DESIGN WORLD MAY 2022 by WTWH Media LLC

www.designworldonline.com

May 2022

inside: MOTION CONTROL:

Linear motor modules: the

heart of mechatronic systems p.

LINEAR MOTION: Part 2 of 2: Electric

actuators as an alternative to hydraulic cylinders p.

FLUID POWER: Selecting the right

interchangeable pneumatic actuator

p. 70

Robotic

solution speeds up PPE manufacturing process page 36

MAY 2022 DW COVER_FINAL2.indd 1

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THINK INSIDE THE BOX Exceptional designs deserve superior components. The developer of the original world-class linear motion systems, THK continues to redeﬁne industry standards and to meet an ever-growing range of needs. From aerospace and machine tool to packaging and medical, THK products play a vital role in the advancement of technology and capability.

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

See us at: 2022 Robotics Summit & Expo • May 10-11 • Booth #332 2022 Automate • June 6-9 • Booth #2155 ATX South • June 14-16 • Booth #1313

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PLC Comparison

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Micro850

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Back in person … finally! While we’re not quite past the Covid-19 pandemic, and many areas of the world are still struggling with this virus, it’s hopeful to see that business travel in the United States has picked up — and getting back together in person is becoming possible once again. A er two-plus years of being able to connect mostly through Zoom, I’ve relished the chance to visit with old industry iends at a couple of recent conferences. Although the idea of attending a mammoth trade show with tens of thousands of people is still enough to make some nervous, I have definitely enjoyed going to some of the smaller events. Speaking of more intimate events, two of our sister publications are getting back into the events game next month, with the Fluid Power Technology Conference and DeviceTalks Minnesota hosting their events concurrently, om June 6-7 at the Hyatt Regency Minneapolis. DeviceTalks, run by Mass Device, focuses on the engineering and manufacturing of medical devices, with attention paid to just about every part of the process: innovation, funding, prototyping, engineering technology, product development, manufacturing, sourcing, and even the regulatory market. Speakers at the event are coming om industry giants like Johnson & Johnson, Philips, Inspire Medical Systems, Abbott, Medtronic, and Stryker. That makes this a must-attend event for anyone who works in the medical device space. Register at minnesota.devicetalks.com. And the Fluid Power Technology Conference, run by Fluid Power World, returns with speakers om component manufacturers, well-known academics in the fluid power space, and some of the most popular industry trainers in the U.S. and Canada for a day and a half of learning and networking. This popular event includes hands-on technology demonstrations, workshops, industry tours, and some fantastic industry panels. It’s one of my favorite events, and there’s always so much to learn om the speakers and so many opportunities for networking with iends old and new. You can register for the upcoming FPTC at fluidpowertechconference.com. I hope I’ll see you at the combined events next month, as they’ll both be worthwhile and a perfect opportunity to get on the road again. DW

(510) 471-4000

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

30097 Ahern Avenue Union City, CA 94587

On Twitter @wtwh_paulheney

Te c h n i c a l S u p p o r t

(408) 460-1345

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May 2022

www.designworldonline.com

DESIGN WORLD

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4/26/22 2:36 PM 4/7/22 2:17

Teschler on Topic

5G phobia I once corresponded with an individual who thought WiFi signals were making him sick. The term describing his ailment is electrohypersensitivity (EHS), a belief that you are allergic to minute electromagnetic fields. EHS isn’t a recognized medical condition. The World Health Organization reports that numerous studies of individuals claiming problems from EHS have shown that their symptoms weren’t correlated with exposure to electromagnetic radiation. The WHO also says studies reveal EHS sufferers are no better at detecting EM radiation than the average person on the street. These results have led clinicians to suggest that belief in EHS follows a vicious cycle: Sufferers experience medical symptoms with no discernible cause, start to perceive relatively normal sensations as being intense and disturbing, then misattribute their symptoms to EM waves, perhaps because of media coverage. Gullible media reports reinforce these beliefs and further freak-out sufferers. Clinical psychologists have proposed treating EHS as an anxiety disorder stemming from a phobia, not much different than being afraid of the dark or lightning. Basically, they say electrophobics interpret symptoms of anxiety as the biological effects of EM radiation. Lending

credence to this idea is the fact that those suffering from anxiety can have the same physical manifestations as those who think they have EHS: irregular heartbeats, muscle aches and tension, trembling, headaches, insomnia, and so forth. EHS as a phobia also explains why the purchase of so-called antiradiation devices brings some relief to EHS sufferers: They reduce the sufferer’s stress levels rather than do much about EM waves. Therapy to treat phobia generally consists of gradually and repeatedly exposing phobic people to the object of the phobia--first in their imagination, then in real life—while teaching relaxation methods. Unfortunately cases of EHS phobias have grown in recent years. To help stem the tide, clinicians have suggested educating people on how to identify false information about the effects of EM radiation. Well, good luck with that. We swim in a sea of false information about EM radiation, and the waters have been rising quickly when it comes to misleading claims about radiation at 5G frequencies. One problem: Some studies purporting to show harm from EM radiation suffer from subtle procedural flaws that make their results questionable. And the flaws are only evident to those familiar with how clinical studies can go awry. A case in point is a study

published two years ago claiming cell-phone use caused cancer. The study used case-control research. A case-control study looks back in time to find the relative risk between a specific exposure (the classic example is second-hand tobacco smoke) and an outcome (cancer). A control group of people who don’t have the disease or didn’t experience the event serves as a comparison. Problem: The subjects in the cell phone study self-selected themselves to participate, and they relied on their memory of cell phone use. These are big no-no’s. Text book introductions of case-control design warn against selection and recall biases, both of which are in play when patients participate in a study they know in advance pertains to whether their past has affected their present illness. A better source of insights about cell phones and brain cancer comes from a plot of brain cancer cases (from National Institutes of Health) and cell phone subscriptions (from World Bank Statistics). It reveals that though cell phone use has risen dramatically since 1992, there’s been no corresponding rise in illnesses such as brain cancer. But my own experience is that trying to explain such facts to someone dead-certain radio waves are making them ill is pretty much hopeless. DW

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

May 2022 www.designworldonline.com Lee.Teschler.Column 5-22_V2_LT.LL.MS.indd 6

DESIGN WORLD

4/27/22 8:21 AM

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Technology Forward

Changes and opportunities Shows and conferences are slowly emerging from the effects of the global pandemic. Some offer both in person and virtual experiences, others are returning to in-person only. The Additive Manufacturing Users Group (AMUG) conference hosted roughly 2000 attendees a few weeks ago, and it was great to see everyone. The conference traditionally offers a range of sessions and opportunities to talk to expert users, and to listen to fascinating keynote presentations. And, of course, there were plenty of opportunities to have fun while learning. The additive industry is maturing, so this year’s AMUG conference focused more on changes throughout the industry as a result of the global pandemic and a bit less on technical innovation. If you’ve been following the news lately, much of it covers partnerships among companies with compatible technologies, such as materials and software, with a few companies buying others to round out the capabilities they offer.

So, let’s cover some of the trends.

Even so, several trends stood out at the AMUG Conference: • 3D scanning is taking on an increasing role with additive operations • additive vendors see the supply chain as a key arena where additive can grow and play a role • the international conflict and the effects it will have on materials and the supply chain.

International Internationally, the war between Russia and Ukraine will affect the additive industry. Ukraine has been one of the largest suppliers of metals for a number of industries, not just additive. These metals include Lithium and aluminum, among others. Russia too offers metals but is now embargoed. Additive vendors are watching the developments here carefully, and looking to keep the supply of metal powders going.

But one of the stronger impressions was that manufacturing is going to experience a resurgence here in the U.S.

3D scanning Expect an increase in the use of 3D scanning equipment. Users are seeing 3D scanning as a key tool when working with 3D printing and additive manufacturing, especially when used for reverse engineering. Newer scanners are more portable and offer better data collection for use in CAD programs or when transmitting data to 3D printers. The supply chain Producers of goods are taking a hard look at how they develop their supply chains. During the pandemic, the additive industry displayed its flexibility and capability to deliver goods practically anywhere. Traditional manufacturers are taking notice of additive manufacturing and looking at how it can be used in their supply chains as well as their production efforts. Additive vendors see this area as a major growth opportunity for the industry.

May 2022 www.designworldonline.com Tech.Forward.5-22_Vs3.LLMS.indd 8

Other trends Before additive can play a strong role in manufacturing, the vendors need to automate more of the steps used to build parts. Much of this automation will come through software, similar to how product management software and enterprise resource software helped automate traditional manufacturing years ago. You can expect to see more software introductions over the next few years. The medical industry is a key application of additive technology. But a few gaps will hinder wider acceptance. One of those gaps involves standards for using 3D printed parts with patients. Right now, there are no standards. Various medical agencies are working with the additive industry to develop them. On a similar note, the medical industry needs additive materials that can be sterilized. As one presenter noted, sterilization is a precise process in medical and requires considerable back-up information. Another trend is the growing use of copper as a 3D printable material. A number of users are looking at copper as a material for electronics because it can be printed sustainably. But it is also popular in applications in aerospace, particularly for small satellites and other components. For example, the copper composite CuCrZRr is being explored by NASA for use in its projects. Other modified high-performance materials for additive applications are Zirkonium Titanium powder and AlMg--aluminum Magnesian.

DESIGN WORLD

4/29/22 7:43 AM

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Technology Forward Continuing with applications in space, the launching of small satellites could become a big industry. The Micro Launcher, for example, is expected to become a $26 billion market by 2027. These micro launchers tackle satellites in the 200 kg mass and under class. Some of the more recent news mentions the introduction of laws that allow the right to repair, giving individual users the ability to fix the items they’ve purchased without needing to go back to the manufacturer. This move is trending

in Europe, with some discussion of it in the U.S., as it is seen as helping with sustainability efforts for the environment. Additive vendors see this as a potentially large market for 3D printing technology. And lastly, one of the keynotes came om Kevin Czinger of Divergent 3D. Czinger plans to fundamentally alter the way cars are manufactured. He has built a proof-of-concept manufacturing hub that showcases fixtureless assembly. Showing what is possible with additive manufacturing, he built a universal assembly cell,

the Divergent Adaptive Production System (DAPS) that can be used to make anything om cars to drones. In addition, he only uses adhesives to assemble parts in the cars. The cars contain a range of materials and to accommodate tolerances and different material properties, he has found adhesives as the way to go. He is in negotiations with most of the major car manufacturers. It will be interesting to see where this takes additive manufacturing. DW

Leslie Langnau llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

May 2022

Tech.Forward.5-22_Vs3.LLMS.indd 10

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Green Engineering

Working to electri existing buses and coaches Paul J. Heney

• VP, Editorial Director

Saietta Group plc, specialists in high-tech advanced e-mobility propulsion, is intensi ing an important overhaul operation to transform existing high polluting dieselengine-powered buses and coaches into clean, sustainable, and zero-emission vehicles. Through its RetroMotion division, the company is working to offer fleet operators an economical and effective solution to ‘electri ’ existing buses and coaches. A real-world zero-emissions driving range of up to 350kms is possible with the all-electric retrofit powertrain, depending on individual specification, application, and vehicle size. “Saietta Group prides itself on being at the vanguard of e-mobility propulsion with the aim of democratizing clean sustainable transportation around the globe and within every sector, om two-wheel scooters to compact passenger cars and right through to bus, coach and heavy goods vehicles,” said Wicher Kist, CEO of Saietta.

May 2022

Green.Engineering 5-22_Vs1_MS.indd 12

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DESIGN WORLD

4/27/22 8:35 AM

“But we also understand that such important yet dramatic change — effectively replacing outdated internal combustion engines (ICEs) with new battery electric powertrains — can’t be successfully achieved overnight. That’s why we are stepping up the efforts of our RetroMotion engineering division. We want to give coach and bus operators an opportunity to transform their aging and polluting fleet into a green mobility service that’s modern and clean. Fleet operators don’t have to make sudden and huge outlays on all-new electric vehicles. These important investments can be done incrementally thanks to the possibility of upgrading and extending the lifespan of existing buses and coaches, in the process also meeting upcoming tough legislation,” said Kist. Delivery of the company’s firstgen e-axles to customers commenced in 2009. Since then, RetroMotion has developed a high-tech secondgeneration e-axle and e-powertrain solution. In real-world bus applications running in European cities, the electrification tech package — both gen-one and gen-two developments — has proved impressive reliability and durability attributes, having accumulated in total 3.2 million kilometres on-road usage so far. Engineering in action The powertrain conversion replaces the aging diesel ICE and all its associated components, including the gearbox, with an advanced e-propulsion system. This means that state-of-the-art, in-wheel electric motor technology is applied to the rear wheels of the coach or bus. Unlike other systems available on the market, this solution is a true in-wheel arrangement and not so-called nearwheel. A twin-tire solution with front mounted rims is used as part of the redesign to ensure the in-wheel motors fit seamlessly to the existing application. Critical systems such as the high-power inverter and motor components like the stator and rotor with permanent magnets

DESIGN WORLD

Green.Engineering 5-22_Vs1_MS.indd 13

May 2022

Fabco-Made NFPA Versatile, rugged cylinders—when you need them

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Our NFPA interchangeable pneumatic cylinders take the guesswork out of cylinder selection. We design and manufacture our NFPA cylinders in Gainesville, Florida—so expect fast delivery, supply chain resilience and local support no matter your application. Built tough, our NFPA actuators feature anodized aluminum heads and barrels and stainless steel hardware for corrosion resistance. They also incorporate high-strength composite rod bearings and PTFE piston wear bands for superior load handling and long service life. Choose from 19 standard mounting options and hundreds of standard conﬁgurable options to meet the requirements of almost any application. Standard catalog not enough? Tell us about your application and let us design a custom solution optimized for your environment. • • • • • •

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Green Engineering

are also installed as part of the transformation. The electric motors and e-platform, branded TheWheel and TheMotion 2.0, have been designed in-house to be a class leading solution. Peak torque of up to 20,000Nm is possible with a 94% real-world efficiency level being realized om battery to wheel. The elimination of a gearbox that was once mated to the diesel ICE means that in the new allelectric powertrain setup, no energy is consumed by having to go through the gears or using a differential, further boosting real-world efficiency. The Lithium-iron Phosphate battery pack is available in a range of power outputs to suit differing requirements, varying om 181kWh to 422kWh. The transformation om an aging diesel-powered coach or bus to a modern allelectric mobility vehicle also sees the integration of Saietta’s vehicle energy manager and body control module systems, its high-voltage power distribution unit, a battery management system and battery thermal management system, highvoltage inverters, and auxiliaries such as air compressors and the power steering system that has been upgraded to be electrically operated. The team also installs a charging communication ECU, a charging system, and CCS charging socket. With the electric motors being an in-wheel setup, and the battery pack having been designed to meet optimum dimensions, the all-electric powertrain is compact and benefits om an small operating footprint size and weight in comparison to the diesel ICE and its associated subsystems, meaning that both passenger and luggage capacity are minimally affected by the switchover. A new, visually engaging operator display unit has also been, providing the driver with clear and coherent data relating to the drivetrain, including real-time battery status. DW Saietta Group saiettagroup.com

Green.Engineering 5-22_Vs1_MS.indd 14

May 2022

DESIGN WORLD

4/27/22 8:37 AM

COUNT ON INDUSTRY-LEADING PRECISION & ACCURACY

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Contents 5 • 2022

•

vol 17 no 5

•

designworldonline.com

46 _MOTION CONTROL Linear motor modules: the heart of mechatronic systems

At the heart of many automation systems for pharmaceutical and medical lab analysis applications are small linear motor modules.

| shutterstock.com

58 64 _MECHANICAL Precision linear modules for semiconductor fabrication efficiency

Precision linear modules are compact, wellengineered mechatronic devices with a range of sizes and motion technology — profiled rail, linear bushings, and ball screws — that offers different levels of precision, stability, and endpoint accuracy.

50 _LINEAR MOTION Part 2 of 2: Electric actuators as an alternative to hydraulic cylinders

Here we offer some tips for converting a fluid-power-driven axis to electrical actuation.

70 _FLUID POWER Selecting the right interchangeable pneumatic actuator

Because no two applications are exactly alike, and many actuators exist, reviewing interchangeable designs and standards is a must for selection.

58 _ELECTRONICS Evaluating free PCB design software

It pays to understand the quirks that pertain to the numerous PCB packages that are available for free.

2022

GOLD REGIONAL AWARD

SILVER REGIONAL AWARD

BRONZE REGIONAL AWARD

asbpe.org

ON THE COVER

May 2022

CONTENTS.5-22_Vs2 MS.indd 16

www.designworldonline.com

Kawasaki Robotic PPE manufacturing cell allows Harbor Technologies to expand globally amidst | Courtesy of Kawasaki Robotics shortage.

DESIGN WORLD

5/2/22 2:43 PM

Digi-Key 5-22.indd 17 220401_AutoProxSens_DW_US.indd 1

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F O K C I S ? S G N I SPR

5. 22 • co n t e n t s departments

COIL

We were too.

That’s why we invented the wave spring.

Insights

Teschler on Topic

Technology Forward

Green Engineering

Design For Industry

Design Notes

Internet of Things

Product World

Ad Index

• Optimize Application Space & Weight • Industry-Specialized Design Support • Large Selection from Stock • Easy to Customize

Crest-to-Crest® Wave Springs

Request Free Samples at 847-719-5900 or smalley.com CONTENTS 5-22_second.page_Vs1 MS.indd 18

May 2022

DESIGN WORLD

4/28/22 7:59 AM

DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Senior Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel

VIDEO SERVICES

WEB DEV / DIGITAL OPERATIONS

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VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com @WTWH_Taylor Digital Marketing Coordinator Jill Bresnahan jbresnahan@wtwhmedia.com @WTWH_Jill Webinar Coordinator Halle Kirsh hkirsh@wtwhmedia.com Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com

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Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

WTWH Media, LLC 1111 Superior Ave. 26th Floor Cleveland, OH 44114 Ph: 888.543.2447

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

2011 - 2020

2013 - 2017, 2021 2014 - 2016

2014 Winner

Medical Design & OUTSOURCING DESIGN WORLD

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May 2022

4/27/22 9:17 AM

Design for Industry Packaging

Retrofit packaging machines to handle paper wrapping

Here’s a more environmentally iendly way to package beverage cans — use paper. This retrofit option makes it simple to convert om film packaging to paper for KHS systems as well as Innopack machines. Customers can either opt for more flexibility by switching between film and paper packaging as required or permanently switch to paper. Since 2020 KHS has offered packaging machines that wrap beverage cans in paper. To give customers maximum flexibility, the function has been integrated into a combined machine: whether wrap-around packs, packs on trays, or pads with or without film or paper wrappers, the system solution can process a range of secondary packaging. Paper may be a relatively new packaging material on the beverage market, especially as an alternative to plastic, however, this material is increasingly capturing beverage fillers’ interest. The paper wrapper meets consumer demand for alternative, environmentally- iendly packaging material. As not every beverage producer wishes to install a completely new machine, however, the paper wrapping unit is available as a conversion option. This means that bottling companies can quickly and easily react

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to marketing trends and consumer demands using existing Innopack packaging machines. KHS provides two retrofit options. If paper wrappers are to permanently replace shrink film as a secondary packaging, all that needs to be done is to substitute two modules; the machine layout can stay practically the same. Here, the former film wrapping module is replaced by the newly developed module that can process paper. The shrink tunnel is also substituted by a module that folds and glues the paper. Beverage producers who do not wish to compromise on flexibility with secondary packaging can retrofit the KHS packaging system as an additional option on their existing machine. In this case, the paper wrapping unit is adapted and the paper folding and gluing module is installed on the machine as an extra. Once the modules have been fitted, switching materials calls for no other conversion except the standard format changeovers. As soon as the packaging materials have been changed over and the hot melt devices are ready for operation, production can begin. From a technical standpoint, on the Innopack packaging machines with a shrink tunnel, only the existing film wrapping module has to be replaced by the module for paper wrapping. The machine can then process both materials. Packers without a film wrapping module have the new module installed as an extension. As opposed to the former machine segment, this now also has a gluing station that sticks the paper together beneath the pack. The packers also require a paper folding and gluing module — either as an addition or a replacement of the shrink tunnel — where the packs are closed. Costs for conversion are lower than those for investment in a new machine. Moreover, only partial commissioning of the current formats is required as these have already been configured for the existing machine modules. New formats can also be set up with less effort than that required for the existing ones. DW

KHS Group www.khs.com/en/media

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Design for Industry Packaging

Robot is easy to work with

Comau is expanding its product portfolio with the new N-220-2.7 (N-220), a 220 kg payload robot featuring a modular set up, direct kinematics, absolute calibration, and enhanced algorithms. The company is targeting a range of applications outside of automotive, such as those involving material handling and packaging. The robots are easy to use, are straightforward to integrate, while ensuring precision, flexibility, repeatability, and minimum backlash. This robot generation offers new levels of quality and supply chain flexibility in addition to cost-effective operation, as required by today’s high-growth market segments. The N-220 industrial robot features an architectural approach based on progressive modularity, component reduction, advanced motors and APC drivers. It has a wide-working area and Performance Level D cartesian safety features with a payload of 220 kg. It has a hollow forearm and an integrated application dressing. The N-220 robot also benefits om its use of direct kinematics, absolute calibration and evolved motion algorithms. All of which combine to deliver repeatability and precision. Furthermore, the robot comes fitted with integrated forkli adapters and optional high-torque washers for automatic anchoring base fixing, easier relocation and faster installation. The first of a new generation of 6-axis articulated robots, N-220 addresses the specific market need for cost-effective and easy to integrate robotics that also deliver high-speed industrial performance. The holistic design and modular architecture of the N-220 also make it easier to install, use and maintain. The robots reliably automate assembly, spot welding, packaging and material handling operations, in addition to continuous process applications such as 3D printing and gluing. The e-Motion so ware algorithm improves cycle time, motion quality and path control. Thanks to the use of a nitrogen balancing system on axis 2, and larger stroke-ends on axis 3, the N-220 enjoys increased agility and a wide backward working area that suits bending and handling 22

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applications. And because the N-220 uses only two motor sizes, and a single oil type, replacing a faulty motor becomes quick and easy. An additional benefit of the simplified, modular architecture is easier overall maintenance and improved Mean Time Between Failure (MTBF) due to a 50% reduction of robot componentry. Recognizing that the integration speed has a direct impact on production potential, the N-220 implements Nodal speech-based coding language for open, easy programming. The easy dressing solution is made of two, separate, flexible harnesses (robot and application power supply) which facilitate an easy and fast upgrade, or replacement. Similarly, the direct assembly between the motor and gearbox simplifies mechanical transmissions and minimizes power loss and backlash, thus increasing efficiency and reducing consumption. In short, everything has been designed to maximize performance, durability, safety, maintainability and ease of use. DW

Comau | www.comau.com DESIGN WORLD

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Semiconductor

Get a better look at defects

The multispectral Camera Link HS (CLHS) line scan camera is a high-resolution line scan camera that provides spectrally independent RGB and NIR outputs making it capable of handling challenging inspection applications. It detects defects both on and under the surface of a variety of materials, components, and products. The Linea ML 8k multispectral camera offers capabilities to meet the increasingly demanding requirements of several challenging inspection applications, like banknotes, passports, and other high security print. It also delivers spectrally independent outputs of the RGB and NIR channels which enables accurate defect detection both on and under the surface of products like semiconductor wafers and printed circuit boards (PCBs) in a single scan, simpli ing vision system designs. The Linea ML 8k multispectral camera uses a CMOS 8k quad linear sensor with a 5x5 µm pixel size and delivers a maximum line rate of 70 kHz x 4 using CLHS fibreoptic interface. The camera also has built-in SFP+ transceivers that convert electrical signals to optical signals and connects directly to fiberoptic cables using LC connectors. DW

Teledyne DALSA www.teledynedalsa.com/imaging

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Design for Industry Semiconductor

Miniature linear guides simplify

mounting in tight spaces As the demand for smaller products continues, the demand

• Corrosion resistance. Stainless steel construction is stan-

for miniature devices that are compact, with a lightweight design, and that mount easily in tight spaces also continues. The LWLF2 linear guide features the same ultra-small 2.5-millimeter height dimension as its predecessor, the LWL1. It is also designed with tapped rails for bottom mounting and stability. The LWLF2 guide is structured with two rows of balls that make contact with the raceway at four points to provide high stability and accuracy — even in applications with varying load direction or complexity.

dard, making the new guides desirable in wet environments and applications where rust prevention oil cannot be used, such as in a cleanroom environment.

• Light weight. The LWLF2’s rail weighs 2 grams per 100 millimeters of length, and the slide unit weighs 0.21 grams. DW

IKO www.ikont.com

Additional features of the LWLF2 include: Compact size. In addition to its 2.5-millimeter sectional height, the LWLF2 has a track rail width of 2 millimeters and slide unit width of 5 millimeters.

•

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Medical

Valves for medical

devices

The Emerson ASCO Series 090 Miniature Solenoid Gas Valves include a new three-way configuration that can perform the same mixing and diverting functions as a pair of two-way valves. It simplifies the design of small, high-precision gas delivery systems for oxygen therapy, compression therapy and gas analyzer devices, as well as home-care devices. Like all Series 090 valves, the threeway unit features compact, lightweight architecture and low power consumption. It delivers precision control without sacrificing critical flow requirements. The Series 090 valves’ exceptional service lifetime of over 50 million cycles significantly increases OEM device efficiency and reliability. The ASCO Series 284/384 Two-Way Solenoid Pinch Valves are designed for use with highly aggressive or high-purity liquids in analytical and medical instrumentation, and sterile and aseptic systems. The aluminum-body, two-way valves are o en used in dialysis equipment because they provide complete hermetic separation of the control mechanism and the fluid within the tubing to prevent particulate contamination caused by iction of moving parts and ensure maximum purity of liquids. Besides hemodialysis equipment, other typical applications include urinary collection and intravenous (IV) systems, and drug dispensing. DW Emerson | Emerson.com

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READY. STEADY. FLOW. Introducing KNF FP 70, delivering 120 - 850 ml/min while producing up to 29.4 psig (2 barg) pressure under continuous operation. Integrated dampers provide a smooth, gentle flow and innovative 4-point valves ensure reliable self-priming even at very low motor speed. FP 70 is well-suited for a range of applications including medical technology, inkjet and 3D printing, and analytical instruments. With its introduction, the KNF smooth flow pump series now boasts a flow rate range of 120 ml/min to 12.4 l/min.

Learn more at knf.com/en/us/solutions/pumps/innovations/fp70-smooth-flow

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Design for Industry Medical

Low viscosity, electrically conductive epoxy meets ISO 10993-5 cytotoxicity standards

The EP4G-80Med is a one-part epoxy for use in the assembly of medical devices. This system is formulated with a non-metallic, graphite filler, which leads to good thermal and electrical conductivity. It possesses a thermal conductivity of 1.44-1.73 W/(m•K) and a volume resistivity of 50-100 ohm-cm. Furthermore, it complies with the ISO 10993-5 guidelines and is considered to be non-cytotoxic. EP4G-80Med bonds well to a variety of substrates including metals, glass, ceramics, rubbers and many plastics. It is effective as an EMI/RFI shielding compound and can also be used for static dissipation purposes. This system does not need high heat to cure; it cures readily in 60-90 minutes at 80°C. Post curing for 1-2 hours at 80°C is commonly recommended as it will optimize the overall properties of the epoxy. Its curing profile makes it suitable for many applications involving heat sensitive substrates. Despite incorporating a graphite-based filler material, it exhibits an excellent flow profile, especially for an electrically conductive system, with a viscosity of 4,000-10,000 cps. It also provides a low coefficient of thermal expansion of around 15-20 ppm/C at room temperature. EP4G-80Med is a dimensionally stable epoxy that offers a tensile strength of 2,000-3,000 psi, a tensile modulus exceeding 750,000 psi and a Shore D hardness DESIGN WORLD

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of 75-85 at 75°F. This system has a high glass transition temperature of 130-140°C and is serviceable over the temperature range of -50° to +175°C. It can withstand exposure to water, antimicrobial agents and many chemical sterilants. EP4G-80Med has a relatively long working life of 8-12 hours and must be re igerated or ozen for storage. This black in color product is packaged in 10cc and 30 cc syringes, which are shipped in dry ice. A er thawing it is easy to apply. EP4G-80Med does not contain any solvents and is RoHS compliant. DW

Master Bond www.masterbond.com/properties/graphitefilled-electrically-conductive-adhesives

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Design for Industry Material Handling/conveying

Efficient drives for horizontal conveying systems Post and parcel distribution centers, among other conveying applications, are fast-paced environments where machine failures and unplanned downtimes cause delays with shipments and deliveries. Reducing machine downtime requires efficient, reliable drive systems that have a long service life and that require little maintenance. A modular system of gearboxes, motors, and variable equency drives om Nord can be configured in more than 20,000,000 unique combinations, tailored exactly to an application’s needs. The modular system provides versatile arrangements, and allows each unit to be individually serviced — minimizing maintenance, downtime, and repair costs. In addition, these drive systems do not take up much space yet are easy to install. These units include the DuoDrive integrated gear unit and motor, IE5+ synchronous motors, and NORDAC ON/ON+ variable equency drives. These innovative units are engineered to maximize performance and efficiency for horizontal conveyor applications. The DuoDrive design combines a single-stage helical gear unit with an ultra-highly efficient IE5+ motor — all in one optimized housing. Not only does the DuoDrive

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provide extremely high system efficiency of up to 92%, the compact design saves on installation space, operates quietly, and reduces variants through constant motor torque over a wide speed range. The DuoDrive also offers full Plugand-Play compatibility for simple commissioning and significantly reduced TCO compared to other drive systems. Also included for warehouse and distribution centers are ultra-highly efficient IE5+ permanent magnet synchronous motors. These electric motors are compatible with gear units and variable equency drives om the NORD modular system and feature

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POWER TRANSMISSION

RETAINING DEVICES & minimal space requirements paired with high overload capacity. With their constant high efficiency over the entire adjustment range, these motors provide economical operation of partial loads and reduce the number of variants. Additionally, every IE5+ motor solution is tailored to a customers’ needs and the individual load range that will be required, ensuring maximum cost effectiveness. NORDAC ON/ON+ variable equency drives were developed for interaction with IE5+ synchronous motors (NORDAC ON+) in conveyor applications. These VFDs are an economic solution for IIoT environments and have an integrated Ethernet interface, full Plug-and-Play capabilities, and a compact design. For safety, these drives feature optional integrated safety functions such as STO (Safe Torque Off ) and SS1 (Safe Stop 1). The intelligent VFDs communicate via an internal PLC that passes data to a main control system, allowing a specific conveyor line to be adjusted if there is a backup to proactively prevent a major shutdown. NORDAC ON/ON+ VFDs also support various fieldbus and Industrial Ethernet systems to integrate seamlessly into new and existing conveyer systems. The LogiDrive complete drive solution is energy-efficient and maintenance- iendly — allowing for a reduction in the number of variants in a system. This in turn reduces parts inventory and maintenance costs. The modular design consists of an efficient 2-stage bevel gear unit, an IE4 or IE5+ permanent magnet synchronous motor, NORDAC LINK field distribution system, power plug connector, signal connector, incremental encoder, and pre-assembled cable. Configuring this solution with the IE5+ synchronous motors minimizes overall costs during service life and achieves higher energy efficiency even with partial load ranges and low speeds. Like the full IE5+ product portfolio, the LogiDrive solution also includes Plug-and-Play capabilities for fast installation and commissioning. Condition Monitoring for predictive maintenance records operating and status data periodically or continuously to optimize operational safety and efficiency of machines. Important information can be derived om the data analysis and applied to proactively maintain the machines and systems, reduce downtimes, and increase the overall system effectiveness. This method focuses on status-based maintenance rather than timebased maintenance to effectively reduce unplanned downtimes. Condition-based maintenance also results in reduction of service and material costs, increases service life of components and machines, and increases system availability with plannable, costoptimized repairs. DW

NORD www.nord.com

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Design for Industry Material Handling/conveying

Modular motor systems suit range of material handling applications

These brushless and brushed dc motors up to 5 kW, ac motors, and linear systems are available as modular systems, allowing designers to combine motors with planetary and right-angle gearboxes, encoders, brakes and integrated or external electronics into one package. Made in Germany, these motors can be configured to a range of conveying, material handling, and packaging applications. Allowing for variable speed/variable torque applications with high bearing load capabilities, they suit VFFS, case packers, conveyor and belt driven applications. The linear systems are fast, precise, maintenance and wear- ee and can replace pneumatic and hydraulic solutions for extended life and environmentally iendly solutions. The linear systems can be single or multiple axis combined into a gantry system. Typical uses include material handling and pick-and-place applications. DW Dunkermotoren www.dunkermotoren.com/en/

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Design Notes

How connectors can help break a sailing speed record Edited by Mike Santora • Managing Editor

Two 3D renderings of the SP80 sailing on the water. courtesy of SP80

During the development of its boat, which is now close to its final design phase, the SP80 team has chosen Fischer Connectors for the data-transmission solutions interconnecting the various sensors that will equip the boat and its pilot to break the world sailing speed record. The technical challenge is to sail at 80 knots (148.16 km/h), powered only by the wind. This is 14.55 knots faster than the record of 65.45 knots (121.21 km/h) set in 2012. The carbon-fiber SP80 boat looks like a Formula 1 car combined with a fighter jet designed specifically to glide on the water, featuring a superventilating triangular hydrofoil and towed by a huge kite wing. “Several projects are in the running to break the long-standing world sailing speed record,” said Mayeul van den Broek, CEO of the SP80 startup based in 32

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Renens near Lausanne, Switzerland, and created in 2019 by a team of engineers and students om the Swiss Federal Institute of Technology in Lausanne (EPFL). “This technological adventure is fascinating, as we’re con onted with extremely challenging physical laws. That’s why our international team of nearly 50 people, some of whom are now finalizing the innovative design of our boat, which is being built in Persico Marine’s shipyard in Italy, is anxious to get the very best in terms of data-transmission performance and reliability. These technical requirements are crucial for interconnecting the various sensors with which our boat and its pilot will be equipped during the launch. The boat’s enhancement runs are scheduled for the end of the year, and the record-breaking event is scheduled for next year.” The data collected by the multiple sensors and loggers monitoring the boat’s structure and the pilot’s performance will be transferred through the connectors, associated cables, and electronic solutions of Fischer Connectors, the Swiss-headquartered supplier of highperformance connectivity solutions that are world-renowned for their ruggedness and resistance to demanding operating conditions such as marine and underwater, defense & security, medical, and test & measurement. “The technology partnership with Fischer Connectors is a logical step forward in our record-breaking ambition,” explained van den Broek. “The innovations we’re putting in place to enhance our boat’s aerodynamics above water and minimize the iction of its hull and foil under water need to be monitored during the boat’s development phase and during the speed run itself. To ensure the efficient transfer of these monitoring data, we need a solutions provider that has not only expertise in signal integrity and data transmission and management but also a holistic approach to electronic systems to provide the end-toend connectivity solutions required for our sensing system.”

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M8 Screw locking with 12 contacts Degree of protection IP67 Versions with and without shielding sheet Easy assembly Dip solder connection Various types

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Design Notes During the design phase, sensors are used to improve and control the robustness of the highperformance materials (carbon, titan, stainless steel) of the boat’s structure. Thanks to the design of the superventilated foil, stability is optimized, and the impact of cavitation — a phenomenon in which water starts boiling around foils at extreme velocities, slowing the boat down — is avoided. During the speed run, data are collected om the various electronic modules and control sensors directly integrated into the boat, and om the monitoring sensor communications between the pilot and the technical crew onshore, including biometric data transferred through sensors worn on the pilot’s body, such as vital and security parameters. “The SP80 project is exciting and inspiring,” said Fischer Connectors’ CEO Jonathan Brossard,” as it combines innovation and performance to push the boundaries of physical laws thanks to unique solutions and daring concepts. One member of the SP80 R&D team is part of our own R&D center, making the exchange of expertise more efficient and easier. We look forward to discovering the technological breakthroughs on which the SP80 team is working.” The final design of the boat for the record will be revealed to the public in spring 2022. The launching of the boat will take place at the end of 2022, while the first tests are scheduled in the South of France for the spring or autumn of 2023 — the two periods of the year that offer the best weather conditions for sailing. DW

Fischer Connectors fischerconnectors.com Under construction at Persico Marine’s shipyard.

800-528-8650 eagletube.com

From Design Concept To Finished Product Eagle specializes in stainless steel, aluminum, copper, nickel and nickel based alloys.

• Stainless steel tubing – hypodermic, fractional, metric, pipe, bar, wire • Custom tube sizes and drawn shapes • Precision cut-to-length tubing • Wire EDM and Laser Machining • CNC Machining (size range .062-2”) • Bending and Coiling • End Forming

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• Assemblies and more

4/27/22 2:40 PM

Design Notes The ultrasonic welding horn end effector on the Kawasaki Robotics in this photo was designed by Harbour Technologies.

Robotic solution speeds up PPE manufacturing process Edited by Mike Santora • Managing Editor

During the COVID-19 pandemic, the healthcare industry faced a large-scale personal protective equipment (PPE) shortage, putting ontline workers at risk of infection. Seeing this struggle, Ontario-based integrator and tool builder Harbour Technologies pivoted their business to include a new title — PPE manufacturer. Harbour Technologies designed a robotic cell to swi ly manufacture FDA-approved isolation gowns, helping the Canadian government provide more PPE to hospitals across the country. Now, because of their success, Harbour Technologies is setting its sights on providing PPE to the rest of the world. “It’s tremendously important for Canada to have resilience in manufacturing PPE,” said Harbour Technologies co-owner Andrew Glover. “We saw it firsthand at the beginning of the pandemic when there was a shortage of PPE across North America … especially in Canada.” Ensuring top quality with automated operations Level-3 isolation gowns — those used by hospital staff during patient encounters involving blood draws, inserting intravenous lines, emergency and trauma treatment, and surgery — must meet extremely high FDA approval standards. The FDA demands that all areas of the surgical isolation gown except bindings, cuffs,

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and hems provide the highest liquid barrier protection level for which the gown is rated … necessitating tight quality control during gown manufacture. “We found a lot of PPE was substandard and put ontline workers at risk,” said Glover. In contrast, automated gown production yields quality far superior to anything made manually, added Harbour Technologies coowner, Andrew Glover. Harbour Technologies’ Kawasaki Robotics-based solution includes an RS050N robot installed to accomplish multiple tasks within the PPE manufacturing cell. The robot uses a tool-changing station to alternate between ultrasonic welding, knife, and gripper tools. It’s a scalable solution that will soon expand to 14 cells between two Harbour Technologies locations in Canada. DESIGN WORLD

4/29/22 8:56 AM

For Harbour Technologies, building an intuitive, easy-to-use system was also important — so their employees could operate the system eely. “We wanted to make sure that when an operator starts the machine, it does what it needs to do,” explained David Glover — so anyone can grab the pendant and start operating.

“We teamed up with Kawasaki Robotics, which perfectly filled the need with its robots and continuous support,” said Harbour Technologies co-owner David Glover. “We sat with their engineering team, gave them the requirements, and worked together to select the proper robot and platform.”

More details on the robotic operation The robotic cell works like this: large rolls of the gown material are loaded into the cell. Servocontrolled rollers release the amount of material needed to produce one gown … and they can be adjusted on the fly to accommodate different products. Once the tabletop workspace is covered in material, the Kawasaki Robotics robot goes to a tool-changing station to don a rotary ultrasonic welding horn designed by Harbour Technologies. Using this tool, the robot traces the gown profile to bond the ont and back pieces of material together. Next, the robot swaps to a knife tool and traces the same path to cut sealed gown panels, neckties, and waistbands. Then, the robot dons a gripper to grasp the completed gown and set it aside for packing. Harbour Technologies employees manually pack the gowns for distribution. Benefits to making the gown in a robotic system abound, according to Andrew Glover — including labor savings and cycle times … as his company can produce a gown a lot faster than what’s being made manually. Automating gown production provides other advantages. The automated cell enables increased production while boosting product quality. Plus, this cell broadens Harbour Technologies’ business to become a global competitor in this space. What’s more, the company’s growth with robotic PPE manufacturing has created hundreds of jobs in their community. “There was never PPE manufacturing in Canada at this level. With the robotic systems, it allows us to compete globally, which therefore creates jobs locally that were never there before,” said Andrew Glover. “Throughout Ontario, our productions are employing over 600 people, which was never there prior to the pandemic. Robotics allow us to continue creating jobs and growing in this market.”

Harbour Technologies uses a Kawasaki RS050N robot (with a 50-kg payload and a 2,100 mm reach) customized to satisfy the intricacies of its PPE gown-making application.

After fitting itself with its third and final gripping end effector, the robot grasps the completed PPE gown and sets it aside.

Kawasaki Robotics USA Inc. kawasakirobotics.com

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4/28/22 2:04 PM

Design Notes Ika Rere fitted with a Thordon seawater lubricated propeller shaft arrangement. | Stellar Studio

Commuter ferry goes fully electric, pollution free Edited by Mike Santora • Managing Editor

The southern hemisphere’s first fully electric, carbon fiber commuter ferry has successfully completed its inaugural round trip with a Thordon seawater lubricated propeller sha arrangement supplied by New Zealand’s Henley Engineering. Ika Rere, Mãori for flying fish, joined the East by West fleet in December, operating the company’s Wellington to Eastbourne route. Commenting on the ferry’s first trip between West Queen’s Wharf and Days Bay, Henley Engineering Managing Director, Mark Power, said, “Ika Rere runs like a Tesla Model S! It’s fast, efficient, smooth, and quiet. It is a truly inspiring vessel. We hope to be involved in more projects like this.” Auckland-based Henley Group – Thordon’s authorized distributor for New Zealand – designed and supplied the vessel’s drivesha s a of twin 325kW battery-powered electric motors. The scope of supply included a pair of SXL seawater lubricated propeller sha bearings installed in Easiflow GRP sterntubes; sha seals with XL oil/grease- ee guide bushes; sha lines and propeller; couplings, mounts, thrust bearings, and brakes. East by West Managing Director Jeremy Ward said: “While the quiet hum of an electric boat is a much more pleasurable experience for passengers, this project was driven by our desire to take climate action. A zero pollution package was the perfect 38

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fit for this eco-vessel. A smooth, quiet, and water lubricated driveline was an essential environmental requirement.” The 62- long, 135 passengercarrying fast cat is also the first vessel delivered by the Wellington Electric Boat Building Company (WEBBCo), a joint venture between the ferry operator and established boatbuilder Fraser Foote. WEBBCo managing director Fraser Foote said: “The ferry is very quiet at 19 knots and silent at 10 knots. It is faster and uses less energy than we anticipated. Ika Rere is a hugely successful project for us. We are the first in the southern hemisphere to have taken a vessel of this kind off the drawing board and onto the water.” DESIGN WORLD

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Foote furthered that collaboration between the yard’s in-house design team and New Zealand’s leading maritime companies “was key to this success. We are extremely proud of what we’ve achieved together.” Thordon Bearings’ Technical Director, Tony Hamilton, furthered that the seal and bearing specialist is well placed to support shipping’s transition to a sustainable future by eliminating oil pollution below the waterline. “We are thrilled to help drive the electric ship and other alternative means of propulsion forward. The pioneering work into self-lubricating polymer materials we started in the 1970s has resulted in the portfolio of environmentally safe products we see today. We were ahead of the game then, and we’re still ahead of the game now. All our products are designed to

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Design-Notes-5-22-Vs4.LL MS.indd 39

reduce the maritime industry’s impact on the environment,” said Hamilton. Thordon Bearings supports the International Maritime Organizations’ World Maritime theme for 2022: New Technologies for Greener Shipping. The theme is linked to the United Nations Sustainable Development Goals (SDGs), particularly SDGs 13 and 14 on climate action and sustainable use of the oceans, seas and marine resources; SDG 9 on industry, innovation, and in astructure; and SDG 17, which highlights the importance of partnerships and implementation to achieve these goals. DW

Commenting on the ferry’s first trip between West Queen’s Wharf and Days Bay, Henley Engineering Managing Director, Mark Power, said, “Ika Rere runs like a Tesla Model S! It’s fast, efficient, smooth, and quiet. It is a truly inspiring vessel. We hope to be involved in more projects like this.” | Will Nelson

Thordon Bearings thordonbearings.com

Featuring full specifications for our check and pressure relief valves, liquid and air pumps, and related components. All products are made to order and ideal for low pressure, low flow applications. DOWNLOAD PDF AT: SMARTPRODUCTS.COM/DOCS/SMART_PRODUCTS_PRODUCT_CATALOG.PDF

5/3/22 10:03 AM

Internet of Things

Edge AI kit accelerates development of AI vision and sensor applications

The Edge AI evaluation kit (EVK) helps users rapidly develop and prototype artificial intelligence (AI) applications at the edge. Based on the Synaptics low-power Katana system-on-chip (SoC) platform, the kit combines vision, motion, and sound detection hardware and so ware with wired and wireless connectivity to simpli the design and development of edge AI for the Internet of Things (IoT). The edge AI hardware market is projected to reach $38.9 billion by 2030, reflecting a compound annual growth rate (CAGR) of nearly 19% om 2021, according to Valuates Reports. While power consumption and size constraints are challenges for the implementation of an edge semiconductor, according to the report, the rise in demand and adoption of AI products and services is expected to create lucrative opportunities. While the market for low-power edge AI solutions is characterized by a broad spectrum of applications that have specific use case requirements, they all require intelligent and efficient detection and analysis of image, audio, voice, and motion data. In some instances, various sensor fusion algorithms are required to provide more accurate—and actionable—data.

Katana Edge AI EVK Highlights: • Baseboard with the Katana SoC with advanced neural network engine for lowpower edge AI processing • Sensors for imaging, audio, voice, and motion • Synaptics Wi-Fi + Bluetooth low energy (BLE) wireless connectivity module • Accessories for people detection application development, including mounting bar and clips for overhead camera • Cabling • Batteries • Enclosure • Instructions and so ware DW

Synaptics www.synaptics.com

May 2022

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Internet of Things

Industrial networking system helps futureproof industrial automation

Industrial Ethernet switches, the EDS-4000/G4000 Series, includes 68 models to help users build futureproof industrial networks to strengthen operational resilience in industrial spaces such as power, transportation, maritime, and factory automation. According to IDC’s Worldwide IT/OT Convergence 2022 Predictions, by 2024, 75% of new operational applications deployed at the edge will leverage containerization to enable a more open and composable architecture that is necessary for resilient operations. As industrial automation applications continue to evolve, OT architectures require enhanced networking capabilities and network security.

May 2022

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While OT/IT convergence is accelerating, enhanced network security, high performance, strong reliability, and advanced usability become paramount to building next-generation industrial networks that strengthen operational resilience. The EDS-4000/G4000 Series are IEC 62443-4-2 certified Ethernet switches also certified by IECEE. Certification was granted due to the built-in hardened security developed by following the stringent software development lifecycle described in the standard. As the number of connected devices in industrial operations grows exponentially, the EDS-4000/G4000 Series provides multiple interface combinations with up to 14 ports and a range of options including fast Ethernet, Gigabit, 2.5GbE uplinks, SFP, and IEEE 802.3bt PoE connectivity. This enables users to connect more devices especially in applications such as intelligent transportation systems that require high-power and high-bandwidth networking. The EDS-4000/G4000 Series is certified for NEMA TS2, EN 50121-4, IEC 61850-3/IEEE 1613, DNV, ATEX Zone 2, Class I Division 2, to fulfill the needs of a wide variety of industrial applications. The EDS-4000/G4000 Series also features Turbo Ring and Turbo Chain fast network recovery to ensure smooth operations. The improved web GUI provides a more intuitive way for users to perform configurations and network management. The rotatable power module offers flexibility to field engineers when they are installing devices and maintaining the network. In addition, the LED indicators on two sides of the device help engineers easily identify the status of networking devices, making their job easier.

DESIGN WORLD

Internet.of.Things.5-22_Vs3.LL.MS.indd 43

EDS-4000/G4000 Series Industrial Ethernet Switch Highlights • Comprehensive portfolio with 68 models, ranging from 8 ports to 14 ports • Multiple interface combinations including fast Ethernet, Gigabit, 2.5GbE, SFP, and IEEE 802.3bt PoE • Developed according to the IEC 624434-1 and compliant with the IEC 62443-42 industrial cybersecurity standards • Turbo Ring and Turbo Chain (recovery time < 20 ms @ 250 switches), and RSTP/ STP for network redundancy • Rotatable power module to simplify installation and maintenance • Wide range of power input options for flexible deployment • Compact and flexible housing that fits into confined spaces • Supports MXstudio for easy installation, operation, maintenance, and diagnostics DW

Moxa www.moxa.com

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

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Internet of Things

Rugged wireless routers available in PoE PSE and PoE PD Two IEEE 802.11a/b/g/n/ac LAN access points offer router capabilities, suitable for challenging industrial network in astructures. The wireless devices allow a user to position their 2.4GHz/5GHz antennas for optimal coverage and signal strength. The ARS-7235-PSE-AC is an industrial-hardened dual-radio IEEE 802.11a/b/g/n/ac wireless LAN access point with added router capabilities boosting network robustness, stability, and a wide network coverage with a low voltage input of 9V. It supports high-speed data transmission of up to 867 Mbps, and is PoE PSE (Power Sourcing Equipment) compliant to supply up to 30 W om one of its two Ethernet ports, allowing users to expand network connectivity to remote locations where a power source is not available. It also comes embedded with the Qualcomm IPQ4029 SoC chipset that has dual Wi-Fi spectral bands of 2.4GHz and 5GHz to reliability handle increased network traffic. Identical to the ARS-7235-PSE-AC, the ARS-7235-PD-AC version has PoE PD (Powered Device) on one its two ports rather than PoE PSE, giving users the ability to power it through the PD-capable Ethernet port. Standard versions of both devices are protected in an IP30-rated metal housing, and provide an operating temperature range of -10°C to 60°C, while extended temperature range models can be used in environments of -35°C to 70°C. Both are capable of operating in different modes, making them suitable for a variety of wireless applications including long-distance deployments. DW Antaira Technologies | www.antaira.com

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5/2/22 12:46 PM

Secure Ethernet The xPico 270, xPico 250 and xPico 240 embedded Wi-Fi IoT gateways have achieved WPA3 Certification for WPA3-Enterprise and WPA3-Personal by the Wi-Fi Alliance. Delivering seamless and secure Ethernet, Wi-Fi and Bluetooth connectivity, the xPico 200 Series gateways enable OEMs to build and deploy smart connected products with reduced complexity and lower risk. Designed to increase resiliency in mission-critical network applications, the features of the WPA3 simplify and strengthen Wi-Fi security, enable more robust authentication and deliver increased cryptographic strength for highly sensitive data for both enterprise and personal use. According to a recent study by HMS Networks, Industrial Ethernet now makes up 65% of the global market of newly installed nodes in Factory Automation. In addition, wireless continues to grow rapidly at a rate of 24%, outpacing both fieldbus and Industrial Ethernet. With industrial-grade design for operation in extreme environments, the xPico gateways feature automatic network connection management. Compatible with ConsoleFlow cloud-based Software-as-a-Service (SaaS) platform, users gain centralized management, allowing them to view and manage globally distributed assets through a single pane of glass from virtually anywhere. Ideal for use in a variety of applications, including industrial automation, medical devices, responsive retail and resource management, xPico 200 Series features the xPico 270 Wi-Fi (802.11 a/b/g/n/ac), xPico 250 dual-band WiFi (802.11 a/b/g/n) and the xPico 240 dual-band Wi-Fi (802.11 a/b/g/n) and Ethernet. The modules also provide a robust selection of other connectivity options for IoT applications, including Bluetooth/Bluetooth LE, Ethernet MAC, USB 2.0, UART, SPI and GPIO. DW

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Interpower offers four NEMA snap-in or screw-mount sockets including 5-15, 5-20, 6-15, and 6-20 sockets with one common panel cutout simplifying product design. Each socket type has four different configuration options—choose from quick disconnect tabs with or without wire binding screws or solder tabs with or without wire binding screws. The different designs allow for various voltages and amperages.

DESIGN WORLD

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May 2022

4/27/22 2:55 PM

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C o n t r o l

Linear motor

modules:

the heart of mechatronic systems At the heart of many automation systems for pharmaceutical and medical lab analysis applications are small linear motor modules. FAULHABER MICROMO LLC Edited by Miles Budimir • Senior Editor

May 2022

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•• •• •• •• •• • • • • ••

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he coronavirus pandemic has put added pressure

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| istockphoto.com

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on many industries, including pharmaceuticals and medical laboratories, to step up production levels. As a result, these and other industries have increasingly turned to automation as a way to meet these new demands. For example, new analysis techniques and testing devices, production lines, as well as filling and packaging systems can all be made more efficient with the use of automation. Miniaturized linear motor axes and modules for single- or multi-axis applications open new possibilities here. Designed as a modular system, they’re suitable for a wide range of tasks in laboratory automation and the pharmaceutical industry. Case in point; engineers from Jung Antriebstechnik u. Automation GmbH JA2 responded to calls from the pharmaceutical industry, the analysis sector, and the medical technology industry for small but functional automation solutions with the development of a new modular mechatronic system called QuickLab. The system uses the small QM02 linear motor modules with up to 160 mm of stroke and the QA02 linear motor axes for strokes up to 220 mm. They make possible high dynamics and accuracy in shortstroke applications such as those in laboratory analysis and testing systems. Through the mechanical construction and precision guides in combination with two ball carriages, the modules and axes are stiff and offer high repeatability during positioning of

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+/- 50 μm in spite of their lightweight construction and low moving mass. Depending on the load, they make possible travel speeds up to 3 m/sec and accelerations up to 50 m/sec². The axes and modules can be individually combined with one another. This makes possible pick-and-place applications and automatic solutions for separating, grouping, testing or plating samples, or other sensitive products. With a width of 22 mm, QuickLab covers the need for miniaturized singleand multi-axis handling systems. Accessories for specific application needs are also available, such as weight force compensation, magnetic holding brakes, external position sensors, and adapter plates. High dynamics and precision At the heart of the QuickLab mechatronic system are linear motors from FAULHABER. As Wilhelm Jung, Managing Director at Jung Antriebstechnik u. Automation explained, “The linear motors are the ‘heart’ of our modular automation system and the requirements placed on them are high. The motors must operate highly dynamically, be precisely controllable and have suitable dimensions. The linear motors from FAULHABER convinced us with their innovative functional principle, which differs from some classic solutions on offer.” May 2022

4/27/22 3:07 PM

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M o t i o n

C o n t r o l

The QM02-2070 miniature linear motor module from Jung Antriebstechnik u. Automation features a stroke up to 160 mm and a peak force of 28 N.

For instance, linear motors can be constructed in a number of different ways. This is because the principle of the rotating electric motor can generally be implemented in linear motors by mapping the round air gap onto a straight line. To do this, the original circularly arranged electric excitation windings are mapped on a flat path. The magnetic field then pulls the rotor over the travel path. There are, however, still other possibilities. For example, the LM2070 dc linear drives from FAULHABER are not constructed as “surface rotors” with a carriage and a guide. Instead, the forcer rod is guided within a 3-phase self-supporting coil. “This design produces an exceptionally good relationship between linear force and current and high dynamics. In addition, there are no cogging torques, thereby making the linear motors ideal for use in our modular QuickLab system,” adds Jung Antriebstechnik u. Automation’s Jung. The linear motor technology from FAULHABER combines the speed and robustness of a pneumatic system with the flexibility and reliability features of an electro-mechanical linear motor. The innovative design uses a 3-phase selfsupporting coil and non-magnetic metal housing, which boost performance. The absence of residual static force as well as the good relationship between the linear force and current make these motors suitable for use in micropositioning applications. Position control for the linear dc servomotors is made possible by the built-in Hall sensors. The useful lifetime of the linear dc servomotors is mainly influenced by the wear of the sleeve bearings, which in

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turn depends on the operating speed and applied load of the cylinder rod. Maximum performance in the smallest dimensions The LM2070 linear motors are available with stroke lengths from 40 to 220 mm. Despite the compact stator dimensions of 20 x 20 x 70 mm (W x H x L), the small linear dc servomotor features robust mechanical performance indicators. It has a continuous force capability of 9.2 N, with up to 28 N of peak force possible. The robust plain bearing of the forcer rod easily handles the high speeds of up to 3 m/sec. At the same time, the small linear motor can be precisely controlled. Already

with the integrated Hall sensors, the absolute positioning accuracy is +/- 0.1 mm and the repeatability is +/- 50 μm. With an optional external sensor, these figures can be improved to +/- 0.01 mm and a repeatability of +/- 1 μm. On top of these specifications comes practically maintenance-free operation as the motor has no moving wear parts. Moreover, the linear drive operates nearly noise-free, which is important above all if personnel and handling systems work in the same room, as is often the case in laboratories. An important point for handling systems is the connection technology. The linear motors are normally delivered with a maximum 30-cm long

An XZ planar gantry incorporates a QA02 linear motor axis and a QM02 linear motor module with weight force compensation.

www.designworldonline.com

DESIGN WORLD

4/27/22 3:09 PM

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cable connection. In automation systems, however, the switch cabinet is usually some distance from the actual drive. “Between the motor and the controller in the separate switch cabinet, there can then be 10, 20 or more meters,” says Wilhelm Jung. With the QuickLab modular system, there is a special, multi-shielded cable that transfers the motor power and the position sensor signal between motor and controller interference-free over up to 30 m. It’s fastened with a cover directly to the

The linear motor technology combines the speed and robustness of a pneumatic system with the ﬂexibility and reliability features of an electro-mechanical linear motor. motor with strain relief, can be plugged in and is also designed for use with cable chains, that is, for mobile use. The singlecable technology simplifies installation due to the prefabrication of both ends. The mechatronic kit tailor-made for laboratory automation has already proven itself in practical use. Wilhelm Jung confirms that “Many manufacturers and suppliers of analysis accessories today rely on our systems. Demand is currently increasing – including from other areas such as optics and testing technology.” DW

FAULHABER MICROMO LLC www.faulhaber.com Jung Antriebstechnik u. Automation GmbH JA2 www.ja2-gmbh.de/

•• ••

Looking for cost effective and energy efﬁcient positioning?

Easy Integration

The simplicity of pneumatics combined with the advantages of electric automation The Simpliﬁed Motion Series axes are ideal for simple positioning and pressing/clamping movements. • Quick and easy commissioning using the integrated buttons on the motor or via IO-Link • Connection via IO-Link for enhanced functionality including diagnostics • Simple control with 2 digital inputs for basic functions or enhanced control with IO-Link for additional functions, multi position download with speed and torque data

festo.us DESIGN WORLD

May 2022

49 SMS-Favro-T2M-7703-Design World-print-5.375x8.625.indd 1

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M o t i o n

Electric actuators as an alternative to

Part 2 of 2:

hydraulic cylinders

Here we offer some tips for converting a fluid-powerdriven axis to electrical actuation. Ryan Klemetson • Business Development Manager | Tolomatic, Inc.

offer long service life, but they’re not as efficient as electric systems. Electric systems also provide precise position, velocity, and speed control with more efficient operation. They operate in a closed loop environment for easy data collection, and they are virtually maintenance free. In fact, as electric rod-style actuators become capable of delivering forces comparable to those of high-end hydraulics, they’ll become increasingly viable replacements for hydraulic systems in many applications. Evaluating capabilities and limitations and aligning them with system goals and objectives will help determine the best choice for the application.

May 2022

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•• ••

s explained in Part 1 of this article series, hydraulic systems

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When switching to electric — know the required force When considering a switch to electric actuators, first determine the application’s required working force. To estimate this force value, the typical approach is to adjust the hydraulic work port or system pressure until the operation can no longer be performed. Electric actuator systems rely on current through the servomotor to produce torque to the mechanical system, which DESIGN WORLD

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drives the screw to turn and generate force. This is a huge advantage; force is instantaneous. In hydraulic systems, where system rigidity isn’t optimized, the hydraulic actuator must wait for pressure to build until force is achieved. Another big advantage of electric systems is that the servo controller automatically regulates current — and so the electric actuator system essentially uses current on demand. Any adjustment happens automatically. In contrast, a hydraulic power unit must always maintain system pressure for the hydraulic cylinder to actuate, which can significantly degrade their overall system efficiencies. www.designworldonline.com

•• ••

When selecting an electric actuator system, it’s essential to consider the motor’s RPM and torque capabilities, coupled with the screw lead in the electric actuator. Matching speed and torque from the servomotor with the leadscrew’s mechanical output can be complex. Getting the extreme forces that hydraulics can produce is entirely possible with electric technology, but typically, the electric actuator deployed will have a larger body diameter and the electric actuator system will have a velocity maximum that can’t be exceeded. The complexity in sizing a system can easily be overcome as actuator and servo component manufacturers provide easy-to-use motion control sizing software packages that factor in all these variables. May 2022

4/27/22 3:44 PM

M o t i o n

C o n t r o l

GOOD: Measure pressure at the valve. This is the most common for conversion applications. it’s the furthest distance from the work point, which can increase error in actual versus measured pressure. Pressure relief line

Reservoir Relief valve

BEST: Measure pressure at the cylinder. The most accurate location for reading pressure is closest to the point of work. This area may be the least accessible.

GOOD

HYDRAULIC CYLINDER

Pressure line

BEST

Control lever (at center position)

Suction line Oil strainer

Oil pump

Control valve

BETTER

Return line

Hydraulic system output force is equal to the area of the piston’s working surface multiplied by the rated system pressure. However, using system pressure in force calculations (to choose an electric actuator replacement) can often result in an oversized and overpriced electric solution.

BETTER: Measure pressure between the valve and cylinder. Pressure-compensated flow controls and needle valves or other inline accessories may influence the pressure value.

The danger of fluid-power sizing Because fluctuations in fluid pressure are common and the cost of fluid-powered cylinders is low, it’s typical that hydraulic cylinders are sized two or threefold larger than that needed by the application. Engineers can consider this oversizing to be a design safety margin or kind of insurance. However, the practice of oversizing can obscure an application’s actual force requirements — making them appear quite high when in fact they are significantly lower than the cylinder’s maximum rating. As a hydraulic cylinder gets bigger, its force capabilities grow because force = pressure × area. As the bore and oil pressure of a cylinder increase, the output force capability grows rapidly. The force output of an oversized cylinder is much higher than what the application specifies.

May 2022

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www.designworldonline.com

In fact, converting from a hydraulic to electric system requires understanding three key variables: force, motion profile and electric actuator technology. Adding actual force and motion data into a manufacturer’s sizing software will yield an accurate recommendation for conversion. Don’t oversize the actuator: The first step in the conversion process is to understand the amount of work being done. This work (force) is a function of the hydraulic pressure in the cylinder. However, getting an accurate measurement of the force being applied by hydraulics can be complex. The most common conclusion is to use the maximumrated pressure of the hydraulic system. This assumes that prior engineering work didn’t significantly oversize the hydraulic system. Oversizing a hydraulic cylinder is common due to the relatively small effects it can have on the overall system cost. The issue is that that same cannot be said of electric actuators. The price of an electric actuator is significantly affected by upsizing — so excess safety margin must be avoided. In fact, the biggest mistake is to oversimplify the force calculation process. DESIGN WORLD

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Know the real peak force: To avoid costly sizing mistakes, determine the real peak force of the hydraulic cylinder to be replaced. Also remember that oftentimes, hydraulic cylinders are intentionally oversized. To be clear — sizing an electric actuator to replace a hydraulic cylinder isn’t as simple as calculating the old system’s capabilities. Such approaches often employ a basic system-pressure formula, so called because the

Matching speed and torque from the servomotor with the leadscrew’s mechanical output can be complex. Getting the extreme forces that hydraulics can produce is entirely possible with electric technology — but typically the electric actuator deployed will have a larger diameter ... and electric actuators will have a velocity limit. DESIGN WORLD

May 2022

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•• ••

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•• •• •• •• •• •• • • • • • •• M o t i o n

•• ••

C o n t r o l

•• ••

ACCOUNT FOR BACK PRESSURE TO GET ACCURATE OUTPUT VALUES 400 psi

1.5-in. bore

LOAD

0.75-in. diameter rod

•• ••

This is the most accurate method for conversion.

132 psi

•• ••

✔Force on each side of the cylinder is calculated ✔Area of rod side of piston = Bore area - rod area ✔Application force = Difference in force for each side

Force = (Area1· πr2 x P1) - (Area2 · πr2 x P2 )

Essential to converting from hydraulic to electric is to avoid oversizing.

calculations assume the application of maximum system pressure to the cylinder’s full piston area. Using this system-pressure value in for force calculations isn’t recommended. Instead, it’s best to determine the hydraulic cylinder’s true peak and continuous working force. One approach is to record values of the application while in operation, though this can be challenging … especially on an existing machine. If it’s in fact possible to record these values, exact pressure readings aren’t necessary … as even an estimation to within 15% of the actual force is a useful range. Another way to determine application forces is to use a load cell or install an electric actuator on the machine axis in question. Of course, these solutions can also prove difficult if not impossible to implement in existing machines. The next best and often most practical way to determine required force is to measure hydraulic pressures in the fluid-power system while the process is in operation. In fact, there

are three different locations in a hydraulic system at which to take pressure measurements. The closer one can get to the actual point of work, the more accurate the measurement. Conservative measurements yield useful results — so that the replacement actuators (and their motors) aren’t undersized or significantly oversized. Measuring hydraulic pressures at the actual hydraulic cylinder (more specifically, on each side of the cylinder) yields the most accurate estimations of required force. The area of rod side of piston equals the bore area minus the rod area. That yields an application force equal to the difference in force between the two sides: Force = (Area1 · πr2 x P1) — (Area1 · πr2 x P2). Other tips for assessing axis required force: Take a video of the process in motion to learn how much time is needed to make the target travel distance. This is useful for sizing

Shown here is one example illustrating how a relatively high back pressure can affect primary working pressure in a fluid-power-driven system. DESIGN WORLD

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May 2022

4/27/22 3:46 PM

•• ••

DznWrldBallSplineNB3.pdf

7/13/15

4:17 PM

Ball Splines

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NB Corp 5-22.indd 56

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

5/2/22 7:50 AM

•• •• •• •• •• •• • • • • • •• M o t i o n

•• ••

C o n t r o l

•• ••

FORCE REQUIRED

Oversizing an electric actuator — by using double or triple the needed force capacity — can add thousands of dollars of unnecessary cost to the system.

FINAL SYSTEM COST

ACCURATE FORCE CALCULATIONS for AFFORDABLE ACTUATION SYSTEM PRESSURE (FORCE × AREA)

CALCULATED

DIFFERENTIAL PRESSURE

GAUGES AND MOTOR SIZING

MEASURED

ELECTRIC PROTOTYPE TESTED

ACCURACY OF FORCE REQUIRED

the mechanical assembly and support finalizing motor and drive selection. Also take videos of any pressure gauges used in measuring pressures. This allows investigation of pressure across the entire stroke to better identify if there are pressure spikes requiring consideration. In addition, be sure to identify special requirements — including the need for constant velocity or the maximum time to complete a given move, for example. Here, an application sizing worksheet can be a useful tool to document these requirements and provide a quick snapshot of what’s necessary for a specific application. Finally, measure the fluid-power system working pressure and the return pressure. Every hydraulic system is different. Usually, there’s minimal backpressure in return lines … though some systems can have high return pressure between the cylinder and the valve. In these instances, this pressure does influence the hydraulic cylinder’s output force. The most accurate force calculations determine the dynamics on both the blind (piston) end and the rod end of a hydraulic cylinder. Force is generated whenever pressure is applied to a surface area. Therefore, any back pressure applied to the rod end of a hydraulic cylinder during an extend move will offset some of the force applied by the primary working pressure on the cylinder’s blind end. The most accurate calculations — which we call the dual-force method — account for this effect of back-pressure offset and the resultant force. DESIGN WORLD

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Example: Why proper measurements are a must for correctly sizing actuators Assume that for a given hydraulic system, the pressure rating is 103 bar. If we use this value alone in area x pressure calculations to calculate force for a given cylinder size, we’ll end up with an electric-actuator solution that’s vastly oversized. In fact, our example application only uses 2,366 N of thrust … so the use of system pressure would’ve resulted in an actuator five times larger than required. This example uses very small forces compared to what typical hydraulic systems can produce, but it highlights the importance of identifying and using accurate application data. When sizing hydraulic cylinders, it may only cost a few hundred dollars to oversize by selecting a larger bore size for more force. However, oversizing an electric actuator — by using double or triple the needed force capacity — can add thousands of dollars of unnecessary cost to the system. That’s why proper measurements are critical to right-sizing electric actuator systems. Using inflated force values when quantifying a hydraulic cylinder’s realworld function creates two challenges for conversion to electric actuation. 1 Without thorough investigation, it may make the application’s force requirement seem much higher than what an electric linear actuator can deliver. It may (mistakenly) look impossible to convert the application to electric. www.designworldonline.com

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With larger hydraulic-cylinder bores and higher oil pressures come increased output force capabilities. 2 Electric actuators can have a higher purchase price than hydraulic cylinders. Unnecessary oversizing can lead render electric actuators unaffordable. DW All article images from

Tolomatic Inc. | tolomatic.com

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•• ••

E l e c t r o n i c s

•• ••

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Evaluating free PCB

design software It pays to understand the quirks that pertain to the numerous PCB packages that are available for free.

Leland Teschler • Executive Editor

May 2022

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If engineers were to prepare a top-ten list of frustrations with online

lists of free PCB software, it might include the reality that some individuals preparing these lists don’t seem to understand the difference between PCB design and circuit design—the two completely different categories of software are sometimes lumped together in online surveys. It’s also easy to find lists containing free packages that can only be used for specific PCB fabrication houses, a fact that is sometimes only discernible by reading the fine print. And then there are packages billed as free but only during a trial period. In our PCB software survey, we’ve tried to avoid these pitfalls. We’ve only included PCB packages that provide outputs that can go to any PCB fab house, not just to the entity providing the PCB software. And we’ve outlined the major factors that will help in making decisions about what to download and what not to bother with. CADStar Express – This is a less advanced version of a non-free PCB program called CADStar developed by Zuken, a software firm offering design software for wiring harness design, multi-chip modules, pneumatics and hydraulics, as well as for PCB work. The free Express version is limited to 300 pins and 50 components. The paid version has a place and route editing tool, and PCB designs created on the Express version seem to be compatible with this tool. But it’s not clear that automatic placement and routing is part of the free version.

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May 2022

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layers, but it is only free to students and educational institutions. EasyEDA – There are commercial versions of this one, but the free version is said to contain the same features as the paid versions. The main difference seems to be that free users see ads in the software whereas paid users don’t. The program runs in a web browser and includes a circuit simulator. Components used in the population of the PCB can be automatically ordered from a Chinese distributor. The provider also offers a PCB fab service, but designs created with the EasyEDA program can be output in standard formats that can go to any PCB design house. ExpressPCB Plus and Classic – These are both free, but it’s not clear their output can be sent to other PCB houses. Plus handles up to six layers, Classic up to four. Plus also handles silkscreens on top and bottom layers and links a schematic capture to the PCB layout so there can be netlist verification between the two programs. Other features of the Plus version include hole sizes ranging from 0.006 to 0.25 in, BOM features,

CircuitMaker – Originally developed by electronic design software provider Altium, it is now available on the open-source hardware site by the same name. It handles 16 signal layers and has no restrictions on PCB dimensions. Trace routing features include auto-routing and obstacle avoidance, hug, hug-n-push, and obstacle ignore. The push modes will push other trace and vias, as well as hop-over. There are also facilities for handling differential pairs and interactively adding accordions to nets that need that extra length for signal delays. The software generates industry standard Gerber and NC drill or ODB++ outputs for manufacturing. DesignSpark – This one will handle a PCB design up to onemeter square. There are no limitations on the number of pads, nodes, connections, or the number of schematic sheets. There’s a library of part models to which users can add their own. The Gerber and ODB++ files that the program generates can go to any PCB maker, though DesignSpark also has a PCB service. Other features include BOM creation and Spice netlist outputs. Additionally, the well-known LTspice circuit simulator (now free from Analog Devices) is integrated into the schematic capture part of this program. DipTrace Lite – This is a scaled-down free version of the commercial DipTrace program. It handles 500 pins and two signal

4/27/22 4:02 PM

E l e c t r o n i c s Package

Where to find it

CADSTAR Express

https://www.zuken.com/en/resource/free-pcb-design-software-cadstar-express/

CircuitMaker

https://circuitmaker.com/About

DesignSpark

https://www.rs-online.com/designspark/pcb-software

DipTrace

https://diptrace.com/buy/academic/

EasyEDA

https://easyeda.com/

ExpressPCB Plus

https://www.expresspcb.com/

FreePCB

https://www.freepcb.com/

Fritzing

http://fritzing.org/

KiCad

https://www.kicad.org/

Layo1

https://layo1.com/layo1pcb/uk/downloads.htm

LibrePCB

https://librepcb.org/compare/

Osmond

https://www.osmondpcb.com/

Pad2Pad

https://www.pad2pad.com/free-download/

PCB

http://pcb.geda-project.org/

PCB 3

http://opencircuitdesign.com/pcb/index.html

PCB Artist

https://www.4pcb.com/free-pcb-design-software.html

PCB Elegance

https://pcb-elegance.en.softonic.com/

Target 3001! discover

https://ibfriedrich.com/en/index.html#home

ZenitPCB

http://www.zenitpcb.com/

and accommodation of both plane and signal inner layers. The Classic version limits silkscreen design to the top layer and also links the schematic to the PCB layout, but there doesn’t seem to be a netlist verification feature, probably because the program handles only relatively simple designs. Inner layers on Classic are plane only, and it handles a preset list of 24 hole sizes. FreePCB – This is an open-source PCB editor for Windows said to be designed for professional-quality work. But it was last updated in 2010, and the support seems to come from only one person, the original author. It lacks a built-in auto-router but can use the FreeRoute web-based auto-router at www.freerouting.net. Among its features are an ability to handle up to 16 copper layers, a max. board size of 60-in square, metric units for most functions, footprint libraries via Ivex Design International, PCB Matrix

A PCB under construction in the KiCAD layout program.

May 2022 www.designworldonline.com

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and the IPC, a footprint wizard and footprint editor for creating or modifying footprints, imports and exports of PADSPCB netlists, a design rule checker, and production of extended Gerber files (RS274X) and Excellon drill files. Fritzing – This one is free on Github but the authors, a non-profit organization, request a $10 donation. It runs directly on Windows and Mac machines and on Linux via an Appimage. The program seems to be oriented toward beginners in that there is a lot of basic tutorial material about electronics on the Fritzing site, which as well offers a PCB fab service. But the software seems to be regularly updated with the latest version released in Sept. of 2021. Services include autorouting, production of Gerber files, and a lot of parts in the part library with an emphasis on those commonly used in home projects. KiCAD – This open-source package is said to create PCB layouts with a wide array of tools including those from thirdparty sources such as Eagle. Although the emphasis seems to be on beginners, the package offers some higher-level tools such as the ability to tune trace lengths for high speed designs with the dedicated tool. Also included are an interactive router, an ability to “crossprobe” between schematic and PCB and jump to components in the PCB, and the ability to update the PCB from the schematic in just a few clicks. Layo1 PCB Home – This is for students and hobbyists in that it has no Gerber or Excellon output and is labeled as being strictly for non-commercial purposes. More capable versions of the program are available on a fee schedule. LibrePCB – The authors of LibrePCB frankly state that their program is less powerful than KiCAD but that LibrePCB might be better for less complex boards. Features include netlists that always sync up between schematics and the PCB, a library manager that organizes by hierarchical categories that are easy to keep track of, and easy version control of PCB files. DESIGN WORLD

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NEMA Socket Series with One Cutout By Interpower® A board design created using the Target3001! program out of Germany. Osmond PCB – This program is strictly for Mac PCs. But it is said to handle boards of any size and shape and with no limit on the number of layers, with a spatial resolution of 10 nm. It allows designers to use both Metric and

Imperial units on the same design and will import the part list and net list and maintain adherence to specified design rules throughout the design process as well as allowing users to start from scratch. The program also includes

Interpower offers four NEMA snap-in or screw-mount sockets including 5-15, 5-20, 6-15, and 6-20 sockets with one common panel cutout simplifying product design. Each socket style has four different configuration options—choose from quick disconnect tabs with or without wire binding screws or solder tabs with or without wire binding screws. The different designs allow for various voltages and amperages. • • •

No minimum order or dollar requirements Same day shipments on in-stock products World-class customer service 7 a.m. to 6 p.m. CST

The construction step in the creation of a PCB using the ZenitPCB program, created by an Italian PCB designer. DESIGN WORLD

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E l e c t r o n i c s

tools that let users move and re-orient parts, connect and route traces, modify existing traces, and edit pads and pad-stacks and make PCB labels using characters from the Mac font library. There’s support for ground or signal planes and a means of defining arbitrary copper flood areas. Osmond provides two silkscreen layers, two solder mask layers, and multiple auxiliary layers, and scripting support using the Lua programming language. Pad2Pad – This is an offering of a PCB fabrication house that will provide design feedback on the PCB you come up with as well as a quote for fabrication. Software features include a big footprint library, auto-routing, netlist import, ability to define ground planes, DFM analysis and BOM integration. It is designed to work on Windows machines; Apple and Linux users can run the program via widely available Windows emulation programs. PCB – This is an interactive PCB editor for Unix, Linux, Windows, and Mac systems. PCB includes a rats nest feature and schematic/netlist import, design rule checking, and can output RS-274X (Gerber), NC drill, and centroid data (X-Y data). Features include an auto-router and trace optimizer and a plug-in API for inserting new functions used from within the GUI as well as in scripts. Another plus: The program seems to be updated regularly. PCB 3.0 – This is the brainchild of a researcher in Germany which now seems to be maintained by a lone researcher at the Johns Hopkins University Applied Physics Lab. It runs on GNU/Linux, Mac OS-X, or Cygwin under Windows. It handles up to eight layers, outputs in either Gerber or PostScript formats for drill files, silkscreens, solder paste, and component masks. It will do design rule checks, handles complex power and ground planes, runs netlist comparisons, and lets users define their own parts for the parts library.

PCBArtist – This is billed as professional-grade Windows-only PCB design software and comes from the PCB fab house Advanced Circuits. It contains over 500,000 components in the library and has live tech support. It handles up to 28 layers and outputs Gerber files. Features include a symbol/footprint/part creation wizard, design rule checks, autoplacement, handling of power planes/ copper pours, integrated schematics, controlled auto-routing, and BOM facilities. PCB Elegance – This Windows program is available on the free software download site Softonic based in Spain. It is said to handle 2,000+ components and 40,000+ traces and generates Gerber output plots (RS274X Gerber) and penplot files. It handles up to 32 layers for traces/area fills/ power planes, can adjust the thickness/ clearance of every trace/via/pin, and has a resolution of 10 nm. Other features include the auto generation of standard geometry types, a flexible use of buses, and use of keys and colors that can be modified. Target 3001! Discover edition – This is a slimmed down version of a commercial package out of Germany. It handles 250 pins/pads, two copper layers, 30 simulatable signals, mid-layer capabilities limited to 10 pins, and a board size up to two-meters-square. But it is not intended for commercial use. Outputs seem to be in a proprietary Target 3001 format, though the provider says many PCB houses will accept this format. ZenitPCB – This program comes from a PCB designer in Italy with the Ariston Thermo Group (which makes heating systems). It is limited to 800 pins but there is no proviso against commercial use. Users can import netlists or create a board with a built-in layout editor, import components from a library, and connect pins with the cursor. However, it seems to be limited to two-sided boards. Outputs are in the form of Gerber files. Minimum dimension size is 1 mil. The component library has 800+ footprints, and the package includes design rule checking facilities. DW

May 2022 www.designworldonline.com

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M e c h a n i c a l

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Precision linear modules for semiconductor fabrication efficiency Precision linear modules are compact, well-engineered mechatronic devices with a range of sizes and motion technology — profiled rail, linear bushings, and ball screws — that offers different levels of precision, stability, and endpoint accuracy. Justin Lackey

• Product Manager, Systems • Bosch Rexroth Corp. One industry with the highest levels of precise, stable, and accurate motion in

manufacturing tools is the semiconductor industry. Semiconductor fabs, and the tool builder OEMs that supply them, have a very special set of automation needs. This includes mechatronic modules designed for smooth motion during wafer handling, noncontact material transport through the process chambers, and nanometer-scale positioning accuracies. The recent global supply chain impact of COVID-19 has placed great pressure on this industry to rapidly expand production capacity. However, semiconductor fabrication requires thousands of process steps that manipulate chip structures and create transistors that are just a few nanometers in size.

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Applications such as semiconductor manufacturing, laser cutting machine tools, and electronics assembly require precision linear modules that operate with tight endpoint accuracy and smooth travel with minimal vibration throughout the motion cycle. Bosch Rexroth’s new generation of precision modules are well-suited for these applications.

Thus, while the ramp-up in production capacity has never been more critical for the world’s digital economy, fab operators and tool builders both recognize the essential need to use the finest linear motion technology to ensure that the new production lines operate with the highest levels of quality and productivity. Understanding several key design and performance characteristics that distinguish precision linear modules can help machine and system designers select the proper precision linear modules to satisfy these demanding requirements. The critical impact of precise motion Ultraprecise and delicate motion requires extremely stable, nearly vibrationfree motion during travel. Reaching

DESIGN WORLD

Mechanical 5-22_Vs2.LL.MS.indd 65

the targeted endpoint with the utmost accuracy is the primary goal. Stable motion is often critical to protecting fragile materials from damage or degradation caused by linear travel. Semiconductor wafers are a perfect example: they are extremely delicate, and a finished wafer may contain chips potentially worth millions of dollars, depending on the size. However, each wafer must be transported through hundreds of process steps — and each time it’s moved from one step to another, vibration in the linear module risks damaging the in-process wafer, reducing its final value — the less vibration, the lower the risk. Endpoint accuracy is equally critical for productivity purposes. If a tray of electronic parts moves through a high-

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speed automated assembly process, maximum throughput productivity is achieved when the linear module delivers the tray into the assembly tool with micron-level accuracy. At the same time, stable motion and endpoint accuracy must be repeatable through thousands of motion cycles every day. If it takes several milliseconds to fine-tune the positioning of the parts, those milliseconds add up to hours of additional production time, reducing throughput and potentially inflating costs, and impacting delivery schedules. Modular elasticity and materials of construction Aluminum or steel is most often used to create linear module housings. Aluminum housings are typically used

May 2022

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•• •• M e c h a n i c a l ••

Ball screw drives are ultra-efficient in converting rotary motion into linear motion. As mechanical drive elements, they can be installed in X-Y-Z orientations and perform movements with the precision and repeatability needed.

Understanding several key design and performance characteristics that distinguish precision linear modules can help machine and system designers select the proper precision linear modules to satisfy these demanding requirements. 66

May 2022

Mechanical 5-22_Vs2.LL.MS.indd 66

in more standard linear modules as they can be cost-effectively extruded to satisfy a wider range of module size and length. However, for precision linear modules used in semiconductor fabrication applications, modules with steel machined housings offer advantages. These housings typically exhibit much less modular elasticity and deviation from the desired travel path than aluminum-based modules. Modular elasticity can cause the module to reflect any slight deviations in a machine’s frame at the linear module’s mounting point. If there is some deviation, like a twist or bow where the module is attached, it can reflect that deviation. Machined steel housings prevent that kind of deviation, helping ensure precise“flat” travel through a motion sequence. This contributes to vibration reduction, endpoint accuracy, and locational repeatability. Motion and linear guide components Precise and stable motion is also a product of the motion components that drive the www.designworldonline.com

linear module. For precision linear modules, ball screw drives provide the optimum solution. Ball screw drives are ultra-efficient in converting rotary motion into linear motion. As mechanical drive elements, they can be installed in X-Y-Z orientations and perform movements with the precision and repeatability needed. Ball screws with full contact seals offer a unique combination of high rigidity, high precision, and respectable speed, making them useful in various precision motion applications. Specifically, their ability to handle substantial axial loading often makes them a better choice than linear motors, particularly in metal-, wood-, and stonecutting applications. Equally important is the design of the linear guides in precision modules. Accuracy in linear guides depends on many factors: the trueness of the rail on which the runner block or bearing travels, the raceways inside the bearing DESIGN WORLD

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•• •• ••

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Configuration and technical support One final element to consider when selecting precision linear modules is the level of technical support available from the supplier to help machine builders choose, specify, configure, and order the modules they need. Choosing a linear module supplier with easy-to-use, step-by-step online sizing and configuration tools can help machine designers quickly configure and order the right modules when needed. Some companies also enable selection and sizing for the mechanics, motor, and drive combination with a single tool. When direct help is required, it also makes sense to work with linear module suppliers who have engineering staff with deep backgrounds in linear motion technologies and applications. In many cases, when machine builders are unsure about specific sizing and performance requirements of their applications, these experts will have solved those kinds of challenges in the past.

Mechanical 5-22_Vs2.LL.MS.indd 67

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Lubrication and sealing considerations No matter how well-designed and engineered, linear modules need proper lubrication throughout their life cycle to maintain precise and stable motion. For the cleanroom conditions common in semiconductor plants, choose precision modules with more advanced LSS standards and LSC cleanroom lubricants. Linear modules require lubrication because they have moving parts — but moving parts can generate tiny airborne particles if the module is not properly sealed (lubricants themselves can also disperse into the air). Look for a precision ball screw nut and linear carriage assembly that’s sealed from both sides with ball screw assembly seals. This design significantly reduces the risk of lubricants escaping outside.

May 2022

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Abrasion resistant | ASTM D466-14

through which the balls or rollers travel, and the flatness of the rail mounting surface. One of the most important areas to assess is the smoothness of ball recirculation inside the runner block as it travels along the rail. Applications at the high end of the accuracy spectrum can be adversely affected by even minute movement of the balls in the recirculation chamber or by just a slight pivoting of the rail system about its axis. Any deflection or clearance reduces accuracy, and any roughness in the recirculation of the balls can cause inaccuracy. To address this issue, leading linear module suppliers incorporate guides that optimize recirculation at crucial transition points, providing smooth motion consistently as the balls circulate in the bearing raceways.

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As the semiconductor industry and the tool OEMs supplying it engage in a major expansion cycle to meet surging demand, achieving critically needed throughput levels shouldn’t require sacrificing quality for speed. The right precision linear module technologies, offering ultraprecise linear motion, vibration-free transport, and tight endpoint accuracy, can play an essential role in meeting these goals.

Applications at the high end of the accuracy spectrum can be adversely affected by even minute movement of the balls in the recirculation chamber or by just a slight pivoting of the rail system about its axis. Any deflection or clearance reduces accuracy, and any roughness in the recirculation of the balls can cause inaccuracy. To address this issue, leading linear module suppliers incorporate guides that optimize the recirculation at crucial transition points.

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F l u i d

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P o w e r

Selecting the right

interchangeable pneumatic actuator Troy Sanders | National Sales Manager | Fabco-Air

Because no two applications are exactly alike, and many actuators exist, reviewing interchangeable designs and standards is a must for selection.

May 2022

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•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• •• ••••••••••••••••••••••••••••••••••••

When your operation calls

for a pneumatic actuator, you’ll find a wide range of products available from various manufacturers. But because no two applications are alike, you must weigh several considerations before selecting and ordering an actuator. This article will discuss the different cylinder types available with a focus on interchangeable actuators and the corresponding standards that ensure you can replace existing cylinders without difficulty. Comparing different types of cylinders As you begin the selection process, you should have a good idea of the characteristics needed in your pneumatic cylinder. Basic considerations should include the size and mounting options as well as any specific features necessary. Here’s a brief overview of four common cylinder styles:

• Compact cylinders. As the name

suggests, compact cylinders are desirable for installations with limited space as well as those with small loads or very small lateral forces acting on the piston rod. Lightweight and repairable compact cylinders have some of the smallest bore sizes available, from 1/4 up to 5-in., and strokes are typically less than 4-in. Compact cylinders have two common styles, including tie rod construction with round or square end caps, and extruded profiles with square bodies. These cylinders are usually mounted via through-holes or tapped threaded holes, or via rear-pivot. Optional features include a choice of male or female rod threads, singleacting versions, magnetic piston for use with sensors, bumpers to reduce noise, double rods, non-rotating types for maintaining a specific orientation, and seals for harsh environmental conditions.

• Round body cylinders. Inexpensive

cylindrical shaped cylinders are designed with small widths for applications with limited installation space or small to medium load requirements. They are typically used for moving, holding, lifting, and pushingtype use cases, or applications with minimal lateral forces acting on the piston rod. Mounting can be Figure 1. achieved through an integrated A comparison of the front-facing nose thread or a most common types of rear pivot 3-in., and strokes pneumatic cylinders. can range from less than 10*Festo ADN Support in. to more than 50-in. They Air Cushions have similar optional features as compact cylinders plus the availability of optional air cushioning to minimize impact forces on internal components. Many round body cylinders are crimped by design and as such, are not repairable. DESIGN WORLD

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• Tie rod cylinders. When you

need a more durable cylinder, tie rod cylinders can meet the requirements thanks to their large integrated piston rod bushings. Tie rod construction accommodates the large bores — up to 12-in. or larger — that provide thousands of pounds of forces. Strokes can typically range from less than 8-in. to more than 100-in. Offered with a variety of mounting styles, repairable tie rod cylinders are designed for medium to heavy loads and applications in which medium lateral forces act on the rod. (If an application presents high lateral forces, we recommend an external guide unit.) Their robust construction makes them suitable for harsh environments, and optional seals and scrapers offer additional protection against contamination.

• Profile cylinders. These cylinders

offer many of the same features and specifications as tie rod cylinders, but their aluminum profile limits bore sizes to approximately 5-in. Profile cylinder construction offers some advantages, including integrated slots to house a sensor without it protruding from the body, a smooth shape and appearance, as well as lower costs. Interchangeability standards Sometimes a machine builder may prefer to replace an actuator with an easier-to-obtain unit or one with more desirable features. To help simplify the transition, the International Organization for Standardization (ISO) and National Fluid Power Association (NFPA) developed standards for cylinder interchangeability. These standards offer the assurance of knowing that a replacement cylinder will be May 2022

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dimensionally compatible across other compliant brands, and machine builders are not bound to one supplier’s products when modifying a machine. That means customers can obtain replacements that have the same form, fit and function as the original, and they can upgrade equipment faster. These standards typically specify: • Piston rod-type cylinders • Standard bore sizes and piston rod diameters • Standard cylinder strokes • Piston rod end thread sizes • All cylinder dimensions that are relevant for customer interfaces, such as length, port thread and mounting dimensions • Accessory dimensions, in some cases Not all actuators are created equal. For example, different manufacturers may use different materials in cylinder construction, or they may offer a different scope of standard features or options for their products. Various manufacturers will also have different price points. You may also encounter de facto industry standards, which typically develop around a product that achieves good market share and is replicated by other manufacturers. Fabco-Air’s Original

Pancake cylinder is one such example. In addition, the company’s varied lineup includes many interchangeable cylinders. Examples include the rugged, high-performance NFPA series available in several versions and 17 mounting styles, and the OEM-NFPA FCQN series of repairable cylinders with OEM pricing. There’s also an ISO 6431 cylinder — the FAQ2R — with a hardanodized aluminum body. If space is a concern, the Pancake II and stainlesssteel F series are also interchangeable. Strategies for solving application challenges Here are some common issues you may need to confront when choosing a pneumatic actuator along with considerations to help meet the challenge: When you need end position cushioning: As a cylinder accelerates across its stroke, it generates energy that, if left undissipated before it reaches its end position, can cause damage to its internal components. Two features can help cushion your cylinder at its end position: elastomer bumpers and air cushions. For low-energy applications with shorter strokes and slow speeds, elastomer bumpers are integrated onto

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Figure 3. Specification options to maintain a specific rod position.

the piston seal or can be positioned separately in sleeve form next to the piston. Air cushions provide protection for applications requiring higher energy to support high speeds or a larger mass. They trap air between the cushion seal and the piston, forcing the air through a small exhaust cap, creating a backpressure that slows down the piston before it reaches the end cap. Air cushions may come with a fixed orifice air pathway, but most are manually adjustable using a screwdriver. A third option — self-adjusting air cushions, patented by Festo — forgoes the pathway and sends the air through tapered slots in the cushion spear, creating optimal cushioning even when application conditions change. When you need maximum force output: Stroke extension creates a higher effective piston surface area, resulting in a higher effective output force, as seen in the following equation: Output force (F) = operating pressure (P) × the piston surface area (A) To increase the cylinder’s output force, each of the variables in the equation can be changed. However, these changes present trade-offs:

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Figure 4. Fabco-Air’s Online Interchange Tool.

• Increase the operating pressure.

While an obvious first choice, this strategy may cause you to hit compressor strength and pressure rating limits. And using a stronger compressor will require more energy. • Increase the piston surface area. Consider this approach when you have static operating pressure. However, increasing the piston surface area may call for a heavier, more robust design as well as additional tie rods to support the larger loads. The increased bore size will also cost more and require more installation space. • Increase the piston surface area by adding more pistons to act on the piston rod. You can, for example, triple your force output by incorporating three pistons on a single rod. This strategy, however, will add length to the cylinder. www.designworldonline.com

When you need to maintain a specific orientation: Some situations do not allow a change in rod orientation between consecutive strokes. If you need to maintain a specific orientation, you have options when specifying your actuator. If your actuator has a small bore, adding a dual, or twin, rod is an easy choice. Since space will be limited, you may need to forgo secondary features like wipers. A non-circular-shaped rod can also prevent unwanted rotation. Choices include a circular rod with flats throughout the piston rod, hex-shaped rods for single-acting cylinders, or square rods for double-acting cylinders. Non-circular rods can be hard to seal, so you may have leakages. A third option — internal guide pins — is attractive because they do not increase the cylinder’s footprint. Note that the pins are not meant to bear loads, so the rod can only handle a limited amount of torque. May 2022

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When you need to withstand a harsh environment or ensure food safety: Any time you specify an actuator, you have to consider its operating environment. We recommend you choose the most robust cylinder possible, based on its orientation and operating environment. Consider whether the cylinder will encounter corrosive materials or harsh chemical agents that may contact the rod and rod seal, and select a robust material like stainless steel to resist these elements. Seals and wipers can help prevent exposure. Food safety and hygienic design should be observed in every aspect of machine design and component selection throughout the food and beverage industry. In food zones, a cylinder can be a breeding ground for bacteria and debris buildup. When specifying a cylinder for a food and beverage environment, follow these best practices: • Look for a self-draining actuator. • Avoid corners or dead spaces. • Avoid fasteners and connectors with threads and crevices. • Specify corrosion-resistant materials.

• •

When it comes to materials, the operating environment along with the cylinder type and size will influence your selection. For example, compact or round body cylinders typically offer units made from Delrin or other polymers. These materials are lightweight, costeffective, and typically resilient to chemicals. Stainless steel is a more robust option, and it is well-suited for acidic applications such as battery production. Stainless steel types 303 and 304 are popular for many applications, while 316 grade stainless steel is desirable for the harshest applications. Fabco-Air’s F-series cylinder is made of 304 stainless steel and features a 303 stainless steel cylinder rod and high-strength aluminum piston, making it well-suited for light-duty applications in food and beverage or packaging equipment. For space-

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Look for FDA NSF-H1-approved lubricants. Make sure the cylinder is well-sealed.

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constrained food equipment, Pancake compact cylinders come in washdownresistant Delrin and stainless steel versions. Don’t go it alone Choosing the right cylinder for your application does not mean you have to go it alone. Assistance is available through online selection tools. For example, Fabco’s online Configure & CAD Tool lets users select a product to configure from the ground up, option by option, or deconstruct a Fabco-Air part they may already have. The website also provides an Interchange Tool for those times when a competitor’s product is not readily available. Simply choose a competitor and enter their part number. You’ll find the Fabco equivalent without the hassle of poring through catalogs and comparing dimensions. Finally, many manufacturers offer sizing software tools to help save time and avoid mistakes. Tools can range from quick and easy basic pneumatic sizing to more sophisticated simulations. Make cylinder selection less difficult Air cylinders come with an abundance of features and options to choose from, and selecting the right unit or choosing the right replacement unit can be difficult. With a proper understanding of the different types of cylinders, interchangeability standards, and the factors to consider when addressing certain objectives, specifying cylinders can be considerably less challenging. Fabco has a wide selection of standard air cylinders and can also provide support and excel at creating custom “specials” for hard-to-satisfy requirements. DW

Fabco-Air fabco-air.com

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better products. better solutions.

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Product World M12 data cables, power cables, and field wireable connectors Automation Direct automationdirect.com/cables New Murrelektronik data cables are high-flex shielded Ethernet Cat5e cables offering various connector styles, including D-coded M12 to M12, M12 to RJ45, RJ45 to RJ45, and M12 to pigtail. These cables are flame-retardant and chemical resistant with a tough TPE (thermoplastic elastomer) jacket for typical industrial applications. A selection of RJ45 IDC field wireable connectors and adapters have also been added to provide custom terminations for specific applications. Supporting Cat5e and Cat6a Ethernet with various cable outlet options, these connectors and adapters are an easy solution for complex field-wiring needs. Another great addition is the M12 L-code power cables, couplers, and adapters. Power cables are available in 14 or 16AWG with current ratings up to 16A. Adapters and couplers provide an easy way to convert the different connection options to match the job at hand.

Round multi-cable bushing system LAPP North America lappusa.com LAPP has introduced its Skintop Multi-M round multi-cable bushing system for applications requiring a high packing density. Up to 30 entry points are available, depending on the Multi-M bushing version, to accept cables, wires, conduits, and pneumatics and media conduits. These metric-style units offer a large, 4-mm clamping range per entry point compared to just 1 to 2 mm typically offered by competitive products. Installation is easy and secure with the Multi-M’s elastic gel technology’s membrane seal. Simply push in the cable, and the gel will hold the cable in place while providing optimal strain relief for the entire cable bundle. The gel does not apply stress to the installed cable, and unused entry points remain sealed.

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Three phase compact energy analyzers Carlo Gavazzi carlogavazzi.com CARLO GAVAZZI announces the launch of its new EM530 and EM540 Three Phase Energy Analyzers. These compact analyzers are a new addition to the company’s range of energy meters and power analyzers, targeted to assist manufacturers and endusers in monitoring and managing escalating energy costs. The EM530 is a Class 0.5S (kWh) analyzer that measures currents up to 10,000 A via 5 A current transformers, and the EM540 is a Class 1 (kWh) analyzer that measures current up to 65 A via direct connection, eliminating the need for current transformers. These three-phase power analyzers can be used for two and three-phase systems, and wild-leg systems. They can measure most relevant instantaneous electrical variables, energy consumption, and harmonic distortion. Both EM530 and EM540 feature high-speed 100 ms serial data refresh rates, making them suitable for load balancing energy storage or EV charging applications. Fast commissioning is possible thanks to an intuitive wizard setup menu, along with instant notification of wiring errors and suggestions for correcting them.

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Product World Inline splicing connectors Wago wago.com With the advantages of the lever-actuated 221 Series, WAGO expands the series with the new 221 Inline Splicing Connector. This connector allows universal conductor connection, a visibly secure conductor contact, and comes with intuitive orange levers for a tool-free wiring experience for solid, stranded, and fine-stranded conductors from 12-20 AWG. Equipped with WAGO’s spring pressure, maintenance-free CAGE CLAMP connection technology, the new Inline connectors offer the option of using additional adapters where multiple poles are required. Whether with or without strain relief, the freedom of a highly modular and flexible connection is possible with a snap-in mounting foot, screw, adhesive, tie-on, or suspended mounting and can be placed on a 15-mm or 35-mm DIN rail.

Quick clamping shaft collars for packaging applications Ruland ruland.com Ruland quick clamping shaft collars require no tools for installation, adjustment, or removal, making them a convenient and efficient choice for various packaging equipment and applications. Designers and operators of packaging machines such as wrappers, bundlers, and cartoners benefit from the faster, tool-less adjustment of quick clamping shaft collars. Ruland offers two types of quick clamping shaft collars: collars with cam levers and collars with clamping levers. Quick clamping shaft collars with cam levers have an integral lever that sits flush with the outside diameter and is finger actuated. The design features a tension-adjustment screw that can tailor axial holding power to application needs. These collars are one-piece clamp-style and require shaft end access to be installed properly. They are best suited for light duty and low rpm applications with frequent change-outs of guide rails or other setup fixturing. Quick clamping shaft collars with clamping lever feature a Ruland manufactured shaft collar combined with an adjustable clamping lever that replaces standard hardware. The final assembly is a shaft collar with a ratcheting handle that can be easily installed, removed, or repositioned without tools. These shaft collars with clamping levers are offered in one and two-piece clamping styles and with outer diameter flats and holes for easier mounting of other components.

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Safety laser scanner SICK sick.com SICK’s newest safety laser scanner, the microScan3 Pro I/O, has an everything-in-one design for seamless, versatile use. Universal I/O integration works with any safety controls, and the intelligent host/guest functionality makes it possible to connect up to three guest scanners to the microScan3 Pro I/O. Additionally, the microScan3 Pro I/O does the work of four standard safety laser scanners with four pairs of OSSD outputs. It also stands out in the microScan3 portfolio with two encoder inputs directly in the safety laser scanner for speed-based case switching. The Pro I/O variant has a 9-m protective field range, safeHDDM scanning technology, 275° scanning angle, and Ethernet connectivity. The addition of I/O connectivity with Ethernet makes for the best of both worlds; the I/O provides universal and versatile use while Ethernet allows for full digitalization functions, like configuration, diagnostics, and measurement data.

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Ad Index Accumold .............................................................................30 Actuonix Motion Devices .............................................. 67 AllMotion ................................................................................ 4 Altech Corporation ........................................ 2,3,21,23,25 Automation24, Inc. ............................................................. 9 AutomationDirect .................................................................1 Bay Associates Wire Technologies, Inc. .......................................................68 binder USA ......................................................................... 34 Bodine Electric Company .............................................. 33 Boker’s, Inc. .......................................................................... 14 Canfield Connector ........................................................... 14 Celestica ................................................................................ 11 CS Hyde Company ........................................................... 72 Del-tron ................................................................................ 53 Digi-Key Electronics .......................................................... 17 Eagle Stainless Tube ................................................35,69 Fabco-Air, Inc. ..................................................................... 13 FESTO ...................................................................................49 igus ........................................................................................54 Interpower ......................................................................45,61 John Evans’ Sons, Inc. ................................................... 77 Keystone Electronics Corp ............................................. 5 Kingway USA .....................................................................63 KNF Neuberger .................................................................26 Master Bond ...................................................................... 67 METCASE ............................................................................ 43 Misumi USA, Inc. .............................................................. BC mk North America, Inc. ................................................... 75 NB Corp ................................................................................56 Novotechnik .................................................Cover Circle,7 PBC Linear ........................................................................... 41 Permco ............................................................................... IBC PI (Physik Instrumente) LP ............................................. 10 Pyramid Inc ......................................................................... 79 ROLEC Enclosures, Inc. ................................................... 19 SIKO .......................................................................................44 Smalley Steel Ring ............................................................ 18 Smart Products .................................................................39 The Lee Company ............................................................. 15 THK America, Inc ..............................................................IFC Trim-Lok ................................................................................ 31 Whittet-Higgins .................................................................29

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