Design World November 2016 by WTWH Media LLC

www.designworldonline.com November 2016

INSIDE:

MOTION CONTROL: Manufacturers respond to the Internet of Things for nextgeneration motion systems. PAGE 58

LINEAR MOTION: Surface degradation due to friction typically arises from lubrication problems. PAGE 68

MECHANICAL The range of applications for hinges is expanding and so are the types of positioning technology available. PAGE 74

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I n s i g ht s Wearable robotics as the next big thing? Popular movies have long imagined robotic assist type machinery, from the Power Loader exoskeleton that Ripley wore in Aliens to the military weaponry showcased in Starship Troopers and Avatar—not to mention what is basically the entire premise of the Iron Man movies. But, as so often happens, the real world is catching up to the imaginations of science fiction writers. At last month’s Fluid Power Innovation and Research Conference, Professor Thomas G. Sugar of Arizona State University discussed the trends in wearable robots. The key to these devices, Sugar argued, is that we’re getting older as medicine has improved. And for those with disease—say, cancer, heart disease, or diabetes—it’s often harder to walk, to get up and down, to lift objects. “People are getting older and they still want to walk, they still want to be agile,” Sugar said, noting that sitting is believed to contribute to diabetes, cardiovascular disease, and greater risks of other types of mortality. “We need to walk, so that why wearable systems [are needed]. We need to walk.” Sugar said that the foundation of technologies for wearables are here now. “We’re got batteries, microprocessors,” he said. “You’ll always need better actuators, but there’s systems out there. Wearable robots are key for the health market, assisted market, manufacturers, military, and recreation.” There is an amazing amount of wearables that are currently in development, including: • Devices that allow stroke victims to practice repetitive tasks and build up those neural pathways • Prosthetics that can test for stiffness in an individual user and tune for it • Rehabilitation exoskeletons attached to treadmills to allow people to walk • Gravity-compensation devices that are used with muscular dystrophy patients • Hydraulic systems for picking up huge weights, suitable for warehousing uses • Hand-assist devices that allow the user to better grip objects • So-called chairless chairs, which allow the user to squat—they then lock in place, so the user can work in an otherwise uncomfortable position, and • Recreational devices, which assist in skiing or running Whether working on exoskeletons, orthoses, or prostheses, he said that designers need to build devices that seamlessly interact with the user; you cannot force them into some type of motion. The person has to be able to walk and have the robot “follow” them—you can’t disrupt the gait cycles or normal movement. People want to be able to move comfortably. And the massive exoskeletons that many people envision aren’t the reality in the near future, smaller units—ideally 10 lb or less in weight—are ideal. Sugar said that in testing, people who wore larger devices, in the 16-lb range, felt like they were walking through a swimming pool or that it was like a piece of exercise equipment. Sugar’s team has created a hip exoskeleton, with 10% metabolic augmentation. He said that it’s actually 10% easier to run with the device than no device at all. They had people running fast, too—12.8 miles per hour. Battery life and component durability will continue to be key concerns moving forward, but there’s no question that these devices—potentially improved upon by readers of this publication—will make our personal and work lives easier in the coming years. DW Pa ul J. He n ey - Edi tor i al D i re ctor phe ney@wtwhme di a.com

On Twitter @ DW—Editor

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

Loser! Should engineers learn to be more civil? Recent events have gotten a lot of people concerned about personal attacks, name calling, and reputational smears. No, we’re not talking about the presidential election. Sadly, it is becoming almost as easy to find examples of bullying and defamation in scientific and engineering research as in politics. This uncivil behavior ultimately cheapens scientific ideas.

So points out Dr. Tee Guidotti, president of the scientific research society Sigma Xi and a physician/consultant in occupational and environmental medicine. “Scientists are human beings and frequently aren’t nice to each other,” he says. “Rather than dealing with disagreements by examining data, scientists are almost as likely as the general public to question the motives of their antagonists.” It isn’t just that bad-mouthing bums people out. It can thwart or delay progress in scientific and engineering endeavors. Perhaps the classic illustration of the trend involves the bile spewed on both sides of the climate change debate, though this might be a worst-case example. “To be clear, I live in a ‘bad neighborhood,’ working on occupational and environmental health, where such tactics are more common than elsewhere in science/STEM,” says Guidotti. On a more granular level, consider this situation from my own past: I once had a drinking buddy who discovered a mistake while making a final review of an engineering specification he’d help prepare. Correcting it saved his client about $30,000. Instead of hearing something like, “nice catch” when he brought the situation to light, his client questioned his intelligence for making the initial mistake. “If I ever find another glitch like that, I’ll just shut up and let them pay the money,” he fumed. Those of us with technical backgrounds would like to think we’re above the kind of

name calling my friend received. But it is surprising how often ordinary interactions degenerate into nasty behavior. “Particularly in hot-button issues like climate change, there can be a straight-to-thejugular kind of one-upmanship or an effort to assert alpha dominance,” says Guidotti. “And a lot of research is characterized by fine differences in how to interpret hard data. The situation can escalate because you have reached the limits of what data can tell you, and you are trying to interpret meaning. The meaning is the sticking point. What is meaningful to one person who states an opinion may violate the values or appear to contradict those of their critics. We end up using interpretations of data as surrogates for arguments that really have more to do with how we feel than with what the data says.” You might wonder how to make interactions more civil. Civility among politicians might be a lost cause, but Guidotti thinks science and engineering students need schooling in this area. “The only way to deal with incivility is to call it out. When students see role models fighting at meetings or deprecating one another or being just plain rude, they model that behavior,” he says. “It ends up debasing the scientific enterprise because all-important discussions about weighing arguments becomes biased and isn’t conducted fairly. And that is harmful to good science and engineering because both are, at their core, social processes.” DW

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

On Twitter @ DW—LeeTeschler

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Te c h n o lo gy Fo r wa rd

How can we make manufacturing “cool” again? It’s amazing that in this day, the

Manufacturing has changed by the shift average employment age person in the U.S. to digital technology. Even if longed for still views manufacturing as a dirty, ugly job. manufacturing jobs returned to the U.S., potential employees would find those jobs That was yesterday’s manufacturing handled by automation. Some might view jobs, which required mostly strength with this new manufacturing reality as harsh, but some tasks requiring specialized smarts. the world has shifted to “digital” today. You Today, robots handle most of these tasks must be able to work with automation for gainful employment. That means employees and processes. Human interaction has must have the ability to work with additive evolved to analysis and problem solving— manufacturing too. Soon, it means working finding ways to make manufacturing even with the Internet of Things and artificial more efficient with more throughput. intelligence. Yet, most Americans, 71% according to a survey conducted by ORC International on behalf of Proto Labs, do not perceive manufacturing jobs as high-tech occupations. On the one hand, this view accounts for the frustration of pockets of U.S. workers struggling to find a job. They are not prepared to work in manufacturing anymore, lacking the high-tech skills needed. On the other hand, those with the skills do not see the manufacturing opportunities in front of them. They seem oblivious to how digital technologies have transformed industrial production.

This situation will be a problem; U.S. industrial companies will need workers to fill an estimated 3.5 million manufacturing jobs during the next decade, notes the Manufacturing Institute, a research group that investigates how to develop and attract skilled workers to the manufacturing industry. Said Vicki Holt, CEO of Proto Labs, “The same skills required of software developers at places like Google, Facebook and Amazon are now being applied in the manufacturing industry.” Noted the survey, only about 10% of the respondents associate a software developer in front of a computer screen with today’s manufacturing jobs. These manufacturing workers develop software that expedites the front end of the manufacturing process — before a machine gets involved — and enables more efficient work on the plant floor. These are high paying jobs too, even though 33% of the respondents don’t believe so. Software developers for manufacturing often earn more than $100,000 per year, according to the U.S. Department of Labor. For U.S. manufacturing to return to its former days of glory, everyone must do their part, “…. to ensure that we have the talent needed to reach our full growth potential,” said Holt. Additive manufacturing may help. It has a “cool” factor even robots no longer display. That’s why 3D printing in schools is such a necessary development. DW

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» Green Engi neeri ng

Hamburg region aiming for 100% renewable future n Paul J. Heney • Editorial Director

Northern Germany is playing an important role in the country’s energy transition. As part of the NEW 4.0 project, the states of Hamburg and Schleswig-Holstein have been merged into one joint energy region. The overall objective is to serve as a showcase for Germany and to demonstrate within a European context that the energy transition is indeed feasible. NEW 4.0 hopes to showcase how a region with 4.5 million residents can be supplied with renewable energy by 2035—using 100% safe, affordable, eco-friendly energy sources that can lead to a reduction in CO2 emissions by 50 to 70%. “This is the first time that the interplay of different technological approaches, the targeted integration into the energy market and the application of the regulatory framework will be tested in an orchestrated manner as part of this large-scale practical trial, and this is what makes NEW 4.0. both unique and challenging,” said Prof. Werner Beba, project coordinator. “The findings of this project will contribute to making the necessary transformation of the entire energy system a success.” The NEW 4.0 initiative will unite stakeholders from industry, science and politics. NEW is an acronym that translates to “North German energy transition” and the 4.0 moniker signifies the fourth industrial revolution and digitization of industry. This digitization will play a key role as intelligent system networks are developed. Approximately 60 regional and trans-regional partners have formed an “innovation alliance” that aims to overcome the challenges of the energy transition based on integrated technological expertise.

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The project is supported by the state governments of Hamburg and Schleswig-Holstein as well as by the Federal Ministry for Economic Affairs (BMWI). Around EUR 90 million will be invested by the project partners within the next four years, and the BMWI is supporting this showcase project to the tune of EUR 44 million. Some 100 individual projects—as well as 30 demonstrators—have been developed over the course of the project’s three-year preparation phase. Current plans call for 70% of the region to be supplied with safe, reliable renewable electricity as early as 2025. Additionally, NEW 4.0 aims to support the process further based on a sector coupling concept. Renewables will be gradually used for heat supply and industrial processes that previously ran on fossil fuels such as gas. The project aims to demonstrate how the full integration of renewable energies can be accomplished even in a region with pronounced, growing imbalances between production and consumption. This will require the comprehensive synchronization of (fluctuating) production and consumption. To achieve this, the project will use an innovative approach for integrating and orchestrating all of the stakeholders and components of the production, transport, distribution, storage and consumption stages by means of intelligent network technologies. DW

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Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting

Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer

Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler

Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion

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DESIGN WORLD

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Co nten t s |

November 2016 • vol 11 no 11

designworldonline.com

F E AT U R E S CONTROL 58 MOTION The Internet of Things...in motion

ETHERNET 88 INDUSTRIAL Better connections for Industrial Ethernet applications

As the Internet of Things becomes reality, manufacturers are responding with products to aide designers of next-generation motion systems.

Industrial Ethernet applications are growing, so your connector choices and options should as well. The M8/M12 connectors continue to evolve to meet pin density and data rates needed now.

MOTION 68 LINEAR Exposing the myth of

zero-maintenance ball screws Surface degradation due to friction typically arises from lubrication problems. Linear-motion designs that address this problem are realistic, effective, and affordable.

92 ELECTRONICS Teardown: Does the Amazon Dash set the tone for IoT appliances?

Amazon’s push-button-ordering gizmo could be a harbinger of things to come on the Internet of Things. But is it a hacker’s dream?

74 Key decision points in MECHANICAL

hinge hardware

The range of applications for hinges is expanding, and so are the types of positioning technology available. Key to choosing the right hinge for the job is to determine the full usage case for the application.

98 SENSORS Nine common errors engineers make when selecting a sensor

When designing a new product or system that needs a sensor to function properly, design engineers have many choices.

80 Smaller preload wave springs MECHANICAL

for smaller bearings

Here’s when and why wave springs make a sound choice for bearing preload and what advances you can expect to see next.

ETHERNET 84 INDUSTRIAL Reduce network cabling with EtherCAT

Power over Ethernet (PoE) began the trend of simplifying network cabling by combining power and communication in network cabling. Now, EtherCAT offers a combined version. 16

DESIGN WORLD

CONTENTS NOVEMBER 2016_first page_Vs4.LL.indd 16

ON THE COVER

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46 Internet of Things

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Contents NOVEMBER_second page_Vs1.indd 18

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» Design for Industry

military/aerospace

Detectors power “electronic eyes” aboard OSIRIS-Rex

When the OSIRIS-REx spacecraft was launched on its mission to reach the Bennu asteroid, it went with three highresolution image detectors that will serve as “retinas” for its mission to explore the asteroid. The CCD retinas are the result of a collaborative development between Teledyne DALSA, a Teledyne Technologies company, and the University of Arizona. Designed, constructed and tested over the last four years, the image sensors aboard the OSIRIS-REx Camera Suite, or OCAMS, will behave in a manner similar to human eyes, from spotting the target asteroid from more than a million miles away to monitoring the sampling process just 10 feet from the surface of the asteroid. Space-qualified and radiation-hardened, the CCD detectors feature low dark signal with a low read out noise, and power. The three cameras that comprise the OCAMS are:

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November 2016

PolyCam, which will collect telescopic images during the approach to Bennu and high resolution images once in formation; MapCam, which will collect color imagery and search for satellites around the asteroid; SamCam, which will deliver context imagery during the Touch-and-Go sample collection.

· ·

The spacecraft will reach Bennu in 2018 and return a sample to Earth in 2023. “Our mission tries to attempt a lot of things at the same time,” OCAMS instrument scientist Bashar Rizk said. “Navigation, mapping, reconnaissance, sample site selection, sampling — we do it on the same trip, so we need to understand what is going on at the asteroid at all times, so we can make decisions in real time when we’re there. The most important goal of these cameras is to maximize the chances of successfully bringing back a sample.”

Two other Teledyne subsidiaries have contributed to the mission, including Teledyne Optech, with their design of the OSIRIS-REx Laser Altimeter (OLA) which will scan Bennu’s surface and create a high-resolution 3D map of the entire asteroid, and Teledyne Scientific and Imaging, which provided a visibleinfrared detector to the OSIRIS-REx Visible and Infrared Spectrometer (OVIRS) that will produce spectral maps of the asteroid’s surface that determine the mineral and organic content of Bennu. DW Teledyne DALSA Inc. teledynedalsa.com

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11/3/16 12:19 PM

machine tool/aerospace/military

military/aerospace

Ethernet cabling helps upgrade F-16 aircraft

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2:55 PM

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When upgrading any aircraft, proper connector-cable termination

practices are crucial to ensure complete and accurate high-speed data transfer. The F-16 upgrade initiative is using Gore Aerospace Ethernet Cables. The 10-gigabit cables exceed Cat6a electrical requirements. They deliver reliable signal integrity with sufficient margin for highspeed data transmission over longer distances. These cables are qualified according to C21091 Specifications for F-16 upgrades that require exceptional electrical and mechanical performance in harsh aerospace environments. These cables can be easily retrofitted into any existing aircraft structure. They are small, light weight, and flexible with a smaller bend radius for easy routing in tight areas. The individually shielded pairs ensure lower signal attenuation and minimal crosstalk for reliable system performance over the life of the F-16 aircraft. DW

High Precision Positioning Stages for High End Laser, Optics, Photonics & Imaging Systems

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November 2016

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Primatics is a manufacturer and worldwide supplier of motion equipment for high end laser,optics, photonics, semiconductor, solar, medical, flat screen, aerospace, astronomy, and consumer electronics industries. Primatics high performance precision motion productsare integrated into automated systems used for these and other related applications: • Manufacturing • Inspection & Testing • Imaging & Analysis • Mass Spectrometry • X-ray Science • Semiconductor • Solar & Thin Films • Deposition & Coating • Optical Sputtering

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• Precision Assembly • Sample Management • Laboratory Robotics • Silicon Photonics • Precision Pick-and-Place • Global Security • Environmental Systems • Exploration & Observation • Metrology & Microscopy

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11/7/16 12:18 PM

Âť Design for Industry

military/aerospace

Material suits light-weight needs of aircraft design Another material has been qualified for the development of light-weight parts for aircraft. The Ixef BM-1524 polyarylamide (PARA) meets the Boeing BMS 8-270 standard governing polyamides for aircraft interiors. It is an alternative to conventional plastics such as polyetherimide (PEI). Ixef BM-1524 PARA is a 50% glass-fiber reinforced, semi-crystalline, semi-aromatic polyamide with good surface finish. This natural-colored, halogen-free flame retardant (HFFR) polymer delivers metal-like strength and stiffness, making it an attractive option for lightweight fasteners, attachments and brackets. It meets Federal Aviation Administration (FAA) 60-second vertical burn requirements per 14 CFR 25.853 Appendix F, as well as toxic gas emission requirements under BSS7239 and ABD0031. DW Solvay Specialty Polymers solvayspecialtypolymers.com

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off-shore

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11/3/16 12:21 PM

packaging

» Design for Industry

Addressing trends in packaging Consumer packaged goods (CPG) makers face many operational challenges claims PMMI’s OpX Leadership Network. Because of a persistent skills gap, designers must continually simplify machinery development, operation, and maintenance. More uptime is a constant demand. Of course, more efficiency of product and package transport is a trend too. And, equipment and machinery needs to accommodate short product life cycles and shorter runs with more frequent changeovers through automation that replaces manual changeover procedures and tools with recipe-driven, pushbutton automated changeovers. B&R Automation offers several systems to meet the needs of these trends. The expanded

mapp (modular application) Technology functions can help overcome the skills gap. This system simplifies machinery development. Networked safety, including safe motion and robotics, can increase uptime by slowing down packaging lines rather than stopping them. The SuperTrak® linear industrial transport technology increases the efficiency of product and package transport

and machine-to-machine integration through synchronization of open robotics. And standards such as OPC UA and best practices identified by the Industrial Internet Consortium (IIC) support Internet of Things strategies. DW B&R Industrial Automation br-automation.com

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November 2016

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9/25/16 1:17 PM

11/7/16 9:40 AM

You Design It. We Build It. INTRODUCING

Weber Knapp, leading manufacturer of mechanical motion control solutions, is proud to introduce Vectis™ - the first design your own (DYO) springloaded counterbalance hinges.

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Vectis™ utilizes standard parts while taking advantage of computer numerically controlled (CNC) capabilities; providing custom characteristics unique to your application. You design it - we build it. Using our proprietary DYO software, simply plug in your product’s critical load parameters - lid weight plus lid center of gravity (CG) to hinge pivot axis dimensions. The slide bar variables will calculate the optimum torque curve to fine tune the open and close feel; making products more reliable and user friendly. Select the model and quantity desired. Order one or as many as your project requires without the costly expense of tooling or engineering. See the new Vectis™ line at vectiscounterbalance.com or call the Vectis™ Help Line at 800.828.9254 x263 Weber Knapp Company | weberknapp.com

Weber Knapp 11-16.indd 25

11/3/16 10:28 AM

robotics

Âť Design for Industry

Robot conveyor system fills molds and other parts on pallets Manually filling and handling molds with plastisol and other fluids can be labor intensive. The bench top RC Series Robot Conveyor system streamlines this type of production and increases dispensing accuracy. The RC Series features a gantry robot with an integrated slip roller conveyor system. The entire X Y Z motion system is located above the dispensing plane to allow straddling over the conveyor with a rigid structure in a space saving compact package. This modular design accommodates up to sixteen (16) valves making it suitable for multiple color applications. The system is pre-programmed and ready to run within minutes of uncrating. Motion paths may be directly imported from CAD and graphics programs and set up in the included Windows Software Suite, or taught with the Jog & Teach function, which draws the patterns on the screen while you teach it on the machine. Any file may be modified with a few mouse clicks. No previous programming experience is required. DW Dispense Works Inc. dispenseworks.com

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November 2016

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11/3/16 12:22 PM

safety » Design for Industry

Your Global Automation Partner

All in one power device CBI all-in-one UPS power device combines multiple functions for use as a power supply unit, battery charger, battery care module, or backup module. This “intelligent” device is compatible with a range of common battery types and comes with a realtime diagnostics system to continuously monitor battery status, charging levels, and potentially emerging battery faults. The CBI device will suit any battery-power application in any industry or setting where battery reliability is essential and the availability of backup power is critical. The CBI UPS (Uninterruptible Power Supply) device is available in 12 Vdc, 24 Vdc, and 48 Vdc output versions for pairing with conventional battery types including open lead acid, sealed lead acid, lead gel, and Ni-Cd (as an option). The device has three charging levels (Recovery, Boost, or Trickle), allows for adjustment of charging current (from 20% to 100% of output current), and automatically distributes available power among load and battery. Switching technology delivers up to 91% efficiency. The device’s battery-charging function is microprocessor-controlled and uses algorithms to detect a battery’s condition and then choose the appropriate charging mode. Real-time diagnostics enable easy battery diagnosis and fault identification (displayed by LED) to protect against potentially occurring faults, such as short circuit, inverted polarity, overload, or battery disconnection. If the CBI device becomes disconnected from the main power source, the battery will serve to supply the load until battery voltage reaches 1.5 V per cell, preventing deep battery discharge. The CBI device performs over a temperature range from -40ºC to 70ºC (-40ºF to 158ºF) and is housed in a compact and rugged metal case offered in three sizes. The device can be DIN-rail mounted using a built-in bracket. DW

WARNING

Not suitable for repairing crummy sensors (or your reputation).

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November 2016

DFI 11-16_Vs.4.LL.indd 27

DESIGN WORLD

Call 1-800-544-7769 or visit info.turck.us/sensors

11/3/16 12:23 PM

» D e s i g n N o te s

Edited by: Lisa Eitel • Senior Editor

Sea trials

demonstr ate that th Seakeepe e r reduces b oat roll by 87% in tw o to fourfoot seas.

Keeping even keel: Gyroscopes for ships use position sensor to track angle Excitement usually originates from experiences — but now engineers at Seakeeper are exciting boaters by minimizing how much they feel heavy seas. Too much roll on a boat underway can make it hard to fish, eat, drink or even move about. So in 2003, Seakeeper began R&D on nautical motion controls to address the problem. Eventually Seakeeper developed a gyroscope that uses industrial motion products for maximum stability. According to Seakeeper, this computer-controlled gyroscope eliminates most boat roll and the fatigue — plus the anxiety and seasickness that go with it. Since then, Seakeeper has introduced six new models of varying sizes and specifications for various boat sizes. The original M7000 is for boats 40 to 60-ft in length. Newer models go on boats from 30 to 220-ft. There have been other improvements too. 28

DESIGN WORLD

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In the Seakeeper design, a heavy flywheel quickly spins to generate angular momentum. For example, the Seakeeper 9 flywheel weighs 590 lb and spins at 9,000 rpm on a vertical axis. The flywheel operates in a vacuum enclosure so there’s no air friction — to allow a lighter flywheel to the do the job while consuming less power. The flywheel’s angular momentum produces a gyroscopic righting torque that counteracts the boat roll. As normal wave action rolls a boat, the rolling and inertia of the gyroscope’s flywheel make the gyro precess — with precession being a changing of a rotational body’s orientation of rotational axis. The gyroscope precesses fore and aft, depending on roll direction. The amount of torque the gyro exerts on a boat’s hull (to counter wave-induced

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11/3/16 12:12 PM

Your Global Automation Partner

roll) is directly proportional to this precession rate — so precession angle and rate are key performance parameters. Accurately controlling the precession maximizes the gyro’s anti-roll function. During powerup, the Seakeeper begins a spool-up cycle of 30 to 40 min. to establish stability. The tradeoff of longer spool-up time allows for a smaller footprint and lower power draw — which accommodates power and space constraints common on watercraft. As the flywheel spools up, a seawater-and-glycol mixture pumps to a heat exchanger to shed flywheel heat (which can be significant, as the flywheel on a midsized Seakeeper rotates to 9,000 rpm when running at rated speed). This action produces an angular momentum rating of 9,000 Nm. Looking down on the Seakeeper 9 from above, the flywheel inside the spherical housing runs clockwise. When the Seakeeper engages, the sphere containing the flywheel precesses fore and aft to create torque to port and starboard. A Novotechnik RFC 4800 position sensor tracks the fore and aft precession angle of the sphere. Time is tracked along with the position to continuously compute the rate at which the sphere is precessing. The sphere position

and boat roll information are output to Seakeeper’s control computer and a proprietary algorithm determines how much braking resistance to apply to the sphere’s movement for maximum boat roll damping. Seakeeper picked the Novotechnik RFC 4800 for its accuracy and reliability. Plus with a housing diameter of 48 mm, the sensor was small enough to integrate into a gimbal shaft supporting the gyroscope. With 0.1° repeatability and linearity of less than ±0.5% of full scale — as well as hysteresis of less than 0.1° and an optional redundant channel — Novotechnik’s sensor met Seakeeper’s requirements and has already proven its reliability in thousands of Seakeeper gyroscope systems. Without active control through the RFC 4800 (including measuring and reporting the position of the sphere) the gyro wouldn’t effectively adapt to changing sea conditions. Seakeeper eliminates up to 95% of boat roll. To see what this means in practical terms, Seakeeper has a control on their home page that visitors can use to turn a simulation on and off. The simulation puts a passenger on the boat or the passenger can change view and see the boat from

A Novotechnik

position senso

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

RFC 4800

r — a key part of the design’s activ e control — track s the fore and aft precession angl e of the sphere. Custom Connectivity Whether it’s a harness with custom wiring topology or a custom cable color for a standard connector, Turck’s expertise creates your best solution.

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Design Notes 11-16_Vs.3.LL.indd 29

November 2016

DESIGN WORLD

Call 1-800-544-7769 or visit info.turck.us/connectivity

11/3/16 12:07 PM

» D e s i g n N o te s

The Calypso S tar II is a 650-ft shar ktank diving tour boat that uses Seakeeper gyros.

Six new models since the initial Seakeeper off the aft to starboard. There is also a video that M7000 offer improved compactness and builds a Seakeeper unit from the flywheel out and bolt-on mounting to make retrofits and new demonstrates the controlled sphere movement installs easier. Going from low to high-volume versus wave action described in this article. In some applications more than one Seakeeper production has let Seakeeper improve reliability through better tooling and quality control. unit of the same or different sizes are installed. Performance has been improved as well with While their control signals are not interconnected advances in the electronics to make Seakeeper electrically, they appear to be synchronized gyros more robust for marine environments because the gyros all react to wave motion in the while introducing advances in precession same way. To install a Seakeeper gyro in a boat it control logic that results in less roll in all sea has to have enough space to mount and access the conditions. Seakeeper also upgraded from unit. paint to powder coating of their units since the Typically, this is not an issue as Seakeeper M7000 to improve corrosion resistance. can be installed virtually anywhere onboard. The boat also has to have Remember toy a mounting structure designed to gyroscopes from childhood? The same physics are withstand the gyroscopic forces. at play in this seacra ft gyroscope. The Current boat owners can retrofit a Seakeeper include s flywheel, spheric Seakeeper gyro and in fact 25 to al housing, vacuum se al, and coolant lin 30% of units sold are retrofitted— es; precession contro l and angle sensor depending on Seakeeper model. ; computer contro l unit, gyroscope electric Today’s boat builders motor, heat exch anger, water pum p, are designing their boats for power and signa l wiring, foundatio n and stabilizing gyros so that even if mounting hardw are. the initial owner doesn’t opt for one, they can be easily installed later. 30

DESIGN WORLD

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November 2016

Seakeeper’s gyros help recreational boaters get more enjoyment from their yachts and let commercial fishermen expand operability in challenging seas. The Seakeeper reduces unsafe working conditions by over 90% according to one commercial enduser. Another commercial enduser says that the gyro reduces fatigue and makes equipment and crew transfers safer. DW Novotechnik novotechnik.com seakeeper.com.

www.designworldonline.com

11/3/16 12:09 PM

Edited by: Mike Santora • Associate Editor

» De sign Note s

ugh to r is tough eno The encode tal en e environm handle extrem ass cl ith protection conditions. W ature wide temper IP65/IP67, a 40 °F (to + 85 °C range of -40 ating co d a special to 185 °F), an bile suited for mo process, it is ands. h tough dem machines wit

Sensor helps keep a firm grasp on angles and paths Safety guidelines and requirements have been a major component in constructing new mobile machines, even before the introduction of EN ISO 13849. With the release of EN ISO 13849, many things have changed with regards to reliably recording angles and displacements. But new draft standards like EN 13000 for mobile cranes or EN 1175 for forklifts even go a step further, requiring additional measures. It’s not always possible to find a sensor that fulfills the standard and meets requirements for robustness and service life. What’s more, these sensors might not be available with the necessary flexibility in terms of interfaces or connection technology.

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Design Notes 11-16_Vs.3.LL.indd 31

November 2016

DESIGN WORLD

11/3/16 12:09 PM

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That’s why SIKO GmbH from Buchenbach, a German producer of sensors for linear and rotary path and angle measurement, developed the VW58MR redundant absolute rotary encoder. The encoder helps users keep a firm grasp on angles and paths under extreme conditions. The rotary encoder has a category 2 construction, for use up to SIL2 and Pld. The rotary encoder is based on magnetic scanning technology. The measurement range of 4096 revolutions (12-bit multiturn) is broken into 16,384 steps (14-bit). The encoder uses a newly developed gear to allow the encoder to capture information. The two galvanically separated sensor units record positions autonomously. Absolute position and speed are continuously sent to the controls through the interface. There are three different versions of the interface. In addition to a version with two separate CANopen interfaces, there is also a version with bus-in bus-out and two node IDs, and one which reliably transmits through CANopen Safety. This process provides full flexibility, allowing application specific encoder adjustments. The encoder handles extreme environmental conditions. With protection class IP65/IP67, a wide temperature range of -40 to + 85 °C (-40 °F to 185 °F), and a special coating process, it is suited for mobile machines with tough demands. There is also a version available with a housing that is resistant to salt spray for use in harbor areas. The strength of the double ball bearings mean high axial and radial loads on the shaft are not a problem. The encoder has internal functions for easy integration for machine designers. Specialized software records slewing ring positions. The design team at SIKO used special software in the WV58MR rotary encoder for this purpose. This software allows configuration of the number of teeth for the slewing ring and the number of teeth for the external gear. It also allows users to generate any gear ratio. Consequently, the rotary encoder returns the exact position and speed of the slewing ring through the interface. This software makes the rotary encoder easy to integrate into any machine. Manufacturers can always use the same encoder system, no matter how big the slewing ring is. DW SIKO www.siko-global.com

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More than 1,400 employees generated a turnover of about USD 1 Billion. With over 70 offices in three continents, the company has transformed since its founding in 1973 into a global player. Connect and discuss this and other design engineering issues with thousands of professionals online

For more information about RUTRONIK: Tel. +1 216 328 8900 | sales-na@rutronik.com Committed to excellence Consult | Components | Logistics | Quality

Design Notes 11-16_Vs.3.LL.indd 32

DESIGN WORLD

November 2016

11/3/16 12:10 PM

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DesignWorld_0916_US.indd Schneider Electric 10-16.indd 133

9/2/16 10:29 3:02 AM PM 11/3/16

» D e s i g n N o te s

Edited by: Mike Santora • Associate Editor

BSE’s Qu est serie s of magle also incorp v chillers orate an O pto 22 con system. trol

Controllers keep it chill The 12th Five-Year Plan (FYP) adopted by the Chinese government in March 2011 focused on energy and climate change. One parameter of the plan was for the city of Shanghai to complete energy-saving reforms on public buildings. The goal of the reconstruction program was to reduce building energy consumption at least 20%. For the Shanghai Pudong Holiday Inn, these goals meant upgrading its original HVAC system. The hotel was still using eight sets of 200 TR (703 kW) air-cooled screw heat pumps located in the technical room. Shanghai-based company BSE was chosen to retrofit the hotel’s HVAC system. BSE picked the SNAP PAC System from Opto 22 to automate, monitor, and control their chiller systems. For the retrofit, BSE used its Energy Loop chiller plant group control system. The Energy Loop system automates the entire chiller plant by monitoring and controlling the temperature, flow, and pressure of water-cooled chillers, cooling pumps, condenser pumps, and cooling towers. BSE replaced the legacy chiller system with five BMMW34

DESIGN WORLD

Design Notes 11-16_Vs.3.LL.indd 34

November 2016

0525 BSE modular chillers, each using one Danfoss Turbocor oil-free compressor. After replacing the legacy HVAC equipment with BSE’s chiller system, the hotel saw an immediate 39% reduction in energy consumption. BSE selected the SNAP PAC System for its flexibility and communication and protocol support, plus Opto 22’s groov mobile interface system. Typically, chiller systems are managed through a direct digital control (DDC) system that communicates with a supervisory industrial PC or PLC. But BSE’s maglev chillers have more points of control than a traditional DDC and PLC system can support. “In PLC ladder-logic programming, it’s difficult to change a single variable or I/O point without that

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11/3/16 12:13 PM

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6/1/15 10:26 5:03 PM 11/3/16 AM

» D es i g n N o te s

change affecting many other points in the chiller control system,” says Zha York, General Manager of BSE. Using PAC Control flowchart-based development software, BSE engineers broke the control programming down into separate functions called control charts. Each chart handles a different function of the control application. For example, one chart monitors a specific valve, and another chart monitors a specific compressor in the chiller system. In this way, individual control charts can operate autonomously or based on input and output from other charts. A supervisory chart then runs in parallel with the other charts to optimize the system. Individual I/O points and variables in each chart can easily be modified to work with other chiller types with different numbers of

Page Holiday Inn Shanghai Pudong scene unit At th e Shanghai Pudo ng Holiday Inn, eigh t older air-cooled screw heat pumps wer e replaced with five BSE modular chiller s. After replacin g the older equipment, the hotel reduced its energy use by almost 40 %.

components, without having to change other charts in the overall control program. “We considered other control system providers but determined their systems were not flexible enough to integrate with other HVAC systems. We also considered

Chi letter will indicate magne tic series opto inst allation BSE I-Chiller series ch iller units demonstrate th e compact dimensions and small footprint that maglev-ba sed compresso rs make possible.

DESIGN WORLD

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November 2016

designing a system based on a Beckhoff PLC and DDC. But after evaluating the PLC we determined that solution was designed more for machining systems and not for our target applications.” Continues Zha. “Programming in Opto 22’s PAC Control software didn’t require prior knowledge of the C programming language to automate our chiller systems.” The SNAP PAC controller BSE provided an easy communication path between existing HVAC equipment and the new maglev chillers. Each SNAP PAC controller supports Modbus serial and TCP as well as BACnet MS/TP and BACnet IP. BSE also used Opto 22’s groov system to rapidly develop custom operator interfaces for chiller plant management. Each refrigeration and cooling system is different. Thus the control interface is different as well. DW Opto 22 www.opto22.com

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11/3/16 12:14 PM

Altech 11-16.indd 37

11/3/16 10:30 AM

» D e s i g n N o tes

Can one slip ring assembly handle power and communication? By: Jesse Shearer • Sr. Application/Design Engineer, UEA

These images show two separate cores, but are within the sam e slip ring assembly.

As a slip ring design engineer, one of the more common questions I get asked is, “Can you provide a slip ring to handle both power and communications together?” The answer is yes. You can save money on design and even certifications such as UL or CE. You can also save space versus having two completely separate slip rings. However, there are a few precautions and design details to consider. One of the first things to do, when possible, is provide two separate cores. Separating the cores keeps the communication (Ethernet, for example) spaced away from some of the power/ higher voltage circuits within the assembly. This isn’t possible for all sizes of slip rings, as they all have their design differences. The pictures (right) show two separate cores, but are within the same slip ring assembly. 38

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Keeping the co res and brushes separa ted by using a sort of divider or separator plate puts a no n-conductive barrier between the power and communic ation sections to help isolate ea ch.

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Another thing to do is keep the cores and brushes separated by using a sort of divider or separator plate, which is done differently in different sizes of slip rings. This design element puts a nonconductive barrier between the power and communication sections to help isolate each. Along the same line as the separator, it is also possible to have a completely separate slip ring assembly inside another ring’s enclosure. In larger-bore and high-power assemblies, this option enables communications to run through a smaller size of slip ring and seal it off from the rest of the assembly. When providing communications such as Ethernet in a slip ring with power, it is recommended to provide the slip ring with shielded cables. Attaching shielded cables at the core and brushes helps protect the signal and data quality, as the cables tend to be routed next to the high power cables and wires. Where possible, it is advisable to route the communication and power cables through separate paths. In some cases, communication cables can be kept on the inside of the mounting tube while the power remains on the outside. This is not always an option, but take advantage of it when it’s possible. This is a sure-fire way to combine communication and power in a single slip ring is to have the component custom designed. DW United Equipment Accessories www.uea-inc.com

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Latest Developments in Multiphysics The latest update of the COMSOL Multiphysics software features major performance increases and the release of the Rotordynamics Module, which is available as an add-on product to the Structural Mechanics Module. The performance speedup of Multiphysics is most notable with models with several thousand domains and boundaries. The Application Builder helps simulation specialists create multiphysics apps, based on their detailed models, through custom interfaces that can be easily accessed through COMSOL Client or a web browser connecting to a local installation of COMSOL Server. Custom applications can be created for anyone from technicians, support staff, designers, to customer service representatives, empowering them to make on-the-fly design iterations and report generation. With COMSOL Server, organizations can deploy industry-specific analysis tools quickly, that can be scaled for global benefit. This update of the COMSOL software product suite includes the Rotordynamics Module, which will aid engineers in analyzing vibrations due to centrifugal forces and other gyroscopic effects in rotating machinery. By evaluating critical speed, whirl, and bearings, this module ensures that rotor vibrations are contained within acceptable design limits.

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“With the Rotordynamics Module, users can take into account the effects of various components such as disks, bearings, and foundations,” said Prashant Srivastava, a Technical Product Manager at COMSOL. “Users will also be able to easily post process their results directly within the software to present the results of their analysis as Campbell diagrams, modal orbits, harmonic orbits, waterfall plots, and whirl plots.” The new module works in concert with the other COMSOL products. For example, additional tools for modeling geared rotors are available when the Rotordynamics Module is combined with the Multibody Dynamics Module. DW

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• Combine mesh files, with or without textures, and with different resolutions— regardless of which device generated them. Ultimately, this enables users to combine both the Go!SCAN 20 and Go!SCAN 50 with textures. VXinspect: • STL-STL comparisons enables enhanced alignment and comparison of two meshes, along with a direct transfer of data from VXmodel to VXinspect. • For a CAD-free workflow, improvements have been made in several features, including alignment creation, overall visibility, GD&T, numerically defining nominal values, and so on.

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Predix, it works with existing systems to provide visibility into the location of work orders in the manufacturing plant. WIP Manager suits companies in the heavy industrial space where cycle times are longer, assembly space on the plant floor is widely dispersed, and raw materials are expensive. With increased material visibility, managers can ensure the right material is available to the manufacturing process at the right time and in the right place. “Many companies don’t know where their orders are in the plant without walking the shop floor,” said Marc Mailman, Product Manager for GE Digital. “It has been mainly a manual process to date where they don’t have visibility into timing of orders, no way to re-prioritize orders in real-time, and can’t easily coordinate materials to take advantage of production flow. With WIP Manager, they can see dynamic queue times for work centers, highlight slow or stuck orders, and get an ‘ETA’ of orders based on progress – without walking the shop floor.” WIP Manager tracks production and service processes through work orders created in the enterprise resource planning (ERP) system, and an operational route through the shop floor imported from the customer’s manufacturing execution system (MES). Once the work order is created and the required materials are available, using WIP Manager, work center operators can begin the operations listed on the work order to build or repair the specified parts. Manufacturers can use WIP Manager to track part production or repair from start to finish using data from work orders. They can also view analytics charts such as average queue, which shows how many parts are queued at each work center. Scorecard charts show the view of a line of balance, where the user can select a part and display how work orders containing the part are balanced for InProgress, Hold, and Rework for each operation. DW

I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ The benefits of embedding HMI ...... .... .. in near edge devices Compact HMI software can be integrated into near-edge devices to add IIoT connectivity and other functions. Scott Kortier InduSoft Web Studio Senior Technical Engineer at Wonderware by Schneider Electric

Machine builders and OEMs often provide human machine interface

Figure 1, Smart edge devices with embedded HMI software, such as InduSoftâ&#x20AC;&#x2122;s IoTView, can be monitored by a smartphone or tablet. Courtesy of AutomationDirect.

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(HMI) functions with a separate component, either a PC-based HMI or an embedded HMI. In either case, the HMI program is developed on a PC and a runtime project is downloaded to the target. The term PC-based HMI means an HMI software runtime application hosted on a PC, which is the target. The term embedded HMI refers to an HMI software runtime application hosted on a target platform capable of running an embedded OS such as Windows Embedded, Linux, VxWorks, and so on. But a new class of embedded HMI is emerging, where a compact HMI runtime is hosted on a target smart edge device such as a smart drive, power meter, special-purpose controller or another componentâ&#x20AC;&#x201D;and viewed on a smartphone or tablet (Figure1). In this case, the HMI runtime is still developed on a PC, but in this case, the target is the smart edge device. Using off-the-shelf configuration software, (such as IoTView), only the HMI functions and data collection required for the device is transferred to the target as the runtime application. For example, some smart edge devices will only require HMI connectivity functions, while others may need connectivity, local data storage and visualization. Customizing the HMI application to the target allows the developer to control and limit the computing resources required at the target, which is critical as most smart edge devices have limited storage space and processing power. In some instances, embedding HMI functions in one or more smart edge devices will eliminate the need for a traditional PC-based HMI or embedded HMI. But in other cases, a traditional HMI will work hand-in-hand with smart edge device HMIs.

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Figure 2, Embedding connectivity and other HMI functionality in smart edge hardware devices enables communication with the virtual world. Courtesy of InduSoft.

One of the main advantages of embedding HMI at a smart edge device is the ability to send data directly to the cloud, a necessity for many IIoT implementations. Sending data to a cloud-based storage system such as an SQL database—or to a commercial data-storage company such as Amazon, Microsoft Azure or Alphabet—is simplified (Figure 2). An HMI/SCADA software package, whether hosted on a PC or an embedded platform, traditionally provides the connection between the plant floor or facility and the Industrial Internet of Things (IIoT). It’s the means or gateway for connecting controllers and smart edge devices to other SCADA systems, company databases, ERP and MES systems, the cloud and the IIoT. Embedding the HMI at the edge Some smart edge devices have embedded connectivity that could, in theory, push data directly to the cloud, but it’s typically not feasible in most industrial systems for security and other reasons. However, modern, platform-agnostic HMI software enables embedded connectivity gateway applications to be developed on a PC and downloaded to the smart device. Such gateways can then establish connectivity between smart devices and cloud-based systems such as database and analytical applications. The embedded smart device HMI delivers connectivity by consolidating, filtering and manipulating the information

through configurable scripts and rules before forwarding it to the cloud. Moreover, builtin security settings and native support for encryption (SSL) represent an additional layer of security and isolation between the real-time control network and the enterprise network and the internet. The smart edge device typically has a serial or an Ethernet port, or a wireless connection. The device may also include a TCP/IP stack. Local or remote users can connect to the smart device—through Wi-Fi for example—using a smartphone, tablet, laptop or another component capable of hosting a HTML5 web browser. Given proper credentials, the user can monitor or adjust the system settings through a configurable rich graphical interface—providing visualization into the smart edge’s embedded HMI. The embedded connectivity at the smart edge device eliminates custom coding of communication drivers and related support of firmware. It also eliminates the need to use custom code to create displays because extensive object libraries and built-in graphical functions are available.

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Future proofing connectivity Eventually, every device or system will eventually be connected to one another through vertical and horizontal networks to get the most productivity and value from each machine. The scope and speed of which devices are connected are proceeding quickly, so design systems need flexible architectures that can keep pace with shifting standards and communication protocols. One way to protect the investment and make current HMI systems future-proof is to design solutions based on off-the-shelf products and open architectures. Key features to look for include: • portability to different target platforms (Windows, Linux, for example) • interoperability with multiple protocols and systems (driver, OPC, Databases, and so on), • support for mobility standards such as HTML5 to access the information from devices such as smartphones, tablets or wearable devices. One example is an IIoT agricultural implementation that deploys intelligent irrigation systems. Adequate water supply is key for

November 2016

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... .. agriculture. Integration of Web Map Service and Sensor Observation Service with the intelligent irrigation system provides a way to manage use. This IIoT agricultural implementation analyses water requirements and weather forecasts to provide only the irrigation needed, reducing water and energy use. Another example is PML Exploration Services, an oil field services company. PML offers real-time information to ensure affordable, efficient and safe drilling practices. The HMI/ SCADA system pushes data on gas and soil composition to the cloud, even in remote locations off the grid, and notifies users of alarms and critical conditions. These notifications can be

used to improve operations and safety while protecting expensive drilling equipment. Embedding HMI connectivity in smart edge devices simplifies communication locally and with the IIoT. It also makes it easier to create advanced operator interface displays and to exchange data with cloud applications and other computer platforms. Instead of custom code, off-the-shelf software is available to develop and configure the embedded HMI functionality and download it to the smart edge devices. DW InduSoft www.indusoft.com

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I nternet of Things

Select the right battery holder for IoT designs

Battery holders come in newer versions that include features such as easy-to-use snap-in designs.

The Internet of Things has sparked a revolution where electronic systems add intelligence to applications ranging from smart cities to smart hotel locks and medical devices and more. This development is affecting coin-cell battery holders, where new versions include features such as easy-to-use snap-in designs. The fundamentals of holder design include ensuring the holder meets basic usage and environmental requirements, that the supply chain is secure from poorly constructed counterfeit replacement parts, and that the end design is compliant with regulations governing battery replacement, especially for medical devices. Shrinkage driving innovation The IoT isn’t the only driver of battery holder innovation. Shrinking form factors also affect design. Take a hotel door lock for example. As they get smarter and use more electronics and communications technologies, one option is to run ac power to each door, through the frame and into the lock to power those electronics. A better option is to have instead a small, coincell battery-driven power supply that requires a battery replacement every six months or so. Of course, the confined space means small holders, which is the general trend, especially for IoT. Other factors driving size and overall www.designworldonline.com

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system cost down are Bluetooth, receivers, RFID tags, home automation, toll tags and bank security tokens. As the number of integrated circuits in a design drops, it pushes the need for lower power, smaller batteries with the sweet spot moving from 1000 mAhr ten years ago to between 100 and 250 mAhr today. Lower power needs have propelled innovation on the battery holder itself. While the basic materials still comprise high-quality thermally stable plastics and gold-overlaid nickel or nickel-plated steel, the holders themselves have become extremely thin. The original BH-800, developed 30 years ago, used a heavy metal contact to keep the battery in place. With newer batteries, the plastic captures and the contacts are made as thin as possible, so the contacts move with the battery like flexible members. The plastic takes care of capturing the battery. Along with making the design simpler to implement, the thinner contacts are free to respond more quickly to sudden jars or drops to avoid intermittent breaks in power delivery. They maintain better contact with the battery. A good example is the Snap Dragon holder. November 2016

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The Snap Dragon design has a base piece and a snap-on cover. The battery goes on the cover. The user slides off the top, replaces the battery, and slides it back into place again. The plastic coverâ&#x20AC;&#x2122;s job is to keep the battery still while the contacts are free to move with the battery.

The Snap Dragon is a design that involves a base piece and a snap-on cover. The battery goes on the cover. The user slides off the top, replaces the battery, and slides it back into place again. The plastic coverâ&#x20AC;&#x2122;s job is to keep the battery still while the contacts are free to move with the battery. That allows them to move rapidly to avoid getting an occasional

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break when jarred or bumped, such as when attached to a generator or a machine. The danger of counterfeits Some products, such as the BH-800 have been mass copied since their debut, and this practice continues for newer products. However, copying carries some danger as it is

unlikely the counterfeit part has gone through accelerated environmental testing as well as shock and vibration. Some products are made with poor-quality plastics. One instance, for example, involves a glucose meter. The holder didnâ&#x20AC;&#x2122;t maintain contact with the battery when the device was jarred, so the meter resets unexpectedly and

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I nter net of Things

.......................................... ................................ ........................ ................... .............. ........... ........ ...... .... .. gave inaccurate readings. In another instance, the plastic pieces of a baby thermometer came loose and became a choking hazard. Such cases abound, making a secure parts supply chain a critical part of successful design.

Ensuring battery holder and supply-chain quality If you rely on a third party for their battery holders, check the product for: • Documentation to show it’s gone through rigorous environmental and vibration testing, and in the case of medical devices, conforms to FDA CFR 21. • Ensure that the holder has proper identification markings. “Gray market” devices, sometimes bought from online sources, generally have no markings and so are suspect. • Perform a simple visual test. Excessive flashing or contact discoloration are big red flags. Flashing occurs when excess

plastic extrudes through the mold and can prevent a battery from making contact. Contact discoloration hints at corrosion. If it’s gold, it should be bright gold: if it’s nickel, it should be highly polished. • Pull on the contacts: if they don’t return to their original position, there’s something wrong. If the contacts are twisted in any way, find another supplier. Taking these basic measures can avoid millions of dollars in repairs where a full system may have to be stripped down and the holder replaced. While it’s tempting to look for legal recourse, if the source of the counterfeit part is China, there’s little to be done, so get it right the first time. You don’t want product recalls. DW

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Marrying gearboxes and the IoT

Rexnord’s IoT-capable powertransmission system was on display at MINExpo in Las Vegas.

Rexnord, a Milwaukee-based manufacturer of bearings, couplings, gear drives and related engineered products, recently previewed its vision of the Internet of Things (IoT) at the MINExpo show in Las Vegas. According to company officials, the goal is to add IoT capabilities to power-transmission systems and give operations professionals real-time data, analysis and feedback—resulting in better machine performance and longer product life. The expansion into “connected” technology is expected to have an across-the-board impact on Rexnord’s broad line of PT offerings. “The concept involves bringing the Internet of Things to the mechanical world,” said Mike Miclot, vice president of commercial marketing. Examples include gearboxes fitted with sensors and indicators that monitor critical performance parameters like vibration, oil condition, temperature, load and speed. While mounting sensors on gearboxes isn’t new, the Rexnord platform offers several significant differences. For one, current users in need of condition-monitoring capabilities tend to retrofit equipment with add-on components like vibration 54

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sensors. Such devices often get mounted for convenience, in locations ripe for physical abuse and less-than-ideal for data pick-up and transmission. The Rexnord system, in contrast, is a comprehensive factory-installed design that tracks all the customer’s critical measurements, with high-integrity sensors best located to withstand heat, vibration and contamination, explained Miclot. Also, sensor output is transmitted not just to the local machine controller, but to higher level enterprise-type Manufacturing Execution Systems (MES). This cloud-based system will offer remote access to real-time data in an easy-to-use format for diagnostics, analytics, equipment-effectiveness reporting and similar applications. Overall, this makes it easier for Rexnord to support customers and products with unique feedback and system-

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I nternet of Things

monitoring capabilities. The end results, said Miclot, are less unplanned downtime, faster maintenance and repairs, and better optimized asset management. On the MINExpo show floor, Miclot demonstrated the IoT/PT set-up with a controller tracking sensor data and providing an internet signal to the asset-management software, which in turn generates predictive machine “intelligence” as well as reactive commands. For example, routine measurements like elevated oil-contamination levels will trigger the machine’s Andon indicator light and signal the control room to schedule maintenance. “It’s different from the clipboard methodology where a machine is serviced every three months, on a set time cycle,” he said. Instead, it’s need-based and measures actual environmental conditions and gives a more-precise window of when to replace the oil. “Otherwise, either you’re performing excessive routine maintenance, which is costly, or you’re rolling the dice, waiting too long and approaching something more catastrophic.” In another case, sensing a sudden critical fault, such as misalignment-induced vibration, illuminates a machine warning light and alerts the control room to take immediate action—like reducing the load or shutting down the equipment. At the same, it reports the exact machine, its history, the type of fault and service procedures to a maintenance provider that, in turn, can dispatch a repair technician already armed with the necessary replacement parts and tools. “Once again, MTBF and MTTR are optimized because we’ve prevented a catastrophic fault and service shows up with exactly what’s needed to quickly make that repair,” said Miclot. “Frankly, we already have experienced and capable service crews. www.designworldonline.com

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It’s taking our existing service model and really putting it on steroids, and ultimately using all this information to better serve our customers.” “Conceptually we’re not just spewing data. We have sophisticated software that actually tells you in human-readable language what the issue is, and the suggested actions to take. We’re actually communicating information instead of just data,” he emphasized. Rexnord has a number of powertransmission test set-ups running at customer sites, and they’re currently collecting real-time data, tuning algorithms, and proving out the overall system, Miclot added. The company will start to roll out products with IoT capabilities in 2017. DW Rexnord Corp. rexnord.com

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I nter net of Things

.......................................... ................................ ........................ ................... .............. High resolution EtherCAT encoder ........... ........ ...... .... .. The Hengstler® AI25 absolute encoder product line has an EtherCAT interface. This feature enables the encoder to integrate into nearly any system that uses EtherCAT protocol. The encoder offers fast cycle times of 62.5 μs and single turn resolution of 22 bit with absolute accuracy of ±35 in. The encoder suits applications in robotics, packaging and high-end motion control. It has 400G shock and 30G vibration ratings. Optional shaft seals and stainless steel housing increase encoder protection. The encoder is available in several configurable options including hub bore or shafted mounting and resolution options up to a combined 32-bit resolution. DW Dynapar dynapar.com

AI25-EtherCat Shafted

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Netbiter is rebranded The Netbiter Remote Management solution will be under the newly acquired brand name eWON. Alongside eWON Cosy and Flexy, Netbiter will be one of the three main product lines within the eWON Remote Solutions offering. All the elements of Netbiter (gateways, Argos cloud service etc) get an updated eWON look, but are technically unchanged. As part of the eWON system, Netbiter becomes part of a complete offering for remote access, data and management of industrial equipment: • Remote Access with Cosy, an industrial VPN router, delivers a fast and easy way to open a remote tunnel to remotely commission and program PLCs. • Remote Data with Flexy, a modular and flexible router that can be customized for remote access and data collection. Remote Management with Netbiter, an out-of-thebox system for remote management of field equipment. DW

HMS Industrial Networks anybus.com

November 2016

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M o t i o n

C o n t r o l

The Internet of things... in motion As the Internet of Things becomes reality, manufacturers are responding with products to aide designers of next-generation motion systems. Edited by Miles Budimir â&#x20AC;˘ Senior Editor

The Internet of Things. A lot has been written about its promise, its potential to revolutionize just about everything we do, from giving us talkative toasters and smart refrigerators to uber-connected factories. Thereâ&#x20AC;&#x2122;s even a counterpart in the industrial world; the so-called industrial Internet of Things (or IIoT). The dream, of course, is to connect everything from the lowliest bearing or sensor on a machine on the factory floor all the way up to the enterprise resource planning (ERP) system, to have one interconnected whole. And companies are beginning to put the pieces together. One important factor impacting the growing availability of IoT offerings is cost. Much of the technology is no longer cost-prohibitive, leading designers to networkenable practically anything with low-cost sensor technology, unlocking and storing data that was previously unavailable. 58

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11/3/16 1:14 PM

The Smart Sensor from ABB/Baldor measures temperature, vibration, and other parameters to help determine motor health.

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M o t i o n

C o n t r o l

The RESTful API for IoT development from Opto 22 helps bring legacy devices online quickly and easily.

A brief survey of some of the latest releases for IoT applications in motion systems shows a range of offerings, from hardware devices to software tools, such as development environments and networking apps that help connect devices, components and systems together.

For designers looking to build IoT-enabled motion systems, a growing number of manufacturers offer ready-made solutions.

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IoT-enabled controllers For designers looking to build IoT-enabled motion systems, a growing number of manufacturers offer ready-made solutions. For example, Omron offers their new NX1P Machine Automation Controllers which are at the heart of the companyâ&#x20AC;&#x2122;s Sysmac automation platform. The Sysmac platform brings integration and intelligence to production operations by creating a variety of application functions with software. The new solutions improve production processes by leveraging expertise in advanced finetuning control gained through the NJ/NX Series used for state-of-the-art large-scale equipment and next-generation equipment. The NX1P provides both advanced motion control and a network environment for IoT at production sites, applying knowhow in advanced fine-tuning control to small and middle-size machines. This offers

equipment manufacturers the ability to add advanced, smart functionalities to small and middle-size production machines as well as state-of-the-art production equipment to increase processing speed and accuracy and to use production data for predictive maintenance The NX1P comes with a built-in EtherCAT port and controls up to eight servo systems, and offers motion control for up to four synchronized axes. It also features electronic cam functions for continuous and high-speed machine operation and interpolation for precise machining, improving productivity and manufacturing quality. The controller offers extensive IoT capabilities. Data can be collected from devices via EtherCAT and IO-Link for high value-added manufacturing. The NX1P can monitor sensor data through the IO-Link master unit to reduce downtime by detecting errors and to perform predictive maintenance by monitoring status. EtherCAT connects I/O devices, motion devices, vision systems, and safety controllers with a single cable. Machine information can be checked by monitoring the status of the connected components.

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11/3/16 1:13 PM

M o t i o n

Meanwhile, EtherNet/IP enables data sharing with a host PC and between controllers on different machines. The built-in PLC features an LD instruction execution time of 3.3 nsec, the fastest in its class according to the company. The built-in EtherCAT master functionality allows the NX1P CPU to perform high-speed motion control and remote I/O control. Sequence control and motion control are integrated in one controller. The built-in position control functionality reduces not only loss of communication time between the CPU and position control unit but also complexity of communication settings between the units. The NX1P conforms to the IEC 61131-3 standard programming and PLCopen (R) Function Blocks for motion control, letting users create complex programs efficiently. Built-in sensors make smarter motors At the level of individual components, companies are adding built-in IoT capabilities. For instance, earlier this year ABB/Baldor announced their new Smart Sensor which integrates into the company’s motors and is used to collect and analyze data on operating conditions.

C o n t r o l

As Michael Offik PE and Director of Packaged Solutions with ABB/Baldor Electric Company explains, “the Smart Sensor actually consists of several sensors and microprocessing capability. The Smart Sensor measures temperature, vibration and a few other key parameters to determine the motor’s overall condition. ABB’s decades of experience with induction motors have allowed us to develop proprietary algorithms that translate these measurements into the health condition of the motor.” The Smart Sensor attaches to the motor mechanically and on newer Baldor motors it will simply be attached with two screws. For retrofits of existing motors, it’s attached to a mounting bracket with screws. Ideally, the sensor is placed on the side of the motor toward the drive end with the long axis in the motor’s axial direction. Primary applications for the Smart Sensor are any low-voltage industrial motors where users want to increase motor uptime, efficiency and operating life. (ABB/Baldor considers motors of 690 Vac and below to be low voltage.) The Smart Sensor communicates to a smart phone via Bluetooth Low Energy. From here, it’s transmitted to the cloud for some additional

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M o t i o n

C o n t r o l

Greater Accuracy. Higher Performance. CUS TO SLID M ES AVA ILAB LE

processing and then the overall condition is sent back to the phone and displayed via a user-friendly app. The smart sensor is a monitoring device only and does not control the action of the motor. In addition, ABB states that it uses the latest security measures to ensure information is safe and secure, a chief concern for many IoT applications. Software tools for IoT development On the flip side, there are vast legacy systems of sensors, motors, machines, and other devices that already are a part of the existing industrial infrastructure but are currently unable to connect to the IIoT. This legacy

Developers can gain

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Actuator Options

Del-Tron’s High Precision Positioning Stages with B.Y.O.S. (Build Your Own Stage) Technology! Del-Tron’s new line of VB, VR and VS High Precision Positioning Stages take positional accuracy, performance and actuator flexibility to a new level. Utilizing Del-Tron’s proven ball and crossed roller technology and more than three decades of experience manufacturing linear slides and stages we offer three new model numbers and you can choose the method of actuation best suited for your application. Build your own High Precision Stage by simply picking out the ball or crossed roller stage that meets your application’s needs, choosing one of the 4 methods of actuation: Micrometer head, Fine thread adjustment, Lead screw or Motorized actuator.

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equipment holds valuable untapped data needed to improve business processes and decisions in almost every enterprise and every industry. “The Industrial Internet of Things is built on the idea of seamlessly sharing data between disparate assets to identify new opportunities for businesses to become more competitive,” notes Matt Newton, Director of Technical Marketing for Opto 22. According to Newton, a communication disconnect between the physical world and the digital world is slowing the adoption and rollout of the IIoT. To cope with this disconnect, current Industrial Internet of Things applications involve layers of gateways 62

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M o t i o n

C o n t r o l

and middleware to translate between the physical and digital worlds, making it difficult to realize the full benefits of IIoT. This is what Opto 22 has been working on, namely to flatten IIoT architecture by bridging the communication gap with open standardsbased Internet tools and technologies. Opto 22’s platform enables developers to rapidly design, prototype, and deploy applications to connect existing assets to the IIoT and share their data, capabilities, and resources with other connected systems and assets. The company’s new RESTful (Representational State Transfer) API has been added to its industrial programmable automation controllers (PACs), significantly closing the IT/OT gap and promising faster IIoT application development, reduced time to market in machine and system design, and faster automation and control project deployment. In effect, they’ve added a secure RESTful server and open, documented API to a PAC. The REST architecture and technology

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Texas Instruments’ new CC1350 wireless microcontroller unit integrates a Sub-1 GHz transceiver, Bluetooth low energy radio and an ARM Cortex-M3 core in a tiny 4x4mm chip. It’s designed for easy integration into IoT applications.

are intrinsic to the IoT and paramount to web and mobile-based application development. Developers can gain secure programmatic access to new or legacy physical assets through control variables and I/O data using any programming language that supports JavaScript Object Notation (JSON). Available through a free updated firmware release for Opto 22 SNAP PACs, the RESTful API includes an HTTP/S server accessible from any HTTP/S-compatible client.

Wireless microcontrollers for IoT At the electronic hardware level, companies like Texas Instruments (TI) are making available new microcontrollers (MCU) specifically designed for IoT applications. The company’s new CC1350 wireless MCU aims to expand the functionality of IoT networks. The MCU is said to be the industry’s lowest-power dual-band wireless MCU supporting Sub-1 GHz and Bluetooth lowenergy connectivity on a single chip. As part

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M o t i o n

C o n t r o l

Complete Motion Solutions Pneumatic, Electric & Hydraulic Actuators

of TI’s pin-to-pin and software compatible SimpleLink ultra-low power platform, the new SimpleLink dual-band CC1350 wireless MCU lets developers move from a three-chip solution to a tiny single chip, while reducing design complexity, saving power, cost and board space. The CC1350 offers a range of up to 20 km on a coin cell battery for wireless sensor network applications as well as building and factory automation, alarm and security, smart grid, and asset tracking. Designed for low-power wide area networks (LPWAN), the CC1350 features a number of helpful features. For starters, the dual-band connectivity expands the functionality of a sub-1 GHz network with Bluetooth low energy implementations such as beaconing, over-the-air updates, smart commissioning, and remote displays among others. This is combined with long-range connectivity paired with ultra-low power consumption that offers a sleep current of 0.7 μA which allows for more than 10 years of battery life. The CC1350 combines an ARM Cortex-M3 core in a single, Flash-based, 4x4 mm QFN package. Developers can get started designing a system with the low-cost SimpleLink CC1350 wireless MCU LaunchPad development kit or connect sensors to the cloud with the SimpleLink CC1350 SensorTag demo kit supported by TI’s Code Composer Studio integrated development environment (IDE) and IAR Embedded WorkBench. TI has also simplified development by providing multiple software options including point-topoint communication examples so that developers can use the small, sensor-based kit which includes 10 lowpower MEMS sensors and can connect to the cloud in less than three minutes. DW

Opto 22 opto22.com ABB/Baldor Electric Company baldor.com

PHD offers an extensive line of pneumatic actuators that are known for long life and high quality. Over our 55 years of innovation, we have extended our product offerings to include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots. From single actuator solutions, to multi-unit systems, PHD and Yamaha Robotics can provide complete solutions for practically any application requirement.

Omron omron.com Texas Instruments (TI) ti.com

To order a catalog, visit

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

phdinc.com/dw1116 • 1-800-624-8511 66

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WHAT DO YOU THINK?

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maxon control electronics for strong DC brushed and brushless motors.

maxon motor control

Power under control.

When good control properties and fast startups are needed, maxon motorâ&#x20AC;&#x2122;s servo controllers are the ideal choice. The 4-Q PWM servo controllers have fast digital current and speed controllers with a large range. They offer highly efficient control of permanent magnet-activated DC motors.

Maxon Motor 11-16.indd 228.6x276.225.indd 13 67

maxon precision motors 101 Waldron Road, Fall River, MA 02720, USA Phone 508-677-0520 info@maxonmotorusa.com, www.maxonmotorusa.com

11/3/16 10:36 AM 04.08.2016 13:40:12

Exposing the myth of

zero-maintenance ball screws Surface degradation due to friction typically arises from lubrication problems. Linear-motion designs that address this problem are realistic, effective, and affordable.

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Maximizing uptime and avoiding downtime for unscheduled maintenance are key to productivity. Mechanical wear of moving parts, particularly the positioning systems, is the most common reason for motion-design malfunctions. Here, surface degradation due to friction typically arises from lack of proper lubrication.

Bruce Gretz

Executive V.P. Steinmeyer Inc.

Consider how machine tools are manufactured to last for decades with continuous service and minimal downtime. This is only possible if users follow proper maintenance and service intervals. In fact, linear motion (from ball screws and other linear components) is one of the most critical functions of any machine tool, as it has a direct impact on accuracy and repeatability of the end product. Premium machinetool companies such as Gleason are particularly focused on ensuring that ball screw performance remains within their exacting specifications. A practical approach to lubrication and innovations in ball screw design lets these machine-tool companies fulfill their promise to their end users.

Steinmeyer offers a variety of wiper designs to meet any lubrication requirement.

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L i n e a r

M ot i o n

This is a combination wiper that has plastic segments plus a felt ring. The wipers contact the ball screw and add a small amount of friction, but seal the nut better than other options.

In the case of ball screw drives, extending the lubrication cycle has an immediate and measureable impact on machine tool uptime. So it’s no wonder that some suppliers make marketing claims that imply their rotary-to-linear components are zero-maintenance. Such claims are incredible and beg the question: Can a ball screw really be infinitely lubricated? The answer is no. Engineers with an understanding of tribology can confirm that claims of zero maintenance are too

good to be true. That said, it is possible to design a ball screw with a much longer lubrication cycle than typical ... to serve as linear-motion axes needing minimal maintenance.

What zero-maintenance really means First things first. The term zero-maintenance in the context of ball screws usually means one of two things. Either the ball screw has no lubrication at all and runs dry, or the ball screw keeps its lubricant for the length of its useful life. Practically

This felt wiper has an inner surface machined to match the ball screw thread. Such wipers excel where ball screws must withstand a dirty operating environment (as in grinding or woodworking machines, for example). Here, the wiper does double-duty as a seal to keep the ball nut clean — and stores lubricant for smooth operation.

speaking, neither design is sustainable for truly long-term operation. That’s because ball screws require a minimal amount of lubricant to allow the balls to recirculate. If the designer attempts to use a dry lubricant, the balls will soon jam. That’s especially risky under slow or reversing movements. Keeping lubricant for the entire life of the ball screw is equally impractical. This is a viable lubrication approach for rotary bearings, which can be sealed. But the same doesn’t apply to linear bearings, as the linear strokes of the nut causes lubricant to seep out. Consider how some vendors advertise ball screws that are lubed for life at high loads. Ball screws billed to deliver maintenance-free operation and high performance sometimes fail, as high loading naturally decreases ball screw life. In other words, this combination is impossible not because the maintenance interval is so long, but because the life of the ball screw is so short. It’s a design-parameter situation much like one in the racecar world. Bugatti offers a 1,001-hp sports car that boasts a top speed of 200 mph. If a person drives the car that fast, it will run out of gas in 15 minutes. Even more comical is that the tires will melt in 12 minutes. Some linear-motion vendors also sell lubrication units that mount inside the nut. These are usually plastic rings impregnated with oil. Such designs extend the time between maintenance intervals early on, but the plastic rings can eventually run out of lubricant. At that point, the end user must send the screw back to have the manufacturer replace the lubrication unit, or revert to typical lubrication methods. Furthermore, the end user has little say in what type of lubricant gets used and is stuck with whatever the plastic rings carry. Given these caveats, sometimes the features of this setup can’t improve motion designs.

Practical approach to lubrication All ball screws are pre-lubricated at the factory. The ongoing maintenance cycle de70

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Why settle for “standard” ? The PITTMAN Difference ®

At first glance, this brushless DC motor looks similar to many others... In fact, this particular motor is not a “standard off-the-shelf” part, but designed exactly to a customer's unique specifications. PITTMAN provided an experienced team of engineers to work directly with the customer to design a unique solution to meet a demanding motion application ... • • • • •

1.7-in (43 mm) diameter custom stainless steel motor

Stainless steel housing, flanges, and shaft for operation in a corrosive environment Stainless steel cable gland and silicon cable sleeve for enhanced ingress protection Protected against fine particulates and moisture by using a labyrinth seal and O rings Specially processed stator laminations to minimize iron losses at very high operating speeds Skewed rare-earth permanent magnets to minimize cogging at low speeds

When a DC Motor Solution is Required, Choose the PITTMAN Difference. Brushless DC Motors

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11/3/16 10:36 AM

How manufacturers understand ball screw lubricant behavior On behalf of Steinmeyer and through a European engineering-consortium EUREKA project — sponsored by the KTI (Commission for Technological Interchange) — Swiss tribology laboratory CSEM (Centre Suisse d’Electronique et Microtechnique) recently designed and conducted a test for commonly used lubricants under the specific tribological conditions found in ball screws. The laboratory used a modified pin-on-disc tribometer with the pin replaced by a regular 52100-steel ball bearing riding a rotating disc made from the same material (heat treated and ground as a ball screw raceway). The laboratory made the material and surface finish of the disc and ball closely resemble the friction partners in a ball nut. Different engineered ball screw lubricants excel under different application loads and speeds.

Surface loads and relative speeds in two pends greatly on the application. Periodic attention to the lubrication can significantly minimize unscheduled maintenance and downtime. For most machine tools, ball screw manufacturers recommend the first lube check at 500 hours. Depending on the results of this check, machine tool users may set future intervals shorter or longer. The ball screw’s lubrication reservoir and wiper system must be designed to minimize lubricant loss while providing maximum wear protection. Ideally, the supply of lubricant and ability to seal the nut from fine particles should be combined into a single unit. This capability is embodied in an innovation called a combination wiper. Combination wipers are plastic wipers with an additional felt wiper inside the ball nut. Felt is an excellent absorber of oil, so 72

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it acts as a reservoir. However, it must be protected from water or water based fluids. That is one function of the additional plastic wiper. Combination wipers increase the nut length slightly, but offer important advantages: • Superior dual stage sealing • Reduced maintenance • Reduced oil consumption (75 to 90%) • Refillable • Choice of lubricant

test series simulated slow-moving and fast ball screws. Because pin-on-disc tribometer causes pure sliding instead of the sliding and rolling typical for a ball screw, the speeds were adjusted to the sliding portion of typical mid-size ball screw kinematics — running at about 50 rpm (for 0.04 cm/sec in the tribometer) and 1,000 rpm (for 32 cm/sec). This closely simulated the lubrication film buildup and wear of real tribological conditions in a ball screw.

These last two points are especially notable compared to oil-impregnated plastics. With the inclusion of felt, users can easily refill during normal maintenance intervals, while also using the lubricant of their choice.

www.designworldonline.com

11/7/16 3:53 PM

L i n e a r

M ot i o n

This is a labyrinth wiper. It consists of a plastic ring with an inner surface machined to match thread, and is a fairly basic and limited option.

If the duty cycle is such that an elastohydrodynamic (EHD) lubrication film can build over a significant part of the motion, then oil lubrication (with a properly selected oil grade and viscosity) will always outperform grease in terms of wear. On the other hand, grease has an edge at slow speeds because it offers better wear protection under mixed friction or boundary friction conditions. Grease can also work for long-term or forlife lubrication. Lubricant loss with grease is lower than with oil. First of all, the coefficient of friction isn’t correlated to the wear rate. Some lubricants yielded low friction, but higher wear at the same time. In addition, wear rates of some greases show that these lubricants really are universal — because they offer moderate wear protection at both slow and fast speeds. At higher speeds, both oils built a hydrodynamic lube film ... so make for extremely low ball screw wear rates. Consider how in some tests, plain mineral oil without wear-inhibiting additive (Vactra4) yielded excessive wear rate at slow speed, despite its high viscosity. It was unable to protect the friction partners once speed fell below the threshold to build a hydrodynamic film. It was squeezed out of the contact patch and did not sufficiently reduce wear in boundary conditions. In contrast, oil with high-pressure wear-inhibiting additives (EP oil), which can bond its hydrocarbon molecules to metal surfaces through chemical or physical reaction, performs much better during conditions of boundary friction. With the exception of a high-pressure grease, which causes lubricant film to collapse at high speeds, all greases perform well and yield acceptable wear rates throughout the test scenario. At the same time, tests show that greases can’t build a perfect fluid film like oils of proper viscosity, so the wear rate with grease lubrication is higher than the wear rate of oil when an EHD film is present. DW

This segmented wiper has plastic fingers loaded by a circumferential spring, shown here in black. The spring loads the fingers to tension them into the threads of the ball screw. They clean the threads and apply lubricant before the threads pass through the nut.

QM35

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Steinmeyer Inc. steinmeyer.com www.designworldonline.com

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QML35

November 2016

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M e c h a n i c a l

Key decision points in hinge hardware

Todd Schwanger Global Product Manager Southco Inc.

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The door hinge is one of the most common and widely used devices. What may not be as well known is that hinge technology offers a sophisticated range of functions that can improve the operation of systems. From fixed-position detent hinges that hold doors open at predetermined angles and eliminate the cost and labor of additional components, to counterbalanced positioning hinges that offer lift and the ability to control user effort to position panels or screens, there’s an array of innovative capabilities engineered into hinge technology. Whether opening and lowering a tray table on an airline, or slightly adjusting a credit card/debit card reader device at a checkout counter, individuals take actions and draw impressions from experiencing these “touch points” daily. The diversity and sophistication of the latest hinge technology offers new tools to achieve unique touch point experiences in products. Positioning technology opens new possibilities The most common hinge is also the simplest: the standard, free-swinging hinge, for opening and closing, with no resistance, and which falls open under gravity and bears the weight of the device being moved. Beyond this basic device, hinges have evolved into a new offering: positioning technology. With positioning hinge technology, designers can define and adjust the operating effort required to move or position doors, display screens, safety shields, lights – virtually any mounted component that is opened, closed and moved. Positioning hinge technology represents a set of tools to fulfill ergonomic requirements and user perceptions of quality in applications. These include: Hold doors open or closed, and move panels securely into position without secondary supports or additional components Create intuitive, zero-drift motion so that, when a door or cover is opened, it holds a user-defined or pre-defined position securely, and with one motion Provide specific tactile feedback to enhance the quality perception of the hinged device Eliminate additional components (such as gas struts) or routine maintenance (tightening screws to maintain hinge resistance), thereby helping to lower overall costs Provide a smoother, more substantial feel to opening and closing action, or to eliminate vibration

• • • •

•

Constant torque hinges with factory-set levels of resistance deliver continuous resistance against motion, making a lightweight plastic table for instance, feel heavier and more substantial for the end user.

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M e c h a n i c a l

fficiency

You can use positioning hinges to change – or elevate – a user’s perception in different ways. Consider the airplane tray table. Seating designers must use extremely lightweight plastic components in these applications to help airlines reduce fleet weight and conserve fuel. However, a tray table that just flops down upon opening can lead a passenger to question the quality of the aircraft itself. Using a constant torque hinge with a factory-set level of resistance, the tray can be lowered by the passenger with just the right level of force, making the tray feel more substantial and instill a perception of quality to their environment. In addition, constant torque hinges designed and manufactured with high-quality materials retain the desired resistance after thousands of flights, without requiring maintenance or parts replacements. Positioning hinge technology can be broken down into four major categories, or “building blocks,” based on the type of controlled motion and positioning they supply:

Fixed-position detent hinges, like Southco’s C6 Series, provide tactile feedback and hold doors open at a predetermined angle.

torque – enables the device to be • Constant held securely at every position along the

range of motion

and bistable – these hinges • Detent automatically drive to and hold a specific

Constant torque positioning hinges, like Southco’s E6 Series, provide reliable positioning with consistent operating efforts, and eliminate the need for secondary support components to hold doors or panels in position.

position, such as to 90 degrees

•

Counterbalance – hinges with technology that enables heavier objects to feel lighter when opened, or pop open with a simple touch – hinges that control the speed of • Damping motion automatically, without holding

Although many applications would need only one type of hinge, these different categories can also be combined into multifunctional hinges that provide multiple positioning functions in a single device.

Constant torque: Hold securely at every position Constant torque hinges provide smooth operation and infinite positioning. These features allow intuitive movement of a device – opening and closing a laptop, a mounted display screen at a checkout counter, and so on – that holds the hinged device at any point throughout the full range of motion when stopped. 76

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M e c h a n i c a l The amount of effort to move it is just enough to respond to deliberate motion, while holding in place for more casual or touch interactions. A now-common example of this is the expanding use of touchscreen interaction monitors at checkout counters. A constant torque hinge attached the monitor to the base allowed the cashier to tilt the monitor up and down for optimum viewing and interaction with ease; at the same time, tapping icons and touch points on the screen can be done without the screen shifting from the cashier’s desired position. Traditionally, this capability is accomplished with clamping or latching mechanisms, which often do not provide the infinite positioning ability that a constant torque hinge supplies, or the smooth, flowing tactile feedback. In addition, a constant torque hinge delivers one-handed operation, rather than pushing a button or flipping a lever to move the device. Constant torque hinges can also be engineered to provide asymmetric torque: Different amounts of effort are required to move the hinge in one direction – open or close, up or down. This feature has been used in certain types of headrests in airplane seats. The passenger can pull the headrest wings forward in the low torque direction easily, while still having the high torque direction resist the force of their head leaning on the rest in the opposite direction. Detent hinges: drive and hold to pre-sets Detent hinges are engineered to provide specific motion and tactile feedback: The door or device is opened and locks into place at a pre-set angle, usually with a distinctive “click” that can be felt. These types of hinges are often useful for lightweight cabinet doors or other devices that must be consistently opened, out of the user’s way. Detent hinges require the user to keep moving the device until it reaches the right position for the working environment, for instance, a pre-set angle of 90 degrees. A variation on detent hinges is called bi-stable, which contains a built-in spring mechanism that automatically drives the door or device to the preset angle once the door is open. This functionality is useful for doors, access panels or covers that must be opened to a minimum angle for easy entry, or to avoid collisions with surrounding equipment. The bi-stable mechanism automatically rotates the panel to one of two preferred positions, November 2016

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M e c h a n i c a l either fully open or fully closed, with simple touch operation. For applications requiring this type of automatic full open and close, some designers may include gas struts or gas springs in addition to a basic hinge to achieve the desired function, adding component cost to the system. With the bi-stable detent hinge, essentially the hinge does all the driving. Counterbalance: move heavy objects with minimal effort Counterbalance hinges help users easily open and move heavy doors and other fixtures. These hinges use heavy-duty counterbalance springs that store energy when the door or fixture is closed; upon opening, the energy is released and the effort to move the door to a fully open position is minimal – the hinge does most of the work. Counterbalance positioning technology suits applications where the element being

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lifted has significant weight, thus making operation safer and easier for the end user. Medical equipment such as blood analyzers or centrifuges is one example; large capacity deep freezers are another. For applications where operators routinely open and close heavy doors – industrial copiers are one example – counterbalance technology can help reduce fatigue and improve operator efficiency. For instance, a door with a symmetric torque hinge may require 2.3 kilograms (kg) of effort to open from fully closed to 90 degrees open. Using a counterbalance hinge instead, the energy required to open the door can be reduced to 0.9 kg. In the past, to help open heavier doors designers would incorporate gas struts or other devices to provide the added lift; counterbalanced hinges offer a more economical, single device solution. And the newest counterbalanced hinges can incorporate a latch to support pop-up opening: When first opened, the heavy door lifts a few degrees, and then the user pushes gently to fully open it to the desired position.

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

November 2016

10/13/16 11:41 AM

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M e c h a n i c a l Damping hinges: Controlled opening Damping hinges provide designers with a unique option: Rather than control the position of the device, they control the speed with which it moves. With a door, compartment or other device using a damping hinge, when force is exerted, it moves steadily to the open or closed position, rather than popping open or requiring the user to push it all the way closed. This kind of smooth, steady motion is becoming widely preferred in a number of high-end applications, such as car interiors. For items such as eyeglass storage compartments, USB port carriers and other compartments that are opened and closed, damping hinges add to the impression of a high-tech, finely engineered interior that is a crucial element many designers seek to achieve. Adding tactile value to “open and close” Leading suppliers of hinge technology have recognized that every time an end user

opens, closes or moves a hinged device, the individual is both exerting force and experiencing a distinctive tactile experience. Positioning hinge technology gives designers a new set of tools to enhance the user experience and thus, the impression they have of the devices. The range of applications is expanding, and so are types of positioning technology available. The four types of hinging technology described can actually be combined to satisfy multiple requirements – for example, detent and damping functionality can be combined in a single hinge, so that a door easily opens to a fixed position and clicks in place, and then moves on its own in a controlled fashion to the closed position when it is pushed shut. The key is to determine the full usage case for each application – what ergonomic effort should be expended to open, position and close a device, what user feedback is

needed or desired to accomplish this motion effectively and repeatedly. The industry’s leading hinge suppliers have extensive experience working through these usage cases to help define the optimum solution, and can provide in-depth expertise to cost-effectively configure the right positioning technology for each application. DW Southco Inc. Southco.com

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Smaller preload for smaller We talked with Smalley Senior Research and Development Engineer, Ben Moskalik to find out what’s new with the Bearing Preload Wave Spring Series. Here’s when and why wave springs make a sound choice for bearing preload and what advances you can expect to see next.

Mike Santora

• Associate Editor

Smaller motion systems require smaller bearings. Naturally, if wave springs are chosen to preload the bearing, those have to get smaller too. According to Ben Moskalik, Senior Research and Development Engineer for Smalley, the industry needs to go small with wave springs. Here’s why wave springs can be a good alternative to other preload options. The Smalley’s Bearing Preload Wave Spring Series, often referred to by its part number SSB, is a coiled flat wire wave spring for giving a slight preload to a bearing for noise and vibration reduction. For a couple decades now, the SSB line has been a 16 mm bore diameter. But now it’s going down to 9 mm. Moskalik explains his take on the recent need for expansion in the following interview. 80

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M e c h a n i c a l

The SSB Series is a coiled wave spring and it has either a gap, if it’s a larger size part, or an overlap, meaning that the beginning and the end to the coiling process, the ends overlap each other slightly.

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M e c h a n i c a l DW: What challenges are engineers encountering with preload? Moskalik: The consistent issue we see with bearings and

An overlap wave spring slightly clings inside the bore, even in it’s free state. This allows a sure fit inside the bore for maximum interaction with the outer race of the bearing. This can be installed upside down against gravity and it willl not fall out.

DW: What changed in the industry? When did you first notice the need for this product? Moskalik: A couple things. The main reason for the new sizes are that the whole world is getting smaller with components. We are finding more products that are miniaturized. Whether it’s a medical device that needs to be smaller, or OEM’s looking to make their product tinier, that is the general push. Not just with this bearing preload series, but a push to go to smaller springs. And so, we were looking at miniaturizing all of our weight spring series. The SSB Bearing Preload Series is the first one that we went smaller on. We did the research on the smaller bearings and decided it made sense to develop the expanded range. Instead of telling a customer, “You have a bearing that you want to preload but we don’t have the right size... Well, now you need a special design.” We felt it would be better to incorporate it into our standard series.

preload arises when the bearing is not precisely sized in its axle, not it’s radial dimension, but it’s axle cavity. Typically, customers might use shims. They might shim a bearing to keep it from moving axially. But shims can be difficult because it then requires the person to have several like diameter shims with different thicknesses. First, it’s difficult to always have the correct shims on hand. Second, it’s also labor intensive. You can think of a spring as almost like a one-size-fits-all. If you have the correct diameter of spring, you can now use it with all different heights; you don’t need different parts to stabilize it. The issue is that the ball floats in between the inner and outer race. That creates a vibration or noise if the bearing is spinning fast enough. That noise is not only undesirable, but can also lead to premature bearing failure. Whether a customer shims it, or uses a spring, it is best to give a little bit of a load on either the outer or the inner race of the bearing. We like to use the spring, or we like to stress the spring. Either way, preload increases the life of the bearing and reduces noise.

DW: What is the installation process like with the wave springs? Moskalik: Installation is simple and there is actually a benefit for the type of wave spring that we manufacture. The SSB Series is a coiled wave spring and it has either a gap, if it’s a larger size part, or an overlap, meaning that the beginning and the end to the coiling process, the ends overlap each other slightly. This is compared to what we call a continuous wavy washer, which would be a stamped wave spring that other manufacturers might make. This doesn’t bind if it’s inside the bore and compressed. A binding situation is when we find a higher load than we expected. When that happens, the wave spring diameter grows

DW: You mentioned that your capabilities have increased. What were some of the challenges with miniaturizing? How were you able to overcome them? Moskalik: The primary concern was the machines themselves. A miniaturized machine is required to make more miniaturized parts. Obviously, all of the moving parts of the machine need to be fine-tuned for precision as well.

The SSB Series is a coiled wave spring and it has either a gap if it’s a larger size part, (shown here) or an overlap. 82

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M e c h a n i c a l because the wave portion of the wire needs to go out. When it goes out it could hit a bore. Designers have to be careful with using continuous wavy washers because if they encounter higher loads there might be too much stress on the bearing. With the overlap, we have it slightly clinging inside the bore, even in its free state. That allows a sure fit inside the bore for maximum interaction with the outer race of the bearing. This can actually be installed upside down against gravity and it doesn’t fall back out.

DW: Can you tell us about the material? Moskalik: Most of our standard wave springs come in two materials. There is the carbon steel spring tempered, and then the stainless is 17/7 pH, and we use condition pH 900. The parts are available in both.

DW: What is next for the spring series? Moskalik: Going small is a focus for us in the near future. Miniaturization is one of our driving factors right now. But I should mention that it’s not just the SSB series that’s getting smaller. We are in the middle of miniaturizing our other wave springs series. We have a standard series of what’s called Crest-to-Crest Wave Springs. Currently we are manufacturing all the smaller sizes. Those are going to go down to being able to fit into a 3/16-in., much smaller than the SSB series. We are also looking to do the same with our single turn wave springs that are not the bearing preload, but just standard turn wave springs. Those will also go down to a 3/16-in. We can make specials that are even smaller than that, but that’s where we decided to limit it out right now for our standard parts. We’re hoping to put these advances in place quite soon. DW

SMALLEY smalley.com

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Reduce network cabling with

Thomas Rettig • Senior Product Manager • EtherCAT Technology, Beckhoff Automation

Power over Ethernet (PoE) began the trend of simplifying network cabling by combining power and communication in network cabling. Now, EtherCAT offers a combined version. On its own, EtherCAT is an established global standard. A newer version, EtherCAT P, combines the fast EtherCAT communication with 24 V power for the system and peripherals in an Ethernet cable. This development means that “One Cable Automation” (OCA) can now be implemented at the field level, enabling the plug-and-play connectivity for machines and other equipment, ranging from 24 V sensors to 600 V drives without the need for control cabinets.

EtherCAT P combines the 24 Vdc power supply for EtherCAT P slaves with connected

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With EtherCAT P, the US and UP currents are directly fed into the wires of the 100 Mbit/s line, streamlining network and power architectures. This configuration makes EtherCAT P a suitable protocol for sensors, actuators and measurement technology components with benefits for connecting small I/O stations in the terminal box, as well as for distributed I/O components. Beckhoff developed a special M8 connector for the cable that provides mechanical encoding and prevents any confusion with connectors for standard EtherCAT slaves. A complete EtherCAT P connector family connects components with higher voltage and current needs, to cover applications up to drives with 400 Vac or 600 Vdc and up to 64 A ratings. The new connectors make it easy to connect field-level components. For I/O applications, the interfaces are available with IP 20 and IP 67 ratings. The EtherCAT P system is also suitable for ac and dc motors, actuators, valve terminals and sensors such as proximity switches, light barriers or rotary encoders. For vision applications, users can connect cameras, barcode scanners and 3D scanners. EtherCAT P simplifies system wiring The fundamental idea of EtherCAT P is to simplify system wiring by reducing the number of connectors on automation components and devices. The onecable solution, which is scalable to individual power requirements, can be deployed throughout the entire field level. For 24 V applications, a standard Ethernet cable can be used. For higher voltages and currents, EtherCAT P is integrated into the respective power supply line. Eliminating separate power lines reduces the cost of materials and assembly, as well as the risk of installation errors. It also minimizes the space requirements for cable routes, in control cabinets, and in the machine itself. Other benefits include smaller and more precisely arranged cable runs, as well as smaller sensors and actuators. Such benefits give machine manufacturers and plant personnel more design options while minimizing hardware and system costs through a convenient, tool-assisted system layout. Flexible topology through power supply forwarding Linear, star and tree structures can be freely combined to achieve cost-effective and efficient system layouts. Unlike with classic Power over Ethernet (PoE), EtherCAT P devices can also be cascaded and supplied by a single feed-in device. The voltage drop limits cascading of EtherCAT P devices, but this can be 86

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I nd ustrial E t h e r n e t remedied with additional power feed-in points. To build custom EtherCAT P topologies, infrastructure and I/O components with IP 20 and IP 67 ratings are available. Since EtherCAT P distances of 50 meters and more can be bridged, even widely distributed machine modules can be easily linked. A seamless shift from an EtherCAT to an EtherCAT P network is also possible. Conversely, system and peripherals voltage on an EtherCAT P network can be blocked with a simple adapter to run EtherCAT devices with their own power supply. A tool in TwinCAT software helps designers plan or configure cable lengths for a machine design. Since the system knows the data of all users, it can also take the individual devicesâ&#x20AC;&#x2122; power consumption over time into account. For example, if a system operates such that two actuators never switch at the same time, they never require full power at the same time. This capability produces additional savings potential concerning feed-ins and power supply units. One Cable Automation for the field level EtherCAT P was developed to establish One Cable Automation across the field level. This simpler system cabling makes machine designs less complex while reducing engineering and production costs. It lets designers use a single cable to deliver power and control signals to automation components, distributed terminal boxes, machine modules and robots. Large control cabinets can be reduced in size or even eliminated. As a result, modular machine and system concepts can now be implemented with lower assembly and startup costs, reduced footprints and greater flexibility. Pluggable technologies will deliver maximum automation efficiency in the future. As EtherCAT P connectors for various power requirements become established, the idea of industrial connector strips for 24 V and higher power classes is not farfetched, but a viable solution. Machine designers could distribute such strips with great flexibility and at low cost in a machine or plant installation according to the individual application requirements. Such a plug-and-play design that requires only the insertion of a matching EtherCAT cable would make it easy to connect all required sensors and actuators as well as distribution boxes and standalone machine modules. DW Beckhoff Automation beckhoff.com/ethercat November 2016

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I n d u s t r i a l

E t h e r n e t

Better connections for Industrial Ethernet applications Industrial Ethernet applications are growing, so your connector choices and options should as well. The M8/M12 connectors continue to evolve to meet pin density and data rates needed now.

Kevin Oursler Director Marketing and Business Development â&#x20AC;&#x201C; US, ERNI Electronics, Inc. Industrial Ethernet offers cost, data volume, and transmission speed improvements over other technologies, including fieldbus. Industrial Ethernet can also handle harsh environments, data collisions, factory noise and process needs. But the continued development and expansion of more complex industrial automation environments, such as Industry 4.0, require higher performance networks with connectors with more density. Bandwidth and dense connector systems once unique to networking and datacom applications are turning into standard requirements in the smart factory of today. The standards around Ethernet have influenced the networking and datacom-application segments. Internet Protocol and IEEE 802 standards create a natural networking infrastructure for industrial applications. Standard interfaces, such as the Modular Jack I/O, dominate the traditional networking segments. But in the industrial world, in particular on the factory floor, these Modular Jack connection points may not be suitable as they are prone to damage during handling and installation. 88

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For Industry 4.0 and IoT, interconnect options include new I/O choices as well as design requirements inside a system or enclosure. Application requisites include choices that support a diverse set of mechanical and electrical solutions. A well-designed network of industrial devices should direct complex operations and store sensitive data at speeds of at least 1 Gbps. Most industrial applications feature harsh environmental conditions of some kind â&#x20AC;&#x201D; signal and data interference, dust and moisture contaminants, extreme temperatures, or shock and vibration. Connectors must be hardened for these applications while minimizing effects from increased data rates and inherent noise within an industrial environment.

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11/7/16 9:30 AM

M12 high density connectors support increased data function requirements in an open pinfield design for customer specific applications and wiring/routing options.

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I nd ust r ia l E t h e r n e t

Enhanced M8/M12 connector developments improve EMC performance and offer unique packaging options to save space in sensor/imaging applications.

M12 Gigabit Ethernet connectors reliably transfer data at high-speed. They also offer improved shielding for industrial data communications. applications.

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Balancing density and reliability It wasnâ&#x20AC;&#x2122;t that long ago when standard connectors from commercial hardware applications were used in industrial process and automation equipment. However, modern industrial hardware has increased I/O requirements, data rates, mechanical robustness and packaging, requiring smaller sizes. These elements are in various connectivity points throughout the network; including passive I/O boxes, sensors, actuators and drives. Design challenges can include higher pin count requirements or better shielding that can support more demanding electrical transmissions, such as in GbE applications while continuing to support harsh environments in a mechanically proven and sealed (IP65/IP67) interface. In the past, M8 and M12 connector variations were used primarily as machine sensor connectors. These sensors and actuators are frequently connected to a passive I/O box that supports various protocols and applications, including Ethernet. The harsh influences of the environment on these boxes make tightly sealed (IP65/IP67) connectors a necessity. As such, the M8/M12 connector systems perform well in such applications, proven and established in sensor technology. Mechanically, the M12 connector supports various protocols with coding built into the male/female mating connectors. These protocols include keying schemes for devices (sensors/ actuators) and fieldbus applications, such as Profibus and EtherNetIP. Designers can expect a migration towards density, but without compromising the mechanical performance required in industrial designs. New variations in the M12 series are supporting Industrial www.designworldonline.com

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11/3/16 3:20 PM

I nd ustrial E t h e r n e t Ethernet and this connector platform continues to evolve. Open pin-field connector options extending up to 17 positions are one way of optimizing networking design requirements. With GbE applications, look for maximum shielding between differential pairs and improved conductivity between the panel and the board ground plane. A proper connector design and integrated components will mitigate signal integrity concerns while supporting reliability inherent is this defacto standard interface. Finally, another way to achieve maximum density and electrical performance is in innovative SMT termination designs with strain relief features to support the most demanding of rugged applications. These SMT termination options prove beneficial not only in optimizing signal integrity and mitigating stub effects associated with traditional through-hole terminals, but they are preferred in manufacturing the host boards or passive boxes that use an M8/M12 connector system. Proven signal and shield terminations will enhance the design and provide confidence over the life of the product once installed in a factory environment. The defacto-standard M8/M12 connector series has long been used in industrial environments. The evolution of this connector series includes coding features to service specific industrial communications applications. Newer and modern additions include density and higher pin count options. Finally, achieving longer transmission lengths even at increased data rates can now be realized with improved shielding designs and a focus on maintaining signal integrity. Industrial Ethernet applications are growing, so your connector choices and options should as well. ERNI product families that can support your industrial applications include M8/ M12, DIN41612, SMC, MicrospeedTM and MicroCon. DW

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E l e c t r o n i c s

Teardown:

Does the Amazon Dash set the tone for IoT appliances? Amazon’s push-button-ordering gizmo could be a harbinger of things to come on the Internet of Things. But is it a hacker’s dream?

Leland Teschler • Executive Editor

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The online retailer Amazon wants you to order items like laundry detergent or coffee by pushing one of its Dash Buttons. A Dash Button is a Wi-Fi connected device that reorders a specific product with the press of a button. When you’re running low, simply press Dash Button to place an order with Amazon.

Users setup and manage Dash Buttons through an app on a smartphone. When everything is good to go, the Button can send a notification to your smartphone every time an order is placed, letting you cancel an order before it ships if need be. There’s also a version of the Dash Button that can be programmed to do other things: place an Amazon order for something else or execute non-ordering tasks such as control smart appliances such as lights. But this programmable Dash Button costs about $20 rather than the $5 that buys a Dash Button already dedicated to a specific product. The hardware on the two is identical. So there is a sizeable web community devoted to analyzing the cheaper version with repurposing in mind. One problem with the Dash Button, as with other appliances making up the internet of things, is that they open up the possibility of being hijacked by hackers with nefarious intent. Cyber security experts say the usual reason criminals hack IoT devices is to use them as proxies that hide the hacker’s true location online. Hackers do this to mask cybercriminal activity such as frequenting underground forums or engaging in credit card fraud. But there’s another potential security problem with the Dash Button: It contains a microphone. The mic is used to configure the Dash Button through ultrasound when the smart phone running the

11/4/16 11:26 AM

Dash app uses iOS. (Android phones use Wi-Fi for configuration.) Those who’ve analyzed the configuration sequence say the ultrasound signals take the form of ASK transmissions in the 18 kHz range. Problem is, a microphone able to pick up ultrasound will also pick up near-by conversations. Thus theoretically, the Dash can be turned into a surreptitious listening device. Perhaps the main factor that mitigates the Dash Button’s security problems is its battery. The battery is neither rechargeable nor replaceable. Amazon says a Dash Button should be good for about 1,000 button pushes before its battery dies. The upside of this relatively short life is that a Dash Button won’t last long as a rogue proxy server or as a listening device. Those who have analyzed Dash Button circuitry say it

The Amazon Dash Button – not to be confused with the Amazon Dash, which is something else entirely -- is a Wi-Fi connected device that reorders a product when you press the button. Each Dash Button is paired with a specific product, selected during the set-up process. The idea is to simply press the Dash Button when you are running low.

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(images from amazon.com)

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E l e c t r o n i c s

With the button and cover removed, the top surface of the PCB reveals the main Atmel processor and Wi-Fi chip, the Cypress Bluetooth Low Energy IC, an RGB LED, the switch mechanism, a tuning capacitor for the antenna, and a port for the microphone. There were five small chips on this side of the board that couldn’t be identified from their markings. Some contributors to online forums on the Dash Button speculate that the ICs have something to do with power regulation.

The Dash Button cover attaches to the PCB via two tiny Torx screws. The AAA battery holder also attaches to the bottom of the board via Torx screws.

draws 200 to 300 mA when on, 2.3 μA when in sleep mode. Thus the Dash Button will last awhile when it only draws hundreds of milliamps during brief button pushes. But if operated as a proxy server or listening device, it would draw this kind of current nearly all the time. From the AAA cell’s current versus service hour curves, the Dash Button might last just four hours if run in active mode this way. To add a bit of confusion, there is another Amazon product resembling the Dash Button but called, simply, the Dash. It is a device for adding items to orders on AmazonFresh, a grocery deliver service. An analysis of the Dash device, published on the web, found that the Dash carried basically the same circuit as the Dash Button but with a barcode scanner and a replaceable battery. Thanks to the onboard microphone, the Dash can also accept voice commands.

“The Dash Button hardware has gone through a couple of revisions that have involved changing the main processor, battery, microphone, and Wi-Fi chip.

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Inside an ordering button The Dash Button hardware has gone through a couple of revisions that have involved changing the main processor, battery, microphone, and Wi-Fi chip. Earlier versions carried an STM32F205 microcontroller and a Broadcom BCM43362 Wi-Fi module. The microphone was from InvenSense and the tab-welded lithium-ion battery was an Energizer. The more-recent version we examined contained quite different hardware. The processor is now an ARM-based unit from Atmel (ATSAMG55J19A). The Wi-Fi chip is from Atmel as well (ATwinc1500B). Also onboard is a Bluetooth Low Energy chip from Cypress Semiconductor (CYBL10563-68FNXI) and a flash memory chip from Micron (N25Q032) that is about the double the size (32 Mbit) of that on the earlier versions. Bluetooth is the means by which the Dash Button communicates with an Android phone during setup.

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Microphone port

The Dash Button comes with a removable plastic loop for hanging on a key chain or a hook. The back has adhesive for sticking. Visible on the front of the device is the port for the microphone, used for receiving ultrasonic signals during setup with an iPhone.

The bottom surface of the PCB carries the Micron flash memory as well as the Texas Instruments boost converter and the inductor that is probably part of the boost network. The microphone’s maker couldn’t be identified from the mic markings. Also visible on this side is the printed antenna which seems to handle both the BLE and Wi-Fi radios.

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E l e c t r o n i c s

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by a lithium battery but this version carried an alkaline AAA cell. Whoever wrote the Dash Button instruction book didn’t get the memo.

One noteworthy item is the battery. The earlier version’s lithium-ion Energizer cell has been swapped for a Duracell AAA unit that sits in a battery holder. (The lithium-ion cell was tab-welded to the PCB.) The AAA cell is less expensive and holds less energy than the lithium battery it replaces, 1.15 A-hr compared to about 1.3 A-hr. The reason for the battery change seems to be that Dash designers found a way to reduce the amount of energy consumed during a click. According to an analysis by physicist Matthew Petroff, the new Dash Button’s energy use is about 4.3 ± 2.2 J per activation while the original Button used 16.4 ± 0.1 J per activation. There are several small ICs on the PCB that lack enough markings to be identified. Commenters on other Dash Button teardowns have speculated that four of them residing on the top surface of the PCB make up some kind of power regulation network. But in that the board carries a boost regulator power supply chip, it is hard to imagine what purpose additional power regulator chips might fulfill. Also of note is the antenna network. The Dash Button contains a tuning capacitor that is evidently 96

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E l e c t r o n i c s

part of a matching network for the Bluetooth and Wi-Fi antenna. The antenna itself is printed on the PCB near the edge at one end. We found only one antenna, implying that both the Bluetooth and Wi-Fi radios share it. Overall, the Dash Button can be viewed as a possible prototype for what much of the IoT could end up looking like. Hobbyists are already figuring out ways of recording data every time a Dash Button is pushed and using that information to control household appliances. At $5 each, if Dash Buttons are a vision of the internet-connected future, the IoT will be relatively cheap. DW References

•

Matthew Petroff’s Dash Button teardown, https://mpetroff.net/2016/07/new amazon-dash-button-teardown-jk29lp/ Reverse Engineering the Amazon Dash Button’s Wireless Audio Configuration, http://www.blog.jay-greco.com/wp/?p=116

• Amazon Dash (Wand) Teardown, https://mpetroff.net/ 2016/09/amazon-dash-wand-teardown/ • Main Processor: Atmel SAMG55, http://www.atmel.com/

Images/Atmel-11289-32-bit-Cortex-M4-Microcontroller- SAM-G55_Summary-Datasheet.pdf Wifi: Atmel ATWINC1500B, http://www.atmel.com/ Images/Atmel-42487-ATWINC1500B-MU_Datasheet.pdf Bluetooth: Cypress CYBL10563-68FNXI, http:// download.opendatasheets.com/pdfs/ 2014/11/11/22/53/36/106/cyp_/manual/procble.pdf Flash: Micron N25Q032, http://www.datasheetspdf.com/ datasheet/N25Q032A.html Boost converter: Texas Instruments TPS61200, http:// www.ti.com/product/TPS61200 How I Hacked Amazon’s $5 WiFi Button to track Baby Data, https://medium.com/@edwardbenson/ how-i-hacked-amazon-s-5-wifi-button-to-track-baby data-794214b0bdd8#.nvisohc7v

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Nine common errors engineers make when selecting a sensor When designing a new product or system that needs a sensor to function properly, design engineers have many choices.

Randy Frank â&#x20AC;˘ Contributing Editor

While a variety of choices is usually appreciated, it can often lead to

mistakes in the selection process. This can occur for both novices and experienced engineers, especially if they are unfamiliar with the sensing technology or troublesome aspects of the application. To prevent these errors, we asked suppliers of different types of sensors to provide some insight. According to Karmjit Sidhu, Sr. director for oil and gas sensor solutions at TE Connectivity, common errors engineers make applies to not one measurand but across sensors in various stages. He elaborated on nine common errors when related to sensing a particular parameter.

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Sen s o r s

Accuracy is problematic because it can be specified and interpreted in many ways. “In one term it can be defined as the error at room temperature or total error over operating conditions such as temperature,” said Sidhu. “For pressure sensing in industrial applications, static accuracy applies to combined error of nonlinearity, repeatability and hysteresis at room temperature; however, in automotive applications it is the sum of static accuracy and thermal errors.”

Temperature “In some measurements, such as vibration, temperature and tilt, the ambient range is required,” said Sidhu. “However, for pressure, the media temperature is also important for safe operation.”

Media compatibility “This is very important for pressure sensors, [as] wrong material selection for diaphragm material can lead to failure and potential serious injury,” said Sidhu. “In marine and outdoor applications, sensor package material must be carefully selected to promote long life against environments.”

Sensing technology is an important topic that affects several aspects and defines the shape, size, limits, price, usage and performance.

Other types of sensors require additional attention to other details to avoid errors.

Inductive sensor errors Inductive sensors represent a sensing technology with some unique requirements. Shawn Day, marketing manager at Balluff Inc. pointed out that inductive sensors are solid performers when the correct options are selected. However, when installing an Inductive sensor in an application, several options must be considered. Day identified three common mistakes that can occur. The first error is selecting Flush versus Non-Flush mounting specifications. “A flush offering can be embedded into a metal bracket or mounting block without false triggering and output,” said Day. “A Non-Flush offering will need a free zone at the sensing face so the sensor does not false trigger from the metal in the mounting block itself.”

Electrical interference is a critical aspect since all sensors with active components are subjected to electrical interference. “Careful considerations should be given to the particular applications where safe operation is of paramount importance—such as airplanes, nuclear plants, cranes, transportation systems and medical devices,” cautioned Sidhu.

5 6

Mechanical noise and mounting details for sensor in high vibration and shock conditions are critical for safe operation.

Humidity/rain/ice/water spray: the sensor’s protection level must be clearly defined against these elements when used in outdoor applications.

Steady state and dynamic operating conditions have to be defined clearly for correct and safe operations for the sensors.

100

For pressure sensors, such as TE Connectivity’s AST4000, ‘errors’ related to accuracy, temperature, electrical interference, humidity/ rain/ice, steady state and dynamic operating conditions and overload are important.

For vibration sensors, such as TE Connectivity’s 8011-8021-01, mechanical noise, steady state and dynamic operating conditions deserve careful consideration.

Overload: all sensors must have sufficient overload capacity for short duration. “For example, in pressure sensing, two times overload of rated pressure up to certain range is required in pulsation applications,” said Sidhu. “Similarly for vibration and shock sensor, they must be able to withstand excessive limits beyond the operating range.”

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Sens o r s

The second error occurs when selecting the correct Inductive sensor for a specific material. Day explained, “If the target is aluminum, selecting an all metal sensor (Factor 1) offering would be the best choice, as there is no reduction in the sensing range on the non-ferrous material.” A third error for inductive sensors occurs when selecting the correct sensor for the application environment. “If the sensor is applied in a hostile application, such as welding, then a sensor with special coatings is required to combat the weld spatter that is present in this type of application,” said Day.

When designing a new product or system that needs a sensor to function properly, design engineers have many choices.

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Depending on the sensed material, the switching distance varies considerably but a Factor 1 sensor extends the range to minimize errors.

Proximity sensor errors Proximity sensors can also have unique selection errors. Jack Moermond, marketing manager at Balluff, provided insight into different types of proximity sensors starting with diffuse sensors. For this type of proximity sensor, the target reflectivity determines sensing ranges. “Sensing ranges listed are based off Kodak paper with a 90% reflectance,” said Moermond. “Therefore, any target that is less reflective will result in a shorter sensing range.” There is another issue for diffuse sensors that must be considered. “Unless using a laser or small beam light source, detecting small parts can present challenges as the target could be too small to reflect enough light back to the receiver,” said Moermond. Background suppression is important for diffuse sensors as well. “The light spot should be smaller than the object being detected,” said Moermond. “If the target is smaller than the light spot, the sensor may detect the background because the light beam passes around the target.” Moermond pointed out that retro-reflective sensors have a couple of issues that must be addressed.

“When using laser retroreflective sensors, ensure that a compatible reflector is used,” he cautioned. “These reflectors will have more precise, smaller micro-cubes or prisms that will reflect the smaller light beam more efficiently. If the wrong reflector is used the output of the sensor could chatter.” The second retro-reflective error can occur because the light beam of a retroreflective sensor is conical shaped, similar to that of light beam from a flash light.

Hybrid capacitive sensors can address errors that affect standard capacitive proximity sensors.

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CS Hyde Company “If the application is detecting small parts, the part must be larger than the reflector or it must bemoved closer to the sensor face,” said Moermond. Through-beam photoelectric sensors can detect objects independent of color, reflectivity and are not affected by second surface reflections. The high gain of these sensors allows them to ‘see’ through opaque materials. Moermond has recommendations to avoid errors in these types of sensors. “Small targets may not interrupt enough of the effective beam causing false triggers,” he said. “This can be corrected by using apertures.” Another potential problem area for through-beam sensors can be cross talk. “If the application requires multiple through-beam sensors to be mounted next to each other, alternately mounting the emitter and receiver may prevent cross talk,” explained Moermond. In some applications, capacitive sensors provide an alternate proximity detection method to photoelectric sensors but have their own unique error aspects. For example, highly conductive liquids, such as acids, can cause false trigger errors for standard capacitive sensors but Moermond has a solution.

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“SmartLEVEL or hybrid technology capacitive sensors will turn on and off correctly,” he said. The hybrid technology capacitive sensors can prevent errors in other applications. “Standard capacitive sensors will have a difficult time in discerning the difference between foam and film whereas a hybrid technology will not,” explained Moermond. Load cell errors Load cells require special considerations to avoid selection errors. Thomas Moore, an aerospace engineer and a technical marketer for Futek, provided some guidelines for selecting the correct load cell capacity and noted that an improperly sized load cell can fail prematurely. “A sensor can be operated at its capacity, but it leaves no room for error since overload protection is there to protect against accidents only,” said Moore. “Ideally, the load cell should be operated at a maximum of 70% its rated output.” The effect of natural frequency and load on sensor response is another critical load cell area to consider. “Natural frequency represents the frequency response of the load cell under no load conditions,” said Moore.

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What’s Next? RMC75 1 or 2-Axis

RMC150 Up to 8-Axis “As load increases on a load cell, its frequency response decreases, meaning it cannot measure a cyclic load changing at a frequency higher than the loaded frequency response without lagging.” Underestimating extraneous loads, the loads applied to a sensor that are not on the axis/axes of measurement, is another trouble spot for load cells. “Extraneous loads should be observed and their limits avoided during application usage as well as installation usage,” said John Truax, head of technical support at Futek. “By estimating, observing and minimizing the extraneous loads on the sensor, unnecessary and unexpected damage to the sensor can be prevented.” One way to avoid extraneous load problems is a load cell designed with a 150% capacity overload protection. Futek’s recently announced LCM100 is an ultra-miniature tension and compression load cell that offers high precision and high accuracy in a compact size and is RoHS compliant.

Pressure sensor errors Martin Murray, an application engineer in Honeywell Safety and Productivity Solutions, admits that selecting the right sensor for the right job is not always an easy decision. “Whether a particular sensor is suitable for a specific application will depend in great part on the sensor’s attributes, the environment it’s specified for, and the job it’s asked to perform,” he said. For Murray, common errors that engineers often make include: • Not taking into account the sensor drift with time (i.e., stability) • Selecting a sensor that is not robust enough for the application www.designworldonline.com

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• Not taking into consideration the cost of calibrating the sensor themselves versus a plug-and-play device This is by no means a complete list. In fact, the total error band (TEB) is one specification that deserves careful analysis. “Not factoring how worst-case scenarios stack up and therefore selecting a sensor that doesn’t have a tight enough total error band, a figure that is used to determine how a specific sensor will perform within the system,” said Murray. “The TEB accounts for all possible errors for a sensing device.” To avoid TEB errors, Honeywell’s heavy duty PX3 Series pressure transducers feature a tight total error band of ±1.0 percent full-scale span. This TEB accuracy specification provides design engineers with comprehensive, clear and meaningful indications of the sensor’s true measurement performance over a specified temperature range in HVAC and refrigeration equipment. While there are certainly other considerations that engineers need to evaluate for a successful design, the experts think you are off to a good start by addressing those areas that have been identified. DW

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All Motion ........................................................................................................ 4 Allied Electronics ..................................................................................... 3,85 Alpha Wire ....................................................................................................79 Altech Corporation .......................................................................................37 AMETEK PMC ................................................................................................ 19 AMETEK/DFS (Windjammer,etc.) ..............................................................35 Anderson Metals Corp. ................................................................................87 Aurora Bearing Co. .......................................................................................48 AutomationDirect ........................................................................................ 13 AutomationDirect .................................................................................. Insert Balluff ...........................................................................................................50 Bimba ...........................................................................................................11 Bishop Wisecarver ......................................................................................65 Bison Gear ...................................................................................................IBC BOKER’s Inc ..................................................................................................18 c3 Controls ................................................................................................... 61 Canfield Connectors ....................................................................................24 Carlo Gavazzi ............................................................................................... 41 Cone Drive ....................................................................................................91 CS Hyde ......................................................................................................103 DATA IMAGE Corp. ........................................................................................97 Delta Computer Systems ..........................................................................105 Del-tron Precision, Inc. ...............................................................................62 DieQua ..........................................................................................................83 Digi-Key Electronics .................................................................................... 17 Dunkermotoren, part of Ametek ...............................................................63 Elesa USA Corporation ................................................................................ 14 Epson ............................................................................................................45 EXAIR Corporation ......................................................................................... 5 EZAutomation ................................................................................................ 1 FABCO-AIR ...................................................................................................104 Fixtureworks ................................................................................................48 Fotofab ..........................................................................................................57 FPZ Inc. .........................................................................................................86 Helical Products Company ........................................................................... 7 Helukabel, USA .............................................................................................31 Hitachi Cable America .................................................................................39 HIWIN ........................................................................................... 107,109,111 IGUS ...............................................................................................................44 J.W. Winco, Inc. ............................................................................................97 John Evans’ Sons ........................................................................................64 Keystone Electronics Corp. ........................................................................51 Kollmorgen .................................................................................................110 Master Bond .................................................................................................24 maxon precision motors ..................................................................Cover,67 MicroMo ........................................................................................................56 Miki Pulley US ..............................................................................................55 Newcomb Spring .......................................................................................106 Novotechnik ................................................................................................. 15 NTE Electronics, Inc. ...................................................................................96 OKW USA .......................................................................................................95 OPTO 22 ...................................................................................................... 53 PBC Linear .............................................................................................. 42,43 Penn Engineering ........................................................................................77 PHD Inc. ........................................................................................................66 Pittman, part of Ametek ............................................................................. 71 Primatics, Inc. .............................................................................................. 21 Proto Labs ...................................................................................................... 9 Quantum Devices Inc. .................................................................................73 Ringfeder Corp. ............................................................................................52 Rutronik Inc. | Electronica ..........................................................................32 Schneider Electric .......................................................................................33 SEW Eurodrive .............................................................................................BC SIKO Products ............................................................................................108 Smalley Steel Ring Company .....................................................................10 Sorbothane ................................................................................................108 Suco Technology Inc....................................................................................18 The Lee Company ........................................................................................78 THK America, Inc. ....................................................................................... IFC Tompkins Industries ..................................................................................... 2 TRIM-LOK, Inc. ..............................................................................................22 Turck ........................................................................................................ 27,29 Weber Knapp ................................................................................................25 Whittet-Higgins Co. ......................................................................................23 Wittenstein .................................................................................................101

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Design World 4. Issue Frequency

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No. Copies of Single Issue Published Nearest to Filing Date No. Copies of Single Issue Published Nearest to Filing Date

37,271

39,568

34,999

39,568

34,999

2,519

1,197

693

625

3,212

1,822

42,780

36,821

452

450

43,232

37,271

92.5%

95.1%

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Date

17. 18. Signature and Title of Editor, Publisher, Business Manager, or Owner

Date

November 2016

Pat Curran, Business Development Manager

9/30/16

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DESIGN WORLD

Ad Index 11-16_Vs1a.indd 112

November 2016

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