 (sold separately) that snaps onto the unit and provides calibration of 10 different parameters, as well as DIP switches for setting different modes of operation. A single CPC300-1, acting as the adder board, can be removed after programming and used with multiple DCL units. Base DCL

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units are Modbus capable and come with one trim pot for calibrating maximum speed, and two DIP switches for closed/open loop operation, as well as inverting the hall effect feedback.

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WE Series Linear Guideway Wide Series Ball Type.

and media guide even for small installation spaces on support legs. Strong, space-saving and easy-to-install, this e-chain guides two hydraulic hoses in addition to power and control cables. The E2 hydraulic chain is a suitable solution for special mechanical engineering, and its use reduces the costs of maintenance and downtime. The E2 hydraulic chain provides efficient protection to internal cables and prevents torsion and bending of the hoses through the predefined minimum bend radius.

For the E2/000 series and the E4.1 and E4.1L systems, extender crossbars, in addition to

normal crossbars, can be used with high holding power to accommodate additional hoses with larger diameters. This chain provides energy and media guidance with one system. For the E2 hydraulic chain, the concept was applied to the installation space-specific conditions of support legs on concrete pumps and mobile cranes. A one-piece, solid extender crossbar design and the

PG Series Linear Guideway Integrated Magnetic Encoder.

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classified purged and pressurized electrical enclosures within Class I Div 1, Groups A, B, C and D; Class II Div 1, Groups E, F and G – and Class III environments. The cooling capacity of up to 5,600 Btu/hr. is suitable for electrical enclosures with problematic overheating. They are CE compliant and available for NEMA 4 and 4X enclosures.

HazLoc Cabinet Coolers circulate 20°F

(-7°C) air inside the enclosure to prevent high-temperature faults. They mount in a standard electrical knockout while keeping the NEMA 4 or 4X rating of the enclosure. Cabinet Cooler Systems include an auto drain filter separator to ensure no moisture passes to the inside of the electrical enclosure. An optional thermostat control minimizes compressed air use and keeps the enclosure at ± 2ºF of the setting.

DESIGNED FOR VALUE. VALUED FOR PERFORMANCE.

COMPONENTS CORPORATION

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

May 2019 www.designworldonline.com

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

Multi-axis servo drive B&R www.br-automation.com LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

The ACOPOSmulti multi-axis servo drive enables even shorter cycle times down to 50 μs. Highly dynamic processes can now be controlled more precisely.

For motion control applications

such as those found in the printing and packaging industries, movements must be controlled very quickly and precisely. The ACOPOSmulti’s cycle time of 50 µs for current, speed,

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

and position control opens up new possibilities for virtual sensor technology.

Using a virtual motor position encoder eliminates the need for an encoder, encoder cable,

and evaluation unit in the servo drive and at the same time increases availability. Other special functions for more precise control and faster reactions can be implemented using virtual sensor technology. These include model-based control with autotuning and a repetitive control function KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

for predictive lag error compensation.

Permanent magnet ac motor Bison Gear & Engineering www.bisongear.com VFsync is a permanent magnet ac motor KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

for machine drive applications. The new synchronous motors run at high efficiency with advanced variable frequency drives. The IP66/IP54 platform of three-phase motors range in power from 0.25 to 1.5 HP, and are supplied with swivel connectors and shielded cables to make installation trouble-free.

AC Servo Motors.

Popular frame sizes include IEC B14, sizes 71, 80 and 90 along with NEMA 56C mounting. The product line includes the new motors, quick connect cables, and a programmable and networked VFD available in an IP 20 panel style or enclosed IP66 models.

The new motors were optimized with FEA software and then tooled with internal

permanent magnet style rotors. VFsync provides a footprint that is 56% smaller and 63%

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

lighter than common 3-phase induction motors.

DESIGN WORLD

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Ad Index

SALES

Accumold.............................................. 125 Allied Electronics............... Cover,3,123 AllMotion................................................... 4 Altech Corp. ............................... 21,23,25 Anchor Fluid Power ...........................48 Aurora Bearing Company............... 46 Automation24, Inc. ............................... 9 AutomationDirect ...................................1 Bansbach Easylift ..............................42 Beckhoff Automation .......................55 Bimba .......................................................10 Bishop-Wisecarver .............................121 Bodine Electric Company............... 130 Boker’s Inc. ............................................49 Caddock Electronics, Inc. .................16 Carlo Gavazzi .......................................44 CMT .......................................................122 Components Corporation.............. 158 Data Modul Inc. ...................................47 Del-tron .................................................124 Digi-key ................................................... 13 Eagle Stainless Tube ........................35 ebm-papst Inc. ....................................33 Emerson ................................................ 57 Encoder Products Company...........56 EZAutomation ...................................... 15 Fabco-Air, Inc. .................................... 139 Fixtureworks ..........................................14 HIWIN ........................................ .155,157,159 icotek Corp ............................................46 IDEC Corporation .............................. 144 IFM Efector .................................... Insert igus ............................................................ 2 J.W. Winco, Inc. ....................................53 John Evans’ Sons, Inc. ................... 129 Keller America .......................................41 Key Bellevilles .................................... 138 Keystone Electronics Corp. .... 39,156

Kuriyama of America, Inc..................38 Madison Co. ........................................ 128 Master Bond ...................................... 138 Memory Protection Devices ...........45 METCASE ..............................................43 MICROMO ............................................ IBC mk North America, Inc. .....................151 NB Corporation ...................................26 Nippon Pulse Americas, Inc. ............ 31 Novotechnik .........................................49 Opto 22 .................................................. 37 Parker Hannifin Corporation Pneumatics .............................. Insert PBC Linear ......................................28,29 Phoenix Contact ...........................51,137 PolySource ...........................................50 Pyramid Inc. ..........................................53 Robotics Summit ................................117 ROLEC ..................................................... 17 Rotor Clip ............................................. 152 RYCO Hydraulics ................................147 Schneeberger .................................. 146 Servo Kinetics, Inc. ........................... 153 SEW-EURODRIVE .............................. BC SIKO Products ......................................40 Smalley Steel Ring ............................... 5 Smart Products USA ............................7 Tech-Etch, Inc. ................................... 143 The Arthur G. Russell Co., Inc. ..... 135 The Lee Company ............................127 THK America, Inc ................................IFC Tormach ............................................... 136 Trim Lok ..................................................32 Vlier .........................................................36 Wago USA .............................................59 Whittet-Higgins ................................... 27 Xcentric Mold & Engineering ..........58 Yaskawa America, Inc. ......................131

Jami Brownlee

jbrownlee@wtwhmedia.com 224.760.1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Bill Crowley

bcrowley@wtwhmedia.com 610.420.2433

Michael Ference

mference@wtwhmedia.com 216.386.8903 @mrference

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Nagle

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com mfrancesconi@wtwhmedia.com 508.446.1823 @wtwh_memich 630.488.9029

Mike Francesconi

David Geltman

dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mmatheson@wtwhmedia.com 805.895.3609 @mmatheson

Follow the whole team on twitter @DesignWorld

Sensor www.sensortips.com

INSIDE:

The Robot Report CGI ............................................. 81 CS Hyde Company ............... 68 Festo ......................................... 69 GAM ........................................... 79 Harmonic Drive ...................... 61 Honeywell Intelligrated ...... 63 igus ............................................ 75 Kollmorgen .............................. 94 LAPP USA ............................... 64 MICROMO ................................ 98 maxon precision motor ...... 70

A Supplement to Design World - May 2019

A Supplement to Design World - May 2019 www.designworldonline.com

• The Robotics Summit 2019 takes a close look at mobile robots ............................62

Sensor Tips Supplement

• What Amazon’s acquisition of Canvas Technology means for mobile robots ..........66 • Augmenting SLAM technology with deep learning ............................................71 • Expert roundtable: mobile robotics challenges and opportunities .........................82 • Integrating AI with fleet management software advances collaboration for autonomous mobile robots ............................88 • How 5G will impact mobile robots ...............95

Mobile robotics

matures Mitsubishi Electric Automation ............................. 72 mk North America, Inc. ....... 74 New England Wire Technologies & New England Tubing Technologies .......................... 93 NSK Precision ........................ 91 POSITAL-FRABA Inc. ............ 80 Renishaw ................................. 87 Rollon ........................................ 96 SICK, Inc. .................................. 85 ROBOT REPORT COVER_5-19_Vs3.indd 60

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KOA Speer Electronics, Inc. ......113 Master Bond ..................................114

A look into factor 1 proximity sensors Sensor Tip cover 5-19_FINAL.indd 109

5/6/19 11:11 AM

Pepperl+Fuchs .............................. 112

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© 2019 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.

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AD INDEX_5-19_Vs1.indd 160

DESIGN WORLD

5/7/19 12:31 PM

FAULHABER coreless (brush) DC motors feature compact dimensions, low power consumption, high efficiency, & low noise, making them an ideal motion solution for challenging medical equipment & laboratory automation applications requiring high-precision dosing & positioning.

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