DESIGN WORLD NOVEMBER 2018 by WTWH Media LLC

www.designworldonline.com

November 2018

inside: Motion Control: Drives propel multi-axis

motion

p. 62

Sensors: Sensors increase material

handling safety

p. 74

Electronics: Energy efficient lighting

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Know your stops:

(open-loop) stalls vs. (servo) holds page 52

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I recently spoke with Dr. Hamid Vejdani, an assistant professor in Mechanical Engineering department at Lawrence Technological University in suburban Detroit. Vejdani’s research interests include bioinspired robotics, behavior design and control design of robots, and dynamical modeling. Before joining LTU, he was a postdoctoral research associate at Brown University, where he studied dynamical agility of flapping flight in hummingbirds and bats. Vejdani has developed and implemented control strategies for walking and running bipedal robots and he has been exploring the mechanics of flapping flight systems inspired by stability, maneuverability and agility of natural fliers. We chatted about the main thrust of his research in robotics, “Bioinspiration.” This concept means getting inspiration from nature and applying the lessons learned into designing and controlling capable engineering products and, in his research, robots. DW: Biomimicry receives a lot of press, especially in the robotics field. You’ve said you’re more focused on bio-inspired designs. How do these two approaches differ?

HV: Basically, in biomimicry you try to mimic nature as close as possible. Although it is a fantastic way to start, it will not be that helpful when you want to expand the findings to other scales or purposes. In bioinspired designs, we try to understand the fundamental physics behind the phenomena (which can sometimes start with mimicking in the beginning) and therefore those principles can be expanded and used for any scale or application because of the laws of physics. Once you understand them and apply them appropriately, they are the same for all of our engineering products.

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HV: I am currently working on two bio-inspired robotics projects here at Lawrence Technological University. One is inspired by agility and maneuverability of a kangaroo running (a kangaroo running robot) and the other is inspired by the efficiency and stability of hummingbird hovering (hummingbird-scale hovering robot). Although it seems diverse in the first glance — running and flying — when you study the principles of animal locomotion in more detail, you notice that there is a common trace in all animal locomotion types. That is the use of their natural dynamics (mechanical design of the system) in providing help to achieve the desired motion. My research is to understand how these natural dynamical characteristics — like mass distribution and sizes — can be used to enhance the stability and maneuverability of locomotion in each case.

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I n s i g ht s DW: Do you see practical applications

DW: Let’s talk a bit about today’s

DW: Do you have any thoughts on how

of bio-inspired design for industry? What are some examples?

college engineering programs. Are they different than they were a generation ago? How have they improved or changed? What is the biggest challenge today in preparing students for jobs in industry?

we can better interest young girls in engineering careers such as robotics? What are we doing right and where can we do better?

HV: Basically, the industry (and in a broader sense engineering) is full of bioinspired design products and ideas from architectural designs and materials for cooling and force resistance to airspace industry and defense. For example, look at airplanes; we do not mimic the wings from birds, we found out that wings and tails are necessary for flight. Now we have airplanes that are basically fixed winged vehicles, in contrast to natural fliers, which have flapping wings. So, we got inspired from nature and developed the airplane industry. I think the robotics industry will continue to grow much faster in developing robots that can get outside of the structured labs and help humans in the real world. And guess who can be the source of the inspiration for designing such machines? Probably those who have been operating in the real world for millions of years: animals.

DW: What’s your strategy for teaching college engineering students about robotics? How or where does bioinspired design fit in? Do you find that gives students a better touch point?

HV: We absolutely have had big changes in college engineering programs, based on the growth in technology and the needs in the engineering world. In the past, students basically needed to learn skills and be able to apply them to solve problems when they graduate. Nowadays, specific skills may even become outdated by the time the students graduate or there might be a new software or AI that can deliver those tasks. Therefore, we need to make our students adaptable to the fast-paced growth of technology. I believe beside teaching them the fundamental principles, we need to train them to think outside of the box, be team players and become efficient self-educators. We need to update our teaching methods and probably the biggest challenge for university professors is to update the way we all learned the engineering concepts which was mainly lecture based. It definitely needs us to come from outside of our comfort zone.

HV: We need to find the motivational points for our targets to interest them. I think women in general care a lot about helping others. If we inform society that robotics is not all about building industrial robots that are used in production lines, but also in robotics we can design and build prosthetics and exoskeleton to help disabled people, that’s a positive. Similarly, robots can help elderly people or robots can be used in rehabilitation, which directly improve the quality of lives for millions. Here, we can get their attention even more. I think establishing direct communication between high schools and maybe even middle schools with universities can be really helpful, because the main source of the impression for robotics nowadays is through movies — that, in many cases, is far from reality and not helpful. DW

HV: My strategy is to connect the robotics concepts to something tangible for students, be their experience of driving a car or running on the beach. If the students can visualize the implementation of those concepts into some familiar phenomena that they have observed or experienced, then they can see the value behind understanding the concepts. It is not a surprise that humans are mesmerized by nature — and that is what I use as the hook to interest students when I am teaching robotics. Fortunately, in robotics, you nearly always can find some good connections, from the human hand for industrial robots to birds for aerial robots.

Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

November 2018 www.designworldonline.com

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Teschler on Topic Is the Professional Engineering license worth the effort? Engineers who do electrical work may be familiar with Mike Holt whose website (mikeholt.com) specializes in educational material mainly devoted to deciphering the National Electrical Code. Holt also hosts a forum where someone recently posted this query: Should I get my PE license? I meet all the requirements…The pay bump is tempting but I feel I will be thrown into the deep end and expected to swim….I have four years’ experience in commercial electrical design. However, the most engineering I’ve done is lighting design, voltage drop, space planning, arc flash studies, TCC coordination, IECC code compliance.….I feel like the vast majority of my experience is in drafting and creating construction documents….I guess I’m afraid of the “You’re a PE, what do you mean you don’t know this?!?” conversation….Should I….wait until I’m confident as an engineer? As you might suspect, the post has received a lot of comments. Most of them have a “just do it” tone to them similar to this one: I got my PE license years ago even though I thought I might never need it because I was working for a huge company with a bazillion engineers. When that company kicked

me to the curb I was…glad I had secured my license. It opened doors for me that would have otherwise been closed off. Get it. Get it now. You will always have the option of not using it. And like this one: I received my license in the mail about 8 weeks ago. I have never felt more accomplished or proud of anything in my life. Take the exam. The writer’s concerns about the implied competence of a PE license seemed to have hit a particular nerve, judging by the number and tenor of the responses. This is not surprising. A lot of the people I went to school with back in the dark ages hesitated to take the Engineer in Training part of the PE exam for the same reasons. But for us, waffling over the EIT exam involved a lot more than self-doubt about our abilities. At least for some of us, it had to do with the anxiety over the interactions with our more experienced colleagues. Even on this point, responders on Holt’s forum provided good advice. One put it this way: I try to stay out of conversations that aren’t part of my skill set. When I can’t (sub-consultant coordination meetings), I keep my mouth shut until the topic comes around to my wheelhouse. Otherwise, I never apologize for my ignorance,

which is always curable. No one can know everything. “Stupid,” on the other hand, I sometimes have to apologize for. Another was more succinct: No one, not even a PE, not even me, knows it all. Repeat after me: “I don’t know offhand, but I can probably find out.” The back-and-forth on the forum also exposed what seems to be an urban myth: That PE’s are basically paper pushers. PEs on the forum were quick to correct this misconception. Said one, There is no “administrative side” to being a PE, per se….It all depends on the road you choose. What you’re thinking of is engineers who have moved into project management….There you have to worry about schedules, budgets, manpower loading, resource availability, etc.…Staying on the design side can have its own stresses, but usually once you hit the door, the day is done. But the most compelling argument I saw for getting a PE consisted of three short sentences: Having a PE license will open doors that would otherwise be forever closed to you, but which of those doors you pass through is entirely up to you. Picture yourself 20-30 years from now. Are you more likely to regret not getting your license when you had the chance, or (to be glad) that you got it? True and well said. DW

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

November 2018 www.designworldonline.com

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Green Engineering Paul J. Heney

• VP, Editorial Director

Container ship goes green

with vesconite

The container ship M/V Marine Rickmers, constructed in 1998, is no small vessel. The ship measures 490 feet long by 75 feet wide and has gross tonnage of 11.925 tons. When its stern tube bearing began to fail, Durban, South Africa-based Elgin Brown & Hamer (EBH South Africa) was called in. Stern tube bearings allow for smooth rotation of the ship’s propeller, making this particular component a critical one for a vessel’s operation and reliability. EBH South Africa decided to replace it with state-of-the-art, pollution-free Vesconite. Vesconite is a specialized hard-wearing thermopolymer designed for challenging operating conditions. It has an impressive dimensional stability, and unlike many synthetic alternatives, it retains its strength under wet conditions. It also displays negligible creep under high load. Vesconite can provide up to 10 times the life of traditional bronze or nylon bushings. Combining internal lubrication, a low friction coefficient and low wear rates, it does not require external lubrication, even where conditions are dry and dirty. The innovative self-lubricating polymer is far superior to oillubricated lignum vitae, white metal and composite bearings, especially with the implementation of ever more stringent environmental regulations. What’s more, Vesconite doesn’t swell in water and machines to +/-0.001-in., so tight tolerances are ensured. It has high compression strength and dimensional stability, and no stick-slip. Long-lived, it delivers up to ten times the useable life of bronze, even in dirty, silty harbor water. The bushing for the Marine Rickmers is 500 mm x 422 mm x 600 mm long, but Vesconite can supply environmentally sound 1,300 mm and longer stern tube bearings. The polymer is ISO 9001 accredited and bears type approval certifications from ABS, Bureau Veritas, China Corporation Register of Shipping, DNV GL, Korean Register of Shipping and Lloyds Register. “The shipping industry is getting greener every day,” said Eddie Swanepoel, Vesconite technical sales consultant. “Converting from an oil lubrication system to self-lubricating Vesconite makes environmental sense.” DW Vesconite | www.vesconite.com

DESIGN WORLD

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www.designworldonline.com

November 2018

10/31/18 10:10 AM

Contents 11 • 2018

•

vol 13 no 11

•

designworldonline.com

Medical

68 52 _MOTION CONTROL

74 _SENSORS

AC servo-motor systems: The difference between continuous ratings and holding continuous loads

Sensors increase material handling safety

Applications needing the holding of a load with little movement require special servo-motor sizing considerations. Here we clarify the definition in context and then relate it to the axis’ effective RMS force-torque calculation for proper motor sizing.

62 _MOTION CONTROL Drives propel multi-axis motion

Drive systems based on parallel kinematics with electromagnetic and electro-ceramic drives can improve dynamics, resolution and accuracy in applications needing high precision and

multiple degrees of freedom.

68 _INTERNET OF THINGS Enhanced Ethernet for a stronger IIoT: Time sensitive networking As more devices connect to a network, top

Medical Tips cover 11-18_FINALFINAL.indd 89

11/6/18 12:03 PM

89-102 • Early collaboration - key to medical device success • 6 questions to ask when designing polymer components for medical devices • Color 3D printed models help explain the nature of disease

80 _ELECTRONICS Energy efficient lighting with laser diodes

Experts say the improved energy efficiency brought by LEDs is only a prelude to what will be possible with laser-generating diodes.

84 _DIGITAL MANUFACTURING The difference between traditional and rapid molding

The “digitization” of nearly every process to make products continues. The latest industry to experience this shift is molding. Here’s a look at how digitization may affect traditional molding service providers.

November 2018 www.designworldonline.com

CONTENTS 11-18_Vs4.LL.indd 12

A Supplement to Design World - November 2018

Color 3D printed models help explain the nature of disease at the molecular level

The rise of Automated Guided Vehicles is driving the need for safer and more reliable sensing systems and controls

companies and consortiums work to advance tools through participation in testbeds, plugfests, and interoperability workshops.

| istockphoto.com

www.designworldonline.com

ON THE COVER The term stall can cause confusion. There’s a better way to calculate RMS force/torque to properly size motors. | istockphoto.com - Thossaphol

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November 2018

DESIGN WORLD

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DESIGN WORLD

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

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CREATIVE SERVICES

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

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November 2018

11/2/18 12:54 PM

Design for Industry Aerospace

Clamping design streamlines welding

and assembly applications The TCC-2E Series Tolerance Compensation Clamps (TCC) provide greater flexibility in welding and assembly applications that require the clamping of components of differing thicknesses or tighter tolerances, such as in aerospace applications. The TCC-2E has been designed to improve the setup and changeover times of production lines by eliminating the need to manually adjust clamps for different sheet-metal thicknesses. The TCC-2E works in conjunction with Destacoâ&#x20AC;&#x2122;s portfolio of power clamps, pin clamps, and pin packages. The TCC-2E model, which is directly interchangeable with the 82M-3E Series Power Clamps, is suitable for flexible manufacturing applications in the automotive, aircraft and consumer goods industries. One automotive industry example is the handling of vehicle chassis of varying thicknesses on a single production line. This operation has historically required the use of two clamps that are adjusted for different material thicknesses, but now with the Tolerance Compensation Clamp, a single unit can be used for multiple material thicknesses, resulting in reduced setup times and production costs. The TCC-2Es are available in a variety of sizes. They feature an enclosed body that protects the internal mechanism and have been tested to be maintenance-free for 3 million operating cycles. Various cylinder designs with unlockable non-return check valves, hold-open devices, and rod-lock units are available to meet the needs of every unique application. DW

Destaco | destaco.com

WHAT DO YOU THINK?

Connect and discuss this and

other engineering design issues with thousands of professionals online

November 2018 www.designworldonline.com 16

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DESIGN WORLD

11/2/18 2:43 PM

Aerospace

Communication modules on a

ruggedized mini-PCIe form factor Rugged I/O modules meet two new MIL-STD-1553 communication modules. The AP571 provides single function MIL-STD-1553 communication and the AP572 provides full multi-function databus communication. Both models provide one dual redundant channel with four open/ground avionics level discrete I/O signals in addition to IRIG-B I/O and Trigger I/O. A SoC architecture features dual-core RISC processors tightly coupled to large programmable logic for host CPU offload and real-time functionality. With 128MB global RAM on-board for data scheduling and buffering, the module can operate dependably at full bus rates. Designed for COTS applications, these mPCIe mezzanine modules deliver a SWaP-optimized solution for avionics test, simulation, and monitoring applications. A variety of carrier cards are available to host a mix of up to four AcroPack I/O modules on PCI Express, VPX or XMC computer platforms. “The advanced hardware architecture provides generous computing and memory resources to guarantee all functions can run concurrently and at full performance specifications,” stated Robert Greenfield, Acromag’s Business Development Manager. “Plus, all the key features and functions from larger platforms are now available in a small package.” AcroPack mezzanine modules improve on the mini PCI Express architecture by adding a down-facing 100-pin connector that securely routes the I/O through a carrier card without any loose internal cabling. Carrier cards in PCIe, VPX, and XMC formats let you combine up to four I/O function modules from more than 25 available models in a single computer slot. Software tools support embedded applications running on Linux®, Windows, or VxWorks operating systems. DW

Acromag | acromag.com

DESIGN WORLD

DFI 11-18 Vs4.LL.indd 17

November 2018

11/2/18 2:43 PM

Design for Industry O f f- s h o r e

New materials and design improve MEC performance

Eric Bucci • Oil & Gas Segment Manage, Trelleborg

Wellhead and tubing hanger sealing materials are subjected to an array of challenges, everything from high temperatures to corrosive fluids—not to mention high pressure. That’s one reason Metal End Cap (MEC) seals have traditionally been designed by wellhead manufacturers and produced to specification by sealing experts. Still, it seems logical that the most robust, capable MEC seals would be created by those with the most sealing experience, especially in a variety of situations. That turns out to be true, with a new MEC design that combines high-performance materials with a state-of-the-art design creating an optimal sealing solution. Choosing high-performance elastomers The key to a superior MEC seal begins with an elastomer that is chemically bonded to metal C-rings. The elastomer must meet all industry standards, including ISO 23936 (formerly NORSOK) and ISO 10423 (formerly API-6A), and also provide a high level of resistance to extrusion, explosive decompression, and downhole fluids. Additionally, it must simultaneously withstand temperatures up to +350 °F and pressures up to 15,000 psi. One fundamental failure mode is the destruction of the elastomer by Rapid Gas Decompression (RGD). Elastomers used in wellheads and various sections of tubing are tested by being subjected to high-pressure gas molecules, such as carbon dioxide, being forced into them. The molecules then force their way out of the elastomer matrix when the pressure is released, potentially causing blisters and cracks within the elastomer that sometimes propagate to the elastomer exterior. Thus, MEC seals should be manufactured from an elastomer that resists the majority of gas molecules trying to enter into its matrix. Most industry RGD specifications assign subjective grades of zero to five to elastomers. The typical test specimen for an RGD test is an O-Ring. After an RGD test, the O-Ring specimen is usually cut into four equal pieces so the interior can be visually examined along with the exterior. Zero is the best rating and means no blemishes or imperfections are noticed within or on the surface of the elastomer. Grade one means no more than four internal cracks are seen, with each shorter than 50% of the O-Ring cross-section. Two means less than six internal cracks are seen, each less than 50% of the O-Ring cross-section, and three means less than nine internal cracks, but two of the cracks are allowed to be up to 80% of the O-Ring

November 2018 www.designworldonline.com

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DESIGN WORLD

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Precision Welding For Critical Plastic Components cross-section. Grades of four and five are typically considered unacceptable and result in cracks extending to the O-Ring exterior and the O-Ring being split or fragmented. In addition to receiving a preferred grade of zero or one during the RGD test, the elastomer in an MEC seal must be highly resistant to downhole fluids such as hydrogen sulfide, drilling fluids, completion fluids, and the crude oil itself. Industry specifications, such as ISO 23936 and 10423, also dictate specific chemical formulations that a seal material must survive in an immersion test. The seal material specimen is immersed in the chemical formulation for specified time periods, temperatures, and pressures. Once removed from the immersion test, the specimens are tested, and results compared to industry-specified failure criteria. Any specimens exhibiting properties within the failure criteria are considered compliant, and those outside are unacceptable. It should be noted that even though a seal material is demonstrated to be compliant to an industry specification, it does not mean the seal material is wholly acceptable in a particular application. Additional testing to specific application requirements is needed. Finite element analysis Once MEC elastomer materials are tested to industry specifications and shown to be compliant, design work can begin on the elastomer and metal end caps. MEC seals are large diameter, and testing in lab fixtures is complex and expensive. Finite Element Analysis (FEA) can, therefore, support product proving. MEC seal designs can be virtually modeled using FEA under multiple conditions to predict seal behavior before spending significant resources on lab fixtures. The FEA results guide engineers to optimize the hardware and seal design as a system to mitigate potential failure modes. The FEA results can also graphically demonstrate what forces and stress the seal encounters under the arduous conditions. This knowledge allows engineers to have the highest confidence possible before spending resources on lab testing. The ultimate goal is to effectively communicate to an industry that equipment and seal manufacturers have collaborated to analyze and engineer the best MEC product possible. MEC seals are expected to provide a multi-year life-span, and proper function is critical to ensure well integrity and overall safety. DW

The Branson GSX Ultrasonic Welding Platform meets the growing demand for the assembly of smaller and more complex plastic components. Precise welds are achieved utilizing an advanced electro-mechanical actuation system that provides unprecedented control and position accuracy, while applying the industryâ&#x20AC;&#x2122;s lowest trigger force. The Branson GSX can also weld across multiple parameters, monitored in real-time to ensure quality. This is possible with a wide range of input materials and best-in-class repeatability across multiple Branson GSX welders.

See us at BIOMEDevice, San Jose - Booth # 1221

For product information: Emerson.com/Branson

The Emerson logo is a trademark and a service mark of Emerson Electric Co. ÂŠ 2018 Emerson Electric Co.

Trelleborg | tss.trelleborg.com

DESIGN WORLD

November 2018

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11/7/18 3:19 PM

Design for Industry Packaging

3D printed grippers increase packaging

machine efficiency

3D printed plastic grippers made with tribo-filaments are 85% less expensive and 70% faster

than the current packaging industry standard. Because 3D printing allows for single batches, and enables personalized serial production of furniture, shoes, and watches, it can be useful in the packaging industry.

Since 2015, igus has been offering tribologically optimized 3D printing filaments for the Fused

Deposition Modeling (FDM) process, specifically for the printing of wearing parts. The filaments are made from self-lubricating, high-performance plastics and are optimized for wear and friction. Germany Cosmetics Company Solves Packaging Issue Carecos Kosmetic GmbH faced an issue with its packaging process and solved it with 3D plastic grippers. If a product had to be changed, the company had to have new grippers made for the packaging machines, which would grip the lids and screw them on to products. The company had previously used an elaborate aluminum gripper that cost more than $11,500 per part and required six weeks to execute a changeover. In an industrial sector that is becoming increasingly nimble, it is essential for manufacturers to transition far more rapidly and economically produce small batches.

November 2018 www.designworldonline.com 20

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11/2/18 2:45 PM

kelleramerica.com

digital pressure gauges

The LEO-1 is a high accuracy, high-speed digital pressure gauge. Use only as directed. Product includes refresh rates of 5kHz to catch rising spikes in system pressure. Common side effects include increased reliability and decreased system downtime. Warning: In many cases, the desire to switch to all Keller instrumentation can occur as this indicates a high degree of customer satisfaction. In such cases, contact Keller America at 877-253-5537 or email sales@kelleramerica.com for assistance.

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Design for Industry Packaging Carecos Kosmetic turned to the iglide I150 filament and found that the material could be used to create a gripper that can be printed within 10 to 12 hours. Almost every element of a gripper is flexible and glides on shafts and pins so that the individual parts are exposed to constant wear. Metallic parts must often be fitted with separate bearings or lubricated in the application. Another feature of iglide I150 is its food contact compliance with EU Regulation 10/2011. With this certification, customers can also use the versatile tribo-filament to print special parts for moving applications that are in direct contact with food, beverages or even cosmetics. Companies that do not have 3D printers can have their wear-resistant parts printed directly at igus using the FDM process or selective laser sintering (SLS). For these cases, igus offers a 3D printing service. Tribo-filaments can be obtained as a filament material, or as an already finished, ready-to-install printed component from the igus 3D printing service. The appropriate data is transferred online into the browser window in STEP format via drag and drop. Next, the required quantities are specified, and a suitable material selected. Depending on the request, a formal offer is made, or an order is placed immediately. In the SLS printing process, igus can also produce complex special parts very quickly and even make components with a height of up to 300 millimeters, which could only be produced in mechanical or casting technology with much more elaborate processing and using expensive, specialized tools. Even today, small batches of up to 500 units are being produced from the company’s own laser sintering material iglide I3 and the SLS material for gears iglide I6 within a short time. DW

High Performance Step Motor Systems Industrial Strength at Competitive Prices: • DC-powered STR drives start at $75

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STR and STRAC Series Stepper Drives are compact, powerful, digital step & direction drives ideally suited to drive 2-phase hybrid step motors.

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All this to help you Make it Move.

igus | igus.com

800-525-1609 www.Applied-Motion.com Email: sales@applied-motion.com

DFI 11-18 Vs4.LL.indd 22

November 2018 DESIGN WORLD

11/5/18 12:14 PM

Wear-Free

Angle Measurement Made Easy

RFC 4800 Series of touchless sensors use a magnet attached to your application’s rotating shaft. Now with IO-Link output option, analog and IO-Link versions of RFC 4800 sensors can be easily connected with three wires—power, ground and signal. Touchless angle sensing technology excels in many applications including: • measuring through a wall or plate • shaft with limited play • sealed-shaft environments • low friction torque • high-vibration shaft • driveshaft misalignment

Magnet size selection and mounting as well as output choice are about the only parameters that need to be decided beyond those of track/wiper technology rotary sensors. Our technical specialists are happy to discuss your application needs.

Key specifications:

• Repeatability to 0.1° • Measures 0 to 360° • Resolution to 14-bit

• Linearity ≤ ±0.5% of F.S. • 2-ch. version option • speed output option

Free touchless angle sensors primer: www.novotechnik.com/rfc48 Novotechnik U.S., Inc. Telephone: 508-485-2244 Email: info@novotechnik.com

Novotechnik 11-18.indd 23

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Design for Industry Packaging

Servo drive and servo motor system solution

The dual-axis AKD2G Servo Drive is a power-dense, industrial servo drive that reduces mains wiring, fuses, and filtering to save panel space and cost. Features include plug-and-play compatibility to Kollmorgen motors and Workbench interface, optimized hybrid connector, and speed. The AKD2G’s current loop update rate of 1.28µs accommodates changing load conditions immediately. Velocity and position loops updates are also market leading at 62.5µs and 125µs. AKM2G Servo Motor: A configurable, high-performance synchronous servo motor with increased power density and improved torque/speed ratio so OEMs can get up to 30% more performance out of an equivalent size motor or achieve the same performance with a smaller motor. With six frame sizes with up to five stack lengths and performance rates 0.3 and 10kW — and selectable options such as feedback, mounting, and performance capabilities — the AMK2G can easily be dropped into existing designs.

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Gliding Surface Linear Guides Redi-Rail® Simplicity® Plain Bearings and Rail Assembly

DFI 11-18 Vs4.LL.indd 24

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Mobile and Robotic Arm Solutions (MARS): An interactive demo of a robotic arm enabled by Kollmorgen Automated Guided Vehicle (AGV) software, hardware, and heavily integrated frameless motion technology. Experience the way Kollmorgen is merging the world of modern robotics and AGVs to develop smarter, more dynamic, and versatile robots. Frameless Gearmotor: TBMTM frameless motors are optimized for fit and performance with industry standard strain wave gearing and torque density to enable smaller, lighter, faster robots. AKMHTM Hygienic Motor: This design stands up to the most challenging washdown environments with an IP69K certification and ultra-durable, food grade stainless steel. The AKMH reduces

cleaning time and the risk of food recalls by eliminating the cracks and crevices where contamination can occur. This hygienic motor can increase OEE at packaging and processing facilities while improving food safety and productivity. DW

Kollmorgen | kollmorgen.com

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Range of Automation Challenges MTB Series

Automation Medical

SIMO® Series Compact Series

Integrated Lead Screw Motors

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DFI 11-18 Vs4.LL.indd 25

11/2/18 2:50 PM

Design for Industry Packaging

Positioning shaft collars for fine linear

adjustment of components

These Adjustable Shaft Collars have a Micro-Adjustable shaft collar

for applications requiring repeatable fine-tune positioning in 0.0005-in. increments with 0.200-in. total adjustment; an adjustable thrust collar that provides bi-directional axial adjustability with superior holding power; and a Micro-Adjust Stop Collar Assembly that offers micrometer-like adjustability of either or both collar faces. Designed to let users precisely locate shaft-mounted components for a range of industrial automation, material handling, packaging, and robotics applications, these Adjustable Shaft Collars are offered from stock in standard 3/8 to 1-1/2-in. bore sizes made from steel and stainless steel. Special sizes and materials can be supplied. DW

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November 2018 www.designworldonline.com

DFI 11-18 Vs4.LL.indd 26

800-933-4915 WWW.TRIMLOK.COM INFO@TRIMLOK.COM

DESIGN WORLD

11/6/18 11:46 AM

NEW high performance connectors

Safety

Survey shows ties between

industrial safety, security and operational improvements

for demanding applications Brand New products launching this November

Industrial companies are using safety to not only mitigate risks but

also to improve productivity and profitability, according to a survey by LNS Research. The survey finds organizations are using the three core elements of safety maturity — which include safety culture, procedures, and technologies — to avoid safety incidents and improve business performance. Also, risk management increasingly consists of both safety and security risks. From a culture standpoint, the survey found that organizations in which EHS, operations and engineering collaborate to improve all aspects of safety reported a median incident rate 15% lower than those without this collaboration. Organizations with cross-functional safety collaboration were also found to have a 12% better on-time delivery performance. On the technology side, 75% of industrial companies said they have seen operational improvements resulting from the use of advanced safety technology. Similarly, 60% of respondents said they have seen financial improvements resulting from the use of advanced safety technology. “The LNS Research survey shows that best-in-class manufacturers are making industrial safety a pathway to operational excellence,” said Lee Lane, Vice President, safety, sensing and connectivity at Rockwell Automation. “These top performers use contemporary safety technologies, make safety a companywide value and use standard processes to design safety and productivity into machinery.” In 2013, Rockwell Automation introduced the Safety Maturity Index for end users to measure and improve safety performance. Many companies use the tool today. Rockwell Automation also introduced a version for machine builders to help them create machines that deliver productivity gains and comply with modern safety standards. The LNS Survey results also support OEMs building safer machines, as 20% of respondents said they are willing to pay a premium for increased safety performance. While the LNS Research survey results confirm that many industrial companies are improving safety maturity, they also identify areas where manufacturers are falling short. Culture: About half of respondents (49%) claim that safety is viewed as a core value across all levels of their organization. However, only 19% said their organization has C-level commitment to make the necessary investments in safety. This disconnect indicates that many companies do not have a culture that is fully supportive of safety. Additionally, only one in four respondents said their EHS, operations and engineering EHS teams effectively collaborate to improve all aspects of safety.

Break away collar Up to +150°C 100g shock

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DESIGN WORLD

DFI 11-18 Vs4.LL.indd 27

www.designworldonline.com

November 2018

11/2/18 2:54 PM

Design for Industry Safety

Technologies: Almost half of the respondents (49%) said top challenges to improving EHS performance included disparate systems and data sources. Meanwhile, almost two-thirds (64%) of respondents said they have not implemented dedicated EHS software. This indicates there is a big opportunity for companies to use modern information-management technology to better manage their safety performance. Only 24% of respondents said they use lockout/tagout alternatives to improve operational performance. And even fewer (11%) said their organization is using industrial IoT technologies to holistically manage operations and safety. However, 20% said they would start using industrial IoT technologies this way in the next 12 months, and 17% said they would require that new equipment be smart and connected within that same period.

Procedures: Widely adopted standards call for a lifecycle approach to risk management which can help companies address risks in their equipment and production from design to retirement. However, only 28% of respondents said they use such an approach. What’s more, only 27% of respondents said they use a lifecycle approach to safety-system management. About the Survey LNS Research surveyed 300 respondents including operations, EHS and engineering managers and professionals from industrial organizations primarily headquartered in the U.S. and Europe. The online survey was conducted between July and September 2017. Data from the survey was selectively supplemented

with data from the ongoing LNS Research EHS Management survey, which has a similar demographic profile. DW

Rockwell Automation rockwellautomation.com

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CARLO GAVAZZI Automation Components

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Werner Lamberger, Technical Support Engineer

10/30/18 4:21 PM

Design Notes

Ultrasonic sensor improves cheese making

Edited by Mike Santora â&#x20AC;˘ Associate Editor

The U.S. is a surprisingly large producer of cheeses. Wisconsin alone produces over 3.2 billion pounds of cheese each year in this multi-billion-dollar industry. Creameries and cheese makers still follow many of the age-old traditions that our ancestors pioneered. But, to craft truly best-in-class cheeses, modern cheese makers must use state of the

The ALPMA coagulator uses the P53 ultrasonic sensor to measure the level in the coagulator. The EHEDG-certified P53 sensor enables efficient cleaning, less wear over time, and lower costs due to its hygienic design and fully encapsulated stainless steel.

art equipment. Alpenland Maschinenbau GmbH (ALPMA) is a manufacturer of machines and systems for the cheese and food industry. Among its many products, ALPMA developed a coagulator that allows for the continuous production of curd. Before its invention, the curd was produced in batch processes. Today, high-quality cheeses can be produced in volumes previously thought impossible. The ALPMA coagulator uses the P53 ultrasonic sensor to measure the level in the coagulator. The EHEDG-certified P53 sensor enables efficient cleaning, less wear over time, and lower costs due to its hygienic design and fully encapsulated stainless steel.

November 2018 www.designworldonline.com

Design Notes 11-18_Vs4.LL.indd 30

DESIGN WORLD

11/2/18 3:44 PM

DURABLE AND RELIABLE The coagulator consists of a stainless-steel trough, up to 262-ft long, equipped with a specific belt and a partition wall system. Thereby, cells are created in which milk and rennet are continuously supplied while the curd is continuously removed at the other end. That means the ALPMA coagulator can produce curd nonstop. The ALPMA 2000 coagulator, for instance, can process nearly 12,000 gallons of milk hourly. That enables creameries to scale production to previously impossible levels — and yet still produce cheeses with the same quality and flavor as though they were making small batches. Many creameries and cheesemakers worldwide rely on ALPMA machines; for example, the majority of the American production of White Cheese / Feta and Cagliata (base product for mozzarella and pizza cheese) is manufactured using ALPMA equipment. Any equipment used in food production, including cheese making, must meet the highest standards of hygienic design; food safety and quality depend on it. That’s why ALPMA now uses the hygienic ultrasonic sensors of the P53 series from PlL for level detection in the coagulator. The coagulator and its components must endure frequent, thorough cleaning using highly acidic or alkaline cleaners – yet also keep cleaning efforts and plant downtimes as short as possible. The detergents used in food production can penetrate even the smallest nooks and crannies to effectively remove any contamination and thus prevent bacteria from taking root and spreading. Often, these cleaning operations can lead to rapid wear, damage, and premature breakdown. However, the P53 offers all-around stainless-steel casing and chemical-resistant seals that can withstand the rigorous cleaning protocols involved. It can also withstand steam, moisture, and the properties of objects and surfaces — none of which can interfere with the P53’s precise distance measurement. Few sensor manufacturers offer sensors or accessories in EHEDG-compliant designs, due to the high costs of certified hygienic development. Many manufacturers of hygienic-critical applications rely on conventional sensors that require special cleaning considerations and are prone to increased cleaning costs and premature wear to comply with hygiene requirements. Thanks to a high degree of protection (meeting lP68 and IP69K ratings), a fully encapsulated gap-free design made of V4A steel, and an allowable temperature range from -15° to 80°C (5° to 176°F), the P53 sensors can be easily cleaned with high-pressure or steam jet cleaners as production facilities wash their machines regularly.

DESIGN WORLD

Design Notes 11-18_Vs4.LL.indd 31

November 2018

Automation HELUKABEL’s high-quality cables and cable accessories (e.g. glands, connectors and cable tracks), guarantee durable and reliable cable systems that can handle the high mechanical stress and repetitive, movements in automated industrial applications.

TOPSERV® PUR 600/1000V-rated, continuous-flex servo and motor cable for drag chains. The PUR outer jacket of the is self-extinguishing and flame retardant.

E-NEWS

11/2/18 3:44 PM

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EPSITRON Power Supply Family - Design World - Print.indd 1 WAGO 11-18.indd 32

8/4/17 3:02 11/2/18 3:09 PM PM

For a smooth move!

Design Notes

The seamless transition of the casing into the front metal-sound membrane and the smoothness of the polished surfaces offer no adhesion for germs and thus guarantee maximum hygiene. Further, added aggressive cleaning agents are no problem for the sensor casing, whose chemical resistance is certified according to ECOLAB. The P53 sensors come in variants with 30-mm or 18-mm casing diameters for measurement ranges of 80 to 1500 mm. The versions with analog output (4.20 mA) are supplied by PlL with fixed characteristic curves, while the desired switching point for models with switching output via teach-in can be set quickly and easily by the user. Also, PIL is one of the few manufacturers to offer an EHEDG- certified holder for their hygienic sensors for reliable mounting or fixing in wall bares and casing openings or holding devices. The holder consists of two half-shells which can be screwed together, and each has a passage for one of the sensor ends. When the halves are screwed together, the transmission seals made of foodstuff-resistant silicone 70/101, which meet the FDA’s approval requirements, are firmly pressed onto the conically shaped sensor ends and seal the gap between the sensor and the holder completely, reliably, and hygienically. DW

Glass-fiber reinforced spur gears & racks

• Easy movement – Low coefficient of friction minimizes lubrication

• High strength to weight – Ideal for metal conversions where weight reduction is required

• Use in corrosive applications

Material has high resistance to chemical agents

Hoffmann + Krippner hoffmann-krippner.com

Elesa. Always more... Operating elements

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Clamping knobs

Indexing and positioning elements

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Lift & Pull handles

Leveling elements and supports

Control elements

Hinges and connections

Rotary controls

Accessories for hydraulic systems

Request Catalog 077AM and Supplement 077.1AM

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DESIGN WORLD

Design Notes 11-18_Vs4.LL.indd 33

November 2018

11/2/18 3:46 PM

Design Notes

The tail and connecting point for the 3D printed step.

3D printing saves costs for

Airbus Helicopters

Edited by Mike Santora • Associate Editor

Airbus Helicopters uses a German RepRap x400 3D printer for validating the design of an integral new step on one of its helicopters. Frank Singer, Head of Department Vehicle System Installation at Airbus Helicopters in Germany explains, “It happens again and again that a crew member of a helicopter stands outside on the runners during the flight due to operational reasons. Under certain circumstances, also during operation of the rescue winch. The relatively small footprint on the runners could be optimized by using a step.”

November 2018 www.designworldonline.com

Design Notes 11-18_Vs4.LL.indd 34

In a first step, the nearly three-meterlong model will be subdivided into printable, individual parts. Afterward, the individual puzzle plug connections are constructed. “In the past, we have had to divide larger prototypes into separate parts because of the print bed size. These were often glued together. However, this was always associated with further processing steps, which we can now save - if the application allows it. The quickly printed parts require no further processing steps or curing time of the adhesive anymore” says Frank Singer. He continues, “With this method, we have found an ingenious application for this design, to have a large component quickly and cost-effectively available with the print bed size that is available.” For Airbus Helicopters, the new plug-in connection is useful in that it requires no glue, no screw connection, or tools. The plug connection can be used at least 50 times without any signs DESIGN WORLD

11/2/18 3:49 PM

POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

of wear. The model is much more stable than it would be in a gluing process. It withstands its own weight of 3.9 kg without any problems and can be mounted on the helicopter for illustrative purposes without wobbling, loosening, or falling off. Engineers chose PLA because the material can be easily and quickly processed and there were no further requirements for the component. Airbus Helicopters use its German RepRap x400 3D printer mainly for the so-called â&#x20AC;&#x153;FIT Check.â&#x20AC;? All designed parts are printed as prototypes. With these parts, the ease of installation and the fitting for the helicopter are checked. Possible changes and adjustments can be easily transferred to the series parts with little effort. Initially, the machine was purchased to make it easier for engineers to make prototypes faster and easier to test. Over the years, the company has acquired more and more knowledge and no longer wants to work without the 3D printer: â&#x20AC;&#x153;The x400 is in use every day and often runs on weekends. The use of the readily available prototypes or demonstrators has become firmly established in our development process. The topic of 3D printing will be expanded. We see this clearly in the future, especially in the development area. The use of the 3D printer makes it easier for the company to work, especially in the area of prototype construction and in automated production. You can see that clearly in the numbers. In 2017, almost 50 print jobs were carried out, often including several parts. In the first half of 2018, we already have 51 print jobs.â&#x20AC;? DW

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Airbus Helicopters use their German RepRap x400 3D printer in the development field to ensure deadlines, cost, and quality goals. In a recent case, itâ&#x20AC;&#x2122;s about validating the design of an integral new step.

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WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly. Visit our websiteâ&#x20AC;&#x201C;whittet-higgins.comâ&#x20AC;&#x201C;to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.

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Design Notes 11-18_Vs4.LL.indd 35

November 2018

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11/2/18 3:49 PM

Design Notes

Machine guarding system creates safety perimeter for welding area Edited by Mike Santora â&#x20AC;˘ Associate Editor

When Stein Bros. Steel, a full-service steel fabricator, wanted to grow its market share by expanding its product offerings to customers, the company decided to invest in a new automated rebar mesh welding system. For safety purposes, this meant that Stein Bros. needed to secure a large amount of fixed machine guarding on a tight time frame.

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After researching several guarding product options, Stein Bros. chose to partner with Air Engineering and Supply, a distributor for Husky Rack & Wire, and used Husky’s Velox machine guarding system. Air Engineering and Supply engineers and Husky engineers worked together to design an effective machine guarding solution that featured quick and easy assembly combined with simple installation and field modification to create the exact fit Stein Bros. needed around the perimeter of the rebar mesh welding system. Velox guarding not only met the company’s required internal security needs but also exceeded regulatory safety standards. The three most important features that made the decision to go with Husky’s Velox guarding were product design, quick order delivery and ease of installation. The Velox guarding system comprised 6,700-sq.ft of guarded area, which included 380 linear feet of 6-ft high guarding panels, sixty – 6-ft posts and three 3-ft swing doors. The Operations Manager for the Stein Bros. facility said that the Velox guarding design was easy to work with and made for an easy installation. Because of the flexibility of the product, he was able to modify on-site to accommodate for some uneven floor issues. DW

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Internet of Things

FPM modular monitor series

The FPM series of modular industrial monitors suits factory automation and IIoT infrastructure applications. Designed to enable precise communication between operators and machines, the monitors feature a modular design, an industrial-grade full HD TFT LED LCD that supports for both 4:3 and 16:9 aspect ratios and is equipped with projected capacitive (P-CAP) touch control, RS-232 and USB interfaces, and diverse video I/O, including VGA and DVI-D ports. The modular design lets systems integrators interchangeably combine monitors and PC modules into diverse configurations. Users can also easily upgrade the core computing module and increase the display size without needing to send the whole system off-site for reconfiguration. Moreover, when equipped with the optional iLink technology, the FPM modular series can support real-time, long-distance (up to 100 m) data and video transmissions to a single client or multiple (up to four) clients in clone mode. The FPM modular series also feature picture-in-picture (PiP) technology that allows them to be integrated with two box PCs for simultaneous dual display and dual

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input control capabilities. Additionally, the die-cast magnesium alloy front panel is embedded with Wi-Fi/NFC antenna for rapid signal recognition and ergonomic control. The incredible flexibility offers performance and cost-saving advantages, including easy repairs/ maintenance, cost-effective upgrades, and reduced total cost of ownership. DW

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Serial to Modbus Gateways

The STM-601C, STM-602C, and STM-604C Serial to Modbus Gateways provide options for a range of applications in industrial applications including 1, 2, and 4 serial ports. These models provide dual Ethernet connections and can provide unique IP and MAC addresses per port, giving the devices the ability to be used in a redundant network design. They also include reverse polarity and overload protected redundant power inputs. The STM-60XC series supports up to 921.6 kbps and any baud rate setting making it scalable for any Modbus RTU or ASCII network. The series of gateways also support up to 16 connections per serial port under Modbus master mode and 32 sessions under Modbus slave mode. DW

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Internet of Things

Four-port serial communication module Many industrial automation applications require communication between the controller and multiple serial devices. The groov serial I/O module, GRV-CSERI-4 plugs into a groov EPIC chassis. This controller provides discrete and analog I/O modules to provide the mix of analog, discrete, and serial signals needed at any location. This new module provides four independent and isolated serial ports for this purpose, communicating with RS-232 or RS-485 serial devices. Up to 4 modules can be installed in one groov EPIC chassis, for a total of 16 serial ports to support these communication requirements. Each port is selectable for RS-232 or RS485 mode, with programmable termination and bias as well as half- or full-duplex options in RS-485 mode. Baud rates of up to 1 Mbps are supported. For serial devices communicating with standard protocols, the included PAC Control flowchart-based programming software has communication handles to serial devices. Alternatively, users can use groov EPIC’s Ignition Edge from Inductive Automation with support for hundreds of communication drivers. For serial devices requiring the development of custom drivers, groov EPIC supports secure shell access, SDKs and a cross-compiler for custom user-written applications. Once communication is established with serial devices, multiple programming options are available with groov EPIC to link devices. PAC Control provides English-language commands, and the included Node-RED, a flowbased development environment and runtime for edge data processing, handling, and communications, offers serial nodes for download. The rugged module operates in temperatures from-20 to 70 °C (-40 to 85 °F) and relative humidity (non-condensing) of 5-95%. Agency approvals include UL/cUL (Class 1 Div. 2); CE, ATEX (Category 3, Zone 2), RoHS; DFARS; and CB Scheme. The GRV-CSERI-4 plugs into a groov EPIC I/O chassis. The module pivots into a slot on the chassis and is held securely in place by a captive retention screw. Wiring is simplified with a top-mounted connector and spring-clamp terminals for easy connection to all types of RS-232 and RS-485 devices. The connector is held in place by a single, captive retention screw—but can be removed with field wiring intact for wiring in advance or easier module field replacement. A swinging, two-position cover protects wiring from inadvertent contact, as does the dead-front design. The two positions of the cover offer the option

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of more space to accommodate wire sizes from 28-14 AWG. The module cover provides a touch-sensitive pad; simply touch the pad and the groov EPIC processor displays information about the module, including specifications and wiring diagrams. The module cover also provides a large LED to indicate module health at a glance, plus a transmit and receive LED on each port. The GRV-CSERI-4 I/O modules are hot swappable—which means they can be installed or removed without turning off the unit or stopping control—and selfidentifying; as soon as you mount the module on the chassis, it communicates to the processor and identifies itself. DW

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NX-Series safety network controller supports two industrial safety networks

The CIP Safety networking protocol has gained popularity among industrial

robot manufacturers thanks to its ability to enhance flexibility and facilitate the industrial internet of things (IIoT). This protocol is now supported by a new version of the NX-series safety controller.

This addition means the new controller supports two industrial safety networks – CIP Safety and Safety over EtherCAT (FSoE). The controller supports applications in industries like automotive manufacturing and food factories where a variety of products are produced and production lines are often modified. Features of the new NX-series safety controller include: • Two different safety networks in one safety system to meet customers’ needs • Integrated development environment – Sysmac Studio – for accelerated safety programming • Easy maintenance and quick troubleshooting CIP Safety enables communication between nodes such as PLCs, I/O blocks, light curtains and interlock switches. Unique among safety network protocols, it was developed to be network- and media-independent as a fundamental part of its design philosophy. It allows safety and standard control devices to reside on one network, eliminating the need for purpose-built safety networks. The new version of NX safety network controller helps manufacturers introduce flexibility into their production lines while keeping design effort and maintenance time down. It enables quick and easy safety program design and improves the efficiency of safety management and maintenance. The new controller is scalable from large automotive production lines to small parts production lines. With both CIP Safety and Safety over EtherCAT, it addresses 40% of the global market’s requirements for safety networking. DW

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Internet of Things First field device with OPC UA and Pub/Sub

The X20BC008U bus controller functions as an OPC UA server and provides all information about connected I/O modules to OPC UA clients from any manufacturer. This includes, for example, controllers, SCADA systems, ERP systems or cloud applications. Interfaces, gateways and the associated loss of information are a thing of the past. All production process data is transferred using a single protocol. With the new publish-subscribe model (Pub/Sub), data can be distributed in a very efficient manner. The X20BC008U bus controller can be used with all controllers and I/O modules from the X20 and X67 product lines without limitations. DW

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Invented in the 1800s. Optimized for today.

Visualization of the von Mises stress distribution in the housing of an induction motor by accounting for electromechanical effects.

In the 19th century, two scientists separately invented the AC induction motor. Today, itâ&#x20AC;&#x2122;s a common component in robotics. How did we get here and how can modern-day engineers continue to improve the design? The COMSOL MultiphysicsÂŽ software is used for simulating designs, devices, and processes in all fields of engineering, manufacturing, and scientific research. See how you can apply it to robotics design. comsol.blog/induction-motor

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CAE Solutions DfR, IoT and PLM: How to achieve betterperforming products Chuck Cimalore • CTO, Omnify Software

Design for Reliability (DfR) identifies key design parameters and potential failure rates inherent in a design and develops procedures to ensure that a product meets its reliability requirements for the duration of its lifetime. Digital Transformation is impacting product reliability. Trends in product personalization and connected devices make DfR increasingly important in today’s market. Unfortunately, according to LNS Research, most manufacturers lack the reliability technology strategy and top management sponsorship to have successful reliability programs. Successful reliability engineering requires the ability to predict what portions of a product may fail as well as the performance, safety, and economic impacts of failure. It requires transparency to current and past issues to improve predictions, react to failures, and continuously improve. Successful DfR must be supported by effective product management strategies. With the rise of the Internet of Things (IoT) and centralized data management platforms like Product Lifecycle Management (PLM) technology, companies can create a closed-loop, data-driven DfR program to improve predictability and reliability and achieve better-performing products.

An LNS Research survey shows challenges to the successful implementation of DfR practices including lack of top management sponsorship and siloed processes and technology

DfR’s top challenges According to a survey performed by LNS Research, the top four challenges to DfR success are lack of top management sponsorship, late engagement in New Product Introduction (NPI), siloed processes and technology, and poor predictability. Furthermore, research reveals that manufacturers primarily manage DfR data with spreadsheets and electronic documents. • 90% of the companies surveyed manage requirements in spreadsheets and electronic documents • 83% manage FMEAs (Failure Modes and Effects Analysis) in spreadsheets and electronic documents • 70% manage new product test data in spreadsheets and electronic documents Like many product design and development processes, this disconnected, document-centric approach is a significant obstacle to the analytics needed to generate accurate historical reliability statistics and lessons learned. It also creates silos among DfR teams and processes, which reduces

Lack of top management sponsorship

41%

DfR engaged too late in the product lifecycle

41%

Siloed/fragmented processes and technology

33%

Poor predictability of product reliability, availability, maintainability

33% 22%

Poor requirements or specifications management Lack of a corporate-wide process for managing test processes and data

19%

Lack of training/competency

19% 15%

Ineffective metrics

No formal, consistent process for managing risks

11%

Lack of visibility to in-service performance and metrics

11%

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cross-functional engagement and creates cross-discipline process silos, and ultimately results in late DfR engagement. This is where PLM technology and the IoT come into play. Together, they can help address top DfR challenges by automating processes, improving visibility/access to key data, and engaging DfR early in the NPI process. Engaging DfR early with PLM PLM technology provides a central location to manage all product information within a controlled environment and provides the platform to plug in reliability and IoT data. Reliability teams tend to engage late in the product development cycle, after the Bill of Material (BOM) is finalized. By leveraging PLM as their data platform, reliability engineers can gain better visibility into product information among all teams and engage earlier in the design process/NPI stage. PLM can be used to tie information from various sources to improve DfR such as IoT data and incidents and issues from test labs. This information can be fed back to engineering and other key departments, including the c-level, via PLM. For example, a design engineer at a medical device company kept designing in the same sensor part with a high failure rate. Because they did not have a central system to track and manage field-level data, Engineering did not have visibility into this issue and the effect the sensor had on the product. Did the failure trigger a service call? What was the sensor component costing the company? By giving engineers access to data on how products perform in the market with IoT-integrated PLM, their product specifications can include data beyond design engineering such as reliability, quality and marketing. IoT is a double-edged sword IoT data often has the ability to deliver data points in real time, removing much of the traditional ambiguity around product performance and usage. Product

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planning, design, and quality departments can learn from a productâ&#x20AC;&#x2122;s operational behavior through IoT to improve features that customers use most. Product quality issues, failures in the field, software bugs, and customer feedback data that are fed into PLM enable manufacturers to track and configure product design requirements based on usage patterns and allow for the redesign of parts or systems to improve quality. IoT devices leverage the technology to report data to collection and analysis systems. These data can also be integrated into PLM systems to provide data directly to the product record. Issues and tolerance breaches from IoT devices can also initiate support and quality processes in the PLM system. The IoT can be a double-edged sword for reliability. It creates product complexity, which inherently poses a reliability challenge, but also delivers greater insight into equipment usage. This insight enables predictive maintenance for existing products, which improves availability. By capturing actual usage and other conditions leading to failure, it also yields data that can greatly improve next-generation products. Used properly, the IoT can result in substantial gains in product reliability and availability. As an example, a global manufacturer of medium, heavy-duty, and severeservice trucks started to monitor fleets remotely as a service. Through that work, the firm found early failures that ultimately indicate a broad issue with the fleet. The truck manufacturer identifies a pattern in sensor data by re-viewing the events and data leading up to a component failure, then automatically checks other vehicles to see if the same pattern exists. This era, which promises real-time product feedback, is a sea change for engineering and there are many great possibilities. Historically, engineers create product designs from a set of requirements then hand off the finished model to manufacturing, which manages production processes with its own systems and tools. Field service

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and maintenance personnel typically have another set of data related to the product, housed in a separate system, and few of the disciplines are likely to share information, let alone work off a common data set. An open PLM platform can integrate with IoT applications to capture data, which triggers automated workflows and alerts to address problems. PLM becomes a platform to push and pull information for helping identify issues early in the design process. Closed-loop, data-driven DfR As mentioned previously, today’s spreadsheet and electronic document approach is the origin of many downstream DfR challenges such as late engagement in NPI and poor predictability. According to a recent report from LNS Research, What’s Your Design for Reliability (DfR) Data Plan?, LNS recommends a closedloop, data-driven approach to DfR that establishes a formal, change-managed process connected to PLM, the NPI system of record. This method provides connectivity to gather risk and reliability experiences from across multiple business and operational systems into a centralized model. It is important to organize these experiences and related metrics against data objects that are relevant and re-usable to DfR, including parts, configurations, and serial numbers. This closed-loop, data driven approach ensures better accuracy and visibility into prior product issues, and comparison of predicted to experienced reliability for the current product. This approach also enables product development teams to engage DfR more fully, including it in their development decisions. It allows DfR teams to participate earlier in the lifecycle, and also creates a closed-loop connection between virtual/physical test, DfR, and product development. DfR and the bottom line DfR can contribute to the bottom line in many ways. Improvements in warranty costs and product return/recall rates, customer satisfaction, and safety can all result from a successful DfR program. It is clear that the market has changed and along with it the importance of reliability. Trends in IoT/connected devices and product personalization will require manufacturers to put new processes and technology in place to accurately capture, analyze and address issues. Companies should look at leveraging their PLM platform, the system used to develop their product, as a source to connect other systems/data into like DfR and IoT to create a holistic view of the product and support data-driven processes. DW

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CAE Solutions “In-the-loop” simulations validate design components

The demand for innovation is universal across industries to meet higher performance standards without slowing time to market. This demand is apparent in the automotive industry, where a range of technologies must come together seamlessly if a new product is to be successful. China Euro Vehicle Technology (CEVT) is developing techniques to bring new technologies into passenger vehicles and ensure successful integration of the many systems present in modern designs.

One of the more advanced technologies is system-level modeling, which uses specialized software to model the interactions across an entire system. By taking a systemlevel modeling approach, CEVT engineer Michael Palander is creating a powerful testing and simulation platform that can be used to verify the functions of new automotive technologies at earlier stages in the design process. With its Modelica standard for system-modeling components, the team decided to evaluate MapleSim as the modeling and simulation tool for their larger simulation platform. The team at CEVT aims to create a simulation platform that can validate a range of design components, from software controllers to individual hardware subsystems, in what is known as “in-the-loop” simulations. For these kinds of simulations, the system-level models are created not only to be highly accurate, but they must be capable of

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efficient computation for real-time usage on test platforms. They chose MapleSim for its ability to create efficient royalty-free code that can run in real-time. To avoid the slowdowns typically involved with taking on a new modeling tool, the Chalmers research team opted for custom training services provided by Maplesoft Engineering Solutions. The team quickly worked through the basics of model creation, before moving on to training related to their specific project needs, including code generation, exporting models to the Functional Mock-up Interface (FMI) standard, and creating custom components to account for their specific designs. By working with Maplesoft’s modeling experts, the teams at Chalmers and CEVT efficiently developed workable processes for integrating MapleSim with their own tools, such as their simulation platform, CarMaker. They now use MapleSim to create vehicle models and export them into Functional Mock-up Units (FMUs), which then connect into the rest of their tool chain. The training also provided the engineers and researchers with MapleSim model optimization techniques so they could make quick iterations on design concepts before moving their testing to their in-the-loop simulation platforms. DW

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CAE Solutions Product design app offers live collaborative 3D CAD editing, not just viewing

Onshape is partnering with Magic Leap on a new 3D product design app for its

spatial computing universe. The CAD app will be developed for the Magic Leap One Creator Edition, a lightweight, wearable computer that allows digital content to step out of the screen and into the real world. Wearing Magic Leap’s Lightwear headset allows users to see contextually aware digital objects in the real world and bring life-size 3D CAD models into their physical surroundings and collaborate on design changes. “We’re excited to bring the many benefits of modern CAD to engineers in the Magicverse,” says Onshape CEO Jon Hirschtick. “For more than a half-century, CAD users were confined to working on a flat screen. The Magic Leap One will push product design into a whole new stratosphere.” “Imagine your engineering team is reviewing the latest design for a race car. With the ML One, they will be able to put that car right on the conference table, go under the hood and examine the engine block. They can then levitate the car above their heads and check out the exhaust system,” he says. “The spatial computing universe has the potential to transform every industry,” says Magic Leap CEO Rony Abovitz. “Along with our other development partners, Onshape is helping us discover new applications and markets for Magic Leap One. I look forward to helping them continue to shake up the world of design and manufacturing.” “The Onshape app will support live 3D editing of CAD models, with design changes updated in real time through the Magic Leap device,” notes Hirschtick.“This is far more powerful and impactful than being able to merely view static, alreadycompleted designs. And using our modern CAD system’s real-time collaboration tools, even team members based in different parts of the world will instantly see each other’s updates.” “Offering Onshape’s cloud CAD system through the rich, immersive view of Magic Leap

will one day seem as natural as designing on laptops, phones and tablets,” he adds. “We’re proud to be ahead of the curve by giving engineers access to the latest tools they can’t find anywhere else, tools that will help them push their creative limits, and ultimately design better products.” DW

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M o t i o n

C o n t r o l

AC servo-motor systems:

The difference between continuous ratings and holding continuous loads For applications primarily needing the holding of a load with little movement, there are special servo-motor sizing considerations. But confusion often arises from the terminology used to describe such designs — especially from the common use of the term stall in the servo-motor industry. Here we clarify the definition in context and then relate it to the axis’ effective RMS force-torque calculation for proper motor sizing.

Hurley Gill | Senior applications and systems engineer | Kollmorgen

Expansion of closed-loop feedback systems into nontraditional servo-motor designs has prompted more demand for specialized motor functions. Some of these servo-motor applications require forces or torques to maintain a load for a time that’s quite long relative to the axis’ motion profile. This necessitates clarification of terminology — especially of terms that aren’t synonyms or only equivalent under specific operating conditions or events … but used interchangeably by those incorporating other motor types. Potentially inconsistent communication can cause incorrect interpretations between parties and degrade motor sizing, machine programming, machine startup, and the troubleshooting of events or product-process issues. For example, the terms stall or stall torque never appear in specifications for induction motors. But the terms are often used to describe conditions arising

November 2018 www.designworldonline.com

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The importance of good communication is paramount to avoid confusion of the word stall (and its derivatives) and the term stall defined within the servo-motor industry as part of normal parameterization, operation, or otherwise. | istockphoto.com - Thossaphol

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M o t i o n

C o n t r o l

For applications primarily needing the holding of a load with little movement, there are special servomotor sizing considerations.

when load on the motor exceeds the fullload or breakdown torque capacity. Nonservo-motors (such as induction motors) in anything other than proper working condition are said to be in a locked-rotor or stalled (zero rpm) state. If an applied load exceeding the motor’s continuous full-load torque persists, the power demand will as well … and the motor will overheat and eventually burn up. If a motor is stalling (0_rpm < actual rpm < full-load rpm) it draws a current greater than its continuous capacity … and if this condition persists, the motor’s windings will overheat. Such abnormal stall, stalled, or stalling conditions of an open-loop style induction motor aren’t a typical part of any normal application — so any induction motor under any one of these conditions is: 1 affected by the motor’s ability to dissipate its heat losses relative to its load demand and 2 will cause the motor’s windings to overheat and burn up if an overload continues.

A stalling motor may continue to run for a while at a slower-than-rated speed, but when it stops running (due to the tripping of an overload protection device or because it burned up) it is not stalled. After all, no unpowered or burned-up motor can recognize a mechanical load. Shown here are Kollmorgen AKM2G ac synchronous servo motors. Unlike asynchronous induction motors, such servo motors’ torque, velocity, and position are limited by drive loop gains and limits and the peak current limit of the drive’s foldback circuitry.

Servo motor designs — where a stopped condition might be by design In contrast, the servo-controlled condition of purposefully holding position under a load (or maintaining a torque/force against a load) can be a normal function of a motion application … and one that’s completely different than our induction-motor example above. Unfortunately, it’s also a motor state that’s associated with and communicated by the terms stall, stalled, stalling, or locked rotor. So when a servo motor (being a closedloop system) is properly sized for a specific operating condition, it will just do what it’s commanded to do and nothing else. When properly sized and operating normally (as sized) such a servo motor can handle its

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commanded load (to hold position under a load or maintain a torque/force against a load) within the defined event or motion profile — without threat of overheating. In fact, most confusion in the servo-motor industry about these terms and their meanings stems from the fact that there’s no designated terminology to describe when a servo-motor is improperly sized or improperly used outside of its specifications. Describing such application issues with terms that should be reserved for open-loop systems generates confusion — mostly because of mixed interpretations and understandings of different styles of motor systems — such as open versus closed-loop control. Because the terms in question are sometimes used interchangeably, let’s first describe how they’re used in the non-servo (induction) motor industry. Significance of the locked-rotor expression for induction motors For a powered open-loop induction motor, the term locked rotor is actually the condition or procedure for determining the maximum possible starting current (locked-rotor current or LRC) drawn by the motor while developing maximum starting torque (locked-rotor torque or LRT). This maximum starting current and its resulting maximum starting torque are typically measured in a lab environment with the motor’s rotor locked in place — hence the term locked rotor. Locked-rotor current (LRC) is typically found on an induction motor’s nameplate identified as the locked-rotor amps (LRA), which is the maximum possible starting current drawn by the motor at zero speed when the power is first applied (and slip is at its maximum). In actual induction-motor applications, this is the maximum possible current the motor can endure for a short (intermittent) period of time when power is first applied to the motor. That’s before the motor’s rotor accelerates to reduce slip (the Δrpm between armature field and rotor) to bring the motor up to a balanced operating point of equilibrium with the applied DESIGN WORLD

11/2/18 4:09 PM

load — preferably within its continuous rating. Induction-motor open-loop intermittent currents exceeding the motor’s continuous capability are typically seen during acceleration (when power is first applied) and occasionally during process load disturbances … but overall root mean square (RMS) currents seen by the motor over time must remain within the motor’s continuous capability. The performance of a servo motor (as that of other motors) is also affected by its ability to dissipate its heat losses — though it’s much less likely to overheat due to an overload than other motor types. That’s because servo controls and feedback along with closed-loop settings and limits from the drive amplifier (and potentially other controller programming) keep the motor within a safe operating range. Unlike the overload condition of an open-loop induction motor, the typical servo motor can be and is controlled to operate | istockphoto.com - sykono

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11/6/18 12:34 PM

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intermittently above its continuous capacity. But just like the open-loop induction motor, the RMS currents seen by the servo motor over time must remain within the motor’s continuous capability Otherwise, the motor’s windings will overheat. Intermittent overload states on a servo motor perform specific functions and are purposeful. So when these states are included in a design, engineers must account for them during motor-drive selection to ensure proper axis operation during normal machine operation, maintenance, safety events, and potential failures. Servo-motor rating techniques used today were developed years ago — when most applications didn’t experience loading that was substantial (in relation to the application’s overall motion profile) during zero movement. So when one of these nontypical applications is under consideration, its requirements during these special conditions or events are evaluated separately. Results from this separate set of calculations may or may not override the application’s effective RMS torque calculation. One specialized servo-motor use in robotic, industrial, and factory automation processes is to hold a specific torque/force against a load with little to no motor movement. The application may be as simple as a holding clamp or maintaining a vertical load against gravity (where a holding brake would increase process times or degrade precision) … or the application could be maintaining a torque/force against a load for testing … or dynamically holding a part in place for some process … or expelling a high-viscosity liquid in a controlled manner. Among other things, a key element for sizing a servo-motor-drive combination for such use is the duration of this (effectively continuous) load with little to no actuator movement within its motion profile — or for some specific event — relative to: • the motor and windings’ thermal time constants and • the drive capabilities. If the servo motor is properly sized and operating with proper drive-system settings for a given application, then it won’t overheat, trip a protection device, or burn up. Under such planned servomotor utilization, the worst-case condition for the servo motor may actually be the motor’s continuous operation against its applied load (due to gravity or otherwise) during normal operation. Or the worst-case condition may be during a situation with a downed machine or line (or maintenance operation) that’s excessive in relation to calculated effective RMS torque/force requirement for the axis based on its motion profile.

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MAXIMUM TOTAL WATTS LOSS OBTAINABLE WITH PUBLISHED DATA

FIGURE A

For our example design, each winding can dissipate 75_watts. 100% RMS CURRENT (Ic) ENTERING PHASE U WITH HALF TO PHASE V and HALF TO PHASE W

FIGURE B

Here we select a motor with a capability Tc => √2 x T_hold. For the sake of simplicity, we ignore statistical failure probabilities. ENTERING PHASE U AND LEAVING PHASE W AS Ic x COS(30°) and PHASE-V WINDING CURRENT = 0.0

FIGURE C

This is the second of our two worst-case commutation positions … when all applicable (86.6%) current is going through two windings.

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Unlike an open-loop asynchronous induction motor (capable of sacrificing itself while trying to satisfy the needs of its load) a closed-loop servo motor’s torque, velocity, and position are controlled and limited by: • the drive’s current/velocity/position loop gains and limits and • the peak current limit of the drive’s foldback circuitry and programming over time — which is I2t foldback, typically set = Ic(motor) or Ic(drive). Thus, even when the servo-motor may appear to be in a physically stalled or locked-rotor state, when properly sized and programmed, it is being specifically controlled within its continuous capacity and thus within the motor’s ability to dissipate its own heat losses. However, to describe this operation, especially when there is an axis issue, our subject words/terms are often communicated, with different meanings or interpretations in mind. The servo-motor industry’s term stall often appears as a subscript on torque/force expressions and in other nomenclature to indicate a servo motor’s maximum obtainable continuous torque (Tc) and its resulting continuous current (Ic) requirement. The continuous torque and its resulting Ic rating is at a specified ambient temperature (with an even steady-state heatloss distribution throughout the motor windings) to deliver the torque capacity based on a specific temperature rise and heat sink (mounting plate) size — without overheating motor windings. Such use of the term stall makes for a meaning that’s entirely different from the common definition of the word — in which stall means to stop and: • when an induction motor can no longer move at its designed rpm against its applied load — with an appearance of a locked rotor (for a fully stalled or stopped condition) or • stalling — on its way to be stopped — or • stalling — running at an rpm that’s slower than rated, but not at zero rpm. So it’s clear the word stall to describe induction-motor systems has a different meaning than stall used in the servo industry. Widespread misconceptions about the term stall means that even some manufacturers’ publications incorrectly state that stall means zero rpm or no rotor movement. Proper use of stall expressions for sizing ac brushless servo motors Now the question is: How does one size an ac (brushless PM) servo motor so it won’t overheat at the windings — especially for designs needing continuous holding torque/force with little or no movement for a duration that makes the axis’ motion-profile effective-RMS calculation invalid? As noted before, this invalidation is due to what would otherwise result in an uneven heat-loss distribution within the motor. We’ll answer the question using an application example. First though, recall how manufacturer ratings for continuous current Ic(motor) are determined. We’ll assume RMS current with sine-

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wave commutation, but some manufacturers use other means to express Ic. Typically, servo motors are rated to establish maximum continuous capacity with heat distribution of internal winding losses that’s even throughout the motor. This means during the rating process, electrical cycles within the motor move at a speed fast enough to make for even distribution of heat due to internal losses … but slow enough to ensure jXL and core losses are essentially zero within the motor. Recall that jXL is inductive reactance. This physical test speed is usually around 1 to 4_rps (revolutions per second) for motors but may be slower or higher — as a function of the motor’s pole pairs. Most manufacturers define continuous Torque (Tc) and resulting current (Ic) at this or similar speeds. The published continuous torque and current specifications are also often identified as stall torque (Tc_stall) and Stall current (Ic) regardless of the type of commutation and resulting current units.

| istockphoto.com - Thossaphol

Note the difference between stall as it’s used in the context of controlled closed-loop dyno tests (for determining a servo motor’s maximum continuous capability) versus our definitions for stall, stalled, and stalling as they describe overload conditions exceeding an induction motor’s maximum capability —whether the rotor has stopped moving or not. Also consider what the servo drive’s output is doing, when a servo motor is held under some load with little or no movement. Because we are using sinusoidal commutation

for our example, the controlled threephase ac output is effectively at a standstill — presenting a continuously PWMed non-moving three-phase output with a value (appropriate to the servo motor’s commutation position) equal to what would essentially be a frozen signal at that position location. This may be envisioned in your mind’s eye as an instantaneous snapshot of the moving sinewaves. The main difference between the two major commutation methods is that: • Six-step or Block (unmodified trapezoidal) commutations only allows current flow through two of the three motor phases at any given time — for 2-ON 1-OFF at all times • Sine-wave or sinusoidal commutation allows for current flow through three motor phases at the same time (when

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appropriate) and each electrical cycle of the motor is presented as a sine- wave to the servo motor. The two different commutation methods require a different representation of the motor’s torque constant (Kt). For more information, download a PDF white paper titled, AC Permanent Magnet and PMDC Brushless Servo Motor Parameters and Conversions and available at www. kollmorgen.com. Most rotary servo-motor designs today have good thermal conductivity between motor windings, laminations, and frame — especially with epoxy encapsulation. That said, each design has a different thermal conductivity between windings and frame … and modeling those values accurately necessitates significant thermal modeling or actual measurements and testing. So for the purpose of this article, we’ll assume each motor winding is a standalone mounted coil — and that no coil sees a thermal advantage of transferring heat to the area of another winding or coil in the motor. Under the condition of a fully loaded servo motor, the two worst-case commutation positions are:

1 All (100%) current (I_actual = Ic ≈ √2 going through one winding and 50% through the remaining two windings — as shown in Figure B 2

All applicable (86.6%) current going through only two windings (I_ actual= Ic ≈ cos(30°) ≈ √2) — as shown in Figure C.

These are the worst-case conditions the motor’s windings would see if the drive’s Ipk elapsed time (controlled by an I2t circuit/ program) folds back to the motor’s published continuous current Ic_stall — established with the even heat-loss distribution of a slow rpm. So for the condition shown in Figure B, assume Ic(motor)_stall = 10_Arms and a 10_Nm load. Also assume the commutation position and load necessitate 10_Arms through phase U to hold that stationary

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Typically, servo motors are rated to establish maximum continuous capacity with heat distribution of internal winding losses that’s even throughout the motor. But a servo motor held under some load with little or no movement (via sinusoidal commutation for our example) makes for threephase ac output effectively at a standstill ...

position. Then phase U actually has 14.14 DC-Amps [10_Arms ≈ √2] continuously PWMed through it. That means the U winding must try to dissipate (14.142 ≈ RmØ) watts-loss versus (102 ≈ RmØ) watts-loss — twice its capacity — which of course it cannot continuously do. Similarly, for condition shown in Figure C, each of the two coils tries to dissipate (12.2472 ≈ RmØ) watts-loss versus the (102 ≈ RmØ) watts-loss — 50% over each coil’s capacity. Calculations show it clearly — a critical factor when sizing a servo motor is the effectively stand-still current (to hold a load still) relative to the motor’s ability to dissipate its windings’ losses under such conditions. So, we need a motor that has a continuous torque rating (Tc) equal to the √2 ≈ T_hold required — not because we need any additional torque from the motor, but because we need each of the motor’s windings to reliably handle (for an effectively continuous period of time) what would otherwise be an instantaneous peakcrest of a moving sine-wave current. Under these conditions (assuming nominal values and no margin) using a servo motor rated Tc (stall) = 10_Nm in an application requiring 10_Nm to indefinitely hold a vertical load is insufficient. However, choosing a slightly larger motor capable of a Tc (stall) => 14.14_Nm would be sufficient. Additionally, if the drive is also rated in terms of Arms, it would only need to produce the continuous RMS current required to produce 10_Nm by the motor (approximately 10_Arms, if the servo motor’s Kt = 1_Nm/Arms). We can prove this by first determining the watts-loss capability at continuous rating — as shown in Figure A. Then we compare the wattage-dissipation capability against the two worst-case commutation points of the three-phase motor coils where current is 100%, 50%, 50% (Figure B) and 86.6%, 86.6%, 0% (Figure C). Given the motor information:

Tc(stall) = 10_Nm Ic(stall) = 10_Arms

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Kt=1.0_Nm/Arms Rm(L-L)_25°C = 1.006_ohms; where Rm(LL)_150°C = (1.006_ohms ≈ 1.491) and Rm Ø_150°C = 1.5/2 = 0.75_ohms Temp (ultimate winding temperature for continuous operation) = 150°C Temp-Rise (max. from a 25°C ambient) = 150°C - 25°C = 125°C So based on this information, application conditions, and our assumption that each motor winding is a standalone phase (Ø) branch or coil (with no advantage of heat transfer to another winding’s thermal area) each winding can dissipate up to 75_watts. If we consider the first of the two worst-case commutation positions with all (100%) current (I_actual = Ic ≈ √2), we can conclude the watts-loss (total) will still equal 225_watts (Figure B) ... but the specific wattage needing to be dissipated through one winding (Ø_UN) is 100% over the previously calculated thermal capability of 75_watts (Figure A) and the other two windings are each at 50% capacity. In this case (Figure B) to keep any of this motor’s windings from overheating due to this specific commutation position, we would need to limit the Ic(drive) to 70.7% of the Ic(motor). For our example, if the given 10_Nm holding load requirement is maintained, this motor selection will not accomplish the job without overheating. Hence, a possible solution would be to select a motor with a capability: Tc => √2 ≈ T_hold, preferably with about the same motor torque constant (Kt) so the maximum required application rpm may be maintained without changing the drive. If we consider the second worst-case commutation position with all available (86.6%) current going through only two windings (I_actual = cos(30°) ≈ Ic(motor) ≈ √2) we see watts-loss (total) will again equal 225_watts (Figure C). However, the specific wattage needing to be dissipated through windings (Ø_UN) and (Ø_WN) is 50% over the previously calculated thermal DESIGN WORLD

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capability of 75_watts (Figure A) for each winding. In this case (Figure C) we would only need to limit the RMS drive current (Ic(drive)) to 81.6% [100 ≈ (75w/112.5w)1/2] of the Ic(motor) to keep the motor’s windings from overheating due to this specific commutation position. That yields a W_loss(Ø_UN) = W_loss(Ø_WN) = ((10_Arms / √1.5 ≈ cos(30°)) ≈ √2)2 ≈ 0.75 = 75_watts. Still, if the 10_Nm holding load requirement is not re-specified to a lower value, this motor selection won’t accomplish the job — as with the case depicted in Figure B. For this specific condition, we could select a motor with the capability Tc => √1.5 ≈ T_hold. However, this still allows a 33.3% wattage overload of the first commutation condition as in Figure B. A better solution is to select a motor with a capability Tc => √2 ≈ T_hold as detailed in Figure B. Understanding stall — for proper calculations Understanding the meaning of the term stall in a servo-motor context lets engineers correctly consider the specifics of an axis’ motion profile and load demands over relative load demand times (versus total cycle times). That way, dominant factors can be determined and analyzed for sizing calculations, machine-axis programming, and troubleshooting — for normal operation or otherwise. These dominant factors allow reasonable consideration between the results: RMS calculations and any effectively constant or constant, loads held for a long time relative to the axis’ total motion-profile time, the motor’s thermal time constants: TCT_motor and TCT_winding, and the servo drive’s I2t foldback algorithm. Solid understanding of the motor’s worst-case commutation positions when holding a continuous load with effectively no movement (and standstill PWM drive commutation that comes with this condition) is core to proper motor and drive sizing. Holding a torque against a load (external or otherwise) for intervals that are long in

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relation to motion-profile times or thermal time constants can (if corrections aren’t made) make for erroneous RMS conclusions. Side note: Similar considerations are required for intermittent torque requirements that are high relative to a motion profile’s times and demands and any proposed motor’s thermal time constants. This is a topic unto itself. Google Kollmorgen — Managing PM AC Servomotor Overloads: Thermal Time Constant to download a white paper on this topic. In real-world applications, the torque multiplier may be conservative considering the good thermal conductivity between today’s motor windings, laminations, and frame. Nevertheless, the author’s experience and collected feedback on motor designs and applications over many years suggests that the √2 multiplier for ironcore rotary servo motors imparts a safety margin of approximately 9 to 11%. Though this information has not been specifically verified, the worst-case scenario with the √2 multiplier seemingly offers enough margin to overcome typical manufacturing tolerances of ±10%. So selecting a motor with a continuous capability equal to the calculated continuous requirement (or slightly above) using the √2 torque multiplier is reasonable. However, for ironless-core motors, no margin is assumed … and for these motors, design engineers are advised to specifically consider each manufacturer’s stall rating definition. The ac servomotor industry’s stall is a limited term with a specific definition, but not so fixed that it couldn’t be redefined in part or in whole — especially for special-purpose servo-motors or those of a certain design — ac PM ironless-core servo motors, for example. DW Kollmorgen | kollmorgen.com

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drives propel multi-axis motion Drive systems based on parallel kinematics with electromagnetic and electro-ceramic drives can improve dynamics, resolution and accuracy in applications needing high precision and multiple degrees of freedom.

Stefan Vorndran | Vice President Marketing Scott Jordan | Director of NanoAutomation Technologies Physik Instrumente L.P. (PI)

Motion simulation is often a crucial piece of the design process for evaluating and improving many devices. This can include vibration testing of vehicles and airplanes, response testing of accelerometers and gyroscopes, and testing of image sensors such as those used in high-end cameras and smart phones. Repeatable multi-axis motion simulation can help tweak advanced algorithms in image stabilization systems, and verify the performance of opto-mechanical or electronic stabilizers. Many emerging fields of structural and active mechanical subsystem analysis, validation and design can also benefit from flexible, multi-degreeof-freedom (DOF) motion mechanisms capable of generating specific motion patterns in real time.

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A miniature 6-axis motion simulator with brushless torque motors/screw drive provides high stiffness and motion resolution better than 100 nanometers.

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For maximum efficiency, motion simulators need to move on highly precise, repeatable trajectories in multiple DOF with precisely the same dynamics as the original motion they are trying to simulate.

In this low-profile, piezo-based hexapod system, Eigenfrequencies in the kHz range enable rapid position control with repeatability in the nanometer range.

While vibration cancellation has been widely employed in imaging, recently it is also becoming more of an issue in precision machining and manufacturing processes where guiding errors, uneven surfaces and imbalance can have a negative effect on the outcome of parts whose quality is measured in tenths of microns and below. To improve processes at this precision level, tools such as the simulation of motion/unwanted motion, along with its compensation, are steadily gaining in importance. Hexapod motion simulators vs. mechanical shakers An established way to simulate motion is to use mechanical shakers or generic stacks of positioning stages. These could sometimes be deployed to simulate simple target motions or approximate a desired mechanical stimulus. However, such setups are inflexible and limited in their capabilities.

Software for multi-axis patterned motion generation with dynamic hexapods, is available for Windows, Linux and OSX.

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For maximum efficiency, motion simulators need to move on highly precise, repeatable trajectories in multiple DOF with precisely the same dynamics as the original motion they are trying to simulate. An alternative option for motion simulation is a hexapod. These systems feature a parallel kinematic design with low inertia and symmetrical dynamic performance. They allow precise and exact repeatable motion in the X, Y, Z and pitch, yaw, and roll axes, and a freely selectable center of rotation. High-dynamic hexapods are available together with software toolkits for rapid development of patterned motion generation from the developmental laboratory to the production floor. These systems can be deployed over a range of applications from simulation and compensation of physiological motions to calibrated oscillation of mechanisms for volume production validation. Hexapods

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Shown here is a high-dynamic, 6-axis motion simulator based on voice-coil linear drives and flexure joints/ guides. Typical areas of application include testing of image stabilization algorithms, and in the medical field for ophthalmology or prosthetics simulating eye motion, eye tracking, and any other human or artificial motion.

are well suited for such uses due to their signature capability for six-degree-of-freedom motions in a user-defined coordinate system that places the rotational center-point at a desired position in space. The hexapods’ coordinate system’s origin and orientation can similarly be cast anywhere in space, rather than being fixed by the mechanical configuration of the system. Their controller’s built-in waveform generation is now capable of internal generation of millions of target positions at speeds of up to thousands of points per second, addressing aliasing and generation artifacts. These capabilities are backed up by extraordinarily fast TCP/IP Ethernet interfaces, together with real-time TTL synchronization interfaces, plus available analog inputs and SPI, EtherCAT, and RS-422 interfaces. Two auxiliary motion axes are also integrated for driving additional linear or rotary actuators. Different mechanical designs Various drive types are available for highly dynamic simulation of predefined motion. Hexapods with brushless torque motors, and the appropriate mechanical design of the drivetrain and sensor technology achieve accelerations to 2 g. They also provide an inherently stiff drive train.

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Even higher dynamic performance is feasible with voice coil drives (intrinsically soft) such as used in the H-860KMAG flexure guided, direct-drive hexapod, developed by Physik Instrumente (PI). Here accelerations to 4 g with velocities of several hundred mm/sec are possible. The special design includes zero-wear flexure guides and joints, and completely dispenses with rolling or frictional elements. The result is zero-backlash motion without vibrational noise caused by traditional mechanical bearings. Undesired frequency components transferred from the mechanical guiding system cannot influence the measurement. When nanometer-level precision and extremely high bandwidth in the kHz range are required, piezo-based hexapod designs are a suitable choice. The space-saving, parallel-kinematic design allows for a low profile, and small footprint, opening up ultra-precision machining applications where the hexapod compensates guiding errors in real time with nanometer precision. The piezo drives are wear-free and also operate under strong magnetic fields or in a high vacuum. Piezo scanners for image resolution enhancement/pixel sub-stepping Low-light conditions pose challenges for imaging applications from astronomy to microscopy. Low light intensity means neither the resolution of the sensor nor the exposure time for changing or moving objects can be freely chosen. Typical applications are fluorescence microscopy, white-light interferometry (OCT in medical technology or general surface structural analysis), or surveillance cameras and cameras for aerial photography. Further fields of application are scanners used to digitize analog data, such as technical drawings, art and paintings. The resolution of digital recording methods is determined by the number of imaging pixels of a CCD or CMOS chip, for example. If one wishes to increase the resolution, the number of imaging pixels must be increased. There are basically two ways of doing this, both of which are relatively expensive and require considerable effort: a) either increase the size of the recording chip; or b) decrease the size of the pixel. The first case requires a larger recording device and also different imaging optics. In the second case, the light sensitivity decreases with the pixel size. This reduces the separation between image signal and noise signal which, in the end, may even decrease the image quality in spite of the higher resolution.

November 2018

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Examples of highly dynamic piezo scanners for image stabilization/ resolution enhancement applications include this low-profile XY scanner (left) and miniature tip/ tilt mirror (right). Both systems are based on parallel kinematics drive designs to provide higher dynamics and precision in a smaller package.

A method called pixel sub-stepping makes it possible to significantly improve the resolution with relatively little effort. With pixel sub-stepping, the recording area is moved on a defined path with a defined frequency. This dithering, where the travel is less than the size of a pixel, causes the pixel to be exposed several times on the recording area, producing a virtual pixel multiplier which can significantly improve the resolution. The rest is data

processing. The various images produced in this way are subsequently super-imposed to form the final, high-resolution image, a process also known as super resolution. Because this method is based on motion, a drive is required which meets all the performance criteria for mechanical precision and lifetime, and provides highly reproducible motion of the sensor chip in two dimensions with sufficient linearity. The displacement only needs to be on the

order of the pixel size, for example a few tens of micrometers or less, with a wide dynamic range from a few hertz for still images, up to the kilohertz range for video recordings. In addition to planar scanners, tip/tilt scanners can also be used. In addition to increasing the resolution of a sensor, the scanners can also be operated to actively counteract unwanted motion thereby stabilizing the image and reducing blurring. Piezo scanners are based on electroceramics and precision flexure guiding systems, providing ideal features for these applications. These include solid-state motion, requiring no lubricants, the absence of wearing parts, and fast response and high resolution in the nanometer range and below. DW Physik Instrumente L.P. (PI) www.physikinstrumente.com

Schematic diagram for moving a sensor chip (a) or the imaging beam onto the sensor (b).

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Enhanced Ethernet for a Stronger IIoT: Time Sensitive Networking

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A large part of the opportunity of the IIoT lies in its networks (Ethernet, WiFi, Cellular, and so on) – an increased number of devices on the network means that there is a need for greater reliability and interoperability to ensure the timely transfer of information to systems with increasingly complex needs. This includes time synchronization that needs to be managed within tenths of a nanosecond in some specific environments. Leading www.designworldonline.com

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Converged TSN Ecosystems.

With feedback from intelligent machines, equipment builders can more quickly and effectively support their customers.

industrial and transportation companies will demand the same high levels of reliability, security and safety for their control systems within the IoT as is provided today by a multitude of specialized but often proprietary and segregated communication technologies; but these requirements with regards to reliability and security must be addressed in a more connected and open infrastructure, leading to challenges in deployment and diagnosis not seen in this type of system. With more operations seeking streamlined processes that save money and time, network infrastructure improvements are a key step in the development of IIoT solutions. This means that there will be an increasing need for interoperability, efficiency and determinism on the network as new automation capabilities arise. Enter: deterministic Ethernet-based networking with Time Sensitive Networking (TSN). Part of the effort to drive interoperability for IIoT devices involves Avnu Alliance, an industry consortium that creates conformance tools for TSN device testing. In 2016, member National Instruments wrote a piece in Design World on the IIoT and the

November 2018 www.designworldonline.com

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need for Time Sensitive Networking (TSN) in these increasingly connected networks. Since then, the industrial segment has worked with top companies and its liaisons to advance tools for TSN through participation in TSN testbeds, plugfests, and interoperability workshops for industrial applications. Testbeds: the Industrial Internet Consortium TSN Testbed Testing a networks’ capabilities before implementation is key to developing a successful network design – testbeds offer systems designers the chance to see how their devices and networks perform in realworld settings, before they are installed. The first testbed for TSN, the IIC’s TSN for Flexible Manufacturing testbed, was developed with two major goals – to show TSN’s readiness to accelerate the marketplace and to highlight the business value of adopting open, interoperable standards in automation networks. It stands as a showcase of the value that TSN standards and the ecosystem of manufacturing applications bring to the DESIGN WORLD

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market, including the ability for IIoT to incorporate high-performance and latencysensitive applications. IIC member participants include industry leaders like: Analog Devices, Belden/Hirschmann, Bosch Rexroth, B&R, Cisco, Hilscher, Intel, KUKA, National Instruments, OPC Foundation, Renesas Electronics, Schneider Electric, SICK, TTTech and Xilinx â&#x20AC;&#x201C; many of whom are also Avnu Alliance members. The work coming out of the TSN Testbed already has an impact on many suppliers and manufacturers who see the technology as a value add for their system structure. The benefit of the testbed is that it demonstrates real-world industrial use cases leveraging TSN. One such envisioned use case is a setup of two separate largescale robot and automation control suppliers who are seeking to implement TSN technology to increase interoperable communication between their devices and systems. They will coordinate and manage controllers and the monitoring of the sensor data between robots and the controllers. This coordination requires a combination of receiving highly timesensitive, synchronized information from sensors and then passing control commands back into the environment to other types of devices on the network. Without TSN, these companies would have to perform this communication with separate proprietary, non-standard networking technologies that may not talk to each other on an IoT network.

Interoperability testing with the IIC TSN Testbed is progressing with hands-on plugfests taking place in the US and Europe over the past two years. As a collaborator of the IICâ&#x20AC;&#x2122;s TSN Testbed, Avnu Alliance is helping to ensure the continued enhancements to Ethernet that TSN brings. Avnu is a third party independent organization providing conformance testing for interoperability of TSN and related standards, giving industrial vendors the ability to respond to market demand. Industry education opportunities, conformance testing and certification Expanding industry education is a key goal of the membership. Cultivating conversations that lead to the greater participation and implementation of TSN begins at the member and organization level, with members taking an industry leadership approach to education around the benefits of TSN for IIoT networking. Interoperability workshops with more than 20 leading industrial companies across silicon, infrastructure, and automation demonstrated interoperability of TSN devices. Face-to-face workshops focused on vetting the usage of TSN for flexible manufacturing and working on configuration for these systems. The lessons learned from the ongoing IIC TSN Testbed activities and the results from this workshop contributed to the conformance test development and will continue to feed into standards revisions as necessary. The OPC Foundation is also involved and is working to provide conformance testing and certification of OPC UA over TSN devices.

Overview of TSN Testbed Design, Source: Industrial Internet Consortium.

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Testbeds and plugfests help test for a certain degree of interoperability and allow companies to create real-world systems as an early check for problems, but conformance testing ensures alignment with the standards in a more complete way. Leveraging the work done through these relationships and interoperability workshops helps to create a stronger environment for interoperability. In November 2017, the first set of TSN conformance test plans for time synchronization of industrial devices were made available for test houses to implement. As the standards and networks continue to evolve, so does the work to define and certify the standard foundation. This eventually will include mechanisms such as frame pre-emption (IEEE 802.1Qbu), redundancy (IEEE 802,1CB & IEEE802.1ASrev), ingress policing (IEEE 802.1Qci), and security. The conformance testing and certifi-cation provided through organizations like Avnu will be critical to provide the needed foundation for interoperable IIoT networks and give industrial vendors a more streamlined vehicle for participation in the TSN ecosystem.

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Enabling a faster path to certification To speed up the path to an interoperable foundation, members have made open source code available for 802.1AS timing and synchronization in the OpenAvnu repository on GitHub. To encourage and enable multiple industry groups, vendors and protocols to share a TSN network, system architecture and requirements for this industrial model have been outlined in a document entitled “Theory of Operation for TSN-enabled Industrial Systems,” which is available for download. This document introduces the fundamental mechanisms needed for a system architecture to build on, including time synchronization, quality of service using scheduled transmission and network configuration and walks through the requirements of several industrial use cases including how to enable and integrate non-TSN technologies where needed. This document will help designers and engineers in the industry understand the real-world application context and build a TSN network that is configured for multiple vendor and industry groups. Test tools, testbeds, open-source code, and certification program supports vendors with tools for rapid adoption of the TSN standards, giving system designers and engineers the foundation to make sure they do not architect networks that are outdated before they are even installed. DW

Avnu Alliance | www.avnu.org

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S e n s o r s

Sensors increase material handling safety

The rise of Automated Guided Vehicles is driving the need for safer and more reliable sensing systems and controls

Alessandro Bosio | Sensata Technologies

The Industry 4.0 revolution is enabling a new generation of Automated Guided Vehicles (AGVs) for use in the first wave of smart manufacturing and distribution facilities. This revolution also requires new ways of thinking across all aspects of materials handling, especially when it comes to functional safety and reducing accidents in the workplace, and in turn, presenting a new challenge to sensing and control manufacturers. The adoption of AGVs into the materials handling ecosystem has been far from spectacular, but all that is changing with the fourth technology revolution and the rise of the inter-connected workplace. AGVs currently represent about 10% of the global market for automated materials handling equipment. The future of AVGs will undoubtedly be autonomous — systems that are adaptive and feature intelligence-based capabilities that allow them to respond within boundary domains to situations that were not pre-programmed in the design. Autonomous vehicles for use in factories, industrial facilities, retail outlets, and warehouses can be categorized into four distinct types:

• forklift trucks (moving goods horizontally and vertically) • pallet lift trucks (horizontal only) • tow vehicles, and • unit load carriers (to convey heavy goods from conveyor to assembly line).

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Figure 3. Sensataâ&#x20AC;&#x2122;s functional safety encoders rated to SIL3/ PLe, Cat.4 are suitable for use in AGVs to ensure the highest system safety, where they monitor ground speed and direction control.

Today, most AGVs are deployed to automate materials handling and packaging logistics, with man and machine working together. A few companies are taking automation to the next level by adding a robot arm to pick the desired object, taking people completely out of the equation. While this is where the industry is heading, object recognition and grasping are two of the biggest challenges yet to be fully resolved. So why are manufacturing and logistics facilities increasingly moving towards AGV-based solutions? One of the reasons is that in the long term, AGVs have been shown to be more efficient and costeffective than human controlled materials handling equipment. In addition, AGVs are intrinsically safer, for they remove the issue of operator error. Arguments against, however, include the high level of initial capital investment required and that not all sites can accommodate such systems on the floor. But perhaps the biggest barrier to the

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wider adoption of AGVs is that there is not yet a single navigation technology against which a consistent standard can be set, compared, and measured. Navigation and steering There are many types of navigation technologies in the market but some (such as wire, optical, and spot) are now less frequently used. AGV manufacturers most commonly consider the four following technologies for new equipment/ installation. In magnetic navigation, various light duty AGVs use magnetic tape for the guide path. One major advantage of tape over wired guidance is that it can be easily removed and relocated if the course needs to change. It also removes the expense involved in restructuring the floor of the factory or warehouse. A limitation of this method is that the routes have to be fixed and well defined by the tape. If any obstacle www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

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S e n s o r s

Figure 1. An automated vehicle would stop if it happens across an obstacle, as it adheres to pre-programmed instructions — while an autonomous vehicle would try to adapt and try a different route to reach the final destination.

is detected in front of the AGV, it stops and waits for the problem to be solved (for example, for the obstacle to be removed by a worker) before it restarts. Laser-guided navigation is similar to an electronic eye, which, by means of reflectors positioned on the surrounding walls, uses triangulation to determine the exact position of the vehicle to allow it to carry out the required tasks in the operating area. The advantage of laser-guided technology is that it requires no floor work as in the case of magnetic guidance systems. Additionally, route changes can be made easily via software updates to ensure maximum flexibility for company logistics.

Vision-guided vehicles (VGVs) use optic sensors (cameras), in addition to other sensors such as speed or laser sensors, to navigate, and software within the vehicle effectively builds a 3D map of its operating environment. This technology allows the vehicles to operate in automatic or manual mode for maximum flexibility. AGVs based on natural navigation technology do not require reflectors or markers, so they require less installation time and are easily integrated into existing systems. This minimizes the impact on current operations. In this type of navigation, LiDAR, Light Detection and Ranging, is the main technology used. Steering Control Configurations A variety of configurations can be used to provide steering control in AGVs. To determine what method is the best fit for a particular vehicle and application, four factors are usually considered: • the ease of building • the steering and driving capabilities • the ability to navigate in confined areas, and • the overall cost of the vehicle.

Figure 2. Magnetic tape, laser, vision and natural navigation technologies are the most popularly used in modern AGVs, depending on the specific application.

November 2018 www.designworldonline.com

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When standard catalog products don’t meet your requirements Selecting the appropriate steering control is fundamental in order to reach the right compromise between performance and cost for any given application. The three most commonly used set ups for steering control in AGVs are the threewheel, differential, and quad configurations. The three-wheel configuration is the most common solution for lift truck AGVs. They are relatively easy to implement and provide accurate control. Frequently, this design relies on encoders to monitor and measure the speed and direction of one master wheel that determines the vehicle’s movement. The differential configuration is a popular solution for unit load carrier and tow-vehicle (or tugger) AGVs since it is possible to rotate around the center of the vehicle, although with some turning limitations. The steering control is achieved using different speeds in either forwards or backwards directions on the two controlled wheels, where a single motor and an encoder are used on each wheel. A quad wheel configuration provides the most maneuverability as it permits 360° of movement in any direction, making it the ideal solution for unit load carriers. The ability to steer the vehicle in a sideways or crabbing motion allows for better and more accurate navigation in tighter and more challenging spaces. As there are more wheels that require steering controls and accompanying motion control components such as encoders and sensors, this type of configuration is the most complex.

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We’ve been designing and manufacturing customized products for more than 80 years. Figure 4. Hall effect sensors like Sensata’s 9360 and 9960 models feature a standard operational life of 35 million cycles, linearity of +/0.5%, up to IP69K sealing ratings and operational temperatures of 85° C, making them suitable for a variety of applications including fork inclination and steering control.

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– motor voltage windings – custom windings – shaft modifications – custom connectors – lead wire assemblies – gear boxes – encoders – brakes Large quantities not required.

Safe automation with sensors Hand-in-hand with the navigation and steering technologies comes a range of sensors that provide critical feedback to the control system about the AGV’s surroundings and operation. The sensors used to navigate, like LiDAR and cameras, and those used to control ground speed and direction, like encoders, are critical to ensure precise and safe operation. One of the most recent innovations in AGV design is the use and application of LiDAR technology. Similar to radar, LiDAR

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Figure 5. Autonomous material handling vehicles rely on a combination of advanced and basic sensing techniques to operate safely and efficiently.

instead uses laser beams of light bouncing off the environment to accurately measure object range and 3D shape while also providing intensity data that helps detect things like lane markings. Whereas camera-based solutions, for example, can sometimes struggle in environments that are prone to sudden vibration, low light or dust, LiDAR systems prove to be more reliable. Compared to other navigation approaches, they do not require external targets such as reflectors, RFID, or markers for navigation. As such, they are well-suited not only for localization and mapping, but also to help prevent collisions and ensure loads are properly and safely engaged and placed. Traditionally, LiDAR sensors have been costly and based on a mechanical scanning design. LiDAR technology is moving forward however, and new, entirely solidstate solutions (i.e. they have no moving parts) require less power and deliver higher resolution at a longer range. Not only is this new generation of LiDAR sensors more reliable than mechanical models, it is also more affordable. By mounting several small solid-state LiDAR sensors in an array, a live 3D surround view is created that can detect and track stationary and moving objects as required.

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A nice fit for applications relying on natural navigation (and a technology that includes both vision and laser-guided components), the latest LiDAR solutions offer the highest resolution with the maximum amount of system flexibility. Areas of interest and scan patterns can be configured as needed and the compact, modular design allows for the integration of third-party performance processing hardware and software. Encoders monitor speed and direction To control ground speed and direction in response to the data coming from the navigation technology in a range of AGVs, highly precise and safety-rated encoders are often used. To minimize or eliminate risk to machinery and systems in industrial applications, components such as encoders can be certified to industry standards of performance and safety levels. For AGV applications, components that are rated up to Safety Integrity Level 3, or SIL3, are ideal, as this allows for the highest safety level in the system. SIL3rated encoders can often be more expensive than those of a lower safety rating, but they greatly reduce the risk of failure to the system, which in the case of an AGV DESIGN WORLD

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navigating a warehouse, could prevent costly damage or injury. Using encoders of a lower rating, like SIL2 or less, often means that additional encoders may be required for redundancy in order to achieve an acceptable level of risk for a given application. The need for extra components adds complexity and cost to the system and can be a serious issue in the space-restricted design of automated/ autonomous vehicles. Draw-wire sensors for mast height The aforementioned sensors and functions are used broadly across the entire range of AGV applications. If we focus on fork lift truck and pallet lift truck AGVs specifically, then several other sensors should be considered. In these applications, additional encoders and position sensors are required to ensure safe and controlled operation. The mast height (or fork height) control could be considered for driven lift trucks but it becomes essential in lift truck AGVs. Controlling the mast or fork height in a lift truck is crucial for proper load positioning, as goods must be safely removed or stored at varying heights and to prevent collisions with overhead items. Also known in the industry as cable transducers, string potentiometers, linear position string pots, and string encoders, draw wire sensors are used to provide precise linear position feedback of the mast. These components use a flexible cable, a spring-loaded spool, and a sensor (an optical encoder with incremental, absolute, analog or potentiometric output or, in some cases, a Hall effect sensor) and are suitable for wet, dirty, or outdoor environments. This type of position sensor can also be used in AGVs to monitor lateral fork movements for automatic pre-setting to various pallet sizes. Rotary Hall effect sensors prevent spills Rotary Hall effect sensors are used in AGVs for different functions like the fork tilt control in lift truck AGVs (and lift trucks in general).

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The Industry 4.0 revolution is enabling a new generation of Automated Guided Vehicles (AGVs) for use in the first wave of smart manufacturing and distribution facilities. Positioned at the bottom of the mast, this sensor provides the functionality to calibrate and control the inclination of the fork and prevent the load from being spilled. In addition, electric-driven scissor lift tables can be integrated into the AGVs, in order to raise and lower a static fixture onto the vehicle for transport, or to position the product for human interface. In these cases, a rotary Hall effect sensor is used to measure the inclination of the lateral scissors and then regulate the fixture to the desired height. There are other sensors used in AGVs: pressure sensors are used to control the load weight in fork lifts, and load cells can be used for the same function in unit load carriers; in magnetic navigation systems, specific sensors for track guidance along magnetic tape are used. The magnetic sensor measures how far from the center of the tape it is and provides the information to the motor controller, which will then adjust the steering, so the vehicle remains at the center of the track. AGVs guided by inertial navigation use transponders to verify that the vehicle is on course, and a gyroscope to detect the www.designworldonline.comâ&#x20AC;&#x192;â&#x20AC;&#x192;

slightest change in the direction of the vehicle. In lift truck applications, in order to prevent the AGVs from colliding and to safely load and unload pallet materials, compact photoelectronic sensors are integrated into the narrow fork cone ends as well as the metal chassis. The materials handling sector is one of the most important to designers, manufacturers, and engineers working with sensing and control technologies, and the rise and rise of AGVs is accelerating the development of new and even more sophisticated sensing solutions. The increasing interaction between workers and machines means that the watchword in materials handling remains safety. This, in turn, means that sensors and controls manufacturers are continuing to raise the bar in innovation and excellence, while at the same time reducing cost and size. Todayâ&#x20AC;&#x2122;s emerging sensing technologies are fast becoming the standard product of tomorrow, as materials handling equipment designers, manufacturers, and operators seek greater efficiencies, better performance, and the highest possible levels of safety. DW Sensata Technologies www.sensata.com

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E l e c t r o n i c s

Energy efficient lighting with laser diodes Experts say the improved energy efficiency brought by LEDs is only a prelude to what will be possible with laser-generating diodes.

A laser headlight assembly on the BMW i8, available for less than $8,000 on eBay.

A view from BMW’s video explaining laser headlight operation reveals the headlights combine the output of three laser diodes through an optical element. The ability to combine multiple laser diode beams this way is considered to be an advantage the technology has over LED illumination.

An interesting deal popped up on eBay recently for a replacement headlight assembly. The headlight goes on a BMW i8 coupe. You can get one – sent from Latvia – for a mere $7,355, plus shipping. That’s for one right headlight assembly. If you want the left one too, it will be another $7,355.

Leland Teschler | Executive Editor

One reason for the high price tags: The headlights use laser-diode light sources

rather than LEDs. Though laser diodes have been around since the 1960s, they have only recently become efficient enough to be considered candidates for general illumination. Besides being energy efficient, they also put out a lot of lumens. In the BMW headlights, the laser diodes make possible a lighting range of almost 700 m. There is an LED version of the same headlight (about $3,000 each on eBay) that only beams out to about 300 m. A typical incandescent headlight only reaches out about 100 m.

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The promise of laser diode illumination has prompted some experts to predict big things for the technology. One is Dr. Shuji Nakamura, inventor of the blue LED for which he shared the Nobel Prize in physics. Nakamura claims laser diodes are the future of lighting. He has backed up this vision with action, founding a company called SoraaLaser (now called SLD Laser) to make laser diodes optimized for illumination. The laser diodes they create use gallium nitride crystals grown on a semi-polar crystal plane, not normally done in conventional GaN laser diodes. (Ordinary crystal planes are electrically neutral. Polar planes are those that aren’t electrically neutral, so there is a charge between neighboring crystal planes. The charge is big in GaN and similar type III-N materials. It can degrade the efficiency of light-emitting devices. But growing the material along certain crystal planes reduces the polarization charge. Materials grown along these special crystal planes are called semi-polar.) SLD Laser says semipolar GaN devices have a gain 3-5X higher than ordinary laser diodes because the semipolar orientation eliminates internal electrostatic fields and provides maximum overlap between energy levels. The semi-polar material also makes it easier to fabricate diodes operating at different wavelengths. The company says it has produced laser diodes exhibiting a continuous-wave output of more than 4 W multimode, and blue laser diodes putting out over 1 W. It also says it has demonstrated green (525 nm) continuous-wave laser diodes putting out 200 mW. But as the price of the BMW headlights indicate, it may be awhile before laser diodes can become widely used sources of illumination.

A schematic of the SoraaLaser (SDL Laser) SMD-packaged laser

Laser diodes described so far generally use a p-type magnesium-doped GaN film grown with GaN buffer layers on sapphire substrates. To make laser diodes practical, fabricators had to give the GaN a high level of p-type doping. The resulting semiconductor material has what’s called a double-degeneracy. Here, the doping level is so high that the material in some ways acts more like a metal than as a semiconductor. Photons having the right energy level can then stimulate the laser action. Generally in a semiconductor diode laser, a resonant cavity is created by cleaving two parallel faces about 250 to 400 µm apart. The cleavage planes act as mirrors, allowing the laser to build up energy. The diode will lase when the system gain exceeds the total losses. Laser diode fabricators use a double heterostructure (DH) as a way to reduce the thickness of the active region and thereby reduce the threshold current density for lasing action. The active region acts as a dielectric waveguide because the active layer material has a larger refractive Inside a laser diode index than the cladding layers on either All solid-state lasers need a gain or amplifying side. The reflectivity of the facets can be medium and a resonant cavity. In a diode controlled by using coatings on the exposed laser, electrons and holes are injected across semiconductor surface. If the refractive a p-n junction when there’s a forward bias, index of the active layer exceeds that of as in an LED. But the injected current is a lot the cladding layers, light reflects at the higher than in an LED. interfaces, as in optical fiber. The larger the The semiconductor material in the difference in refractive indices, the better diode is typically GaN, used because it has a the optical confinement and the sharper the bandgap that allows efficient light emission. lasing modes.

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diode. The SMD includes the laser diode, phosphor that converts the blue laser to warmer light, and a beam dump area designed to prevent laser light from exiting the package directly

To reduce the total current flow, the current injection area is usually confined to a narrow stripe contact region on top of the diode. Then injected carriers stay in the region under the stripe contact. The stripe geometry has another advantage in that if the stripe is narrow enough, single-mode lasing can take place. The resulting action generates blue laser light. But blue light isn’t optimum for illumination, so the laser light must be converted to something warmer. In the BMW headlights, laser-created light bounces off a series of mirrors in the headlamp assembly and eventually gets focused into a lens. The lens contains a yellow phosphorus that reacts to the laser light. Laser light interacts with the yellow phosphorous to create a bright, highly intense white light. The light then goes through a diffuser to reduce its intensity and gets reflected out through the front of the headlight. The white light projected from the headlights is ten times brighter than LED-created light. BMW says that this technique is also 30% more efficient than

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E l e c t r o n i c s

LED alternatives. The laser light optics occupy a smaller volume than an equivalent LED version, so designers can reduce the size of the housing and optimize the headlights for aerodynamics. It is also interesting to note that the drive electronics for laser diodes resembles that for LEDs because both devices work best when powered from a current source. And as with LEDs, light output from a laser diode drops with rising temperature, so heatsinks will be a part of most laser lighting circuits. Future directions You might think that the high cost of BMW’s laser headlights doesn’t bode well for the practicality of laser diodes in everyday uses. But the headlight’s high cost doesn’t arise from the laser diodes alone. For example, the headlights can spotlight animals and pedestrians up to 300 ft away and carry an infrared camera that illuminates these obstacles. The headlights also connect with the car’s GPS which helps predict upcoming turns in the road so drivers can better see them. A built-in camera detects oncoming vehicles to automatically dim the beam. And the laser diodes can be controlled to literally project information like MPH onto the road in the driver’s field of view. However, technological hurdles do remain. One is in the area of efficiency. Energy efficiency is typically measured as wall-plug efficiency (WPE), the fraction of the electrical input power emitted as light output. Some GaN-based blue LEDs can hit 80% WPE, but GaN-based laser diodes are generally below 40%. The mechanism behind the poor efficiency isn’t well understood. Recent research indicates that a phenomenon called Auger recombination might be the source of the problem. Here, the excess energy given off by an electron recombining with a hole gets absorbed by a second electron instead of being emitted as a photon. The newly excited electron then gives up its additional energy in a series of collisions with the GaN crystal lattice. Indications are that Auger recombination worsens with the high currents that are involved in laser diodes used for illumination. There is also some self-heating in the semiconductor material that lowers the optical gain, boosting the amount current carriers needed to compensate for optical losses. A WPE lower than that of LEDs won’t keep laser diodes out of illumination applications. SDL Laser points out that the key metric in directional lighting applications is the lumens per target

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area per watt of power consumption. SDL says laser-diode illumination excels at this metric for distances of 5 m or more and improves dramatically beyond 10 m compared to LEDs. In terms of raw output, laser diodes can hit 40-50 lm/W levels today. Expectations are that laser diode outputs can rise to 100 lm/W and beyond. As an example of what’s possible today, consider one of SDL’s products: a laserdiode-based white-light source packaged as a 7×7-mm surface-mount device (SMD). It produces up to 500 lumens of output from a 300-μm emitting area in collimated beam angles as low as 1-2°. The SDL device contains the same optical elements as the BMW laser headlight, but all within the SMD package. Inside is a high-power blue indium gallium nitride (InGaN) semipolar laser diode that excites a tiny (1 × 1 mm) remote phosphor target (<300 μm diameter) that converts the laser light to directional white light. There is also a beam dump, essentially a passive absorbing element, that blocks any blue light that could reflect from the single-crystal phosphor and leave the package. Additionally, there are collimating optics that narrow the output beam to about one-tenth that of an LED of the same size and lumen output. SDL says it gets 1,000 candela/mm² spread over 120° from a single 7-mm² SMD. The same approach can produce luminaires with one-tenth the diameter but 100X lumen output of LEDs, SDL says. SDL has a second form factor for its laser diodes wherein the laser and phosphor element are in two different packages with a length of fiber optics carrying the laser

light to the phosphor. The firm uses this configuration when it’s advantageous to keep the laser separate from the phosphor – the phosphor can heat up significantly when the laser passes through it. SDL says the fact that laser diodes approximate a point source simplifies the process of shaping their output. For example, laser beams lend themselves particularly well to diffractive type optical elements for beam sizing and shaping. A light shaping diffuser element can transform a 1° spotlight to a rectangle of 1° ×10° with an efficiency exceeding 92%. And liquid-crystal lenses added downstream can electronically control and dynamically change the beam angle and its shape. Currently, laser diodes aimed at illumination can emit up to 500 lumens. As illustrated by BMW’s headlight design, laser diodes work well when combined into a single beam. Their overall lumen output is expected to rise with new designs, and future work in phosphors and laser diode fabrication is expected to result in devices covering a wider light spectrum complete with warmer, higher light levels for indoor applications. DW

An example of a laser diode structure comes from researchers at Suzhou Institute of Nano-Tech and Nano-Bionics, Huazhong University of Science and Technology, and Wuhan University, all in China. Visible features include the cladding and the current injection area made up of a narrow stripe contact region on top of the diode. Then injected carriers stay in the region under the stripe contact. The researchers grew the epitaxial material with metal-organic chemical vapor deposition (MOCVD) and used a sequence of aluminumgallium-nitride (AlGaN) and aluminum nitride buffer interlayers to manage the differences in lattice parameter and coefficient of thermal expansion between Si substrate and the GaN.

References BMW LaserLight technology, www.bmwoffreeport.com/blogs/827/ how-bmw-lasterlight-work-and-what-are-benefits/ Soraalaser (SDL Laser), www.soraalaser.com

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D i g i t a l

M a n u f a c t u r i n g

The difference

between traditional and rapid molding The “digitization” of nearly every process to make products continues. The latest industry to experience this shift is molding. Here’s a look at how digitization may affect traditional molding service providers.

Pierre Viaud-Murat | Senior Vice President of Sales

Digital manufacturing offers many benefits across multiple touch points: it can reduce time to market, labor overhead and asset use, plus it helps customers control quality and inventory. These advantages allow users to explore new revenue streams, develop and enhance innovative designs and respond to market demands. The digital age can enhance designers freedom to create and develop through one streamlined methodology. The traditional manufacturing process The traditional manufacturing process usually consists of a several-step sequence within the manufacturing flow. Team members monitor and ensure that safeguards are in place throughout the entire part lifecycle. Throughout the process, various testing for form, fit and function are required to discover any part flaws. Each team member should be aware of these critical-path processes, as the traditional method of manufacturing requires more manual than automated production.

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M a n u f a c t u r i n g

The traditional injection molding manufacturing process usually consists of several steps. Throughout the process, various testing for form, fit and function are required to discover any part flaws. Usually, the traditional method of manufacturing requires more manual than automated production.

For example, generating a quote using a DFM analysis and confirming an order manually can take approximately a week, if all of the process steps are accurate and on track the first time through. In the event that any modification is required, the same process steps would be repeated before finalizing the order. Once an order has been placed, the mold design is reviewed for viability. When that design is finalized, it will go onto the next

phase of the traditional manufacturing process. This can be a lengthier portion of the process, ranging from three to eight weeks. Additional delays may also occur if project issues are not identified early in the quoting process, which will result in re-quoting, redesigning or redefining the project. Any of the three can result in significant delays. With all of the production factors in place, the part will then be molded. After

the first shots, a visual and dimensional inspection will be done. If the part passes inspection, it is shipped out to the customer for review and feedback. Once the customer inspects the part, they have the opportunity to approve or reject the run. In the event of a nonapproval, the process would be modified and revisited again with continual iterations until the optimal part is achieved. Any combination of these factors can impact

An evolution of traditional injection molding manufacturing is referred to as digitization. It involves digitizing as many injection-molding steps as possible to streamline many traditional molding steps to reduce total costs.

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the cost, quality and timing in a traditional manufacturing process. The digital manufacturing process Another approach to injection molding involves the digitization of as many injection-molding steps as possible. This approach is referred to as rapid or digital manufacturing, and is a natural progression of traditional manufacturing. The streamlining possible by digitizing many traditional molding steps can reduce total costs. Digital manufacturing begins with the upload of a 3D CAD file to a service provider’s servers. The geometry and part requirements are analyzed, usually with proprietary software. Then the customer receives an interactive quote. Once the customer approves the quote, an order is generated and the mold design finalized and a tool-path created, often within hours. The initial mold can often be created with modular components, which is another cost savings. Then, the mold is usually machined, a process that takes a couple of days. After benching and finishing, the mold tool is assembled for first production shots and inspection. This process of rapid mold development can shorten development lead-time to weeks instead of months. Digital manufacturing can accelerate every step of a part creation process. In traditional manufacturing, the retooling investment could push the break-even manufacturing numbers into the thousands – a cost-prohibitive change for many smaller businesses. Digital manufacturing, however, can implement that small design change for approximately a quarter of the investment in a quarter of the time. Digital manufacturing is scalable and flexible. Should demand rapidly increase, the digital manufacturing process can move between low-volume to mass production. Thus, designers can react to market behaviors quickly and easily. If demand drops, rapid manufacturing enables adjustments while still achieving the lowest total cost. Thus, regardless of a market’s volatility, digital manufacturing lets users respond accordingly.

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The digital manufacturing process allows customers to quickly go through multiple iterations easily. Low-cost tooling makes low-production runs economical enough to test on select markets and use the feedback as a learning curve. Customers can maintain their existing quality controls, while developing good parts that can get to market faster. Some service providers offer optional services, such as inspection and project management consulting. Digital inspection allows for rapid feedback and tool modifications, if necessary. Service providers usually have experienced tooling experts who can consult during the mold development process to solve any problems that arise. Mold considerations Mold service providers strive to ensure a mold tool is available over the lifecycle of a project. Often, the tool is made from a high-grade aluminum base material, like QC-10, which offers an excellent strengthto-weight ratio. Compared to steel, aluminum is softer and less dense, dissipates heat quickly and efficiently and costs up to 75% less. It’s also a recyclable material, an attractive feature when material waste can be higher than 50% per part. Recyclability and material reuse can help recoup initial material costs. Although aluminum may not be the right material for every type of mold, it works well for prototyping, bridge tooling and low volume production. Depending on the size and structure of the parts, the heat dissipation within an aluminum mold can be up to 50% higher than steel or other metals, creating faster production turnaround times. Aluminum molds will usually last through production runs of several thousands of parts. DW Xcentric | www.xcentricmold.com

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A Supplement to Design World - November 2018

Color 3D printed models help explain the nature of disease at the molecular level

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Early collaboration: The key to medical device success

Early engagement and close partnerships between medical device developers or OEMs, contract manufacturing organizations (CMOs) and suppliers can reduce delays to the market, decrease costs and prevent common roadblocks.

Claudio Hanna â&#x20AC;˘ Web Industries

Getting a medical device from concept to market takes a significant amount of time and money. Supply delays, unforeseen costs, and production challenges can all make the path to commercialization daunting. How can these challenges and delays be avoided? The answer is simple: proactive and effective collaboration. By engaging with trusted partners early in the product design, developers can avoid material and manufacturing challenges that can create delays and impact costs.

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The importance of design for manufacturability Developing a medical device is a complicated endeavor that involves a network of suppliers, different types of materials, reagents and other parts. At the development stage, the goal is just to get the device to work, but the component selections made during this stage can have huge implications on cost and manufacturability. Raw materials and components are typically selected based on performance, but there is also a need to consider other important design for manufacturability (DFM) factors such as quality, availability and scalability. When a developer or OEM approaches a contract manufacturer, the DFM factors are the first thing that the manufacturer should consider. They need to understand the format that the material is available in and whether that format can easily be

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integrated into the production process. They will need to evaluate material width, roll length, core sizes and tensile strengths to better understand the material’s limitations. Variations in material quality can increase scrap, limit run rates, create production delays and possibly decrease the quality of the medical device itself. By collaborating with a CMO and materials suppliers during the design phase, developers can eliminate material and manufacturing challenges that may affect the manufacturing process while still being able to optimize device performance. It’s crucial to leverage collaboration partners’ resources to make the device design successful through to commercialization. This will allow the CMO and suppliers to plan for their responsibilities in getting a device to market. If the product requires new equipment

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or modifications to the manufacturing process, this will be discovered well in advance. Instead of looking for a “turn-key” solution at the end of the road, use the CMO and materials suppliers to help create the right solution from the beginning.

collaboration, help you determine how the company will manufacture a safe and effective device and how they will overcome problems along the way. They should be willing to discuss their process and manufacturing controls and their quality assurance strategies. Their answers should instill a sense of confidence in their ability to successfully manufacture the devices and manage the supply chain.

Effective collaboration When choosing a collaboration partner, consider their record of accomplishment and references. Try to get a sense for the company’s place in the market, who they do business with, how long they’ve been in the industry and if there are any violations or complaints in their history. Another consideration is the company’s willingness to show their operation. Can you readily visit their facilities? Are they willing to undergo regular audits? This can indicate their openness and commitment to

Remember: Trust trumps all The ideas of “trust” or “trustworthiness” can seem like a soft skill or capability — something nice to have but hard to quantify alongside more tangible metrics such as cost, quality and delivery time. However, without trust, there is no effective collaboration. Trust can be earned through clearly defined needs, transparency, and honest communication.

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The earlier in development collaboration begins, the more defined each partner’s expectations and scope of work. Planning is everything in the life cycle of a medical device. Without proactive thinking and time considerations, delays and costs are bound to increase. Every company has weaknesses, and every product will encounter challenges. Good partners are willing to communicate those weaknesses or shortcomings in their capabilities and provide strategies to overcome them, and the best partners will always find ways to help each other succeed. DW Claudio Hanna is business development director for Web Industries Inc., a specialist in outsourced flexible material converting and end-product contract manufacturing.

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questions

to ask when designing polymer components for medical devices Choosing the right polymer for the job can be a daunting task. Here are the right questions to ask before you begin the process.

Karen Heroldt â&#x20AC;˘ PolyOne Distribution

Choosing polymers is complicated in the high-stakes world of medical and healthcare devices. Materials can have varied tool design, molding and secondary processing requirements that can affect time to market and total production costs. Here, we explore six critical questions to ask when considering polymer options for healthcare applications and pharmaceutical packaging. 1 Will the polymer work in the design? Material selection and product design should be parallel processes. Parts may utilize undercuts, threads, living hinges, thick or thin wall sections, snap features or draft allowances. Strategically designing parts with material characteristics in mind from the onset will optimize performance, durability and functionality. Itâ&#x20AC;&#x2122;s important to understand how a material will behave during manufacturing. For example, mold shrinkage is a key factor to consider during the design phase. Some polymers shrink at one rate with the flow path and at another rate across the flow path within the tool. This means the dimensions of a part can vary when different materials are used. Even the slightest of changes in final dimensions can affect form, fit or functionâ&#x20AC;&#x201D;especially with parts that have critical dimensions and components that go into a multipart assembly.

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2 What are the limitations of your chosen processing method? Different grades of thermoplastic resin families each have different processing and moldability traits. While some materials can be used in several different processes, others can cause problems. Engineers might be able to adjust a process to make an incompatible material work, but cycle times, throughput and product consistency generally suffer. Properly matching processing technique and material will generate both economical and robust components. Identifying processing methods and material combinations will not only optimize performance and minimize production costs but also reduce cycle time and decrease scrap due to out-of-tolerance parts.

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Choosing polymers is complicated in the highstakes world of medical and healthcare devices. Materials can have varied tool design, molding and secondary processing requirements that can affect time to market and total production costs.

3 What is the operating environment for the device? When evaluating material options, consider the environmental exposures that are commonly present in healthcare applications. Some products will come in direct contact with aggressive drugs or bodily fluids. Many will require repeated sterilization. Products might also be subjected to temperature extremes, and could come into contact with strong disinfectants. Materials must be able to maintain physical and performance properties such as strength, flexibility and seal integrity, in these conditions. Technical data sheets offer a basic indication of a materialâ&#x20AC;&#x2122;s ability to withstand chemicals, temperature and pressure. However, materials are measured using a specimen of a particular size and shape determined by ASTM and/or ISO standards. Your part will almost certainly be different than the standardized test sample and will, therefore, behave differently. Ultimately, product testing under anticipated environmental conditions should be your deciding factor.

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4 What forces (impact, load, wear, etc.) will my device need to withstand? Your application may require a certain degree of impact strength, flexural strength, tensile strength, elasticity, wearability or hardness. Determine these properties early so you have targets in mind as you evaluate potential materials. Physical and mechanical property information on technical data sheets is a starting point. But the thickness, weld lines, corners and unique geometry of your component can make it respond markedly different than the test specimen. Conducting finite elemental analysis (FEA) testing can identify weak spots or potential failure points under a particular load. Design engineers will use stress/strain ratings from technical data sheets to conduct these testsâ&#x20AC;&#x201D;although some FEA software already has a database of stress/strain information for many thermoplastic grades.

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5 Can I use prequalified materials to speed the required regulatory approvals? Depending on your product’s classification, you may need to acquire certain regulatory certifications, plus comply with particular manufacturing environment requirements, quality control systems and traceability methods before you can go to market. One common regulation for healthcare applications calls for using materials that have FDA approval. Other regulatory groups have established additional standards to ensure the safety of the patient or end user. Look for these ratings such as FDA, USP IV, etc. on technical data sheets. However, the material manufacturer might omit this information, so it is good practice to ask your supplier outright for compliance ratings.

Manufacturers are not required to submit documentation for a material to the FDA Drug Master File (DMF). But choosing a material that already appears on the DMF may help you obtain other necessary regulatory approvals for a new medical device.

Using the considerations listed here will help you identify the ideal material for your application and establish confidence in the performance of your product. DW

6 What are the most likely ways my part might fail, and how can I mitigate the risk? In high-risk scenarios, choosing a highly engineered, but more expensive material may be justified. But choosing materials that are “over-engineered” for your needs can add unnecessary cost or complexity to your product. Appropriately assess the risk of your application and do your due diligence in selecting a material.

Karen Heroldt is senior industry manager, healthcare, at PolyOne Distribution.

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End-To-End Solutions

Cadence, Inc. is a full-service contract manufacturing partner for medical device companies worldwide. We specialize in: Critical Components

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Color 3D printed models help explain

the nature of disease at the molecular level Early engagement and close partnerships between medical device developers or OEMs, contract manufacturing organizations (CMOs) and suppliers can reduce delays to the market, decrease costs and prevent common roadblocks.

Edited by Leslie Langnau â&#x20AC;˘ Managing Editor

November 2018 www.designworldonline.com

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The Stratasys J750 3D PolyJet Printer can print more than 500,000 color combinations, accurately match colors, offer transparent to opaque color gradients, and advanced clear material with texture.

The engineers at Biologic Models visualize and create 3D models of highly detailed proteins. They use 3D printing to create them. The multi-colored models help explain the nature of health and disease taking place on the molecular landscape and are a useful visual aid for educators explaining the properties of a specific protein.

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For Biologic Models, 3D printing is used to create detailed models millions of time larger than a protein’s actual size. These models help explain the nature of health and disease at the molecular level.

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Two companies are working together to help engineers build realistic prototypes and streamline design-to-prototype workflows. Shapeways, a 3D printing service and Stratasys, a 3D printer manufacturer, are making full-color, multi-material 3D printing more accessible. For Biologic Models, it’s exactly what the company needs. The company designers visualize protein data and use 3D printing to create highly detailed models that are millions of times larger than the protein’s actual size. These multi-colored models help explain the nature of health and disease taking place on the molecular landscape and are a useful visual aid for educators explaining the properties of a specific protein. The engineers send the data to Shapeways for 3D printer. Shapeways uses a Stratasys J750 printer to create the protein models. “J750 is the best of both manufacturing worlds, full-color 3D printing combined with high-quality transparent plastics. This is exactly what my customers want,” says Casey Steffen, Founder and Director of Operations of Biologic Models. “Transparency and color coding are necessary features to create the highest quality and most durable models. The J750 tackles these design and manufacturing challenges head on.” The Stratasys J750 3D Printer offers more than 500,000 color combinations, accurate color-matching, transparent to opaque color gradients, and advanced clear material with texture bringing to life fine, delicate details. The PolyJet-driven system creates parts that look, feel, and operate like finished products. Eliminating requirements for painting, assembly or heavy postprocessing, the Stratasys J750 shrinks production cycles thanks to reliable and consistent printing, part after part. Shapeways is positioned to wrap an entire workflow around Stratasys’ innovation. This includes helping design printable objects that fully use the printer’s capability, running the printers at scale, and delivering finished products that are ready to use or sell. DW Shapeways www.shapeways.com Stratasys www.stratasys.com

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The advantages are pointed: • Exceptional reliability y n • Low noise & vibration

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Cadence, Inc. is a contract manufacturing partner ranked among the top companies providing outsourced design and manufacturing solutions for medical, life science, and industrial applications. We use integrated and advanced technologies while offering complete services that range from design through manufacturing and full supply chain management of specialty metal components, complex subassemblies, and finished devices. When it comes to new product design and development, Cadence strives to be the partner of choice as we continue to invest in new technologies for the betterment of our customers. We specialize in products that require high-performance components that are difficult to manufacture, single use products, and consumable replacement parts for machinery. Contact us today to make your new product a reality!

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MEDICAL

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Ultra Low Viscosity Biocompatible Epoxy for Medical Electronic Applications Formulated for medical electronic applications, Master Bond EP621LPSPMed is a biocompatible two part epoxy that has a mixed viscosity of 150300 cps. Its ultra low viscosity makes it ideal for use in underfill, impregnation and porosity sealing applications, while it also performs well in bonding, coating or encapsulation. This product exhibits excellent wetting properties and can readily flow by capillary action in tight clearances or beneath devices. It adheres well to metals, plastics, composites, polyimides, glass and ceramic substrates. EP62-1LPSPMed has an advantageously long working life of 12-24 hours for a 100 gram mass and requires moderate heat for curing. Cure schedule is overnight at room temperature followed by 60-90 minutes at 80-100°C. The higher the temperature the faster the cure. Post curing at 100-150°C for 3-4 hours will optimize its properties. Master Bond EP62-1LPSPMed passes USP Class VI and ISO 10993-5 cytotoxicity requirements. It also has been tested for 1,000 hours at 85°C/85% RH. It has excellent toughness, tensile strength of 11,000-12,000 psi and resists repeated cycles of ethylene oxide, radiation, and chemical sterilization. This compound has volume resistivity of more than 1014 ohm-cm, withstands mechanical shock/vibration and is serviceable from 4K to +400°F. In very thin sections it will transmit light, but in

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DC Motor-Driven Pumps Nitto Kohki’s DC motor-driven air compressors and vacuum pumps are ideal for applications requiring exceptionally reliable air flow, pressure or vacuum performance. Featuring oil-free operation, a single moving part, low noise, and low vibration, this line of linear air compressors comes in 12V and 24V models. Other benefits include: • • • •

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thicker sections it is opaque. Shore D hardness is 75-85 and its glass transition temperature is 125-130°C. EP62-1LPSPMed has a 100 to 25 mix ratio by weight and can be supplied in standard sized units: ½ pint, pint, quart, gallon, 5 gallon kits. It can also be packaged in premixed and frozen syringes, as well as in cartridges for gun dispensers. Shelf life in original unopened containers is 6 months.

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Product World Shaft locking device with single screw Zero-Max zero-max.com The ETP Express shaft locking bushing is a suitable choice for locking into position gears, pulleys, sprockets and other components in automated machinery.

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Positions in seconds and can be readjusted hundreds of times just as quickly. No axial movement of the bushing or

component along the keyless shaft during installation. Much faster installation than other mechanical bushings requiring multiple screws. An Allen wrench is all that is required to mount and lock ETP Express bushings into place. They have sealed, clean lines that resist debris collection and clean easily without any special maintenance.

Using pneumatics to detect proper workpiece loading Carr Lane carrlane.com/arb Air Rest Buttons allow using pneumatic position control to detect proper workpiece loading in a machining fixture. Made in USA, these modular units consist of a threaded body installed in a fixture, which holds a precision floating plunger. The plunger has a reamed hole, available in a choice of three diameters, that accepts any height of Carr Lane’s standard pressfit-type rest buttons. Proper placement of a workpiece on the Air Rest Button assembly causes the plunger to fully retract into the body. This seals off air flow, which increases the overall pressure of the system. This pressure value can be read using an analog or digital pressure sensor which can then be tied into a PLC or control system.

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Product World Micro stackable PLC system AutomationDirect automationdirect.com The micro stackable P1000 PLC system provides communications, user-friendly programming, integrated data storage, and a full lineup of discrete, analog and specialty I/O modules in a compact size. The P1000 PLC system can be expanded with up to 8 I/O modules for a total of 128 discrete I/O points or 48 analog I/O channels.

Newly added direct current P1000 modules include higher

density 16- and 15-pt Vdc models, and 8- and 16-pt Vac/Vdc input versions.

8-point 120-240 Vac input and output modules have

been added; new analog I/O includes RTD 4-channel input and combination 4-channel input, 2-channel output, 0-20 mA and 0-10 VDC modules.

Fully Integrated Display

Absolute encoders with EtherCAT communications Encoder Products Company encoder.com The EPC Model A58HE and Model A58SE are EtherCATready, multi-turn absolute encoders for harsh factory and plant environments. They are particularly suited to applications where fieldbus connectivity is required, and the encoder must retain absolute position information after power-off events. The Model A58HE is a 58 mm encoder in a hollow bore construction, and the Model A58SE is a 58 mm shaft encoder available with either a clamping flange or synchro flange.

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

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Precision feedback for collaborative robots POSITAL electromate.com/posital-fraba.html Encoders measure rotation and return a digital signal that reports the angle of rotation (absolute encoders) or rate of motion (incremental encoders) to the control system. The ‘right’ encoders for cobots need to be accurate, reliable, and compact, with excellent dynamic response characteristics.

These new sensing technologies – magnetic

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Product World High-resolution global shutter image sensors OmniVision ovt.com The OG02B1B/OG02B10 and the OV9285 are designed to be cost-effective solutions for a range of consumer and industrial machine vision applications. In particular, OEMs developing products for high-growth markets such as AR/VR headsets and accessories, industrial automation, robotics, agricultural drones and 3D modeling will benefit from these higher-resolution global shutter image sensors that can quickly capture precise images of fast-moving or faraway objects while consuming very little power.

Modular angle encoders Heidenhain heidenhain.us This new series of angle encoders is called the ERP 1000 and is designed for high resolution, high speed, and high contamination resistance.Â These encoders are useful for accurate measurement and positioning applications within semiconductor and metrology equipment. Â

Consisting of a glass disk bonded to a hub and a scanning unit that scans

the fine graduation on the surface of the disk, these ERP 1000s are offered with four different size disks and segments. The disks can have up to 63,000 lines with accuracy to +/- 0.9 arc seconds and up to 2600 RPM.Â A reference mark is included, and multiple scanning units could be used to increase accuracy even further.

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Rotary encoders with blue emitter LEDs Pepperl + Fuchs pepperl-fuchs.com The ENI58IL rotary encoder with BlueBeam Technology equips industry-standard rotary encoders with the precision required for rotational speeds of up to 12,000 RPM. This is achieved by implementing a blue emitter LED and the corresponding receiver diodes. When used in conjunction with a powerful sensing chip, a highly efficient use of light is possible.

Compared to the long-wave infrared light that is typically used in conventional rotary

encoders, the blue light from the new emitter LED has a shorter wavelength while at the same time featuring identical splitting width. This allows sharper imaging. With BlueBeam Technology, users can also reduce the tolerance of phase position A:B to far below 10%. Compared to the values that can be reached with conventional infrared technology, this more than doubles signal quality.

Telescoping tube clamp Stafford staffordmfg.com This telescoping tube clamp is a rigid clamp-style linear mounting component that holds without damaging the tube and provides infinite adjustability, unlike set-screw style devices. Featuring a quick-release handle to establish and lock a position, this tube clamp is suited for applications that require frequent repositioning.

Available in 9 sizes to accommodate tubing from 2.75 to 0.75-in. O.D. in 0.25-

in. increments, this telescoping tube clamp can be manufactured from aluminum, steel, and stainless steel and provides superior holding power and will not mar tubing. Applications include sensors, medical devices, packaging systems, displays, and more.

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Product World High elongation, two component epoxy system Master Bond masterbond.com EP110F8-3 is a two-part epoxy system suitable for sealing, encapsulating, potting, and casting applications. This toughened system provides very good flexibility and possesses a relatively high elongation of 120-150%. It offers a low tensile modulus of around 5,000-15,000 psi and a shore A hardness of 40-50 at room temperature.

EP110F8-3 has good thermal cycling

and shock resistance, passing 10 cycles from -55 to +125°C with no signs of cracking. It has a good electrical insulation profile with a low dielectric constant of 2.67 as well as a low dissipation factor of 0.006, both measured at 75°F for 1 KHz.

EP110F8-3 has a convenient mix

ratio of one to two by weight; the color of Part A is clear while the color of Part B is amber. It has a mixed viscosity of 1,0002,000 cps and flows readily. Working life

LVDT signal conditioner for power generation applications Alliance Sensors Group alliancesensors.com The S2A is an LVDT signal Conditioner that has smart and fast LVDT/RVDT setup. The S2A has been designed to work with a range of LVDTs, RVDTs, and inductive half-bridge sensors including 3-wire GE LVRTs and GE gas turbine buck-boost style LVDTs. The signal conditioning module has cyber security tamper prevention and notification features. • S2A Operating Features: • Push button calibration • Built-In null indication • 4 excitation frequencies, 8 analog dc outputs (6 dc

voltage and 2 current loop outputs)

• 16 addresses for RS-485 digital communications • Hot swap capability • Advanced master/slave capability to reduce cross talk

for a 100 gram batch is 2-3 days at room temperature and can be cured within a few hours at 250-300°F.

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Profile rail guides SKF skf.com LLT profile rail guides have the ball circuits placed in an X-arrangement, which optimizes load sharing in all four main load directions and accommodates moment loads, while maintaining self-aligning capability. The arrangement further compensates for mounting deviations, even under preload, contributing to smooth running performance under a variety of operating conditions.

Guides are available in sizes 15-45 with rail sizes up to 4000 mm in a single piece with longer lengths available

as attached rails. LLT guides are available with a variety of preload and precision classes, mounting configurations, and accessories. They can resist temperatures up to 100ºC and achieve speeds up to 5 m/s. The use of eight carriage types with a single rail profile to meet most industry-standard dimensions greatly increases flexibility.

Electric power steering series Allied Motion alliedmotion.com This new electric power steering (EPS) series is for steer-by-wire warehouse vehicles, autonomous AGVs, and similar material transport vehicles needing a robust electric steering solution.

The EPS series is a compact, fully-integrated motor, gearbox, controller, and optional output

pinion. It is available in 3 frame sizes and 16 models to cover virtually any electric steering requirement in applications from small pallet lifters to AGVs/AGCs to multi-ton reach trucks. Features: • 24, 36, or 48 Vdc battery operation (72-80 Vdc optional) • EN13849 approved • Customizable mounting flange, output shaft, and output gear • Can be used in cold storage environments with temp down to -35°C • Optional tiller arm

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It’s not a web page, it’s an industry information site So much happens between issues of Design World that even another issue would not be enough to keep up. That’s why it makes sense to visit designworldonline.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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Product World Six custom molding processes Caplugs caplugs.com With six different custom molding processes and thousands of material options, Caplugs offers additives to enhance parts with UV stability, chemical resistance, gripping finish, and more. In addition, Caplugs’ in-house team of engineers will work with designers one-on-one to design a solution — from concepting and prototyping to packaging and inventory management.

The entire custom molding process is performed in-house under Caplugs’ quality

management process to ensure consistent, quality products. The facilities offer more than 200 machines ranging from 7 to 1,000 tons, allowing for the manufacturing of a wide range of part sizes.

Modular zero-point clamping system

Sanitary conveyor platform

Carr Lane carrlane.com

Dorner dornerconveyors.com

The Roemheld DropZero

The AquaGard 7350 V2 is built for numerous sanitary

Modular Zero-Point

applications within baking, snack food, pharmaceutical, pet

Clamping System enables

food, packaging and other industries that require occasional

workpiece machining in one setup,

wipe-down cleanings of the conveyor. The conveyor comes

significantly reducing setup time

in straight belt, as well as modular belt straight and curve

and fixturing costs. With

models. Belted LPZ, modular belt LPZ and positive drive

a few turns of a wrench,

models will be available in the coming months.

DropZero locates, supports,

and securely clamps the workpiece

modular curve chain conveyor in the industry today. The

from underneath, providing full machining

modular belt curve conveyor has no openings greater

access to 5 sides.

than the international standard of 4mm, even within the

curves, which increases safety by eliminating pinch points

Pull studs (round, diamond, and floating) are mounted

The AquaGard 7350 V2 is the safest, most advanced

directly to a part, and clamping modules can be mounted

for operators. Added safety measures are also achieved

to anywhere on the fixturing plate, elevating the

by covering the upper and lower chain edges, and fully

workpiece for machine-spindle clearance. Clamp modules

containing the drive system, which reduces catenary belt sag

are stackable for added clearance and can fit on all of Carr

and conveyor noise.

Lane ½-in. and 5/8-in. modular tooling plates and blocks. They can also be used with non-modular tooling.

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SALES

Ad Index Aignep USA ...................................................................39 Allied Electronics & Automation ................................. cover/corner,3,51 AllMotion .........................................................................4 Altech Corp ............................inside gate cover, 15,17 AMETEK - Haydon Kerk Pittman ............................77 AMETEK DFS .................................................................41 Applied Motion Products, Inc. ................................ 22 Aurora Bearing Company ........................................46 Automation24, Inc. ......................................................29 AutomationDirect ........................................................1 AZCO Corp. ....................................................................46 Boker’s Inc. .....................................................................49 Brother Gearmotors ...................................................85 Carlo Gavazzi ................................................................28 COMSOL .........................................................................43 Cornell Dubilier Electronics, Inc. ............................47 DATA IMAGE Corporation ....................................... 104 Del-tron ...........................................................................56 DeviceTalks ....................................................................88 Digi-Key ..........................................................................13 Dynatect Manufacturing, Inc. .................................59 Elesa USA Corporation .............................................33 Emerson Industrial Automation .............................19 EXAIR Corporation ......................................................5 Harwin .............................................................................27 HELUKABEL USA ........................................................31 icotek Corp .....................................................................39 J.W. Winco, Inc. .............................................................72 Keller America ...............................................................21 Key Bellevilles Inc. .......................................................65 Master Bond .................................................................65 Maxon Precision Motors ...........................................7 Miki Pulley US ...............................................................14 NB Corporation ............................................................9 NBK America LLC .........................................................82 Novotechnik ..................................................................23 NTE Electronics, Inc. ................................................. 105 OKW USA ........................................................................45 Oriental Motor................................................................58 PBC Linear ................................................................24,25 PCB Cart .........................................................................42 Penn Engineering .......................................................66 PHD Inc. ..........................................................................37 ROLEC .............................................................................71 SEW Eurodrive ............................................................. BC SIKO Products ...............................................................49 Smalley Steel Ring ............................................... 10,IBC Tensility International Corporation .......................55 The Arthur G. Russell Co., Inc. ................................36 The Lee Company ...................................................... 72 THK TOS ....................................................................... IFC Tompkins Industries, Inc. ..........................................2 Traco Power ..................................................................73 Trim Lok ...........................................................................26 Wago USA ......................................................................32 Whittet-Higgins ............................................................35

Medical www.designwo

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A Supplement to

Design World -

November 2018

Medical Tips Supplement Bay Associates Wire Technologies Corp. ...........92 Cadence .........................................................................97 Master Bond .................................................................93 Nitto Kohki USA, Inc. ................................................ 100 11-18_FINALFINAL.indd

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Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months

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Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. c. Total Paid and/or Requested Circulation of 15b (2), (3),telemarketing and (4)) (Include direct written (Sum request from(1), recipient, and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.) Outside County Nonrequested Copies Stated on PS Form 3541 (include b. Legitimate Sample copies, Requests Over 3 years old, Requests induced by a Paid and/or (1) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541. Premium, Bulk Sales and Requests including Association Requests, Requested (Include direct written recipient,Lists, telemarketing Internet reNames obtained from request Businessfrom Directories, and otherand sources) Distribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.) and d. NonreIn-County Nonrequested Copies Stated on PS Form 3541 (include Outside quested Sample copies, Requests Over 3 years old, Requests induced by a Sales Through Dealers and Carriers, Street Vendors, Counter (2) the Mail) Distribution (3) Premium, Sales Requests including Association Requests, Sales, andBulk Other Paidand or Requested Distribution Outside USPS® (By Mail Names obtained from Business Directories, Lists, and other sources) and (4) Requested Copies Distributed by Other Mail Classes Through the USPS Outside (e.g. First-Class Mail®) the Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4)) Limit mailed at Standard Mail® or Package Services Rates)

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Total Distribution (Sum 15cPrint and e) b. Total Requested andofPaid Copies (15c) + Requested/Paid Electronic copies (16a)

34,997

34,982

2,170

702

575

411

2,745

1,113

37,742

36,095

417

325

38,159

36,420

92.7%

96.9%

5,000 39,997

Date

5,000 39,982

42,742

41,095

93.5%

97.3%

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17. 16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication. 17. Signature and Title of Editor, Publisher, Business Manager, or Owner 18.

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November 2018 Date

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I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

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AD INDEX_11-18_Vs1(Statement of Ownership).indd 112

2. Publication Number

Design World 4. Issue Frequency

DESIGN WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2018 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

Color 3D printed mode help explain the nature ls of disease at the molecular level Medical Tips cover

Jami Brownlee jbrownlee@wtwhmedia.com 224-760-1055

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