THK is committed to meeting the worldwide demand for linear motion products. We manufacture, assemble, and ship across North America from our location in Hebron, Ohio. We’ve also ramped up our automating processes at existing facilities, including our U.S. manufacturing plant, where over 70% of THK Robotics Components are manufactured. Automated processes at this state-of-the-art facility enable increased production while maintaining the high standard of precision associated with THK products.
To learn more, call us at 1-800-763-5459 or visit www.thk.com.
See us at: Rapid + TCT, Chicago IL, May 2-4 Booth #1634
See us at ATX West, Anaheim CA, Feb. 7 - 9, Booth #4254
Robotics Summit & Expo. Boston MA, May 10-11, Booth #332
Automate, Detroit MI, May 22-25, Booth #5610
THK Manufacturing in Hebron, Ohio
1–2 Week Delivery of Select LM Guides and Actuators
AutomationDirect carries a full line of almost 4,000 sensors from photoelectric to limit switches, proximity, and ultrasonic. Our sensors have the best pricing available with fast FREE shipping on orders over $49*. When it comes to buying sensors, it makes sense to choose AutomationDirect.
NEW! Schmersal Compact Limit Switches
Starting at $37.00 (PS116Z11-L200S200)
Schmersal compact limit switches provide an affordable solution for a range of object detection applications. They are available in a variety of actuator types, and their small size allows easy installation in confined spaces.
• Zinc die-cast switch in a thermoplastic housing
• 2-meter cable or M12 quick disconnect
• Connection exit from bottom or right
• 1 N.O. and 1 N.C. contact on all units
Contrinex Specialty
Inductive Proximity Sensors
Starting at $105.00 (DW-AS-711-M12-967)
• Models for high-temperature applications up to 230°C [446°F]
• Models for high-pressure applications up to 500 bar [7251 psi]
• Models with metal chip immunity eliminate the risk of false switching due to metal debris
• Models DNV-GL certified for maritime use
• IO-Link v1.1 on select models
• Protecting ratings up to IP69K
Photoelectric Sensors
Starting at $76.00 (OPT2133)
• Diffuse with background suppression, retroreflective, retroreflective for transparent objects, and through-beam models
• LO/DO, NO/NC outputs
• IO-Link compatibility
• Visible light spot allows easy target set-up
• IP67/IP68 rated
Linear Transducers
IP69K Rated Photoelectric Sensors
Ultrasonic Sensors
• Snap-action and slow-make/ slow-break contacts
• 45-degree adjustable head
• IP66/67 protection rating
ProSense RW Series
Mini Rectangular
Photoelectric Sensors
Starting at $44.00 (RWRT-LP-0A)
• Small footprint - rectangular
14 x 8 x 28mm
• Diffuse with background suppression, diffuse reflective, retroreflective, through-beam models
• Sensing distances up to 3m
• Axial cable or M8 quick-disconnect models
• Complete overload protection
• IP65/67 protection rating
Limit Switches
Starting at $14.50 (ZS-236-02Z)
• Available in 30mm and 40mm body widths
• Zinc alloy, aluminum or glass-fiber thermoplastic bodies
• 90-degree adjustable head, with levers adjustable to any angle
• Snap-action contacts in a variety of NO/NC configurations
www.automationdirect.com/sensors
At the recent IFPE and CONEXPO shows in Las Vegas, there was plenty to see for fans of mobile hydraulic technology. Hydraulics has long been the technology of choice for many o -highway vehicles thanks to its excellent power density. In the past decade, it’s been increasingly married to electronic controls, and these shows confirmed that trend.
On the machinery side, it was particularly interesting to hear how CASE Construction Equipment and CNH Industrial have been doing — in 2022, they grew an incredible 20% year over year. CASE has been electrifying more product lines to try and build a quieter, more satisfying workplace while also reducing emissions and lowering ownership and operating costs. They unveiled a host of new products at the show, including mini excavators, small articulated loaders, mini track loaders, wheeled excavators, and compact wheel loaders.
In addition, CASE is introducing five new backhoe models, so they now have models from entry-level machines to something being used as a utility workhorse (and ideal primary machines for owner-operators). Backhoes are seeing a huge resurgence in construction these days. That’s actually being driven by the ongoing labor shortages since these small, nimble machines provide plenty of job site flexibility and functionality for customers.
I asked Brad Stemper, CASE Construction’s Director of Product Management, how the company sees the future of hydraulics with the continued move toward electrification.
Stemper told me he thinks there absolutely is a convergence of electric and hydraulic technologies, and that we’ll continue to see a meld of electric, hydraulic, and mechanical components on their machinery. He explained that it really is something that’s a cost/value justification. It comes down to their engineers asking, “Are we able to provide a solution that allows the machine to do the work for a justified cost?”
One of the things that they’re most concerned and involved with now, is the control of the machine. Their focus is managing how much energy is being used by the hydraulic and electrical systems to really maximize how much work can be accomplished. To me, this is a great illustration of what engineers do best — combine older and newer technologies in innovative ways — to increase e ciency and create an exciting new generation of machines. DW
Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com
On Twitter @wtwh_paulheney
Before attending the 2023 AMUG Conference, I was told exciting tales of networking lunches, themed evening parties, friendly competitions, and hands-on workshops. This one-of-akind event was filled with enthusiasm, camaraderie, and a commitment to advancing the additive manufacturing industry.
A common discussion point was that additive technology isn’t here to take over or magically solve all manufacturing problems. It’s an innovative solution for creating parts, next to machining and injection molding, that has advantages and drawbacks and lends itself well to specific applications.
Lightweight components with complex geometries are AM’s breadand-butter. Aerospace, defense, and medical are still the top sectors willing to adopt 3D printing and gain the most value. But collaboration across industries is where innovation really takes o .
Keynote speakers Rob Ducey, technical supervisor at LAIKA Studios, and Nicholas Jacobson, MDes, clinical research faculty at CU Anschutz Medical Campus, showed how an unlikely pair of AM enthusiasts could swap stories
and solve problems together. Their “Collaboration Between an Animator, an Architect, and a Surgeon” discussion demonstrated the vast use cases for 3D printing and how leveraging the right technology can save lives.
In industry, most manufacturers’ current challenges are volume and scale. 3D printing has been traditionally used for prototyping and low-volume production, but there’s a push to integrate AM into highervolume applications. However, experts caution against viewing additive technology as the holy grail or buying 3D printers without thinking it through. As Diana Kalisz, vice president of materials for 3D Systems, explained on stage, there must be a reason and value for 3D printing.
“One of the biggest challenges to moving 3D printing into manufacturing is that you’ve got to have a champion on the customer side willing to stick their neck out and who knows what they need,” said Kalisz.
Customers often approach AM experts with a list of unnecessary
attributes and desires that prompts engineers to go back to the drawing board and understand the problem better.
“Many people have no idea how hard it is to make anything,” said Kalisz.
Yet customers propel the industry every time they speak up about their problems and hint at desired solutions. AM experts who learn from customers build technology around what matters most. Customers keep the conversation going and are encouraged to share more so that the industry and technology can continuously advance.
“Don’t hide your problems,” said Kalisz. “We need to get more knowledge out there so the technology and industry can improve.”
The same can be said for any industry. Instead of shying away or viewing every problem as something that needs to be fixed, we can take a few steps back and learn to embrace failure as a starting point for something new and improved.
DW Rachael Pasini rpasini@wtwhmedia.com
The world’s first wireless IoT sensor node based on Wiegand technology. Left: The two Wiegand Harvesters between the bar magnets (inside the white enclosure) and the transmitter board with microcontroller, temperature sensor, and UWB transmitter module. Right: The receiver station located 60 m away, collecting the data by radio.
UBITO, a member of the FRABA family of technology companies, has announced a development of Wiegand technology as an energy source for smart sensors. After more than two years of e ort at FRABA’s R&D center in Aachen, Germany, a research team has demonstrated a prototype of a wireless sensor powered by Wiegand technology that could support Internet of Things (IoT) networks. The project involved the development of a new Wiegand Harvester capable of capturing enough energy to power the sensor’s electronics package, including a high-e ciency ultra-wide-band radio transmitter.
This achievement (a world first) helps to position Wiegand technology (which collects energy from movements of an external magnetic field) beside established energy harvesting techniques such as solar, piezo, or thermo-electrics as an energy source for sensor nodes in the emerging industrial IoT (also called Industry 4.0).
“Wiegand sensors have been a core component of our encoder products for over 15 years,” said Tobias Best, global head of the UBITO startup. “While this technology has provided a highly reliable way of detecting and recording rotations in flow meters
and multiturn encoders, we have always been looking forward to its wider potential, especially for energy harvesting.”
With this goal in mind, FRABA undertook a development project aimed at improving the energy output from Wiegand devices and demonstrating the possibility of self-powered sensors that could detect events and transmit data wirelessly to an IoT network. The R&D project was conducted by specialists from FRABA and Aachen’s University for Applied Science, with financial support from the German Ministry of Education and Technology. The project team succeeded in producing a new Wiegand Harvester — a device that could generate more than fifty times more energy than commercial Wiegand sensors.
“This level of output makes it possible to dream of energy selfsu cient sensors that can communicate data wirelessly over a significant distance,” said Best.
The team chose a window sensor system for a practical demonstration of an IoT sensor node powered by Wiegand-harvested energy. Two Wiegand harvesters and their associated electronics were mounted on the window, with bar magnets mounted on the frame. The harvesters, made up of a 21 mm long pieces of Wiegand wire surrounded by a copper coil, are the size of an AAA battery (d=7.5 mm). Whenever the window is opened or closed, the harvesters pass the magnets, triggering abrupt magnetic polarity changes in the Wiegand wires. The amount of energy delivered is largely independent of how quickly or slowly the window is moved … a key benefit of Wiegand technology.
The current pulses induced by these polarity reversals generate about 10
microjoules of energy. A key goal had been achieved: the amount of energy captured was su cient to activate a microcontroller and collect a reading from a temperature sensor built into the system. The team added an ultrawide-band (UWB) transmitter module that could transmit 134 bytes of data to a receiving station 60 m away. This lab demonstration, which marks a milestone towards self-su cient Wiegand-based IoT sensor nodes, was presented in April at EnerHarv 2022 in the U.S.
“This is a lab demonstration, not a commercial product. However, by showing the capabilities of a system made up of Wiegand devices and othe-shelf electronic components, we hope to spark interest in the wonderful potential for this technology. With the Industrial IoT projected to grow by a factor of three over the next decade, the future is very exciting,” said Best. DW
UBITO | www.ubito.com
“Wiegand sensors have been a core component of our encoder products for over 15 years,” said Tobias Best, global head of the UBITO startup.
Part two: Scalar and vector VFD control methods
In the first of this two-article series, we considered VFD operation types to satisfy process and motion-control applications. Here we delve deeper into two advanced types of operation.
14 experts on
For the annual Design World Trends issue, we asked industry experts to share their insights into linear-motion trends.
What types of magnets contribute to sustainability?
E orts are underway to develop new magnetic materials that improve sustainability and maintain performance in industrial applications.
SAM increases electro-mechanical sensor reliability
Scanning Acoustic Microscopy testing ensures that oilfield and optical sensors are built without essential material defects.
Follow the whole team on twitter @DesignWorld
EDITORIAL
VP, Editorial Director
Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney
Managing Editor
Mike Santora msantora@wtwhmedia.com @dw_mikesantora
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
Senior Editor
Rachael Pasini rpasini@wtwhmedia.com @WTWH_Rachael
Associate Editor Heather Hall hhall@wtwhmedia.com @wtwh_heathhall
CREATIVE SERVICES
VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics
Senior Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer
Art Director Allison Washko awashko@wtwhmedia.com @wtwh_allison
Senior Graphic Designer
Mariel Evans mevans@wtwhmedia.com @wtwh_mariel
Director, Audience Development
Bruce Sprague bsprague@wtwhmedia.com
WEB DEV / DIGITAL OPERATIONS
Web Development Manager
B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave
Senior Digital Media Manager
Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick
Front End Developer Melissa Annand mannand@wtwhmedia.com
Software Engineer David Bozentka dbozentka@wtwhmedia.com
DIGITAL MARKETING
VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia
Digital Marketing Manager
Taylor Meade tmeade@wtwhmedia.com @WTWH_Taylor
Digital Marketing Coordinator Meagan Konvalin mkonvalin@wtwhmedia.com
Digital Marketing Coordinator
Francesca Barrett fbarrett@wtwhmedia.com
Webinar Coordinator Emira Wininger ewininger@wtwhmedia.com
Webinar Coordinator Dan Santarelli dsantarelli@wtwhmedia.com
FINANCE Controller Brian Korsberg bkorsberg@wtwhmedia.com
Accounts Receivable Specialist
Jamila Milton jmilton@wtwhmedia.com
EVENTS
Events Manager
Jen Osborne josborne@wtwhmedia.com @wtwh_jen
Events Manager
Brittany Belko bbelko@wtwhmedia.com
Event Marketing Specialist
Olivia Zemanek ozemanek@wtwhmedia.com
VIDEO SERVICES
Videographer Garrett McCafferty gmccafferty@wtwhmedia.com
Videographer
Kara Singleton ksingleton@wtwhmedia.com
PRODUCTION SERVICES
Customer Service Manager
Stephanie Hulett shulett@wtwhmedia.com
Customer Service Representative
Tracy Powers tpowers@wtwhmedia.com
Customer Service Representative
JoAnn Martin jmartin@wtwhmedia.com
Customer Service Representative Renee Massey-Linston renee@wtwhmedia.com
Customer Service Representative
Trinidy Longgood tlonggood@wtwhmedia.com
Digital Production Manager
Reggie Hall rhall@wtwhmedia.com
Digital Production Specialist Nicole Johnson njohnson@wtwhmedia.com
Digital Design Manager
Samantha King sking@wtwhmedia.com
Marketing Graphic Designer
Hannah Bragg hbragg@wtwhmedia.com
Digital Production Specialist
Elise Ondak eondak@wtwhmedia.com
With lingering supply chain challenges and uncertain futures, manufacturers and design engineers seek flexible solutions that check all the boxes for harsh environments, compact areas, digital transformation, and built-in safety.
Siemens’ new Sinamics G115D is a compact drive system specifically designed for motor-mounted and wall-mounted horizontal motion control conveyor applications. The drive system includes the motor, drive, and gearbox in one unit with power ranges from 0.5 to 10 hp (0.37 to 7.5 kW) for wall-mount applications and 0.5 to 5 hp (0.37 to 4 kW) for motor-mounted applications.
The drive system is characterized by a high IP protection class (up to IP66/ UL Type 4X) and is suitable for harsh environments and confined areas. It can be operated over a wide temperature range of -22 to 131° F (-30 to 55° C), enabling operation in deep freezing applications. It is also suitable for applications in intralogistics, airports, automotive, and food and beverage industries.
The drive system integrates with the Totally Integrated Automation (TIA) portal, including Startdrive commissioning software or the Sinamics Smart Access Module (SAM) web server for WiFi setup and diagnostics. To prepare for digital transformation and enable cloud-based analysis, it is also integrated into the entire MindConnect portfolio and compatible with MindSphere applications, such as Analyze MyDrives.
Safety is integrated with Profisafe in the form of STO (Safe Torque O ) SIL2, which standardizes and facilitates the certification process. The solution is also equipped with a plug-in connector and flexible connection possibilities. The device is particularly suitable for interaction with Simatic controllers, such as the S7-1200 or ET200, for motion control. DW
Siemens | www.siemens.com
A new laser-based system continuously monitors the surface of flat fabric or steel cord conveyor belts in industrial and mining applications. The system automatically and constantly scans for damage to the belt to reduce the risk of catastrophic belt failure and minimize downtime. It evaluates the belt for cuts, gouges, or large impact damage events and surface adhesion issues. The data is continually analyzed and reported, alerting operators to the exact position and size of any damage, even for di cult-to-access conveyors.
The Conti SurfaceProtect system from Continental provides an early warning when belt maintenance or replacement will be required. This
allows for planned, orderly belt service, which is faster and less costly than repairing belts after a catastrophic failure.
“With the Conti SurfaceProtect system, industrial and mining belt conveying applications can be monitored on a constant basis, reducing the need for manual reviews of the belt condition,” said Anthony DiGiacobbe, communications manager for North America at Continental. “The belt profile information can be used to determine the remaining life of the belt and identify the exact location and severity of wear and damage. The system is especially useful in applications where conveyor belts are di cult to access or
inspect, allowing for remote examinations of the belt condition. By monitoring over the entire belt life cycle, operators can maximize belt life.”
The top cover monitoring unit projects a laser line on the running conveyor belt surface. An optical sensor records the shape and position of the laser line to create a digital map of the belt cover surface topography. This digital profile is analyzed in real time with user-defined thresholds for damage detection. The software reports on large impact defects, slits, cuts, gouge events, edge damage, misalignment, splice surface control, and abnormal abrasion.
The bottom cover monitoring unit provides overall belt shape monitoring and optical monitoring for longitudinal belt rips without the need for rip detection inserts in the belt. The bottom unit includes automatic alarm and belt stop functions. DW
Lead frames are used in the semiconductor assembly process. They are essentially thin layers of metal that connect the wiring from tiny electrical terminals on the semiconductor surface to the large-scale circuitry on electrical devices and circuit boards. In lead frame design, one size does not always fit all, and very often, demand is for customized features, designs that enhance electrical and thermal properties, and specific cycle times.
The micrometal Group has developed a next-generation photo-chemical etching (PCE) process well-suited for lead frame production. The process allows manufacturers to make innovatively designed lead frames with tight tolerances repeatably and accurately concerning miniaturization and weight-saving trends.
“We etch simple or sometimes more complex lead frames from metal and alloys that demonstrate a very low expansion
rate at room temperature. These low thermal expansion alloys have found use in modern applications which require joining metal to glass or ceramics and preventing associated problems within the joint area,” said Jochen Kern, head of sales and marketing at the micrometal Etching Group.
Lead frames can be highly complex and fragile. In many instances, geometric complexity, exacting tolerances, and precision requirements limit the technology capable of producing certain lead frames. When stamping lead frames, complex designs often require complex mold tools, which increases costs and lead times.
PCE is agnostic to the geometry and tool complexity. It can produce lead frames with tighter tolerances and finer detail than stamping, minimal to no metal degradation and deformation, and little to no likelihood of burrs or defects. Failure rates are minute, and unlike stamping, every lead
frame produced is absolutely flat, which is a vital prerequisite.
“micrometal’s unique process can achieve dimensional tolerances as low as ±0.005 mm, small feature sizes of 25 microns, a minimum hole diameter of 80% of the material thickness, and single-digit micron tolerances repeatably. Compare this with traditional chemical etching, which can only achieve the smallest feature size of 100 microns, and the smallest hole diameter is a factor of 1 to 2 when compared to material thickness. Our PCE process opens up numerous impossible design opportunities when manufacturing lead frames,” said Kern.
micrometal’s tight tolerance manufacturing processes are appropriate for numerous lead frame applications and ideally suited to high lead/pin count and ultra-fine pitch lead frame manufacture in high volumes DW
Micrometal | www.micrometal.de
New ultra-compact linear modules position small masses accurately and economically, thus paving the way to electrification.
Bosch Rexroth has a portfolio of small-handling linear axes and recently added new Small Modules Screw Driven (SMS) linear modules with an ultra-compact range and ball screw assembly. These linear axes are suitable for handling cost-sensitive small parts and are an alternative to complex pneumatic solutions. They can position small masses in a wide range of applications with low to medium dynamics, including the consumer goods and packaging industry, semiconductor and battery production, 3D printing, automotive, and medical technology.
The low-profile and light linear modules allow economical electrification with high repeatability of up to ± 0.005 mm. Design engineers can select from five predefined sizes from 30 to 120 mm and optional attachment sets for motors and drive controllers from various manufacturers.
The electromechanical axes have a compact, low-profile aluminum design with integrated precision guideways. A magnetically fixed steel cover strip protects the components inside. The product range includes five tailored module sizes from 30 to 120 mm for travel ranges up to 1,200 mm. DW
Bosch Rexrothwww.boschrexroth.com
The proportional pressure regulator VPPM controls the air volume on the input side of the DPP piston pump.
A critical step in folding box manufacturing is the highly precise gluing of the box blanks. Folding-gluing machines process box blanks from a die cutter by folding and gluing them into finished folding boxes. Afterward, the folding boxes are assembled and filled by automatic packing machines. Many boxes must be folded in and across the machine’s direction of movement before the glue is applied to ensure that the boxes can be put together e ortlessly later.
“Applying the right amount of glue in the right place is no easy task,” said Marco Ahler, technical director at Baumer hhs, a German manufacturer of industrial adhesive application systems.
Gluing machines achieve speeds of more than 700 meters per minute and can glue well more than 40,000 folding boxes per hour, depending on the packaging size. Baumer hhs builds systems that apply glue with millimeter accuracy and without contacting the blank, even at high production speeds. Its modular systems include a high-pressure adhesive supply, fast-switching electromagnetic application valves, and a control unit.
The centerpiece of this gluing process is the DPP-8 doublepiston pump, which must provide a specific fluid pressure to apply the adhesive accurately. Each piston takes in compressed air on the upward stroke and displaces liquid from the glue cylinder on the downward stroke.
“You could call it a two-cylinder engine with the performance of an eight-cylinder,” said Ahler.
The DPP-8 piston pump regulates the air input pressure to set the required adhesive fluid pressure. The precise proportional pressure regulator VPPM from Festo controls the air volume on the input side. The VPPM has a linear pressure regulation range between 0.06 and 6 bar. For a delivery pump with a transmission ratio of 8:1, this means a reliable fluid pressure regulation range of 8 to 40 bar. The regulation starts with small increments to the control quality at 2 bar.
WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.
Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.
The advantage of regulating the input pressure instead of fluid pressure on the output side is that only the amount of compressed air required for the actual operating conditions is consumed. Compressed air consumption is proportional to the material pressure, so operational costs can be reduced if the maximum delivery pressure is rarely required.
The air pressure on the input side is converted into a largely fluctuation-free fluid pressure in accordance with the transmission ratio of the delivery pump. This enables the delivery volume to be quickly regulated and adjusted. A pressure sensor in the pump measures the fluid pressure on the output side. A closed-loop pump control circuit ensures the pressure is automatically
adjusted if the actual pressure deviates from the target pressure. This is particularly advantageous when the fluid is delivered intermittently. Tests show that when a delivery valve is opened, the spontaneous drop in the pump is 25 to 50% less than with a pump with a downstream material pressure regulator, while the drop is intercepted much faster and more reliably by the closed-loop control. In addition, critical fluids are subjected to less stress and largely retain their original consistency. DW
Festo
www.festo.com
Lightweight mobile robots improve production speed and e ciency by reducing energy consumption and recharging time. The nimble maneuverability of lightweight robots is also a huge advantage for tasks that require frequent turning or have limited space.
As such, Techman Robot released a new lightweight high-payload AI cobot, the TM20 robotic arm. At only 32.8 kg, the cobot carries up to 20 kg and can reach up to 1,300 mm with six rotation joints. Despite being light, the cobot’s high payload capacity makes it suitable for heavy-duty AMR applications. It can also be used for automotive, semiconductors, and secondary packaging for food, plastics, or machine tools.
The built-in smart vision compensates for positioning errors and ensures precision in fast pick-and-place tasks without additional visual or positional monitoring. This reduces integration time and costs. Moreover, Techman’s exclusive TM Landmark capability allows real-time updating of the relative position of the arm and key points in the environment, keeping the robot safely oriented in 3D space regardless of its position.
This robot’s versatility is suitable for high-volume packaging and palletizing, massive pick-and-place jobs, material handling, and heavy machine tending. Specific applications where the TM20 excels include semiconductor backend processes that require a large amount of manual loading, unloading, lifting of wafer boxes weighing more than 10 kg, and the retrieval and transfer of medical equipment and drugs.
DW Techman Robot www.tm-robot.comWHAT DO YOU THINK?
In the world of cobots, the spectrum of human-motion sequences poses a safety challenge. A robot’s power and power-limited mode is usually designed for the permissible force values of arms and hands. The robot must also avoid contact with sensitive body regions, such as the face, skull, and forehead, and therefore must stop near personnel.
safeVisionary2, a new 3D time-of-flight (ToF) camera with Performance Level c (PL c) from Sick, detects a person’s upper body and upper limbs so that safety distances can be reduced around the cobot. The sensor enables extended protection of the robot work area at human-head height such that a robot standstill is only necessary when a person’s head moves into the work area.
The compact 3D camera helps increase productivity and provides precise 3D measurement data to enhance automation. In addition to human safety, it can detect empty pallets for object localization and measurement, and it is especially e ective for AMRs for autonomous and intelligent navigation.
With safeVisionary2, obstacles above the scanning field level of a safety laser scanner are also reliably detected in the direction of travel, preventing collisions. In contrast to 2D anticollision solutions, safeVisionary2 can automatically restart in many cases.
Side protection safety is also increased during turning and pivoting maneuvers after loading and unloading. The 3D environmental information can also be used in mobile applications for precise localization and navigation via Gigabit Ethernet.
Mobile service robots used in unstructured environments require careful risk assessments. Obstacles such as stairs or ramps can pose potential crash risks for the robot. In addition to track protection, safeVisionary2 also enables cli detection and contour-based navigation. DW
GuardLink 2.0 from Rockwell Automation is a serially connected safety input solution designed to reduce downtime and installation costs. GuardLink 2.0 o ers advanced diagnostics through the new Allen-Bradley 432ES GuardLink EtherNet/IP On-Machine Interface or a combination of Rockwell Automation’s Dual GuardLink Relay and EtherNet/IP Interface. GuardLink 2.0 protocol also enables safety-rated control device status reporting and automatic diagnostic reporting to an HMI using CIP Safety over EtherNet/IP.
The new 432ES GuardLink EtherNet/IP interface allows design engineers to connect up to 96 safety devices via three independent safety channels. The interface can cascade power to additional interfaces and keep track of the timing and frequency of events to improve maintenance and create process e ciencies. The 432ES supports linear, star, and Device Level Ring (DLR) topologies while meeting the highest safety ratings up to SIL 3, Cat 4 PLe. DW
Rockwell Automation
www.rockwellautomation.com
The recently released Zero-Max IP65-Rated Crown Gear Drives are used in the OpenAire Vertical Opening Glass Wall System for a swimming pool enclosure on a Cruise Ship. This retractable Wall System provides a naturally ventilated, healthy, safe, and energy-e cient environment made possible with a mechanical drive system using the IP65-Rated Crown Right Angle Gear Drives.
OpenAire is a designer, manufacturer, and installer of custom glass wall panels, retractable roof structures, and operable skylights. There are many di erent applications for this OpenAire window system, including use as a retractable enclosure for patio restaurants.
Retractable vertical opening glass wall systems promote the extensive use of daylight and natural ventilation. Not only do they give access to an outdoor experience, but these systems also save significant energy. As a result, these glass wall systems
Providing this level of performance is assured with the high precision gears, quality materials, and construction of the IP65-Rated Crown Gear Drive. These drives feature spiral bevel gears, having curved teeth that always maintain tooth contact, which are designed to reduce vibration and noise during operation.
The Zero-Max IP65 Right Angle Gear Drive is ideal for the OpenAire retractable glass wall system application. Connected to the mechanical system lead screws, the Right Angle Gear Drives handle the torque and shaft speed requirements of the application.
OpenAire Vertical Glass Wall System in a swimming pool enclosure on a Cruise Ship uses Zero-Max IP65-Rated Crown Gear Drives ensuring smooth open and closure operation.
may be operated frequently and must provide e cient, trouble-free operation.
To ensure this, OpenAire uses a well-planned mechanical system incorporating IP65-Rated Zero-Max Crown Right Angle Gear Drives. These drives deliver dependable and economical transfer of speed and power in an e cient and compact design with quiet operation. In congregate settings, quiet and smooth operating mechanical features are crucial.
The IP65-Rated Crown Gear Drive has a nickel-plated aluminum housing, stainless-steel shafts, and purpose-built shaft seals. It provides an added level of protection to withstand conditions such as frequent washdowns, corrosive elements, and outdoor installations that can include temperature extremes, sunlight, rain, humidity, and condensation. This fully enclosed design prevents contamination from water, chemicals, and debris, allowing it to hold up to harsher operating environments.
of as water,
Another important feature is that the IP65-Rated Crown Gear Drives are pre-lubricated, making them a “Lubedfor-Life” design o ering maintenancefree operation for the life of the product. Most importantly, these Zero-Max Crown Gear Drives have been tested by an independent laboratory to obtain the IP65 Certification for ingress protection against dirt and water.
One particular OpenAire project for a patio restaurant consists of 17 Vertical-Opening Glass Wall Systems
incorporating the IP65 Crown Gear Drives. Each system has three, two-inch thick panels and measures 12-ft high by 15-ft wide. In addition, retractable roof panels are incorporated into this OpenAire patio design. The overall system makes for a true open-air patio restaurant, providing the maximum “open air” experience, which can be quickly closed up tight at the touch of a button during cooler or rainy days.
Panels
The bottom window panel is stationary. The upper window panel is directly connected to the lead screws on either side of it. The window panels stack side-by-side next to the stationary panel as the upper window panels are lowered, forming a railing when the windows are opened. When the top panel is lowered, the middle panel is also lowered until it comes to rest alongside the bottom stationary panel. Once the middle panel comes to rest, the upper panel is lowered further, sliding alongside the middle panel until it reaches its fully lowered position. The
three windows, when stacked sided-by-side, only require 6 inches of total thickness.
For each glass window system, two IP65-Rated Crown Right Angle Gear Drives are enclosed in a header beam above the window mechanism. A Crown Gear Drive is positioned on each side of the window system, with both Crown Gear Drives interconnected by an intermediate shaft, allowing one motor to drive the system. Included are vertical lead screws on both sides of the window system, which are connected to the output shafts of the Crown Gears to run the windows up and down.
The intermediate shaft connecting the pair of Crown Gear Drives synchronizes the assembly so that each side of the window panel lifts at an even rate, providing a smooth vertical lifting and lowering of the window panels. The framework has all the mechanical and electrical components concealed within the framework, making for a very clean, contemporary exterior design. DW
Emulate3D can integrate virtual reality (VR) features so that detailed safety checks or danger predictions can be completed in virtual environments in addition to checking on machines running PLC programs.
Hirata Corporation is an OEM machine builder based in Kumamoto, Japan. It is active in automotive and semi-conductor industries and end-toend machine supply from design and engineering through commissioning.
2019: Hirata’s challenge
It seemed that everything was on track, but program debugging and position education had been a headache at Hirata for a long time. The program itself can be checked even before machines are built, but debugging can be done only after machines are built and running the program. Then the teaching follows. Typically, teaching is done through HMI — inputting the position of each axis of the robots. It must be done with a great deal of care to ensure precise position input. Therefore, it was only natural for Hirata
to think, “What if we can start the debug process without waiting for the machine to be built?” At the same time, commissioning is another challenge for Hirata. Especially when it comes to overseas projects, people at the site had to wait several weeks (or even months, depending on the destination) before machines arrived at a site. They then wondered if there was anything they could do during shipping and freight time.
Hirata then encountered Emulate3D software from Rockwell Automation. Hirata and
Rockwell Automation had a business relationship in component supply with programmable logic controllers (PLC) or servo products, especially for machines shipped to the United States. In January 2019, Rockwell Automation acquired Emulate3D for its expanding digital engineering capabilities and started the sales promotion of the digital tool. At that time, o ine teaching through simulation software was becoming popular, but simulation could not test the program, so debugging could not be done with simulation tools. Emulation allows engineers to run the program on the virtual environment with the 3D computer-aided design (CAD) objects so engineers can start to debug the program without waiting for the machine to be built. Hirata was impressed by the first demo done by technical consultants from Rockwell Automation Japan.
It was June 2019 when the Rockwell Automation Japan team conducted an Emulate3D demo in front of Hirata engineers. The Hirata team
was impressed by the presentation and demo but felt the need for technical verification as well. Then the collaborative proof-of-concept journey started. Hirata gave some technical information to Rockwell Automation consultants to let them set up a more tailored demo. Rockwell Automation consultants returned to Hirata with a tailored demo and gave Hirata additional inputs for more rounds of setup.
After the rounds of communication back and forth for several months, Hirata engineers became more confident in the tool and turned to management for budget approval. Mr. Shimizu in the #2 Kumamoto Business Division, #2 Business Unit, referenced that moment by saying, “We’ve encountered multiple simulation solutions that resulted in a smallscale deployment. But Emulate3D was di erent. Once we obtained the demo program developed by Rockwell Automation with our real 3D CAD data, we were impressed by its quality and could feel the potential in various use cases.”
After the budget was approved, dedicated engineers were assigned in January 2020, and intensive hands-on training began by Rockwell Automation technical consultants. Months of training enabled dedicated engineers to fully use the emulation tool and resulted in strong outcomes within some actual projects. This success led to the new “Digital Engineering team” under Mr. Kusuguchi, general manager’s division, including four new engineers. The next year in April 2021, #3 Business Unit, the next business unit to Mr. Kusuguchi’s organization, established the “3D Design Promotion team” which included four engineers. Now, Emulate3D has been expanded with a 30% reduction in engineering time and a 70% increase in e ciency and debugging work.
Hirata Corporation is an OEM machine builder based in Kumamoto, Japan. Founded in 1951, Hirata strives to have a wide ranging customer base in more than 40 countries by leveraging its own developed modules.
Emulate3D can integrate virtual reality (VR) features so that detailed safety checks or danger predictions can be completed in virtual environments in addition to checking on machines running PLC programs. This can also be used for virtual commissioning, which enables Hirata to reduce the needed engineer dispatch and commissioning time. Additionally, troubleshooting or factory acceptance testing (FAT) can be done with virtual emulating machine operations. In fact, according to Hirata, due to the global pandemic, more and more remote FAT/troubleshooting requests are being received. It is a huge benefit, not only for Hirata, but also for end users to change their business behaviors from real/in-person to remote. Furthermore, combining Emulate3D with VR can help realize the virtual training environments so that site workers can complete operation training while waiting for oceanic transportation. This virtual training is also applicable for newly hired employees seeking training. DW
Rockwell Automation rockwellautomation.com
can
Since Greg Kordalski founded KES Machine LLC, the business has been helping engineering and manufacturing companies maximize productivity and minimize downtime with its accredited calibration and repair services. KES Machine LLC’s technicians help machinists solve geometry errors, lead screw errors, and repeatability concerns.
While the company initially focused on CNC service work, in 2008, it invested in its first Renishaw ML10 laser system and began developing its calibration services. In 2019, KES opened a Polish subsidiary to support manufacturers there. “Since I was
• Managing Editor
“Renishaw o ers a range of calibration solutions for improved machine performance, increased machine up-time, and preventative maintenance schedules,” explained Je rey Seliga, Marketing Manager at Renishaw Inc.
born in Poland, I visit quite frequently, so this is why I chose Poland as the first country on the European continent,” explained Kordalski. In 2016, KES obtained ISO 17025 certification and became a fully capable calibration service company.
“ISO 17025 accreditation demonstrates our capabilities to our customers,” said Kordalski. “Showing that we follow industry requirements for testing and calibration enables us to provide a value-added service to engineers and ensures all our equipment is up-to-date and our technicians o er the best service to customers.”
Component quality is dependent on machine performance. Without understanding a machine’s error profile, it is impossible to have confidence that components will fall within specifications during manufacture. KES works with highprecision industries, such as aerospace, defense, and medical. This led KES to investigate volumetric machine tool compensation and explore the systems available on the market.
“In the past few years, we have seen manufacturers invest in more automated machining systems,” said Kordalski. “Probes and calibration are key to the success of these systems, so we’ve seen a growing interest in the annual calibration of equipment and machines using probing systems.”
Krzysztor Siergiejczyk, Head of KES Machine in Poland, explained, “After having a good experience working with Renishaw in the USA, when opening the Polish subsidiary, we quickly established contact with Renishaw Poland. We were the first company in Poland to adopt Renishaw’s XM-60 and we have a big ambition to take care of customers within the European market over the upcoming years.”
With over 1,400 standard products to choose from, you can count on the engineers at Bodine to help you find a gearmotor with the right torque, power and speed for your application. We’ll get your design moving. Contact us today!
vertical straightness at the same time it takes to collect a single measurement using conventional techniques.”
When he founded KES, Kordalski purchased his first ML10 laser and QC10 ballbar from Renishaw. Since then, KES has purchased a range of Renishaw equipment, including XL-80 laser systems, XR20 rotary calibrators, o -axis rotary software, and QC20 ballbar systems (pictured here).
Renishaw has had a long-standing relationship with KES. As Kordalski explained: “When Renishaw comes out with a new product, it sparks our interest. As a result, we’ve worked with Renishaw for many years.”
When he founded KES, Kordalski purchased his first ML10 laser and QC10 ballbar from Renishaw. Since then, KES has purchased a range of Renishaw equipment, including XL-80 laser systems, XR20 rotary calibrators, o -axis rotary software, and QC20 ballbar systems. The company is also an advocate of Renishaw’s machine tool probes, tool setters, and broken tool detection systems, and is a full-service representative of Renishaw products.
KES Machine LLC ultimately selected Renishaw’s XM-60 and XM-600 multi-axis calibrators. KES can use the equipment on both CNC machine tools and CMMs to perform volumetric compensation. This laser measurement system can measure errors in six degrees of freedom along a linear axis,
simultaneously from a single setup. It provides a powerful diagnostic tool to measure all geometric errors in the axis from a single capture.
Additionally, the XM-600 multiaxis calibrator is designed with extra functionality, enabling it to communicate directly with Renishaw’s UCC controllers and is compatible with Renishaw’s CARTO software suite. These features make it a good calibration solution for manufacturing facilities using both machine tools and CMMs, such as KES.
“Renishaw o ers a range of calibration solutions for improved machine performance, increased machine up-time, and preventative maintenance schedules,” explained Je rey Seliga, Marketing Manager at Renishaw Inc. “By using the XM-60, the KES team can collect a range of measurements, including the pitch, yaw, roll, linear positioning, horizontal, and
“I would say that about 80% of our equipment is now Renishaw,” explained Kordalski. “Although we still investigate other brand systems, ultimately, we are looking for the best technology, and Renishaw typically wins. For example, we recently invested in the XK10 alignment laser system. While it’s still a new product for us, we’ve already seen its benefits when testing spindle direction or when installing machines, to help adjust straightness and squareness.”
KES Machine used the XM600 to implement CNC volumetric compensation and will soon o er CMM calibration to its customers and support for Renishaw CMM hardware, as the XM-600 directly interfaces with Renishaw UCC controllers. For years, before the release of the XM60 and XM-600, KES typically used multiple pieces of di erent equipment to measure linear positioning, pitch, yaw, and roll. The XM-60 manages this process with one pass and will include horizontal and vertical straightness over the completed travel. Measurements that used to take two to four hours are now reduced to under 30 minutes, depending on the length of the machine axis.
The equipment can also be used to diagnose machine errors. KES uses CARTO software, along with its own custom software, to simplify its processes. The KES team uses the “cut and paste” feature in CARTO software to help the compensation process and saves time using the report builder feature. DW Renishaw |
FLOW-3D AM simulates powder-based DED process parameters, such as powder feed rate, laser power, and scan speed.
| Courtesy of Flow Science
Melt pool flow dynamics is a critical and often overlooked aspect of the metal 3D printing process. Changes in heat input, powder, and alloy properties directly impact the melt pool evolution, a ecting a part’s quality and mechanical properties. Since the melting process occurs at the microscale in space and time, it is quite di cult to do in-situ measurement and characterization.
Computational fluid dynamics (CFD) simulation provides a detailed view of the physical phenomena during 3D printing. It directly models the melt pool fluid dynamics as the laser interacts with the metal powder. CFD software provides a level of control and accuracy that cannot be replicated by measurement or lower-fidelity models.
More than 40 years ago, C.W. Hirt, the founder of Flow Science, established a computational technique for tracking the evolution of an interface between two fluids with drastically di erent densities — such as the free surface between air and water. This technique, called the Volume of Fluid (VOF) method, is the foundation of Hirt’s commercial CFD software, FLOW-3D. Since its original development, FLOW-3D and the VOF method have been used in research and design processes for a range of applications, such as dam spillways, high-pressure die castings, and inkjet microfluidics.
In the last decade, Flow Science engineers applied the VOF method to melt pool dynamics in the metal AM industry. The result was FLOW-3D AM, which combines the fluid solver in FLOW-3D with laser physics and powder dynamics to model the full process of powder settling,
FLOW-3D AM simulates powder settling and spreading on an LPBF build plate, accounting for particle collisions, powder size distribution, and geometry e ects of the blade or roller.
| Courtesy of Flow Science
spreading, melting, and solidification in laser powder bed fusion (LPBF) and directed energy deposition (DED), along with the dynamics of non-laser-based AM processes, such as binder jetting and material extrusion.
In LPBF, metal powder is spread over a build plate and subsequently melted by a laser beam into a specific pattern. The process is repeated hundreds or thousands of times to build a part layer by layer. Using the discrete element method (DEM), engineers can simulate the powder settling and spreading process in detail by accounting for the particle collisions, powder size distribution, and geometry e ects of the blade or roller that spreads and packs the powder layer.
Once the powder bed is generated, a CFD simulation models the lasermaterial interaction during the melting process. To do this accurately, engineers must account for the large body of relevant physics, including the viscosity of molten metal, surface tension, heat transfer, laser reflection and absorption, phase change, recoil pressure, and solidification, among others. Clearly, there is a lot going on.
The norm in metal additive manufacturing is to use thermomechanical simulations to predict part-scale stresses and distortions. While useful, these models are lower fidelity in nature and cannot accurately predict track geometry and defects, such as keyholing, balling, porosity, and lack of fusion, which are all related to the evolution of the melt pool. Process parameters must be
optimized to reduce the formation of defects and provide a low scrap rate for additively manufactured parts to compete in the industry.
By adjusting the process input parameters, such as laser power and speed, scan path, beam shape, and powder size distribution, in the software, researchers and engineers receive deeper insights into the physical phenomena at play behind the process issues, which can then drive the development of process parameter windows.
Keep in mind that high-fidelity modeling is limited by its high computational cost. The large number of physics being solved for is computationally intensive, meaning that simulations are limited to the mesoscale — track lengths on the order of millimeters and singledigit layers. The software also does not directly solve for stress and microstructure formation, although information can be gained about both using the accurate thermal data from a simulation in other models.
Despite these limitations, the value of the information obtained using high-fidelity modeling tools like CFD is an order of magnitude higher than that gained from lower-fidelity, partscale tools. But since the AM process involves multiple scales, process design must rely on multiple tools. As of now, there is no modeling tool that
can do everything engineers need, so integration is key. Each company or university uses di erent measurement, simulation, and in-situ process tools, and it is imperative that these tools can communicate with each other.
“The overwhelming number of process parameters in AM calls for automated optimization tools based on physics-driven simulations,” said Marcin Serdeczny, Ph.D., CFD engineer at Flow Science. “To drastically reduce the cost and time of new developments, we can no longer rely on a trial-anderror experimental approach. Tools like FLOW-3D AM are exactly a step in that direction.”
As the metal 3D printing industry advances, high-fidelity simulation tools will play an even greater role in manufacturing. With continued advancements in computing power, material science, and machine learning, the accuracy and capabilities of these simulation tools will only improve. DW
FLOW-3D www.flow3d.com
Over the past decade, industrial digital transformation has enabled organizations to leverage the growth of data and connectivity to improve operations and engineering. Connecting Industrial Internet of Things (IIoT) devices and embedding tools, such as digital twins, across the IT/OT infrastructure allows deep data to be gathered, analyzed and contextualized to add meaning and value, providing complete and early visibility across an enterprise.
Having this visibility empowers engineers to make informed decisions that can help lower operational risks, respond faster to changes, and operate more e ciently. It can also reduce the time and e ort needed to deploy engineering solutions by creating new means to execute activities virtually.
As designers and customers are aware, time is costly when dealing with the construction and commissioning of equipment. Often, much of the investment comes directly from facility commissioning. Technologies leveraging digital twins can save organizations up to 40% in time compared to conventional methods
through the application of a practice called virtual commissioning. While virtual commissioning is not a new capability, we are seeing a wider adoption of it in recent years.
Before diving deeper into virtual commissioning, it’s important to first understand digital twins and their industry adoption. A digital twin is a superior, virtual representation of a physical entity or system across its lifecycle using comprehensive data, analytics, simulation,
and emulations. They can help virtualize physical designs, products, and processes, resulting in faster prototypes, more agile processes through simulations, and the ability to spot design issues early in the cycle, minimizing rework and accelerating cycle time. This means systems or processes can be tested and validated, and potential failures identified, before they even exist in the real world. Digital twin has many di erent applications in industrial manufacturing, including virtual commissioning.
The global digital twin market value is set to surpass $53.5 billion by 2028, exhibiting a CAGR of 42.1% during the forecast period 2022-2028. Therefore, it comes as no surprise that many organizations, from mining and manufacturing to healthcare, are adopting digital twin strategies as part of their digital transformation roadmaps. The application of digital twin spans the value chain and can be used for design, system simulation, integration, monitoring, training, and maintenance across industries.
While virtual modeling has commonly been used for product design in industries like aerospace and
auto, the wider adoption of modeling in operations used for the testing of engineering equipment is relatively new.
Applied to industrial enterprises, digital twins enable engineering teams to virtually perform activities that have conventionally been done through empirical calculations or physical work. This includes design validation, throughput analysis, and equipment testing. Doing this work manually can be labor intensive and often inaccurate.
There are considerable investments being made in digital twin technology to improve operations throughout the lifecycle of a facility. This is where virtual commissioning comes in. It can bridge traditional and virtual development by leveraging the technology to model and emulate real equipment and engineering systems.
As industrial organizations consider expanding facilities or constructing new ones, it’s critical that every step in the design and deployment of these projects is executed smoothly, e ciently, and cost-e ectively to ensure operations begin and ROI is achieved
Scheduled orders allow customers to lock in a price and have their North American and international cord sets shipped whenever they need them year-round. Scheduled orders allow customers to set predetermined schedules, such as ordering 1,000 cords and having 250 delivered quarterly or monthly—how many you need when you need them.
Our cord sets ship straight from the factory. Want the cords hanked, coiled, tied, bagged and boxed? Need 1-D or QR barcodes for easier warehousing? Customize lengths and colors for countryspecific cords.
A pathway to 40% time reduction through virtual commissioning.
as quickly as possible. Delays must be minimized or, ideally, eliminated completely.
The digital replica of the physical entity allows engineers to design, test, and virtually validate their work. This requires considerably less manual e ort and, in turn, less time. Organizations have also seen benefits such as increased safety, enhanced agility, and lower cost of design changes compared to legacy physical commissioning.
By using digital twins, engineering teams are able to test any number of system elements, including Programable Logic Controller (PLC) logic and code, software integration, and user interfaces.
Creating digital twins requires that aspects of the engineering system be accurately and virtually replicated. Typically, this involves the modeling of mechatronics systems, including elements such as motors, actuators, and conveyors, all connected to a controller (usually a PLC). The digital twin for system engineering replication includes two aspects:
• System modeling using CAD
• Controller code
During program testing, the virtual system is integrated with either a physical or simulated controller. It’s at this stage that the benefits of virtual commissioning are realized. The ability to test the integration of controller code with the physical system in a virtual environment enables an organization to test various code configurations, create and analyze various failure modes, and conduct comprehensive throughput analysis. ‘What if’ scenarios can be run, and potential program issues or bugs can be identified and triaged before expensive equipment fabrication and physical testing is started. Engineers can also make improvements to the products at this stage, based on the simulated interaction between the product and the equipment.
This kind of virtual testing leads to a valuable reduction in physical testing time, risk, and uncertainty by converting a sizable
portion of that physical testing to be finished virtually, prior to the fabrication of equipment. It is traditionally executed on the shop floor. At this point however, making design changes is significantly restricted and significantly more expensive.
With the increase in model fidelity, more processes and critical elements can be factored in within virtual testing. Typically, an organization will move towards a convergence of five di erent types of digital twins to accelerate the commissioning of new equipment and processes.
1. Geometric Design: Digital representation of physical assets (3D model of a product cell or line)
2. Physical Dynamics: Digital representation of physical processes and dynamics (details around how equipment physically moves, where the constraints are, and the interaction of di erent mechanical components)
3. Programmed Behavior: Digital emulations of logic and animations of physical processes (incorporating physical kinematics of the equipment with software control)
4. Human Interface: Digital representation of the interface between human and equipment (virtual version of an equipment HMI or enhanced methods of interacting with the equipment such as using VR)
5. Analytical Insights: Digital characterization of data, measurements, sensor readings, and telematics of assets or processes (utilizing sensor data to monitor equipment condition and to predict failures)
The development of industrial engineering systems goes through three generalized phases:
1. Planning and Concept: In this initial phase, the work, functions, business
requirements, and selection criteria are defined. Front-end engineering studies are conducted, options are narrowed down, and the first conceptual designs generated.
2. Engineering and Construction: Moving from conceptual to tangible, all the functional and technical requirements are laid out. This phase includes elements such as safety, mechanical, electrical, software, and instrumentation specification, as well as the selection and fabrication of systems and equipment based on the previously defined specifications.
3. Installing and Commissioning: The final stage is the installation and testing of systems against design specifications and pre-defined acceptance criteria to identify any gaps. This phase also includes work done to resolve any issues. This step leads to the performance of site acceptance and final equipment commissioning.
All three phases require the engagement of multiple stakeholders, such as general contractors, subcontractors, and equipment suppliers. Any undiscovered design or development issues in phases one or two can cause substantial problems downstream during the installation and commissioning phases of engineering systems.
After the first two phases, the cost of resolving issues grows exponentially and can be between 200 and 800 times more costly compared to issues addressed in early phases. Running scenarios to troubleshoot software and hardware in the early phases also allows engineers to generate feedback and plan accordingly to avoid these costs later down the road.
Crucially, digital twins can shorten physical testing time during the Installation and Commissioning phase.
By creating a virtual commissioning phase prior to physical testing, teams can perform actual acceptance tests and resolve issues encountered within the specified equipment in short order and with minimal disruption.
We’ve seen first-hand that enterprises that deployed virtual commissioning were able to reduce time to steady-state operations by up to 40% compared to using conventional methods.
By using digital twins to capture the design, engineering, construction, and commissioning elements of a facility expansion, organizations can reduce risk and enable faster ramp up.
Digital twins are one of the technologies at the heart of digital transformation, powered by the digital thread that unifies data across an organization, removing legacy silos and creating a truly connected enterprise. It enables the integration of the internet of things (IoT), artificial intelligence and software analytics to enhance outputs, evolve, and scale with organizational needs. Over time, the digital twin can be leveraged to help realize significant breakthroughs, including generating PLC code or even removing the PLC programming step of the commissioning process entirely.
Virtual commissioning can be leveraged alongside other capabilities of this technology, such as facility layout planning, capacity planning, and operator training. It can even be combined with AI and other forms of advanced technology to perform dynamic system optimization, AI-enabled control, and intelligent model training. As merely one application of digital twin technology, virtual commissioning’s benefits include decreased commissioning times, reduced risk, increased reliability, and lowered costs throughout the manufacturing operations commissioning process. As the technology continues to evolve and incorporate more capabilities, organizations will have to adapt their strategies or risk missing out. DW
Bringing your supply chain back home? Let Interpower worry about manufacturing your cords and cord sets while locking in your price—have your North American and international cord sets delivered on your schedule year-round!
Our cord sets and accessory power systems ship straight from the factory. Want the cords hanked, coiled, tied, bagged and boxed? Need 1-D or QR barcodes for easier warehousing? Customize cord lengths and colors for countryspecific cords configured and ready to use right out of the box!
In recent years, smart mechatronics applications have become increasingly common in various industries. Smart mechatronics refer to the combination of mechanical engineering, electrical engineering, and computer science to create intelligent systems that can interact with the environment and make decisions based on real-time data. This technology has proven to be e ective in improving the e ciency and e ectiveness of many industrial processes. Here’s a look at five applications where smart mechatronics make sense.
Smart mechatronics technology is being applied in a variety of industries, where the benefits include increased efficiency, improved accuracy, and enhanced productivity.
The increasing demand for electric vehicles (EVs) has led to a surge in research and development of smart mechatronics in the battery and EV industry. Smart mechatronics technology is being used to improve
the performance and reliability of battery packs, which is critical for the widespread adoption of EVs. There are a multitude of use cases within battery and EV manufacturing where smart mechatronics are necessary.
Within the EV manufacturing process, assembling battery covers and
windshields requires accurate dispensing of sealants and thermal materials which is done e ciently with a smart dispensing system. Using precise dispensing technology, manufacturers can control the flow rate through the dispensing head along with the cartesian motion profile to create an accurate, repeatable process.
Smart handling or pressing systems can simplify battery production by automating precise steps in production such as picking up battery cells, press fitting the caps on cylindrical cells, or pressing the casing onto the packs themselves, all while providing a continuous feedback loop. In sorting and cell testing, a smart mechatronic handling system is beneficial because it automates the process and provides real-time feedback. Easy commissioning and intuitive programming commands allow users to generate complex pickand-place cycles in minutes. Recent innovations such as the Bosch Rexroth Smart Flex E ector can provide increased precision to battery automation processes with pouch, cylindrical, and prismatic type battery cells. The e ector can also be used to
guide collaborative robots in welding or cabling applications by providing the robot controller with continuous positional deviation commands to maintain accurate motion paths. By measuring the position deviation of the gripping device in relation to the workpiece in six degrees of freedom, the robot can adjust its position to ensure accurate placement. Smart mechatronics technology improves precision and increases the overall e ciency of battery and electric vehicle manufacturing processes.
Consumer packaged goods (CPG) manufacturers are always looking for ways to increase their flexibility, maximize the use of space, and minimize the time and e ort required to modify or add new production tools. Plug-and-produce smart mechatronics systems are designed to meet these needs by combining established linear motion components with smart controls and easy-to-use engineering tools. By using these systems, CPG manufacturers can benefit from accelerated engineering, commissioning, and faster time to market for their products. These systems also provide more transparent, e cient, and reliable production processes. Smart mechatronics systems o er high operating performance and sustainability through permanent updates, ensuring that manufacturers always have access to the latest technology and capabilities. Handling systems, such as the Smart Function Kit for Handling, are an example of how smart mechatronics technology can improve the accuracy of packaging, create a repeatable process, and increase production speeds in palletizing operations. These systems can also monitor the quality of products in real-time, allowing manufacturers to identify and address any issues quickly. Open interfaces allow software engineers the ability to customize the operator interface and collect system
Smart mechatronics systems can automate material handling, sorting, and transporting processes, reducing the need for manual labor, and increasing the speed of operations.Consumer packaged goods is one industry benefitting from smart mechatronics systems. | Bosch Rexroth
data to increase throughput and e ciency of the operation.
One of the largest challenges in CPG operations is e cient product changeover. Most manufacturers o er multiple sizes of a single product, each with their own packaging designed for that specific size. To switch production from a 12-in. package to a 6-in. package, traditionally a manufacturer would have to pause production and reset the line to accommodate the new handling requirements of the smaller package. Advances in smart mechatronics are helping to tackle this challenge head on with sensor-based innovations that can sense the size of a bag and automatically adjust the handling system for the exact product it needs to grab.
Smart mechatronics also play a critical role in improving ease of use for factory operations. For example, a simple Galaxy Note touchpad or an iPad can program smart mechatronics. This plug-andplay mentality eliminates the need for operators to receive specialized training, so manufacturers do not have to hire somebody with a robotics programming background to run the line. As an added benefit, the plug-and-play mentality also saves space in the production line, because a large electrical control cabinet is no longer needed to manage the robotics.
Smart mechatronics is playing an increasingly significant role in the semiconductor industry. Within semiconductor manufacturing, even the slightest vibration when wafers are in motion can compromise chip quality — requiring precise and accurate automated manufacturing processes. Smart mechatronics technology can help achieve this. These smart systems are being used to improve the accuracy and precision of semiconductor manufacturing equipment, reducing defects, and improving product quality.
Specifically, sensor-based compensation units, like the Smart Flex
Sensor-based compensation units, like the Smart Flex Effector from Bosch Rexroth, are used in wafer production in the semiconductor industry. They ensure accuracy of linear motion devices with high-resolution sensors, which are then translated into active correction movements.
Effector, ensure accuracy of linear motion devices with high-resolution sensors, which are then translated into active correction movements. This tactile sensor can enhance the accuracy of automation systems used for wafer handling and processing, while also providing a digital twin throughout the process. This smart device can also incorporate in-process metrology to robotic applications, enhancing currently existing equipment used throughout the industry. Incorporating smart mechatronics systems is critical to meeting the ever-increasing demand for precision in the semiconductor industry, enabling greater productivity and quality control.
Intralogistics is the process of managing and optimizing the internal flow of goods in a warehouse or distribution center. Smart mechatronics technology is being used in intralogistics to improve the efficiency of these processes. Smart mechatronics systems can automate material handling, sorting, and transporting processes, reducing the need for manual labor, and increasing the speed of operations. Specific smart technology such as the Smart Flex
Effector can be used with collaborative robots to increase accuracy of linear motion devices and pick-and-place operations. Smart handling systems can be commissioned and monitored easily and can provide greater efficiency in palletizing operations. These systems can also help digitalize the value stream through software-based commissioning and monitoring, and even creating digital twins for a streamlined process, allowing for better management of the supply chain.
Smart mechatronics has been playing an increasing role in the medical device industry, especially in areas such as cartesian pick-and-place operations and sorting operations. One notable application of smart mechatronics in this industry is the use of pick-and-place robots and cartesian systems for sorting test tubes. In medical laboratories, pick-and-place robots equipped with cameras and sensors are used to sort test tubes based on specific criteria such as sample type, patient ID, or test required. These robots can quickly and accurately sort large quantities of test tubes, reducing errors and minimizing the risk of contamination. Overall, smart
mechatronics is a rapidly advancing field that is revolutionizing the way designers approach medical device design and manufacturing. DW
Bosch Rexroth www.boschrexroth-us.com
In the first of this two-article series, we considered VFD operation types to satisfy process and motion-control applications. Here we delve deeper into two advanced types of operation.
Lisa Eitel | Executive editorBrushless AC (BLAC) motors are driven with sinusoidal AC currents and (due to skewed magnets and sinusoidally distributed windings in their stators) also produce sinusoidal back EMF. Sinusoidal commutation is a common way to control BLAC motors, as it provides a very consistent torque output with little torque ripple. But at high speeds, sinusoidal commutation begins to sacrifice motor e ciency.
Another method called field-oriented control (FOC) or flux-vector control also generates sinusoidal waveforms and produces consistent torque … and it yields better motor e ciency, especially at high speeds.
Precise vectorbased modes of VFD operation are often useful in advanced conveyor applications.
| Itsanan Sampuntarat
Shown here is a block diagram of field-oriented control with space vector pulse width modulation. The goal of FOC is to align the stator current vector to be orthogonal (90°) to the rotor flux.
Kirchho ’s current law states that at any junction in an electrical circuit, the sum of currents flowing into the junction is equal to the sum of currents flowing out. In the case of a three-phase motor, Ia + Ib + Ic = 0. So if two currents are measured, the third must be the negative sum of the first two to maintain a zero sum of the three.
Sinusoidal motor commutation
Torque output in any motor is maximized when the stator and rotor magnetic fields are orthogonal at 90° to each other. Sinusoidal commutation works to generate a rotating current vector with a constant magnitude and direction that is orthogonal to the rotor. Recall that vectors have both magnitude and direction.
To achieve this, two of three stator phase currents are generated 120° phase-shifted from each other based on rotor position, which is provided by an encoder. The third is determined using Kirchho ’s current law. The result is a smoothly rotating current vector with constant magnitude that is always orthogonal to the rotor.
Sinusoidal commutation provides smooth motion with very little torque ripple. But as motor speed increases, e ciency deteriorates. This is because with increasing speed, the frequency of the sinusoidal current command signals also increases, making it di cult for the current loop controllers to track the command signals. In addition, as speed increases, motor back EMF increases in frequency and amplitude. The result is phase lag between the stator and the rotor, taking the current vector out of the optimal 90° alignment with the rotor flux. This reduces the torque produced for a given current and decreases the motor’s e ciency.
Where sinusoidal commutation is based on a three-phase system that is dependent on time and speed, field-oriented control transforms this
Field oriented control transforms a threephase, time-dependent system into a twocoordinate (d and q) time-invariant system. SVPWM is used in the final step to determine the PWM signals to be applied to the motor.
VFDs regulate the motor speed by using either scalar control or vector control to vary the frequency of the supplied voltage.
system into a two-coordinate system — d and q — that is not dependent on time … similar to that of DC control. There are two inputs to FOC:
• The torque component (aligned with the q coordinate) and
• The flux component (aligned with the d coordinate).
First, in a manner similar to sinusoidal control, the current in two windings is measured (recall that current in one of the windings is not controlled. It is the negative sum of the current in the first two windings). Then, a Clarke transform is used to convert the three axes of current into a two-axis system. The resulting two-phase waveforms have the same amplitude as the original three-phase waveforms.
Next, a Park transform is used to convert the two-axis system from a fixed reference to a rotating reference frame that is in synchronization with the rotor flux. The result are the d and q values. The d axis current is aligned with the rotor flux, and the q axis current is orthogonal to rotor flux. Because it is orthogonal to the rotor flux, the q axis current is responsible for torque production. In other words, torque is increased by increasing the q axis current and decreased by decreasing the q axis current.
A separate PI controller is used for each axis, d and q, to read current error signals and amplify them to produce voltage to the motor. But because the voltages are on a rotating reference, an inverse Park transform is performed, which converts them back to a stationary reference frame. An inverse Clarke transform is then performed to convert the two voltages back into three values so they can be applied to the three motor windings.
While field-oriented control seems more complex on the surface (and admittedly, it is more mathematically intensive), the decreasing cost of processing technology makes it a viable solution for many motion control systems. On the other hand, sinusoidal control is the preferred choice for simple, low-cost control of brushless motors.
We’ve now reviewed how one common modern method for controlling three-phase induction motors and permanentmagnet synchronous motors (also called BLAC or PMAC motors) is field-oriented control — a technique that independently controls the magnetizing and torque-producing components of the stator current. This allows the torqueproducing component to be kept orthogonal to the rotor flux … maximizing torque production.
Space vector pulse-width modulation (SVPWM) is a technique used in the final step of field-oriented control to determine the pulse-width modulated signals for the inverter switches to generate the desired 3-phase voltages to the motor. The following is a summary of how FOC with SVPWM operates.
1. Measure two of the three motor phase currents and feed them into a Clarke transform to convert them from a
For each leg of the inverter output, either the top transistor will be open (and the bottom closed) or viceversa. Therefore, there are eight total states (23) for the inverter output.
three-phase system (ia, ib, ic) to a twodimensional orthogonal system (iα, iβ). Note that it’s not necessary to measure all three currents because the sum of the three must equal unity (0). So the third current must be the negative sum of the first two.
2. Apply a Park transform to convert the two-axis stationary system (iα, iβ) to a two-axis rotating system (iq, id) where the d axis current is aligned to the rotor flux and the d axis current (the torqueproducing component) is orthogonal to the rotor flux.
3. The stator current flux and torque are independently controlled — typically by PI controllers. Voltages to be applied to the motor Vd and Vq are determined from the PI controllers.
4. Next, an inverse Park transform converts the two-axis rotating system (Vsqref, Vsdref) back to a two-axis stationary system (Vsαref, Vsβref). These are the components of the stator voltage vector and are the inputs for the SVPWM, which generates the 3-phase output voltage to the motor. (Note that
the use of SVPWM eliminates the need for an inverse Clarke transform to obtain the three-phase output voltages.)
The details behind SVPWM
Voltage is delivered to the motor by a three-phase inverter with six transistors (two on each leg of the output). Each of the three outputs can be in one of two states (top transistor closed and bottom
The values of T1, T3, and T0 can be determined with the equations shown here. Then a simulation of Vout can be expressed as shown.
transistor open, or vice-versa), giving eight (23) total states for the output. These are called base vectors.
The eight base vectors are plotted on a hexagonal star diagram. Each vector makes up a spoke of the star, with 60° phase di erence between adjacent vectors. The two vectors V0 and V7 that contain outputs which are either all plus or all minus are called null
vectors and are plotted at the center (origin) of the star.
Each base vector makes up one segment of a hexagonal star with the null vectors V0 and V7 plotted in the center. The goal of SVPWM is to produce a mean vector during the PWM period (TPWM) that is equal to the desired voltage vector Vout.
The location of Vout is determined on the star diagram, and the base vectors that constrain that sector (V1 and V3 for example) along with one of the null vectors, are used to synthesize the desired voltage. This is done by applying V1 for a specified time T1 and V3 for a specified time (T3) and the null vector for the time necessary (T0) to provide a resultant vector equal to Vout.
Compared to standard field-oriented control, using FOC with space vector pulse width modulation enables more
e cient use of the DC supply voltage and provides lower harmonic distortion; the latter, in turn, improves the power factor … and reduces torque ripple. DW
Motion Control Tips | motioncontroltips.com
Turn your design challenges into next-generation, marketleading medical devices with our extensive manufacturing capabilities and engineering expertise. We have facilities in Fremont, CA and Santa Ana Sonora Mexico.
Connect and discuss this and other engineering design issues with thousands of professionals online
For the annual Design World Trends issue, we asked industry experts to share their insights into linear-motion trends. Here’s more of what they had to say on linear actuators, linear guides, and stages.
WWhat’s new in linear guide slides and ways?
Walden: This past year, we’ve seen linear guidance used for aerial vehicle (drone) hangers to service and protect the vehicles when not in use.
Rice: There are new ways of integrating the linear guide and linear bearing into the actuator body. Instead of being constrained by manufacturers’ available dimensions, the OEM uses one of these new guides where it makes the most sense for linear motion. For example, the guide can be wider for higher moment loads or mounted closer to the actuator base to strengthen the carrying system foundation. Festo has developed a guide that is part of the actuator body, which makes more e cient use of materials and reduces weight. Assembly is easier, and performance is higher.
What’s behind the growth of leadscrew, ballscrew, and roller screw applications?
Orozco: Leadscrews are known for high static force applications, withstanding excessive vibration, and operating quietly. They’re cost-e ective options and have been traditionally used in machine slides and heavy-lifting applications, such as vises, presses, and jacks. However, miniature as well as precise leadscrews are attracting industries such as photonics and autofocusing optics.
Ballscrews are the most commonly used screws that provide high-performance solutions for a range of applications where high loads, high speeds, precision driving, durability, and value are prerequisites. Roller screws are more expensive than but outperform the capabilities of ballscrews. Roller screws are well suited for heavy loads, high duty, high rotational speed, high acceleration, and rigidity, and for operation in harsh environments. Roller screws are good for high-precision applications with high positioning accuracy and repeatability.
Enhanced feedback technologies help linear-motion endusers verify position and speed and monitor actuator performance.
| courtesy of Emerson
Falasco: Adoption of ballscrews and especially roller screws is due to more companies switching from hydraulic to electromechanical technologies for cleanliness and economic reasons. Roller screws o er high load capacity in a small footprint, and ballscrews o er high load and (with recirculating ball bearing technology) moderately high speed capacity. Will ballscrews and roller screws replace all hydraulics applications? No, but change is happening in the linear-motion world, and customers see the benefi ts of electromechanical solutions that similar hydraulics can’t o er.
Rice: Ballscrews are a primary mechanical drive system in our linear actuators. They provide high-precision motion and positional repeatability along with high forces. Engineers can easily optimize ballscrews to the application by simply changing the lead or pitch of the screw. Roller screws extend these benefi ts by increasing the force capabilities and are now used frequently in high-force applications. Roller screws are encroaching into the high-force areas traditionally dominated by fluid-power actuators.
Multi-axis gantry attachment kits extend the working envelope of linear actuators and enable the fast and simple connection of several actuators into a more complex motion system.
| courtesy of Bishop Wisecarver
Zaske: We’ve been a primary manufacturer of planetary roller screws for over a decade and see an increasing interest in and application of roller screws due to their dense power capability and long life. Customers consider them a key component as they explore ways to eliminate or reduce hydraulics in production applications. This doesn’t mean that roller screws are a panacea, but with a proper understanding of their benefi ts and limitations, we see planetary roller screw applications continuing to grow for a long time.
Describe how motion-subassembly design work is increasingly outsourced.
Rice: OEMs that outsource subassemblies gain competitive advantages. These turnkey solutions decrease engineering time and procurement costs. Outsourcing shortens design cycles and speeds up new machine development and production. Areas of acute interest for outsourcing today include XY tables and Cartesian gantries. These systems o er maximum work envelopes in a compact footprint; do not require safety guarding; are fast, flexible, and precise across the entire envelope; and are more coste ective than an articulated arm and SCARA robots in many applications.
Lackey: It all began with the semiconductor industry — partnering with customers to provide completely engineered-to-specification subassemblies for wafer lifts that fall outside of the standard catalog product o ering. While Rexroth currently supplies thousands of engineeredto-specification subassemblies in the semiconductor market per year, we see increased demand for custom-engineered or engineered-tospecification subassemblies in other industry segments.
Dave Walden | Applications engineer • PBC Linear
Eric Rice | Product market manager — electric automation • Festo
Samuel Orozco | Product marketing manager — Electric actuators • Emerson
Eric Falasco | Product manager — Screws, bushing/shafting, small handling modules • Bosch Rexroth
Andy Zaske | V.P. of sales and marketing • Tolomatic
Justin Lackey | Product manager — Systems • Bosch Rexroth
Andrew Jung | Director of engineering • Bishop-Wisecarver
Tim Sharkey | Director of market management for electric automation • Festo
Saurabh Khetan | Product line manager — Leadscrews • Thomson Industries Inc.
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
Jung: Bishop-Wisecarver currently provides stages, gantries, and XY tables to support the needs and cost constraints of low to highaccuracy applications. With evolving design features, more subassemblies are completed in-house to reduce leadtime and produce high-quality products.
How has the convergence of ISO, DIN, and JIS standards affected OEMs?
Orozco: It’s di cult to assimilate change, especially when industry standards have been established for a long time. Some of these standards (depending on the feature or geometry) have similar specifications varying in items, such as tolerance or load capacity di erences for ballscrews. Customers and manufacturers have had to update processes; change quality inspection routines; and adjust machine assemblies to accommodate updated standards. Over the long term, universal standards will benefi t the industry and customers.
Jung: There’s been increased demand for components that conform to di erent materials standards. While having suppliers globally, conforming to ISO, DIN, and JIS standards hasn’t been an issue. Although the three standards have very similar requirements, there are some di erences — and we understand the di erences to provide optimal solutions for our customers.
Sharkey: We’ve invested heavily in online, free engineering productivity tools and our customer solutions center. OEMs are under pressure to become more e cient and hold down costs, and suppliers help the OEMs
along two important tracks. First, suppliers must continually improve product capabilities and features, such as assured interoperability, small size, and energy e ciency. Second, suppliers must decrease engineering and assembly time.
Rice: For OEMs looking for XY tables and Cartesian robots, Festo has developed an online engineering tool, Handling Guide Online, that compresses the design process from an industry-standard two weeks down to 20 minutes. At the end of the Handling Guide Online session, the OEM receives a 3D CAD drawing that enables machine design to continue while the unit is being kitted, assembled, and tested. The OEM receives a bill of materials, an estimated delivery date, and a quote. Handling Guide Online lowers internal costs and makes the OEM more competitive.
Khetan: We don’t o er engineering services per se, but during detailed engineer-to-engineer discussions with mature customers about new or ongoing programs, we’ve provided engineering support and specialized services to better understand and complement the customer’s design.
Lackey: Over the last few years, there’s been a growing need for completely engineered linear solutions. As the goal is to keep profi tability up and costs down, we see many companies reducing or minimizing design and electrical engineer headcounts … and
here, our open-market tools can help minimize overhead.
For example, customers can download LinSelect, our free, easy-to-use sizing software, to input application parameters and find multiple solutions. The software sizes individual axes, multi-axis gantry systems, and electromechanical presses, and the outputs will also size motor and drive needs. With a couple of clicks of the mouse, engineers get downloadable models. Some of these standard catalog products include linear modules, connection bracketry, motors, drives, cables, industrial PLCs, and HTML-based drag-and-drop programming software with our Smart Mechatronics product. Customers who use Smart Mechatronics solutions keep overhead down by minimizing the need for design and electrical engineers.
Sharkey: For complex linear-actuated Cartesian systems that fall outside of the Handling Guide Online parameters, the Festo customer solutions center at our Mason, Ohio Global Production Center works with customers to design and build cartesian subassembly. Customer solutions also designs and assembles the gantry’s control cabinet for plug-and-play setup and function block programming. With our Electric Motion Sizing software and Automation Suite software, mechanical engineers can select all motion components knowing they’re interoperable. The sizing tool file gives the purchasing agent a complete bill of materials that eliminates potential order errors. And the controls engineer receives a file that contains all operational parameters to commission the unit directly on the commissioning software, thus saving precious time.
Read the rest of our 14 experts’ insights into linear-motion trends by visiting linearmotiontips.com and searching on Andaya. DW
Linear Motion Tips | linearmotiontips.com
Areas of acute interest for outsourcing today include XY tables and Cartesian gantries, like the one shown here.
| courtesy of Festo
Efforts are underway to develop new magnetic materials that improve sustainability and maintain performance in industrial applications.
There are three primary magnet types — temporary, permanent, and electromagnets — each with multiple subcategories. Subcategories for permanent magnets and electromagnets include materials and designs optimized for specific characteristics and improving sustainability.
Temporary magnets are magnetic only in the presence of an external magnetic field. Materials like iron, nickel, cobalt, and many types of steel can act as temporary magnets. The field strength of temporary magnets is related to the material being used and the external magnetic field’s strength, proximity, and other characteristics. As soon as the external field is removed, temporary magnets stop being magnetic.
Characteristics of temporary magnets include:
• Easily magnetized by an external magnetic field
• Simple structures
• Low cost
• Can be used to set metals and nonmetals
Most nonmetal magnetic materials are temperature sensitive, and the strength of their magnetic field decreases at elevated temperatures. In addition, many of these materials have low corrosion resistance.
While temporary magnets are often associated with ferrous materials, paramagnetic and superparamagnetic materials can also be used for temporary magnets. Paramagnetic materials, such as alkali metals, some transition metals, aluminum, tin, and oxygen, have a weaker field strength than ferrous materials.
Superparamagnetism is paramagnetism at a very strong level, and superparamagnetic temporary magnets can be very strong, but there’s a catch. Superparamagnetism is highly size-dependent and only exists in nanocrystals. It’s a form of magnetism that appears in small ferromagnetic or ferrimagnetic nanoparticles. Like the case of a paramagnetic material, an external magnetic field can magnetize the nanoparticles in a superparamagnetic material. Still, the magnetic susceptibility — the degree of magnetization in an external magnetic field — is much larger than that of regular paramagnets.
Permanent magnets
Unlike temporary magnets that need the application of an external field to become magnetized, permanent magnetics generate their own field. Permanent magnets can retain their magnetic properties for extended periods, even multiple years, and provide the magnetic field to use temporary magnetic materials.
Permanent magnets are often divided into two groups: (1) metal alloy magnets, such as aluminum nickel cobalt and samarium cobalt magnets, and (2) neodymium iron boron and ferrite or ceramic magnets.
Ceramic or ferrite magnetic materials can be soft (easily magnetized and demagnetized) or hard (difficult to magnetize and demagnetize). Ceramic or ferrite permanent magnets are made with hard magnetic materials
like barium hexaferrite (BaFe12O19) and strontium hexaferrite (SrFe12O19). Both materials are hard and brittle and represent the largest permanent magnets used today. They generate moderate remanence induction but have performance advantages in terms of resistance to demagnetization and corrosion and the absence of eddy current losses. They have good availability and are low cost. If the performance of these materials could be increased even modestly, they could take away market share from higher-performing metal alloy magnets.
Permanent magnets made with aluminum, nickel, and cobalt are called alnico magnets. They have good temperature performance but are relatively easy to demagnetize. Their overall performance and cost place them between ceramic or ferrite magnets and rare earth magnets. Alnico magnets can be fabricated using sintering or casting processes. Sintering results in mechanically more robust magnets, while casting produces higher magnetic energy levels and can support the production of magnets with more complex shapes.
Samarium cobalt (SmCo) magnets are rare earth magnets and can be made with Sm1Co5 and Sm2Co17, referred to as 1:5 and 2:17,
Permanent magnets made with aluminum, nickel, and cobalt are called alnico magnets. They have good temperature performance but are relatively easy to demagnetize.Each of the three basic types of magnets consists of multiple subcategories. | Javapoint Operating temperature capabilities of the most common permanent magnet materials.
| Arnold Magnetic Technologies
OVER 25 YEARS’ EXPERIENCE WITH MANUFACTURING AND SOURCING OF MATERIAL, SUB-ASSEMBLIES AND FULL TURNKEY PRODUCTS.
• PRODUCTS: We offer component manufacturing, engineering, sourcing, custom component manufacturing. Kingway offers components and subassemblies all the way to full box builds.
• LOGISTICS: Kingway can help develop a custom Logistics plan to meet your needs including Expedited Air Freight, Sea Freight and Domestic Warehousing.
• VISION STATEMENT: Kingway Electronics offers Direct Sourcing and Customized Logistics Management by utilizing our 25 plus years of relationships and experience to deliver better Pricing, Shorter Lead Times with the Goal of Maximizing our customers profitability.
respectively. Magnets made with 1:5 have an energy range of about 15-20 mega-gauss-Oersted (MGOe), and 2:17 magnets have an energy range of about 22-30 MGOe. SmCo magnets are not easily demagnetized. They have low mechanical strength and are expensive but can operate up to 350° C higher than most other types of permanent magnets. They are best suited for extremely high-temperature environments such as downhole oil and gas exploration.
Neodymium iron boron (NdFeB) magnets are also rare earth magnets. NdFeB magnets feature very high energy products, up to 45 MGOe, and have extremely high coercive forces. These magnets can be used up to about 200° C, and their high energy products enable the use of smaller magnets to achieve the same energy product. However, NdFeB magnets have low mechanical strength and are very brittle. They find use in highperformance applications like motive motors in electric vehicles.
Samarium iron nickel (SmFeN) magnets are still mostly under development. They have a saturation magnetization strength comparable to NdFeB but can operate over 400° C. They have superior oxidation and corrosion resistance and do not need cobalt or other heavy rare earth elements, potentially giving them superior sustainability performance. Most applications have operating temperature ranges between -40 and 150° C. All the common permanent magnet materials discussed previously can operate over that temperature range.
Using rare earths to fabricate highperformance permanent magnets is fraught with sustainability challenges. Most notably, the mining and processing of rare earths produces toxic byproducts, leading to ecological and sustainability challenges with rare-
Electromagnets are made with a coil of insulated copper wire, a ferromagnetic or ferrimagnetic material core, and an ac or dc power supply. Current flowing through the wire coil creates a magnetic field. The magnetic core concentrates the magnetic flux and makes a more powerful magnet.
earth mines and refineries. Demand for high-performance magnets with improved sustainability is driving numerous research efforts.
For example, scientists at the University of Leeds are developing a hybrid film from a thin layer of cobalt (which is ferromagnetic) covered with Buckminsterfullerene, a form of carbon. While carbon is not magnetic, when bonded to the cobalt surface, the carbon causes a magnetic pinning effect, preventing the magnetism in the cobalt from changing directions, even in the presence of strong opposing fields. The carbon layer boosts the energy product of the resulting structure by five times at low temperatures. The next step in the research aims to increase the operating temperature of these magnets to room temperature.
In another instance, a team at the Critical Materials Institute at Ames Laboratory has identified two forms of cerium cobalt, CeCo3, and CeCo5, as potential materials for making strong permanent magnets. Although cerium is a rare-earth element, it is abundant and easy to obtain without detrimental environmental impact
EPMs can be controlled to have no net magnetization or produce a strong external magnetic field.
| Wikipediaand with good sustainability. While CeCo3 is a paramagnetic material, adding magnesium transforms it into a ferromagnet. CeCo5 is natively a strong ferromagnet. Adding copper and iron to CeCo3 and CeCo5 can increase the materials’ ferromagnetic capabilities and potentially make them candidates to replace NdFeB rare earth permanent magnets.
Electromagnets are made with a coil of insulated copper wire, a ferromagnetic or ferrimagnetic material core, and an ac or dc power supply. Current flowing through the wire coil creates a magnetic field. The magnetic core concentrates the magnetic flux and makes a more powerful magnet.
Electromagnets are often used in place of permanent magnets. The strength of the magnetic field can be increased or decreased by increasing or decreasing the current flow in the coil, while the magnetic fields of permanent magnets are fixed. The magnetic field can be reversed by reversing the current flow direction. In addition, an electromagnet can be turned completely off with no remaining field. Disadvantages of electromagnets include the need for a continuous supply of power and their tendency to get hot when current flows are high. Combining an electromagnetic section with permanent magnets can result in improved sustainability.
An electro-permanent magnet (EPM) consists of two sections: a very hard, high coercivity (H) magnetic material such as neodymium iron boron (NdFeB) with an H of about 1,120 kA/m, and a
lower coercivity material such as alnico (AlNiCo) with an H of about 50 kA/m connected with two iron horseshoes. The direction of magnetization in the soft material can be changed by a current flowing in a winding. When the two types of magnetic materials have opposing magnetizations, the EPM produces no net external field across its poles. The field is restricted to the interior of the iron horseshoes. When the magnetizations in the two materials are aligned, the EPM can produce a strong external field.
EPMs can be a form of a programmable or controllable magnet. A common use of EPMs is in industrial holding magnets. When the magnetic circuit is off, it allows for less current (no power flow) and safe holding of magnetic workpieces. When the coil is turned on, the permanent magnetic field is canceled at the holding surface, and the workpiece can be easily removed. These controllable magnetic systems are very energy efficient and sustainable. The current flows only briefly to allow the removal of the workpiece. At all other times, there is no current flow. This design is especially efficient for applications that require long holding times or when loads or workpieces must be safely held, even during a power failure.
EPMs are commonly used for highly energyefficient industrial lifting of ferrous metal objects. Before EPMs were developed, the only way to produce a programmable or controllable magnetic field was to use electromagnets that consume large amounts of power when in operation. The development of powerful NdFeB rare earth permanent magnets made EPMs possible. Researchers are also investigating the possibility of enabling self-building structures using EPMs. DW
References
3 Key Parameters to Consider when Choosing a Permanent Magnet, Arnold Magnetic Technologies
Atomic Cooperation in Enhancing Magnetism: (Fe, Cu)- doped CeCo5, ScienceDirect
Electromagnet, Wikipedia
Electropermanent magnet, Wikipedia
Hope for a new permanent magnet that’s cheap and sustainable, Science Daily
Permanentmagnetic electro holding magnets, Kendrion
Types of Magnets, Javatpoint
Scanning Acoustic Microscopy testing ensures that oilfield and optical sensors are built without essential material defects.
Edited by: Mike Santora • Managing editor
Electro-mechanical sensors, such as pressure, flow, and vacuum switches, composed of electrical and mechanical parts, interact and transmit information or commands to other components of a larger, more complex system. To keep the entire system functioning safely, sensor producers must manufacture these devices to deliver accurate measurements. Traditionally, however, if there was an issue with a sensor, it was often found when the product failed the field.
Now, sophisticated testing like Scanning Acoustic Microscopy (SAM) is being used to assess the physical sensing elements to determine that the components are sound before they are assembled into sensors that will be used in critical applications.
SAM is a non-invasive and non-destructive ultrasonic testing method. The testing is already the industry standard for 100% inspection of semiconductor components to identify defects such as voids, cracks, and the delamination of di erent layers within microelectronic devices. Now, the same rigor of failure analysis and quality testing is being applied to specialty metals and materials to detect subsurface flaws, dis-bonds, cracks, and other irregularities.
“Previously, sensor manufacturers had no way to test the functionality of a sensor until it was in the field. If it gave incorrect results on a known good test, they called it a failure. They had no metrology to test the sensors elements during the manufacturing process,” said Hari Polu, President of OKOS, a Virginia-based manufacturer of SAM and industrial ultrasonic non-destructive (NDT) systems.
SAM is being used to assess physical sensing elements for determining whether components are sound before they are assembled into sensors that will be used in critical applications.
For example, SAM can be used to ensure sensor quality in oil drilling equipment. These sensors are sensitive to vibrations or generate vibrations at a specific frequency. These sensors provide metrology attributes of fluid properties in real-time.
Electro-mechanical advanced sensors are used in critical areas such as oilfield exploration and production processing to take pressure data and fluid samples from the bottom of highpressure and high-temperature wells. The sensors establish the hold-up of fluids using the density and electrical properties of oil, gas, and water. The characteristics of the vibration can help to determine the density of the wellbore fluid mixture.
“If a manufacturer is building defective sensors and anything fails anywhere in the process upstream, that’s extremely costly for an oilfield application,” said Polu.
Oil drilling equipment manufacturers can test tuning fork sensors’ piezoelectric crystals with SAM to determine if flaws exist before shipping. Since piezoelectric ceramics are fragile, sensitive components may present internal cracks undetectable to visual inspection. Ceramics presenting cracks, even if internal and invisible, must be discarded to avoid the premature fault of ultrasonic transducers and converters in which they are mounted and the resulting losses from repairs and technical assistance.
Scanning acoustic microscopy works by directing focused sound from a transducer at a small point on a target object. The sound hitting the object is either scattered, absorbed, reflected, or transmitted. By detecting the direction of scattered pulses as well as the “time of flight,” the presence of a boundary or object can be determined as well as its distance.
To produce an image, samples are scanned point by point and line by line. Scanning modes range from singlelayer views to tray scans and crosssections. Multi-layer scans can include up to 50 independent layers. Depthspecific information can be extracted and applied to create two- and threedimensional images without the need for time-consuming tomographic scan procedures and more costly X-rays. The images are then analyzed to detect and characterize flaws such as cracks, inclusions, and voids.
When high throughput is required for 100% inspection, ultra-fast single or dual gantry scanning systems are used along with 128 sensors for phased array scanning. Multiple transducers can also be used to simultaneously scan for higher throughput.
Lithium niobate (LiNbO₃) is one of the most versatile and well-developed active optical materials and is widely used in electro-optics, acousto-optics, nonlinear optics, waveguides, and fiber optic gyroscopes (FOGs).
Scanning Acoustic Microscopy testing ensures that oilfield and optical sensors are built without essential material defects.
This year, PBC Linear marks 40 years of engineering linear motion solutions. Since our founding in 1983, PBC Linear has surpassed many business milestones for growth, brought an abundance of innovative achievements to the marketplace, and provided engineering expertise to customers around the globe. As we continue to evolve, our vision and commitment to long-term investments and established core values will position PBC Linear and its customers for future successes.
To all of those who have been a partner in our long journey, we say “Thank you, and we look forward to working with you in the future!”
Versatile, rugged cylinders—when you need them
One potential application is for oilfield sensors. Traditionally, in this application, when cutting, separating, and assembling lithium niobate wafers into sensor housing, only a small percentage prove to be good in the field. The challenge is determining which wafers are defective before incorporation into products.
For this type of application, the SAM VUE400 from OKOS is suitable to detect bad wafers before use in an electromechanical device. The medium-sized SAM system designed for lab use or manufacturing floors is traditionally used to detect voids, disbands, cracks, delamination, and internal defects in semiconductor package failure analysis.
The SAM equipment can inspect various items with unique product geometry or sizes, from crystal ingots, wafers, and electronics packages to miniature physical packaging, metal bar/ rods/billets, turbine blades, and more. However, as important as the physical and mechanical aspects of conducting a scan, the software is the key to analyzing the information to produce detailed scans.
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.
• Standard bore sizes: 1.5–6 inches
• Standard strokes to 99 inches
• Pressure rating: 250 PSI
• Temperature range: -10° to +165°F
• Conforms to NFPA dimensional specifications
• Lead time for standard configurations: 7–10 days
www.fabco-air.com
For this reason, “OKOS decided early on to deliver a software-driven, ecosystem-based solution,” said Polu. The company’s ODIS Acoustic Microscopy software supports a wide range of transducer frequencies from 2.25 to 230 MHz. Multi-axis scan options enable A, B, and C-scans, contour following, o ine analysis, and virtual rescanning for metals, alloys, and composites.
Today, manufacturers have the potential to save significant amounts of money per year in oilfield sensors or similar applications by detecting and eliminating defective lithium niobate wafers before use in high-value, electromechanical sensors. These savings stem from screening at the wafer level, which prevents packaging and shipping bad products. The total does not even account for substantially improved wafer yields. DW
80
How real-time data can increase uptime
Today in automation, predictive and preventive maintenance are constantly in the conversation.
86
SLAM technology improves AMR autonomy
Dynamic warehouses seek robots that can adapt to change with minimal human intervention. With localization and mapping software, AMRs can build facility maps, orient themselves, detect di erences, and share changes with their fleet for uninterrupted and safer operations.
92
Top five robot trends in 2023
Why did the global stock of operational robots hit a new 3.5-million-unit record? Why did the value of installations reach an estimated $15.7 billion? The IFR analyzed five key things shaping robotics and automation.
98
What’s the difference between an AMR and an AGV?
Despite the growing popularity of warehouse automation, confusion remains around the various acronyms and technology. For those in the discovery phase of an automation journey, here’s an overview of two of the most talked about warehouse solutions.
Today in automation, predictive and preventive maintenance are constantly in the conversation. While the ideas may be clear, the implementation and advantages are not. Is this a fad that will fizzle out soon?
By Gerry Paci, Marketing Manager — Material Handling, Pepperl+FuchsFFor many years in the material handling industry, warehouse operators have strived to achieve minimal downtime and optimal operation. There are countless ideas and aspects for attaining this milestone within the warehouse.
In this era of intralogistics, the requisite for automation has become apparent. While some automate more than others, the necessity has proven clear. Managing automated equipment and potential downtime is crucial to production and intralogistics.
When a machine is down, the alarm will sound, reminding those on the floor that time and money are paramount. It is one thing to fix the issue quickly so that the process can continue, but understanding when this type of issue or downtime could occur again is the real prize. Moving from reactive to proactive maintenance in the warehouse can be the di erence between a streamlined process and a chaotic event within intralogistics.
The industry has learned over the years that regularly scheduling maintenance helps minimize problems with automation. A planned approach involving inspecting and repairing equipment to prevent failures has proved successful. Based on history, the warehouse maintenance team may understand that a motor controlling the conveyor needs to be inspected once per quarter
for potential loosening due to vibration. This tactic helps extend the equipment’s lifespan and identify and address problems before they cause downtime. Nonetheless, if the maintenance team had access to the motor’s vibration velocity and temperature over time, they could predict when a failure could occur, streamlining their maintenance process.
This information and data have become widely available from the software and sensor technology intertwined with the automation process. From a simple photoelectric sensor that detects whether an AS/RS shuttle has entered the proper level of the rack to a 2D LiDAR system looking down over a conveyor to understand the flow of parcels over time, real-time data is constantly surging into a PLC, IPC, or data collection tool within the warehouse. How this real-time data
is used is one of the most interesting portions of the process.
As with any newer process or idea in a long-standing industry, challenges and speculation will arise. The transition from preventive to predictive maintenance is not free of these challenges. Where the data comes from, how to process it, and how much upfront implementation time it takes are all common questions during development.
In many cases, some of these questions can be answered using the data from the sensors already living in the warehouse. For example, it is becoming more difficult to walk into a warehouse without seeing the major use of automation, which requires sensors. To implement preventive maintenance, the data from an IO-Link capable sensor can be used as an analytical tool to understand when the machine could fail.
Vibration sensor data extends automation equipment’s lifespan and helps maintenance teams identify and address problems before they cause downtime.
Now that the data is located and available, networking technology such as a managed Ethernet switch can transfer the data to the next step. A gateway can also be added if the data needs to be converted to a different programming language. The final step is employing a digital transformation strategy to examine the information in a centralized repository.
It is essential to remember that not every problem has a standardized solution, and a new solution can create a new silo of data. The strategy must ensure that every portion of the warehouse with data — from the AGV that carries a tote to the conveyor that transfers the tote to the production worker — behaves as one system.
After this convergence is coordinated, valuable preventive maintenance and condition monitoring analysis solutions can finally occur. A digital dashboard is a simple way to make informed decisions using the available data. To avoid making data
For most of my life, I pushed myself while working out at the local gym. I used my feelings to balance reasonable rest periods between exercises while keeping my heart rate elevated. After training sessions, I self-evaluated and asked myself if I had trained hard enough or could have pushed a little more. Then, I adjusted the next training session’s intensity, higher or lower, based on my feelings. Over time, I saw gains, which convinced me that my method was successful.
However, was the method optimal? Was there a more efficient path to success or progress? The answer is yes.
Now, instead of using my feelings, I use a smartwatch to record my heart rate and manage rest between exercises. Instead of guessing whether I’m having a rigorous training session, I check my calories burned and make informed decisions based on real-time data.
This example is how I like to think of preventive maintenance compared to predictive maintenance. Preventive maintenance allows me to make decisions based on my feelings. Predictive maintenance allows me to make more accurate assessments based on real-time data and a simple dashboard.
Automated warehouses use many facets of automation, such as autonomous storage and retrieval systems, moving conveyor systems, palletizing and sorting systems, and automated guided vehicles and robots. Found throughout industries such as automotive, machine building, food and beverage, material handling, logistics, and e-commerce, warehouse automation is a fixture in today’s industrial environment. HELUKABEL offers a wide array of flexible and continuous-flex control, data, VFD/servo power and feedback cables, as well as the guidance and protection systems to ensure the transmission of power and data remains constant so materials stay on the move and arrive at the right place in your facility just in time.
analysis difficult, an open architecture solution can converge the data from the various systems to produce a much clearer view in the digital dashboard. When analytics highlight a problem, data sources can be analyzed to detect which system generates the issue, from micro-stops to AGVs receiving incorrect instructions.
In the end, a process analysis can be overlaid on top of the productivity metrics to get a picture of the overall health of the operation and a clear understanding of where the process can improve or where the next bottleneck or failure will occur.
A critical component of this datadriven, preventive maintenance solution is to share all the data sources from the smart sensors and machines to constantly evaluate the health and condition of the process. This is typically managed in the background of the operation in a non-time-sensitive fashion. The advantage is that rather than having the maintenance team periodically or regularly check the systems, the software-driven solution queries the smart sensors for their IOLink-provided health diagnostics. This data can be shared to help operations, engineering, and management understand the warehouse’s long-term health. This requires the previously mentioned methods of converging systems and the technology connectivity that provides the data to be analyzed.
As we continue to debate which diagnostic approach is right for each specific warehouse organization, there are two aspects most may agree on today: having the ability and resources to prevent downtime and failure is strongly desired, and it’s a very interesting problem to solve. l WH
Pepperl+Fuchs
pepperl-fuchs.com
| Courtesy of Pepperl+Fuchs
For an effective preventive maintenance program, all data sources from smart sensors and machines should be shared to constantly evaluate the process and equipment’s health and condition.
| Courtesy of Pepperl+Fuchs
analytical tools to predict potential machine failure and provide health diagnostics.
Realize your vision with Festo’s approach to smart automation for food processing and packaging. Partner with Festo today.
Industry Leadership
Superior Quality Products
Global Training & Support
By Rachael Pasini • Senior Editor
Dynamic warehouses seek robots that can adapt to change with minimal human intervention. With localization and mapping so ware, AMRs can build facility maps, orient themselves, detect di erences, and share changes with their fleet for uninterrupted and safer operations.
When people were building warehouses 10 or 15 years ago in the U.S., few considered employing robots over human labor. In time, autonomous guided vehicles (AGVs) proved useful, and workers gradually appreciated their help. Yet AGVs need tape on the floor, magnets, or some sort of infrastructure, which requires well-thought-out strategies and sometimes permanent facility designs.
In comparison, emerging autonomous mobile robots (AMRs) live on the wild side and don’t necessarily need such infrastructure. They can navigate a facility’s current layout without adjustments to aisle widths or flooring. They’re characteristically flexible and can be less costly to implement.
However, the AMR market is still maturing, with new vendors popping up every day. And there’s a sustained resistance to change and an underlying fear that robots will steal jobs and be a headache to deploy and maintain. Many still ponder who will get the call at 3 a.m. when the robots aren’t working — and whose career will be on the line if the automation fails.
It’s fair to say that AMRs are only as e ective as the people who commission them. So, the robots need a little human support during and after deployment to ensure they fulfill their intended purpose and function correctly.
“We make deploying robots sound really simple, but it’s a change. It’s an automation project and a people-change project,” said Chris Mercurio, sales product manager for AMR solutions in North America at Bosch Rexroth. “Once people get a chance to work with the robots, they realize they don’t have to walk all the way across the floor to get more supplies. They can just press a button.”
But make no mistake, warehouse robots aren’t servants that make people lazy. Sure, they can take over mundane, repetitive tasks, but they can also spare people chronic back pain, reduce trips and falls, and mitigate common safety risks.
“There are a lot of accidents involving forklifts and other industrial trucks. So, we let the robots take the strenuous and unsafe jobs and reserve people for critical thinking, problem-solving, and handling complex tasks. Everything else, we can automate,” said Mercurio.
Post-pandemic labor shortages and supply chain issues drive reshoring and automation efforts to recover from setbacks and prepare for new waves of uncertainty. Over the past few years, more companies have welcomed automation to fill vacancies long-term and move remaining people toward value-add operations. Hence, more AMRs are being deployed with no signs of slowing down.
AMRs’ popularity is intertwined with the advancements of their underlying technologies. For example, scanning and sensing technology improves
alongside increased AMR demand and subsequently improves affordability. Similarly, the electric vehicle industry drives battery technology forward, and the AMR industry can take advantage of longer life and more uptime.
Additionally, software advancements have made AMRs more intelligent, and open-source solutions lower the barriers to entry. Manufacturers can use open-source technology, libraries, and development tools as a base to build upon without reinventing the wheel.
AMRs usually need three pieces of software: (1) a fleet manager that manages tasks and traffic, (2) a navigation piece that plans the paths and controls the robot’s motion, and (3) a localization piece that tells the robot where it is and where it’s going. The localization software is a key differentiator that makes AMRs more independent.
For instance, Bosch Rexroth’s Rokit Locator software is a simultaneous localization and mapping (SLAM) technology that determines the robot’s position and orientation based on an environment’s natural features, such
as the building columns, walls, and machines.
“Rokit Locator creates a map based on the natural environment, and then it’s able to understand where it is on that map and navigate the facility,” said Mercurio. “It’s scanner agnostic and uses existing scanners on the robot to constantly scan the environment, draw a map, and position itself. An algorithm constantly compares the map to what the robot sees so it knows where it is.”
This type of software is special because it’s a standalone solution that AMR manufacturers can use to upgrade their systems. They can also use it for other vehicles, such as forklifts, so that all mobile equipment uses the same map as the robots. This improves real-time location tracking to manage warehouse traffic better. Plus, it’s really easy to use.
“It helps our implementation engineers when they can show up, take the robot out of the box, turn it on, and start mapping the facility with a couple of clicks,” said Mercurio. “Just by driving the robot around, it can create that map of the facility. It almost looks like a video game.”
When the robot comes out of the box for the first time, a user will connect the robot to the facility’s wireless network and software. Then, the user manually drives the robot around with a controller, joystick, or interface, such as a tablet. Many safety features are turned off during the manual run-through, which can take as little as one hour or more than three hours, depending on the facility size. Once the initial map is
| Courtesy of Bosch Rexroth
In dynamic warehouses, AMRs must understand their location as shelves, pallets, and carts move around.
AMRs use simultaneous localization and mapping (SLAM) software to map a facility, orient themselves, and respond to layout changes.
created, the robot can move around autonomously, and personnel must be coached on interacting with the robots to ensure everyone’s safety.
Many warehouses are dynamic environments. Some have wide-open spaces with few landmarks, while others constantly move pallets and carts, making it difficult for robots to orient
Users can monitor AMR locations and pathways along the SLAM-generated map in real time.
themselves. Over weeks or months, enough small changes can throw off a robot such that personnel must redraw the map periodically or deal with the robot getting lost. Most likely, personnel will grow frustrated and stop using the robots.
However, when localization software is deployed to a robot fleet, the fleet
records all detected changes. Then, the software modifies the base map and distributes the changes back to the fleet.
“It doesn’t matter how good your fleet management software is or what kind of robot you have. If the robot can’t localize itself, you’re going to have problems,” said Mercurio.
Rokit Locator can use up to two
During initial setup, a user manually drives an AMR to create the base map. Then, the AMR can operate autonomously and update the map with detected changes.
| Courtesy of Bosch Rexroth
lasers and the wheel odometry for location accuracy. In the near future, Bosch Rexroth will also include a navigation solution to help plan paths. With localization, the robots know where they are; with navigation, they’ll chart an optimal course and respond to obstructions and traffic more intelligently.
“The next big trend in the AMR space will be interoperability — robots from different manufacturers being able to work together in the same environment,” said Mercurio. “And as the adoption rate goes up, warehouses might want to diversify providers to accomplish different tasks. That will push manufacturers to find ways to add value. I’m sure we’ll see all kinds of integrated solutions around robots.”
As AMRs evolve, we may see more 3D vision and more efficient motors and wheels. We may also find more mobile robots outside factories and warehouses, as they’re already in hospitals, grocery
stores, and restaurants. And just as other industries advance warehouse automation technology, hardware and software improvements in warehouses influence applications and make robotic solutions more available and affordable.
l WH Bosch Rexroth boschrexroth.com
Edited by Rachael Pasini • Senior Editor
Autonomous mobile robots safely and efficiently transport different payloads in manufacturing and warehouse logistics operations.
Why did the global stock of operational robots hit a new 3.5-million-unit record? Why did the value of installations reach an estimated $15.7 billion? The IFR analyzed five key things shaping robotics and automation.
Robots play a fundamental role in securing the changing demands of manufacturers and warehouses worldwide. The International Federation of Robotics describes how five robotics trends attract users from small enterprises to global OEMs.
Energy e ciency is critical to improving companies’ competitiveness amid rising energy costs. In many ways, adopting robotics helps lower energy consumption in manufacturing and warehouses. Compared to traditional assembly lines, considerable energy savings can be achieved through reduced heating. At the same time, robots work at high speed, increasing production rates so that manufacturing becomes more time- and energy-e cient.
Today’s robots are designed to consume less energy, which leads to lower operating costs. Companies use industrial robots equipped with energy-saving technology to meet sustainability targets for production. For example, robot controls can convert kinetic energy into electricity and feed it back to the power grid. This technology significantly reduces the energy required to run a robot.
Another feature is the smart powersaving mode that controls the robot’s energy supply on-demand throughout the workday. Since industrial facilities must monitor their energy consumption, such connected power sensors will likely become an industry standard for robotic solutions.
Resilience has become an essential driver for reshoring in various industries. For example, car manufacturers invest heavily in short supply lines to bring processes closer to their customers. These manufacturers use robot automation to manufacture powerful batteries cost-
effectively and in large quantities to support electric vehicle projects. Such investments make shipping heavy batteries redundant, and more logistics companies refuse to ship batteries for safety reasons.
Relocating microchip production back to the U.S. and Europe is another reshoring trend. Because most industrial products nowadays require a semiconductor chip to function, placing the supply close to the customer is crucial. Robots play a vital role in chip manufacturing, as they fulfill extreme precision requirements, and specifically designed robots automate silicon wafer fabrication, take over cleaning and cleansing tasks, or test integrated circuits. Recent examples of reshoring are Intel’s new chip factories in Ohio or the chip plant in the Saarland region of Germany run by chipmaker Wolfspeed and automotive supplier ZF.
Robot programming has become easier and more accessible to non-experts. Software-driven automation platforms let users manage industrial robots with no prior programming experience. Original equipment manufacturers work with low-code or even no-code technology partners, allowing users of all skill levels to program a robot.
The easy-to-use software paired with an intuitive user experience replaces extensive robotics programming and creates new robotics automation opportunities. Software startups are entering this market with specialized solutions for small and medium-sized companies. For example, a traditional heavy-weight industrial robot can be equipped with sensors and new software for collaborative setup operation. This makes it easy for workers to adjust heavy machinery for different tasks. Companies
will thus get the best of both worlds: robust and precise industrial robot hardware and state-of-the-art cobot software.
Easy-to-use programming interfaces that allow customers to set up the robots themselves also drive the emerging new segment of low-cost robotics. Many new customers reacted to the pandemic by trying out robotic solutions. Robot suppliers acknowledged the demand for easy setup and installation and preconfigured software to handle grippers, sensors, or controllers for lower-cost robot deployment. Such robots are often sold through web shops, and programs for various applications are downloadable from an app store.
Propelled by advances in digital technologies, robot suppliers and system integrators offer new applications and improve the speed and quality of existing ones. Connected robots are transforming manufacturing and will increasingly operate as part of a connected digital ecosystem, where cloud computing, big data analytics,
or 5G mobile networks provide the technological base for optimized performance. The 5G standard will enable fully digitalized production, making cables on the shop floor obsolete.
Artificial intelligence holds great potential for robotics, enabling a range of benefits in manufacturing. AI’s main aim in robotics is to better manage variability and unpredictability in the external environment, either in realtime or offline. Consequently, AI and machine learning play an increasing role in software, for example, where running systems benefit from optimized processes, predictive maintenance, or vision-based gripping.
AI technology helps manufacturers, logistics providers, and retailers deal with frequently changing products, orders, and stock. The greater the variability and unpredictability of the environment, the more likely it is that AI algorithms will provide a cost-effective and fast solution — for example, for manufacturers or wholesalers dealing with millions of products that change regularly. AI is also helpful in environments where mobile robots must distinguish between the
objects or people they encounter and respond differently.
Since an industrial robot has a service life of up to 30 years, new technology is an excellent opportunity to give old robots a second life. Industrial robot manufacturers such as ABB, Fanuc, KUKA, and Yaskawa run specialized repair centers close to their customers to refurbish or upgrade used units in a resource-efficient way. This prepare-torepair strategy for robot manufacturers and their customers also saves costs and resources. Offering long-term repair to customers is an essential contribution to the circular economy. l WH
By Mike Oitzman • Editor
An automated guided vehicle (AGV) is a type of unmanned guided vehicle (UGV) that moves throughout a facility by following a set of predetermined paths. An AGV is not a sub-class of a mobile robot. Instead, AGVs are the predecessors to mobile robots and have been in operation since the 1950s. However, they still have a variety of uses within a modern manufacturing or warehouse environment.
An autonomous mobile robot (AMR) is a di erent class of UGV that has more capabilities than an AGV. AMRs are capable of free-movement and real-time path planning, enabling them to collaborate in material handling tasks with humans.
In addition, while AGVs are all-wheeled vehicles, AMRs come in various locomotion configurations. This includes wheeled vehicles, tracked vehicles, bipedal robots, quadruped robots, and multi-legged robots.
Despite the growing popularity of warehouse automation, confusion remains around the various acronyms and technology. For those in the discovery phase of an automation journey, here’s an overview of two of the most talked about warehouse solutions.
The best analogy for understanding one of the primary di erences between an AGV and an AMR is that an AGV is like a railroad train engine, constrained only to operate on its train tracks. On the other hand, an AMR is like a taxi, able to freely move between any two points and replan a route when tra c is too dense.
The term industrial mobile robot (IMR) was introduced in the recent safety standard ANSI/RIA R15.08. Although it was widely debated by industry experts and voted on within the new standard, IMR has yet to reach broad usage as of the writing of this article but may emerge to replace the term AMR in future years.
In addition to UGVs, there are also unmanned aerial vehicles (drones) and unmanned marine vehicles (autonomous boats or ships).
Similarities between AGVs and AMRs
AGVs and AMRs perform similar functions in different applications. Both types of vehicles can:
• Move material from one point to another within a facility.
• Avoid collisions with objects that might come into their path.
• Operate collaboratively and safely with humans within their workspace or intended paths.
• Carry cargo between 2 kg and 1500 kg.
Differences between AGVs and AMRs
It’s not that one technology is better than the other, but their differences make them useful for specific applications and environments. Such differences include:
Simplicity and cost: AGVs have simpler control systems and sensors than AMRs. In some cases, AGVs are a less expensive solution than AMRs.
Paths and infrastructure: AGVs follow paths along a fixed infrastructure, such as magnetic tape or wire, painted lines, QR code stickers, or laser targets, and they remain within the confines of their lanes or paths. Contrarily, AMRs freely navigate their operational space and between a starting point and a destination. They can also operate outside of a building and follow humans around in a “follow me” application.
Payload: AGVs can be designed to carry extreme payloads, such as locomotive engines and airplane fuselages.
The best analogy for understanding one of the primary differences between an AGV and an AMR is that an AGV is like a railroad train engine, constrained only to operate on its train tracks.
On the other hand, an AMR is like a taxi, able to freely move between any two points and replan a route when traffic is too dense.
AMRs are best suited for unstructured environments, creating more opportunities for warehouse flexibility.
| Courtesy of ABB
AGVs can be designed as carriers, scissor lifts, forklifts, or other variations and include modules such as box carriers.
| Courtesy of Jungheinrich.
Obstacles: AGVs may become “stuck” if they encounter an object in their intended path. This often requires the help of an operator to move the object and restart the AGV on its mission. AMRs not only avoid obstacles but actively navigate around obstacles to continue toward a mission goal. However, AMRs can become “lost” if they can’t recognize their surroundings. This often occurs when crossing large expanses of floor space without any recognizable infrastructure, such as airplane hangars or large meeting spaces. AMRs can also become lost in repetitive environments, such as similar-looking warehouse aisles or chaotic work areas, such as loading docks. AMR manufacturers have a variety of methods to keep their machines “localized.”
Applications: AGVs work best in welldefined conditions and applications, such as material handling or WIP in a manufacturing facility. AMRs work best for applications in unstructured environments, such as security, deliveries, and person-to-goods and goods-to-person intralogistics.
Unfortunately, some AMR manufacturers have adopted the term AGV to describe their autonomous machines. This is unfortunate, as it causes confusion within the market. Remember, the primary requirement of an AGV is that it needs some infrastructure within the vehicle’s workspace to enable navigation and cannot navigate around obstacles. l WH
The Spinea DriveSpin brushless DC servo rotary actuators come packed with several impressive features that make them stand out from the competition. First and foremost, these actuators offer high precision and repeatability, thanks to their integrated high-resolution encoder and zero backlash integrated TwinSpin cycloidal reducer technology. This makes the DriveSpin actuators ideal for a wide range of applications that require high positioning accuracy and tight tolerance control.
Another key feature of the Spinea DriveSpin rotary actuators is their high torqueto-weight ratio, which makes them incredibly powerful despite their compact size. With torque capacities ranging from 18 Nm to 460 Nm, these actuators can handle heavy loads with ease, making them suitable for use in industry 4.0 and automation applications, such as robotics, packaging, and assembly systems.
In addition to their wide range of features, the Spinea DriveSpin rotary actuators also offer many benefits to users. These benefits include reduced maintenance requirements, long service life, and high efficiency. Unlike hydraulic or pneumatic systems, these electric actuators do not require regular maintenance, resulting in significantly lower operating costs over time. Furthermore, they boast a long service life, thanks to their robust construction and high-quality materials. With an efficiency rating of up to 95%, DriveSpin actuators also help users conserve energy, further reducing their overall operating costs.
Advantages:
• low lost motion
• low moment of inertia
• high reduction ratio
• high kinematic accuracy
• high moment overload capacity
• high capatity of the integrated radial-axial output bearings
• high dynamic performance
Applications:
• Robotics: 6-axis robots, gantry robots and manipulators
• Machines: CNC machine, grinding machine, lathe machine
• Special machines: bending machine
• Medicine equipment
• Aerospace applications
• Flight simulators
• Defense industry
• Semiconductor industry
• Radar and monitoring systems
In the last decade, the e-commerce industry has become a facet of modern society and has fundamentally changed how we view retail today. The ability to purchase anything online and have it delivered to your door in a matter of hours has become vital to both individual consumers and businesses alike.
This change from traditional retail environments has been good for consumers but challenging for retailers and suppliers to keep both prices and delivery times down. It has spurred on significant changes in warehousing, from the way they’re managed all the way to where and how they are built.
As an intelligent motion company, Dorner gets an inside peek at many different industries. These are a few of the areas we see growing in warehousing development and management in the future.
Automation has had exponential growth in recent years, and with continued improvements in AI and adaptive machine learning, automation is the way of the future. Not only can automating manufacturing and logistics help companies maintain productivity through staffing shortages and other unforeseen challenges, but it can also improve lead times and accuracy in operations.
In warehousing, automation can help speed up the picking and packing process, while also improving accuracy and efficiency. The popularity of e-commerce means retail suppliers have moved away from shipping large quantities of the same product to brick-and-mortar stores, to shipping individual items directly to consumers. Rather than staff locating and picking several different products that may be across the warehouse for one order, the use of an automated picking system, such as AGVs, vertical storage systems, or a network of conveyance lines, can speed up order processing and packaging while still maintaining a high level of accuracy.
To aid in tracking products throughout the picking and packing process, as well as managing warehouse inventory, some companies are turning towards innovative warehouse management software and Industry 4.0 technology. With RFID tags or other unique product IDs used throughout warehouse inventory, automation tools such as scanner-integrated conveyors can index, sort, and monitor product as it moves throughout the warehouse and shipping process.
Some of the leaders in warehousing and consumer goods distribution are already utilizing full automated warehouse management systems to track product, monitor inventory, and even measure machinery performance. A completely integrated system like this puts important data in one place so it’s easy to put the data to work towards meaningful development and growth of the facility.
Finally, with available commercial space shrinking every day, sprawling warehouses are becoming more difficult to achieve. However, retailers still need to maintain a huge range of products in their warehouse inventory to keep up with consumer demand. The solution to this challenge is a growing adoption of vertical storage systems.
Offering a compact solution to sorting and storing product, automated vertical storage can be easily integrated within a warehouse to make moving product from the shelves to conveyors and through packaging simple, accurate, and fast.
Automating warehouse operations can help improve throughput, efficiency, and accuracy. Whether it’s switching over the entire warehouse to a completely automated system or automating small processes, it can make a significant difference for companies.
Dorner is here to help you design and build custom conveyor systems to automate your warehouse and logistics processes. Our team will work with you to help determine what system will meet your needs and improve product throughput in the warehouse. Contact us to learn more and get a free quote.
In today’s automated warehousing industry, Amazon and Walmart have distinctly established themselves as the household names of global consumers. How did they achieve such a demand of consumer usability and market share? They designed an infrastructure so that their customers at the push of a few buttons, could quickly purchase and receive almost anything they want or need without having to step outside their house, except maybe to grab the package they ordered just a few days earlier.
The brilliance of this application is its simplicity and ease of access to its users. What is not so simple is the actual infrastructure itself. Warehouse automation involves so many moving and programmable components that if any of those components are not functioning properly, it disrupts the entire flow of the automated process. From the automated storage and retrieval system and the conveyor system down to the pick and place center, getting inventory sorted, packaged, labeled and shipped properly is a very complex process. Even the cable and electrical system solutions being specified for these components add another level of complexity to ensure the longevity of the system itself and safety for its users. Designing a robust, efficient and competitive automated system is a delicate balance for everyone involved. Once the system is commissioned, the facility operations become almost completely self-sufficient with just ongoing routine maintenance and control station monitoring oversight.
As conveyors and automation components require significant technical aptitude and focus from both designer and supplier, pairing artificial intelligence and robotics with your warehouse automation moves things to another level. Automated guided vehicles can interoperate algorithms, and independently move inventory to and from dedicated areas around the clock. Traditional multi-axis robots pick, sort and place products as well as handle heavier products that employees can’t manage without assistance. This improves not only efficiencies but safety as well.
Amazon has over 520,000 robots working in unison with their automated warehouses and have added over one million jobs worldwide to transform their business. Walmart recently partnered with Symbotic to deploy and retrofit all 42 of its regional distribution centers over the next 10 years with robots. These industry leaders are paving the way in industrial automation, which is starting to see smaller type companies with sizeable warehouses follow suit as it relates to warehouse automation and efficiencies just to stay competitive. The importance of factory floor space,
fulfillment process flow, reducing idle and/or downtime, and improving employee safety and efficiencies is critical to these types of business models.
With these factors in play and more within the infrastructure of an automated facility, you also have to be fully prepared to respond to any electrical, mechanical or software issues that can create significant delays to consumers or end users and revenue loss. Robust and sustainable cable systems are key to the life of the automated warehouse, so qualifying and selecting the right component manufacturer and/or electrical system supplier becomes more important than ever. Suppliers who control not only the design quality and manufacturing of their products, but also provide the added value of complete component and electrical system solutions for automated applications quickly rise to the top.
HELUKABEL is a global cable system solutions provider specializing in the production of cables, wires, accessories, cable assemblies, and guidance and protection systems found in equipment used throughout today’s automated warehouses. HELUKABEL offers a wide array of flexible and continuous-flex control, data, network and bus, VFD/servo power and feedback cables to reliably transmit power and data to keep materials on the move.
Our ability to provide cable solutions from bulk cable to complete, plug-and-play cable sub-assemblies makes us the one-stop shop for complete electrical system solutions within the automated warehouse ecosystem.
In true WAGO fashion, the manufacturer is continually innovating and improving its product offering. WAGO’s 221 Series Lever Nuts are an excellent example of this, representing the company’s answer to the twist-type splicing wire connector. This termination device quickly and easily connects different wire sizes and types, using 2, 3, and 5-wire connectors.
“A few years ago, WAGO developed the original 222 Series LEVER-NUTS®, which has been effective and successful,” shares Evan Syens, Product Manager, Electrical Splicing Connectors with WAGO Corporation. “However, innovation doesn’t stop for us just because a product has hit the market. We never settle for ‘good enough’ and are always striving for better. WAGO is all about ongoing advancements.”
To this end, WAGO created their newest version wire-connector solution, the 221 Series LEVER-NUTS®— and they’ve quickly become one of the company’s top-grossing products.
“The biggest difference between the original 222 and the latest 221 Series is the size, as the newest version is smaller,” says Syens. “But, perhaps, the most notable feature of our 221 Series LEVERNUTS® products is their transparent housing, which is significant.”
This is because with a typical twist-type connector, it’s impossible to know how secure the wire connections are for each terminal, which is a maintenance and safety concern.
“The clear housing completely takes the guesswork out of the installation process,” Syens explains. “Without it, how would you know how many twists are ideal for a secure connection? There’s room for error. In fact, installers will often secure wires with electrical tape to maintain the twist-type connection. But that’s unnecessary, thanks to WAGO’s innovation. Simply pull the orange lever up, insert a stripped conductor (according to the strip-length gauge on the side of the 221) and push the lever back down. That’s it. You’re done.”
Since every 221 Series LEVER-NUTS® also includes CAGE CLAMP® technology (the spring-pressured connection technology that WAGO pioneered back in the ’50s), installers can also ensure a secure a reliable connection. The CAGE CLAMP® is starting to become the industry standard for electrical interconnection technologies.
What’s more, is WAGO has incorporated test slots in the LEVERNUTS® Series for additional safety — one in the direction of wire insertion and one on the opposite side. This allows an installer to insert a test probe into the slots to determine if a wire is live.
“Another unique feature about these products is that they’re reusable, without any added steps. For example, there’s no need to re-strip the wires. Simply lift the lever and connect the new wires,” he says. “Again, it’s that simple.”
WAGO offers two different versions of the 221 Series:
• The original variant: 24-12 AWG
• The 10 AWG variant: 20-10 AWG
“The 20 to 10-gauge version also has three variants — a 2, 3, and 5-conductor, which goes up to 600 volts and 30 amps. And, as for the operating temperature, each variant is approved to 105° C,” says Syens.
Along with these innovative connectors, WAGO also offers a line of mounting carriers that can be mounted onto a DIN Rail or chassis, easily cleaning up your cabinet, panel, or junction box.
“It’s really about peace of mind because with CAGE CLAMP® technology, you can be confident in a secure connection for your application,” says Syens.
Whether for an electrical contractor, DIY home projects, lighting applications or use in hazardous locations, WAGO’s 221 LEVER-NUTS® Series offers fast, safe, and dependable connection technology.
“Now when people see the orange lever, they associate it with WAGO and know the product can be trusted.”
• Terminate conductors from 24–10 AWG (with two models: 24-12 AWG and 20-10 AWG)
• Connect solid, stranded, and fine-stranded conductors
• Combine different wire sizes and types
• Install devices with higher levels of power consumption
• Save time connecting wires without the use of tools
Design equipment faster, smarter, and under budget with TiPS from leading suppliers.
Acoustic cameras consist of microphone arrays used to locate and characterize sounds. There are various microphone array structures to support specific analysis needs. Some acoustic cameras also have an embedded visual camera to supply an image over which the acoustic localization information can be presented. Acoustic camera application examples range from analyzing noise inside automobile cabins, aircraft, and trains, to quantifying the noise signature of wind turbines and monitoring industrial environments for anomalies and potential machine faults.
An acoustic camera consists of a microphone array, a sound processing section, and a display. Microphone arrays can consist of dozens or hundreds of microphones. The sound processing section acquires the incoming sound information from the microphones simultaneously or with precise relative time delays. As the sound travels from the source, it arrives at the various microphones at di erent times and with di erent intensities based on the relative locations of the microphones.
Figure 3. This handheld acoustic camera is designed to identify the location of leaks in compressed gas systems and localizing partial discharge conditions in HV electrical systems. | FlukeBeamforming is one method used for sound localization. It works by adding delays to the microphone signals and adding the signals to amplify the sound coming from a specific direction while minimizing or canceling the sound coming from other directions to essentially “point” the array in a specific direction. The calculated sound intensity information can be displayed on a power map.
Two techniques for sound localization are time di erence of arrival (TDOA) and angle of arrival (AoA). They can be combined using a generalized crosscorrelation (GCC) algorithm. GCC is relatively simple to implement and has low computational requirements. The tradeo is that many microphones are needed to achieve accurate localization results. Using a more complex algorithm can reduce the required number of microphones but will require a more capable (and more expensive) computational section with a faster processor and more memory.
Going beyond simple sound localization, sound intensity is quantified in dB and can be measured using acoustic probes. Some acoustic cameras include sound intensity and sound particle or pressure sensing measurement capabilities. Acoustic holography is another acoustical measurement technique and is used
to determine the spatial propagation of acoustical waves or for the identification of acoustic sources. It is based on spatial Fourier transforms to estimate the near-field sound intensity around a source by using an array of particle velocity or pressuresensing transducers.
Advanced acoustic cameras are available that combine digital microphones with AI. The use of AIbased measurement software enables developers to o er acoustic cameras with higher performance capabilities at a lower cost.
Two-dimensional (2D) acoustic mapping can be implemented using a variety of microphone array structures including rings, stars,
octagons, Fibonacci structures, and rectangles, sometimes called paddles. The di erent structures provide varying performance options for near-field, far-field, and other mapping characteristics. These arrays all have unidirectional microphones all facing the same direction. 2D acoustic mapping is suited for measuring planar surfaces with the acoustic camera array perpendicular to the surface. Many surfaces are not completely flat, making it di cult to produce precise measurements with a 2D array. When 2D mapping is used to approximate three-dimensional (3D) surfaces into a plane, it can introduce measurement errors in the calculations of sound intensity. The approximations typically don’t account for the distance di erences
Key technology content produced by the editors of Design World compiled in individual design guides. Collect these free technical PDFs!
GEARMOTORS
HUMAN-MACHINE INTERFACES (HMIS)
Find these and additional guides in our DESIGN GUIDE LIBRARY, bookmark this site as guides are added on an ongoing basis! designworldonline.com/design-guide-library
SERVOMOTORS
COUPLINGS
BROUGHT TO YOU BY:
resulting from the surface being measured having di erent relative depths at di erent points. If the space is large, those errors can be small, but in small spaces, the error can be significant.
When implemented with a double-layer channel system of microphones, 2D arrays can implement near-field and far-field measurements using intensity mapping. In addition, with the necessary software, acoustic pressure can be mapped while particle velocity/ acoustic intensity measurements are being mapped. Handheld 2D arrays are available for troubleshooting and portable applications, while standalone arrays can provide higher precision laboratory and engineeringgrade measurements. Various array structures are available that are suited for di erent applications:
Ring arrays are suitable for beamforming and are used indoors and outdoors for far-field and nearfield measurements.
Star arrays are also suitable for beamforming and are mostly used for far-field measurements.
Fibonacci arrays are suitable for holography or beamforming and can be used for near-field and far-field measurements with the same array. Based on a Fibonacci spiral pattern of the microphones, these arrays can provide a wider dynamic range than other structures.
Paddle arrays are good lowfrequency, near-field measurement tools (Figure 1).
3D acoustic cameras consider surface nonlinearities and correct errors in measuring the distance between the microphone and the surface being measured. These cameras use a 3D model of the surface or space being analyzed. If the camera encounters a sound from a source that is not included in the model, errors can
arise, like mapping the sound to a random location, or the sound may be eliminated from the measurements.
3D acoustic cameras are especially suited for analyzing enclosed spaces like room or vehicle interiors. These cameras consist of a sphere of microphones, with each microphone pointing outward perpendicularly to the surface of the sphere, that can provide omnidirectional sound measurements (Figure 2). These cameras often employ beamforming with the measurements mapped into 3D point clouds or a 3D computer-aided drawing (CAD) model of the environment being measured.
A handheld acoustic imager has been developed for applications like identifying leaks in compressed air, gas, steam, and vacuum systems and detecting and localizing partial discharge conditions in insulators, transformers, switch gears, or high voltage (HV) powerlines. The 64 microphones in the acoustic array operate from 2 to 100 kHz with a detection range of up to 120 meters. The array has a field of view of 63° ± 5° and takes images at 25 frames per second. The integrated digital camera has the same field of view plus a 3x digital zoom capability with a resolution of 5 megapixels. In addition to displaying still images, the system can take videos up to 5 minutes long (Figure 3). To minimize background noise interference, the imager automatically compensates for background noise and has multiple bandwidths that are selectable via manual inputs or with usermade presets.
Devices called sound scanners are available that can simulate up to 480 microphone positions using 5 microphones on a boom that’s rotated in a circle (Figure 4). The scanner has been developed specifically for use in field measurements since it’s lightweight and compact, making it easy to transport. It’s intended for use in building acoustics and environmental noise measurements. The 1.32-meter diameter of
the sensor structure means that precision visualization of lowfrequency sounds is supported.
Two arrays can be better than one
A new method has been proposed that uses two microphone arrays with only two microphones in each array to form “left” and “right” channels. TDOA was used to convert the channels into angles using simple GCC without additional algorithms (Figure 5). A prototype of this two-channel approach produced a position error of about 2.3 cm and an angle error of about 0.74°using only four microphones in an indoor environment.
Summary
Acoustic cameras are a well-established technology and include both 2D and 3D imaging systems. They use algorithms based on techniques like beamforming, sound intensity measurements, and acoustic holography. The addition of AI is enabling the development of high-performance acoustic cameras at a lower cost. In addition, techniques are being developed that enable fewer microphones to be used to produce high-accuracy measurements, further reducing the cost of employing acoustic cameras. DW
This engineer just set up several ultrasonic sensors for a new machine line. Despite the varying ranges he had to set, he used a single software application. He set the distances. He adjusted gain. He filtered out anomalies. And those settings will remain for future replacement sensors.
Figure 4. The rotating boom in this sound scanner can simulate up to 480 microphone positions. | Seven BelThat was “Simply easy!”
Whether in mechanical engineering, welding processes, storage and material handling, mobile equipment, or in the automotive or process industries – Pepperl+Fuchs provides sensors and the corresponding connection components from a single source, thereby increasing the productivity and availability of machines and plants. Our portfolio ranges from sensor-actuator cables, cordsets and splitters to data cables, field connectors, junction blocks, and sensor-actuator receptacles.
The redesigned M8 and M12 connectors impress with maximum service life, particularly rugged design, and simplified installation. An innovative locking mechanism increases vibration resistance and durability. Cable types range from solid and economical to extremely durable or application-specific options, including selections with UL listing, for welding areas or challenging outdoor environments. IP67, IP68, and IP69 types of protection are available.
No two applications are alike. Pepperl+Fuchs o ers the right cable for every process.
The Italian Trade Agency, in cooperation with UCIMU-SISTEMI PER PRODURRE, is pleased to announce this one-day forum
YOU ARE INVITED TO JOIN US TO LEARN AND NETWORK WITH:
Leading Italian suppliers to industry and how each contributes to a more scalable, resilient, and secure manufacturing environment.
Scalable, resilient, and secure manufacturing principles are important for businesses to ensure that they can handle growth or changes. These principles can be applied to build greater resilience into supply chains, structure organizations and decision processes for resilience, build resilient and scalable machinery and technologies, and build more secure and resilient next-gen U.S. supply chains and manufacturing ecosystems.
MORE INFO & REGISTRATION: www.italtradeusa.com/vitruv-2023
Thought leaders delivering Manufacturing Market Outlook and Smart Manufacturing Trends presentations.
SABIC sabic.com
Two new LNPTM CRX polycarbonate (PC) copolymer resins o er a distinct combination of robust chemical and impact resistance, thin-wall transparency, dimensional stability, and processability. In device applications such as clear covers, screens, and display lenses, the new materials can overcome key drawbacks of incumbent PC resins and copolyester resins when exposed to disinfectants or aggressive chemicals.
Customers can choose LNP ELCRESTM CRX1314TW copolymer or its bio-based equivalent, LNP ELCRINTM CRX1314BTW copolymer, which o ers up to a 42% reduction in carbon footprint based on life cycle assessment (LCA). Both grades feature limited biocompatibility according to ISO 109931 and coverage under SABIC’s healthcare product policy, which provides stringent management of change processes.
Like all LNP CRX materials, the new grades feature exceptional resistance to harsh disinfecting chemicals, such as quaternary ammonium compounds, alcohols, and peroxides, which can lead to the environmental stress cracking (ESC) of medical device displays and covers. Furthermore, these materials o er transparency equivalent to that of PC resins at thin-wall geometries of 0.8 mm to 1.0 mm and o er translucency at higher thicknesses. They also deliver high impact resistance across a wide temperature range (down to -40° C), excellent dimensional stability, and good processability. Both grades meet the UL94 HB standard for horizontal burning.
AutomationDirect automationdirect.com
The new Murrelektronik surge suppression devices help protect and lengthen the life of motors, contactors, relays, solenoids, and PLC outputs. These surge suppression devices support a variety of applications and provide protection from voltage spikes and electromagnetic noise caused by inductive loads.
New additions include universal surge suppressors that reduce high voltage spikes created when contactor coils are de-energized, motor surge suppressors that protect 3-phase motors from the damaging e ects of line surges, and valve surge suppressors that mount between the valve base and valve plug to protect against damage caused by voltage spikes from solenoid coils.
The new Murrelektronik surge suppressors are CE marked, RoHS compliant, o er a 1-year warranty, and start at $8.00.
teledynedalsa.com
The Z-Trak LP2C 3D profile sensor family for in-line 3D measurement and inspection applications is the latest member of the Z-Trak family. The LP2C 4K sensors deliver 4,096 samples per profile and an x resolution down to 3.5 microns, allowing customers to measure and inspect parts with tighter tolerances, and to identify smaller defects cost-e ectively.
Ready to use straight out of the box, Teledyne’s Z-Trak LP2C 4K sensors are factory calibrated and combine high scanning speeds with easy-touse software tools, delivering highly repeatable and accurate height, width, and length measurements. With its compact size and simplified cabling, Z-Trak LP2C is suitable for applications in battery, automotive, factory automation, robotics, and logistics markets.
Z-Trak models are available for measurement ranges of up to 650 mm and have a horizontal field-of-view of up to 1200 mm. The LP2C 4K series can also handle a wide variety of surface and material types with its red and blue eyesafe lasers.
For further information about products on these pages visit the Design World website @ www.designworldonline.com
us.mitsubishielectric.com
The iQ-R Series CC-Link IE TSN Plus module supports CC-Link IE TSN and EtherNet/IP networks in one module. CC-Link IE TSN is an open industrial network technology that combines gigabit Ethernet bandwidth with Time Sensitive Networking (TSN) allowing for high-speed motion control, safety, and standard communication I/O devices. EtherNet/IP networks allow for communication with third-party devices. The new iQ-R Series CC-Link IE TSN Plus module allows users to connect CC-Link IE TSN devices to port 1 and EtherNet/IP devices to port 2 without a ecting CC-Link IE TSN communication performance. The module functions also include an easy configuration in PLC programming software, saved space on a PLC rack, centralized control of servo motors, and dual ports that allow for customization of use to best fit your needs.
Aside from the main benefit of dual support of networks that were once separate entities, a user will appreciate the saved cost of not having to purchase and implement additional devices, easy network troubleshooting to reduce downtime, and an overall decrease in the need for additional spare parts.
Advantech advantech.com
The EKI-8510G is the next generation of industrial Ethernet switch which supports real-time communication through TSN technology, providing determinism over Ethernet-based networks to guarantee data delivery for critical time-sensitive applications. Designed with industrial use cases in mind, EKI-8510G supports full layer 2 managed functionality and complies with EN 50121-4 transportation regulations for approval for railway track use. Equipped with 8 Gigabit ports and 2 Gigabit SFP ports, EKI-8510G o ers high-speed transmission and an SFP socket for easy and flexible fiber connectivity.
Collaborating with CLPA, Advantech has participated in the Automation Taipei exhibition for the last three years, from 2020 to 2022, demonstrating Advantech’s development and commitment to continued success in the field of TSN technology. The TSN technology framework is empowered by the development of interoperability and stability, enabling industrial operators to enhance industrial communication automation, timing accuracy, and furthermore, realizing the blueprint of the Industrial Internet of Things (IIoT).
NewTek newteksensors.com
These spring-loaded LVDTs provide ultra-precise dimensional measurement of high-volume molded automotive parts in plastic mold testing. Di erent interior, exterior, and mechanical automotive parts, such as bumpers, heating components, and door handles, are manufactured through an injection molding process. To ensure product consistency, quality, and adherence to federal and state standards, the molded parts are tested for defects.
MBB Series gaging probes are used in test stands to provide roundness and size measurements of finished auto parts to ensure their dimensional stability. As plastic can shrink or distort, the spring-loaded linear position sensors can help detect units that are out-of-tolerance and provide output for product acceptance or rejection. Detecting defects is important to maintain product quality to ensure fit and function.
Sensors o er strong linearity (< ± 0.5% full range), great precision, infinite resolution, and extreme reliability with greater than 100 million cycles. Available in ranges ±.040-in. (±1.0 mm), ±0.100-in. (±2.5 mm), and ±0.200in. (±5 mm), the MBB Series sensors features high precision linear ball bearings for smooth probe movement without stiction and excellent repeatability.
SALES
Ryan Ashdown rashdown@wtwhmedia.com 216.316.6691
Jami Brownlee jbrownlee@wtwhmedia.com
224.760.1055
Mary Ann Cooke mcooke@wtwhmedia.com
781.710.4659
Jim Dempsey jdempsey@wtwhmedia.com
216.387.1916
Mike Francesconi mfrancesconi@wtwhmedia.com
630.488.9029
Jim Powers jpowers@wtwhmedia.com
312.925.7793
@jpowers_media
Courtney Nagle cseel@wtwhmedia.com
440.523.1685
@wtwh_CSeel
Publisher Mike Emich memich@wtwhmedia.com 508.446.1823
@wtwh_memich
CEO
Scott McCafferty smccafferty@wtwhmedia.com 310.279.3844
@SMMcCafferty
EVP
Marshall Matheson mmatheson@wtwhmedia.com 805.895.3609
@mmatheson
DESIGN WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. DESIGN WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.
DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2023 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.
Subscription Rates: Free and controlled circulation to qualified subscribers. Nonqualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.
Subscriber Services: To order a subscription or change your address, please email: designworld@omeda.com or visit our web site at www.designworldonline.com
DESIGN WORLD (ISSN 1941-7217) is published monthly by: WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices.
POSTMASTER: Send address changes to: Design World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114
On those occasions when I’m asked, “How stupid do you think I am?” my standard smart-ass response is “What units would you like me to use?” There is, to the best of my knowledge, no recognized unit of stupidity. Lack of recognized units, whether for stupidity or other measures, can be a problem.
Environmental, social, and governance (ESG) reporting is now all the rage. The business world measures and tracks things it cares about. The blossoming in ESG trackers shows a clear desire on the part of business to care about the planet and society. Scott Adams took aim at ESG in a series of Dilbert cartoons. He describes ESG as worse than something devised by “a crooked politician and a crooked financial advisor.” I don’t agree about crooked intent, but I do see systemic issues. I trace many to a lack of units.
Units are important. Society recognized the importance of standardization for both engineering and finance centuries ago. Platinum/ iridium cylinders and rods in vaults are evidence of the importance placed on standardization in engineering and commerce. A recognition that there were many meters being used (all slightly di erent) led the French to define the meter in the late 1700s based on natural quantities. The meter would be one ten-millionth of the distance from the equator to the North Pole. The distance was measured, math done, and a platinum bar crafted to length. Except, they got it wrong. The meter was defined as the length of miscalculated bar, o by 0.2 mm. In 1960, the meter was redefined based on krypton-86 emission. In 1983, the distance light will travel in a vacuum in 1/299,792,458 of a second became the meter we use today. The speed of light now replaces the pole-to-equator distance as the natural quantity. The meter is invariant in time and place, still o by 0.2 mm from the original intent.
Engineering relies on units being invariant in time and place. The inputs to calculations are not subjective. They are absolute with error bars defining precision. Engineering exists to do something useful, to make products and processes for society. Engineering and economics combine to determine whether a product or process is practical. Success is measured in dollars, cold hard cash. Everything collapses to a single figure of merit, an NPV, an IRR or simple ROI, that, when compared to other investments, shows promise or not.
The push to add ESG metrics to the mix, noble as it is, has a units problem. Measures of ESG are indices. An index is an admission that there is no single figure of merit. Di erent measures are mushed together, each with subjective coe cients to make an index. Let me explain. For the environmental part of ESG metrics, there will be various metrics tracked, such as total GHG emissions, spending on environmental projects, the amount of renewable energy used, and more. Kilograms, dollars, and watt-hours can’t be directly compared. The creator of the index applies subjective coe cients when creating the index, ultimately presenting a unitless result. Some may value GHG emissions, others di erent metrics. Further, the coe cients are not guaranteed to be constant year-to-year. The result is an uncertain, ultimately subjective, metric that can vary in place and time.
We are left with ESG being an inexact add-on to business metrics we’ve come to know. ESG is a Dilbert topic because of the ambiguity, the lack of clear units, and the subjective nature. We’ve got to get closer to something everyone agrees upon, like we did with the meter — even if it is imperfect. DW
PBC Linear supplies American-made cut-to-length steel, stainless steel, and aluminum shafting with various available machined end options. Their modernized manufacturing facility is set up to keep shafting products in-stock and their Midwestern location offers quicker and cheaper shipping while avoiding the uncertainty of border customs.
Matching your bearings and shafting is critical to maximizing system performance. PBC Linear certified shafting works in sync with Simplicity bearing product lines for optimal plain bearing performance.
Request a FREE Sample at:
Using corrugated tubing to manage robotic cables shortens cable lifetime and makes replacement a hassle, and if any damage occurs the entire tube needs to be replaced. triflex R cable carriers solve these issues by allowing cables to be pressed in externally, minimizing installation time while using a built-in strain relief system to protect the cables from additional load.
