Design World October 2017

www.designworldonline.com

October 2017

inside: Linear Motion: Servomotor couplings:

Stiffness, damping, hunting, and stabilization considerations

p. 58

Fluid Power: How valve technology

improves operator control of telehandler booms.

p. 80

Mechanical: Key tips on proper bearing

selection.

p. 90

Using a dedicated pulse LSI vs. a control CPU for motion control 50

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OFFSET SHAFTS. SOLVED. Offset Couplings from Zero-Max reduce space requirements for parallel offset shafts in large system applications. These specialized couplings provide machine designers with an important option for reducing overall machine size and footprint.

Compact in design, Schmidt Offset Couplings transmit constant angular velocity and torque in a wide range of parallel shaft misalignments. Handling high amounts of parallel offset up to 9 inches, they are available with torque capacities up to 459,000 in-lbs.

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I n s ights

Three

tech disruptions

for the future

Kevin Surace of Appvance spoke at the NFPA’s recent Industry and Economic Outlook Conference, about how some technology disruptions will change the world drastically in the coming years. Here are three changes to watch.

1

Automation is going to make our jobs irrelevant. So much of our psyche is embroiled in our jobs. What’s the first thing you do when you meet a new person? You ask their name, followed quickly by, “What do you do?”

Surace says that by 2050, 80% of all of today’s tasks will be automated. Automation has been slowly taking away the routine occupations and bringing in more nonroutine occupations. That’s because the non-routine ones are harder to automate, while the routine ones are easier to automate. It’s happened from windmills to industrial robots to ATM machines.

“Technology is driving down costs, and has been driving down costs for a long time,” Surace said. “But once we had the advent of the smartphone, we began to drive down costs of certain key components like we’ve never seen before—because all of a sudden, there was a consumer product that would sell over a billion units. Those numbers are staggering. We’ve never had a consumer product that sold to two billion people. Many consumer products would sell a million or two million pieces a year, which was big—like a clock radio—but nobody ever had something like this. Hence, the cost drivers to drive down certain items has been remarkable.”

This type of pressure to cheapen and shrink key components is evident in gyroscopes. 70 years ago, they were large, bulky objects the size of a microwave. Today, they can sit on top of a quarter and likely cost less than the quarter itself.

2

Artificial intelligence is really coming In the late 1990s, it cost real money to move data one megabit per second.

Today, it certainly doesn’t—in fact, it costs basically nothing to get that kind of speed out of the Internet. Most people have it in their homes, and don’t even think about it.

“The cost per million instructions per second went from something like a trillion dollars to a trillionth of a dollar,” he said. “This is incredible. In fact, we’ve never seen anything like it. All of this has led to really interesting things happening in the AI space, in the machine intelligence space, and in the deep learning space.”

Deep learning involves computer systems trying something—playing a game, testing a way to achieve something—over and over and over. The developed neural nets now can be hundreds of millions or arguably billions of pieces of information.

“AI for the first time is true machine learning, where a machine can learn for itself with virtually no help. We just have to teach it how to play a game once and it will get better and better and better at it,” Surace said. “In May 2017, Google AI created a better AI neural net than humans can. They said, ‘What would happen if we trained our AI to create these neural nets, and keep creating better and better neural nets?’

Now, AI creates better versions of AI than we can create of AI. That’s a little spooky.”

Surace noted that bots are a whole new platform. In fact, bots can now replace humans in customer service.

“Before the bot responds, it will analyze millions of other responses from your competitors, and then responds with the one that got the best response from the audience. Why would you ever put a human on [a customer service line]?” he asked.

4 October 2017 www.designworldonline.com DESIGN WORLD

Insights 10-17_Vs3.LL.indd 4

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I n s ights “We’re about to encroach on a time where the AI and the robotics and the automation goes well beyond the average human intelligence.”

3

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Insights 10-17_Vs3.LL.indd 6

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Driverless cars … and driverless everything else “If you’re in Silicon Valley, driverless vehicles are on all the roads. They’re everywhere … they’re legal. There is a human riding in it right now, making sure that they can take it over. But nevertheless, they rarely have to take over. In fact, in all of Google’s research, they found the most dangerous thing that can happen in a driverless vehicle is asking the driver to take over,” Surace said.

The modern car has about a hundred million lines of code in it. But the driverless vehicle is now approaching a billion lines of software. It’s basically becoming a computer on wheels.

“In a driverless world, we might need 92% fewer vehicles, he said. “Where is your car right now? Is it running or is it parked?

It’s probably parked. It’s probably doing nothing. It turns out your cars do nothing 92% of the time. We don’t really want to pay for assets that do nothing.”

If driverless vehicles truly become on-demand, Surace said we simply won’t buy any cars. We won’t need taxi drivers.

We’ll reduce assets. He predicts that human driving will be outlawed in some cities in a handful of years, based on how much safer autonomous vehicles are.

“If there are 92% less vehicles, and the only vehicles that are on the road are owned by very large corporations that have Lloyds of London backing them, you don’t have a lot of auto insurance to put out there, do you?” he asked. “This is when we start to think about how things are going to be impacted. Already, the insurance industry as a whole is trying to automate where people will be able to take a picture of their accident, upload it, and a whole set of systems will automatically evaluate that and transfer money to your bank account or not, because that makes a lot of sense rather than spending $350 to process a claim.”

Surace said that U.S. long-haul truck drivers will disappear; Tesla is working on an automated long-haul truck. He claims that a cross-country with a driverless vehicle will get there in half the time and will be half the price.

“The average U.S. household will save $5,600 a year going driverless on-demand,” he said.

But ethical questions will remain. Surace joked that systems would be programmed to favor the lives of a vehicle’s occupants over the lives of pedestrians. Why? “Because if any car company says, ‘Number one, I’m going to kill you, instead of someone on the street,’ no one’s going to get in that car.” DW Paul J. Heney - Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

6

October 2017

www.designworldonline.com

10/3/17 1:17 PM

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Teschler on Topic

Last days of the car guys The time when autonomous vehicles dominate the roads will mark the end of the auto industry as we know it. That was the message from now-retired GM vice chairman Bob Lutz who spoke recently at an automotive electronics forum sponsored by Mentor Graphics, a Siemens business. At the forum, Lutz shared a number of thoughts that probably have crossed the minds of auto industry insiders watching autonomous technology unfold.

Lutz has championed the development of striking vehicles that include the Dodge Viper and Chevy Camaro. So it’s worth taking note when he predicts autonomous vehicles will bring an end to personalized styling in transportation. Instead, most future cars will be anonymous sausageshaped modules, he predicts.

The shape will come from the necessity of nose-to-tail separation that will characterize the future conveyor-belt-like virtual trains of autonomously driven vehicles. The average speed of these virtual trains will probably be in the 150 to 200 mph range, Lutz thinks. Modules

will decouple from these trains at the right point to get passengers to their destination. Wireless charging cables buried in the ground will recharge the batteries that power these vehicles.

The resulting system will be far more efficient than today’s and might even extend to quad-copter low-altitude transportation also piloted robotically, Lutz thinks. Of course, there’s no reason to produce “muscle-car” vehicles when everything on the road travels only inches apart and no one passes.

If you are in the auto business, this scenario probably leaves you wondering what happens to vehicular OEMs. One outcome: “The branded model is in trouble,” Lutz says. “And motorcycles are really doomed.” You can also surmise that vehicle stylists will be out of jobs 20 to 25 years from now, the time when Lutz figures sausage-shaped modules will begin to dominate.

Lutz sees the auto industry transforming into something that looks a little like the cell phone companies of today: The money will be in providing services rather than in selling hardware. “Nobody makes money on phones today. And so it will be with autonomous vehicles,” he predicts. His reasoning is that the main buyers of vehicles will be ride providers like Uber and Lyft. They’ll likely procure 200,000 to 300,000 vehicles at a time. So say

goodbye to your local car dealers. More concerning if you’re in the business of selling cars, the basic profitability of the auto business goes away when its hardware gets sold by the freight carload.

And it won’t just be local dealers who go away. So too will brand names. “The modules that get sold as transportation won’t be branded as Ford or GM. They’re more likely to be branded to the service provider.”

Of course, the transition to vehicular modules won’t be immediate. Lutz thinks there will be a blend of autonomous and regular versions until insurance companies realize that 90% of traffic accidents arise from human error.

Eventually the government will step in and phase out human-piloted vehicles on main roads. At that point, the few remaining vehicles with steering wheels will be found on what will be the equivalent of today’s dude ranches for horse riding aficionados.

All in all, the future that Lutz envisions will render the ability to drive a car about as common as the ability to ride a horse.

That leaves us with one piece of parting advice: If you happen to have a collection of muscle cars that you plan on leaving to your descendants, you might consider liquidating soon. It’s likely your future kin won’t know what to do with a garage full of Mustangs, GTOs, and street Hemis. DW

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

8

October 2017

Lee Teschler Column 10-17_Vs3.LL.indd 8

www.designworldonline.com

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Green Engineering Paul J. Heney

• Editorial Director

Pneumatics manufacturer hits green in all the right spots

Koganei Corp., headquarted in Tokyo, has long been an advocate of green engineering principles, from their building grounds to their manufacturing lines to their products.

When the company expanded its main manufacturing facility in Komagane, Japan, the so-called “E Building,” in 2011, the idea was hatched to add solar panels to the roof. Two years after the addition opened, 1,330 panels were brought fully online, providing 330,000 kw/hours annually—even more power than was expected from the design.

Within the plant, the company has seven dual arm NEXTAGE robots installed to assemble special valves. The company, which manufactures the end of arm portion of the robot, is using motors that are below 80 watts, so the speed is a little slower than human motion. But they can work 24 hours a day, and they have remarkably improved production, which has a near zero rejection rate.

William Miller, Sales Manager for the company’s U.S. subsidiary, Koganei International America, noted that just like in any company, there is differentiation that makes each manufacturer unique.

“With Koganei, even back as far as the 1960s, everything that they’ve done, they’ve said, was that our niche and competitive advantage is going to be that we are going to make high quality parts— but we are going to make everything with more time spent in engineering. We’re

DESIGN WORLD

Green Engineering 10-17 Vs3.LL.indd 11

going to make the product physically smaller, use less power, have a longer life cycle. In this way, we can achieve more environmentally friendly products.”

Globally, the company was one of the first to make all of its 512,000 products RoHS compliant—a directive that aims to reduce the amount of hazardous materials in electronics manufacturing and therefore minimize toxic waste. Miller said Koganei’s compliance program was unique, in terms of environmental metal use, as a manufacturer.

“Now everybody is pushing to have RoHS compliance,” he said.

The company follows an action plan in achieving environmental improvements, including focusing on environmentally design; promoting reduce, reuse and recycle initiatives in www.designworldonline.com

its plants; and educating its workforce on pollution prevention and conservation.

“Koganei has been making such environmental efforts because of our corporate environmental policy,” said Kenji Kuroo, President of Koganei International America. “As a global company and manufacturer, we believe that it is our responsibility to meet the world’s environmental requirements.” DW

Koganei International America Inc. www.koganeiusa.com

October 2017

11

9/29/17 10:26 AM

Technology Forward Making parts fast through

chemistry Additive manufacturing processes need speed if the cost per part is going to drop to levels competitive with traditional machining and injection molding.

Thus, additive vendors are exploring how chemistry can make processes faster. HP and Carbon both developed processes that take advantage of chemical reactions. Here are a few more recent innovations that use chemical interaction to build parts fast.

Voxeljet recently introduced a new way to additively build parts. The company calls this process HSS, for high speed sintering. This process involves depositing a fine layer of polymeric powder, such as PA12 or TPU, onto the build table, then using an inkjet print head to selectively deposit an infrared absorbing fluid onto the powder surface where sintering is desired. No further liquids

The Orchid DLP 3D printer, from Collider using DLP technology to create a hollow shell mold that is then injected with a material to create parts.

are used for the printing process.

The build area is then illumined with infrared light, causing the printed fluid to absorb this energy and then melt and sinter (fuse) the underlying powder. This process is repeated layer by layer until the build is complete to form functional plastic parts.

Another innovation comes from Concurrent Technologies Corporation (CTC). CTC engineers are working with an established process that is more than a century old and is currently used commercially to extract metals from ore. The Mond process is good at creating thin-wall parts with precise thickness and complex geometry on substrates of arbitrary shape and controlled temperature distribution.

CTC’s concept uses a gas (carbon monoxide) that reacts with any of 18 different metals to form a more complex gas at elevated temperatures. The metal then deposits on hotter substrates that define the shape of the finished component. This action frees up the carbon monoxide for reuse in reacting with additional metallic atoms and continuing the additive process.

Another innovation combines injection molding and 3D printing/ additive manufacturing. The Orchid DLP 3D printer uses its DLP technology to create a hollow shell mold that is then injected with a plastic material or metal powder combined with a binding

resin. After the material in the mold hardens, the mold is immersed in a warm bath until the shell melts away, revealing the part. The goal behind this innovation is to speed up the development of tooling.

The material used inside the shell is standard off-the-shelf material (rubber, silicone, metal or a polyurethane) that Collider makes available in cartridges.

Post processing in a furnace eliminates the binder and solidifies the part.

Now, how about 3D printing in water?

Researchers at the Hebrew University of Jerusalem’s Center for Nanoscience and Nanotechnology, have developed a photoinitiator for 3D printing in water.

The innovation is the use of semiconductor-metal hybrid nanoparticles (HNPs) as the photoinitiators-molecules that induce chemical reactions necessary to form solid printed material by light. Previously, such molecules were not soluble in water.

A key market for 3D printing in water is medical. This technology opens opportunities for tailored fabrication of medical devices and for printing scaffolds for tissue engineering. For example, the researchers envision personalized fabrication of joint replacements, bone plates, heart valves, artificial tendons and ligaments, and other artificial organ replacements.

This is just the beginning of additive innovation that will lead to more interesting ways to make parts fast. DW

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

12

October 2017 www.designworldonline.com

Leslie Column 10-17_Vs2.LL.indd 12

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Contents 10 • 2017

•

vol 12 no 10

•

designworldonline.com

66 50 _MOTION CONTROL

74 _HARSH ENVIRONMENTS

Using a Dedicated Pulse Control LSI vs. a CPU for Motion Control

Optimizing battery performance in extreme temperatures

Demand for industrial grade primary lithium and rechargeable lithium batteries continues to grow. Even though such batteries use nearly identical in chemistry, quality differences will affect product design. Here are factors to keep in mind to maximize long-term lithium battery performance.

Pulse control LSIs specialize in motion control and feature high operational reliability.

58 _LINEAR MOTION Servomotor couplings: Stiffness, damping, hunting, and stabilization considerations

Here we address considerations when specifying a servomotor coupling to satisfy servo requirements--ever-evolving specifications that become more demanding all the time.

66 _3D CAD Small and mid-size companies need CAD too

Small to medium-sized companies are adopting CAD and other engineering technologies to bring new innovations to market and, in some cases, to found entirely new market sectors.

14

80 _FLUID POWER The gravity of precise boom control

Recent changes in valve technology have allowed engineers to drastically improve the operator’s control of a telehandler boom—and the efficiency of the overall hydraulic system in the process.

90 _MECHANICAL The 3 bearings questions manufacturers hear most

Key factors can simplify your bearing choice. Here are questions application engineers like Matt McCormack of SKF hear frequently, and his recommendations.

October 2017 www.designworldonline.com

CONTENTS 10-17_Vs7.LL.indd 14

ON THE COVER Pulse control LSIs, dedicated chips for motion control, can simplify motion profile programming. | istockphoto.com

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10.17

• contents

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October 2017

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EDITORIAL

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

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October 2017

17

9/29/17 10:48 AM

Design for Industry Medical

Power supplies for standalone machines

When design situations require that all components be enclosed in one unit, this power supply could be a solution. With these enclosed power supplies, the hardware is designed for inclusion in a self-contained piece of automation equipment.

They mount with basic screw holes to the machine. The small IP20 enclosure makes them suitable for small desktop equipment, like medical testing machines or 3D printers. They can be installed directly in the device enclosure.

• Output voltages available: 5 Vdc, 12 Vdc, 15 Vdc and 24 Vdc • Output power available: 20, 35, 60, 100 and 150 W versions • Short-circuit protected, UL Recognized (UR) DW Balluff Inc. | www.balluff.com

October 2017 www.designworldonline.com 18

DFI 10-17_Vs5.LL.indd 18

WHAT DO YOU THINK?

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

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9/29/17 11:13 AM

Medical

Voice coil

with 1 micron positioning resolution For the small medical instrument needs, this compact HCDS-025038-02-B1-01 Voice Coil Stage from Moticont has a foot print of 2.000 in. (54.0 mm) wide by 5.000 in (127.0 mm) long and features a positioning resolution of 1 micron and a 0.125 in. (3.175 mm) open aperture. This precision cross roller stage has a 0.97 in. (24.6 mm) range of motion with 1.0 lb. (4.4 N) of continuous force and 3.2 lb (14.2 N) peak force. The zero cogging, clean, quiet, efficient, low inertia, high acceleration, high speed voice coil driven stage has a built-in home switch for accurate initialization. As the coil is fixed and the magnetic assembly moves, there are no moving electrical components to fail. Designed for closed loop servo operation an integral quadrature optical encoder with differential outputs is included.

The stage table has 4 8-32UNC-28 mounting holes. Pre-drilled and counter-bored mounting holes in the base and a plug -and-play wired connector for easy integration into new or existing applications. This black anodized voice coil stage with a clear aperture suits applications in laser drilling, optical focusing, testing, laser steering, mirror positioning, scanning, oscillation, switching, applications in industrial, medical, metrology, and research fields.

The HCDS-025-038-02-B1-01, voice coil driven stage is available as part of an XY or XYZ stage. DW Moticont | www.moticont.com

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Traditional methods for synchronizing multiple actuators can be inflexible. Gas spring technology, for example, is limited in application, while hydraulic cylinders can be prone to leakage and costly to maintain.

Non-integrated electronic systems have more flexibility and are cleaner but require external devices such as encoders and potentiometers to track position and send feedback to an external PLC or other logic solver.

Designers of equipment in which large or awkward loads must be moved repeatedly and evenly, such as large solar panels or heavy hoods on construction equipment, can simultaneously distribute that load using up to four Electrak HD heavy duty electromechanical linear actuators.

The synchronization is achieved by embedding load-handling technology into a single electromechanical actuator, which is then wired in sequence with up to three other similarly equipped actuators.

Designers install these wherever linear movement is needed without the need for external assemblies. Once the actuators are installed, customers synchronize them by wiring them together and operating a single unit with a simple switch. During operation, system electronics detect speed changes that indicate load imbalances, thereby eliminating bouncing or other effects of imbalance.

By using multiple actuators, synchronization increases system movement speed more efficiently. A larger load that might normally use a single, heavy load actuator, for example, could be moved faster by combining multiple, lower load actuators.

Synchronization also retains all Electrak HD mechanical capabilities, including the handling of bidirectional loads of up to 10 kN (2250 lbf) with stroke lengths up to 1000 mm (39 in.) and accuracy of 1% of stroke from 100-1000 mm. High-quality ball screw assemblies provide efficient current draw and support speed options up to 43.5 mm/sec (1.7 in./sec) (using the 1.7 kN [382 lbf] version).

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There are numerous opportunities to apply this synchronization. In addition to solar panels and off-highway agricultural equipment mentioned earlier, potential applications include: • Industrial logistics trains for automatic correction of imbalances between the front and backend loads, which can cause stoppage, noise or unnecessary wear.

• Doors on ovens and large processing equipment for smoother, safer opening and closing.

• Ergonomic patient-handling equipment such as lift tables, synchronizing operation of lift columns for smoother movement and higher-quality patient experience.

• Marine applications, such as rudder assemblies, for smoother, more responsive steering.

• Structural engineering applications such as automatic loading doors in factories and warehouses. DW

Thomson Industries, Inc. | www.thomsonlinear.com DESIGN WORLD

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Design for Industry Semiconductor

Liquid analyzers deliver the data The analyzers will help your design meet data compliance needs. The precision accuracy and reliability of the family of modular S80-T80 Liquid Analyzers delivers consistent data for a range of global, regional and local quality, environmental, safety and other certifications, as well as government regulatory operational compliance needs.

All S80-T80 Analyzers are approved and certified to ISO9001 and IECEx Directives and Quality Assessment Standards.

The S80 Sensors measure pH, ORP, pION, dissolved oxygen, turbidity, conductivity or resistivity in liquid processes. They suit applications in bio-tech, chemical, food/beverage, pharmaceutical, power generation, semiconductor, water disinfection, wastewater treatment and more.

S80 Sensors feature two universal sensor designs: (1) Insertion/Submersion (2) Valve Retractable with flared end to prevent blow out.

The standard S80 Sensors have a rugged 0.75-in. OD 316 stainless steel body and come with varying cable lengths or an optional waterproof detachable cable assembly.

The design of the S80 Sensors recognizes the universal T80 Transmitter for automatic configuration set-up. They can be combined into a plug-and-play analyzer system for any of the available measurement parameters. The S80 Sensors are ready for direct in line pipe insertion, submersion, or open tank applications.

They contain a replaceable electrode design for lowering overall cost and ease of use. Only the electrode needs to be replaced, not the complete sensor.

The T80 Universal Transmitter is a single channel device for the continuous measurement of multiple parameters in a generalpurpose industrial environment. It communicates with any precalibrated S80 sensor and automatically conďŹ gures the transmitter’s menus and display screens to the measured parameter.

The T80 Universal Transmitter is flexible and user-friendly. It offers membrane switch navigation, a simple menu structure with soft key menu choices and an easy-to-read 2.75-x-1.5-in. LCD display. It is available with 4-20 mA output with MODBUS RTU on 24 Vdc and 110/220 Vac instruments. DW

Electro-Chemical Devices | www.ecdi.com

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Design for Industry Semiconductor

Force controlled actuator New packaging technologies and materials, especially for fragile components or substrates are challenging semiconductor developers. The The ZAO Force-Controlled Actuator addresses these semiconductor back-end and electronics challenges and helps ensure the integrity of fragile component or target substrates without compromising the machine throughput.

The ZAO Force-Controlled Actuator is suited for semiconductor pick and place, die bonding and probing machines. Coupled with the AccurET controller, the actuator is a state-of-the-art solution to reduce machine cost of ownership.

ZAO is a 30-mm travel actuator with a frictionless bearing arrangement and a light moving mass, ensuring very low and repeatable force application as well as low force overshoot at impact on a contact surface.

The actuator is compatible with the sensorless force-control algorithm, delivering force control accuracy (0.2 N ±10%) with high dynamics capability (up to 20 g). DW ETEL | www.etelusa.com

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Design for Industry Food & Beverage

Can smart technology combat the food crisis?

British scholar Thomas Robert Malthus once predicted that the world’s population would outgrow the rate of food production. While things have changed in the two centuries since, population projections indicate that we remain set for a global food crisis. But technology could offset the crisis.

Thomas Malthus’ theory, which has since come to be known as the Malthusian trap, predicted that human nature meant any abundance in food production would result in higher populations rather than better living conditions.

Malthus foresaw that, ultimately, this unsustainable approach to population growth would lead to widespread famine and poverty.

According to US Census Bureau historical population data, the worldwide population was estimated to be between 813 million and 1.1 billion when this theory was conceived in the late eighteenth century. At the upper end, this makes the global population at the time of Malthus’ prediction 15% of the 7.5 billion people inhabiting the Earth as of April 2017.

While some take such a substantial growth in population as proof that Malthus’ proposed pattern of human behavior

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

was correct, others argue that the Malthusian trap cannot be true as we have seen improvements in living conditions and general quality of life. This is reflected in longer life spans across the globe, with countries such as France seeing the average life doubling between 1800 and today.

However, these developments were only achievable due to the green revolution that introduced new agricultural techniques and food production technologies between 1930 and the 1960s. With the global population set to be between eight and ten billion by 2050 and the UN stating food production must double in line with this, another widespread uptake of advanced technology is necessary to facilitate this growth.

Fortunately, developments in technology used at each stage of the food supply chain show how this can be realistically achieved. Farmers at the beginning of the chain, for example, can use more advanced automation systems to manage the climate conditions and feed of livestock more efficiently from a central location.

Using systems, such as ABB’s AC500 series of PLCs, to control inputs such as ventilation flaps and feeding dispenser motors, farmers can maximize productivity and produce higher yields.

Farmers simply use an operator panel to schedule feeding times or set input parameters and the system does the rest.

Another technological revolution, however may not be effective unless it addresses the issues of the previous one, particularly the energy costs for farms in developing countries. As several of these countries, such as South Africa are powered by coal-fueled power plants, the cost of providing electricity to farm irrigation systems is constantly increasing due to the scarcity of the fuel.

ABB recently worked with a farm in South Africa to tackle this exact issue. In this instance, engineers replaced the manual valve-based control systems on the farm’s water pumps with new variable speed drive (VSD) technology.

This switch simplified the operation of the irrigation system by reducing the need for manual labor and made the overall system more energy efficient, which reduced energy usage by 40%.

This reduction in usage, in addition to the saved man hours, significantly decreased the farm’s operational costs and streamlined the food production process — while simultaneously reducing the farm’s CO2 footprint.

Technology such as this shows promise for a sustainable agricultural revolution that could offset the Malthusian trap for good. With much of this technology already available for businesses to use, it is possible that we could witness the first steps towards tackling food poverty through food manufacturing being taken in our lifetimes. DW

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9/29/17 11:17 AM

Design Notes Edited by: Mike Santora • Associate Editor

Control system helps improve pipe production

trolLogix With the memory of Con e to abl s wa controllers, the plant h eac for store and retrieve recipes size pipe for the first time.

26

Drilling pipe is the lifeline of the oil and gas industry. Vallourec, a global supplier of drill pipe for energy companies has a presence in 20 countries. Inside its Houston, TX plant, seamless steel tubes that have been rolled in rolling mills elsewhere undergo the final step in the manufacturing process. Specially prefabricated tool joints are welded onto each end of the alloy tubes, which are either 30 or 45-ft long.

In 2009, the weld line was producing just 35 finished drill pipe per shift instead of the expected 100-plus. This was mainly due to the controls architecture which was inefficient, labor-intensive and plagued with downtime.

“The material-handling system used to move the mother pipes into position on the welding line was a complete mess,” recalled Joe Klun, who at the time had recently been hired as engineering and technical manager at Vallourec Drilling Products. “Equipment repeatability was the main problem.”

The plant used ultrasonic sensors on the pick arms that lifted the pipes from outdoor storage and placed them on racks that convey them to the industrial machines inside. The sensors were supposed to precisely position the steel pipe on rollers that moved them into the chucks, which grips the tubes inside the welding machine.

“The conveyor needs to move to a certain height,” Klun explained. “Then it needs to roll into a certain position. After that, it needs to stop. All these things need to happen in sequential steps.”

But that synchronization wasn’t happening. A lack of control over the positioning process hampered throughput and productivity.

“First and foremost, there were 19 PLCs on the weld line,” Klun explained. “The response time required just for the electronics to talk to each other created a position error of three-quarters of an inch, plus or minus.”

That was compounded by the effect of outdoor light and moisture on the ultrasonic sensors. On a cloudy day, for instance, the sensors would respond differently than on a clear day.

Klun explained the cumulative result. “When a pipe came in, the machine really didn’t even know the pipe was there. There was no handshake between the machine saying, ‘Yes, I’m here, you can start, I’m in the right position.’ Consequently, pipes would overshoot or under-shoot the lift position. We had pipe flipping up or pipe would run into the equipment because it wasn’t at the right height.”

Fixing this daily problem was a labor-intensive process.

“We had 12 ultrasonic sensors on each rack. Each one had to be set individually to the same height, using an overhead crane to reposition pipe,” Klun recalled. “We were only running at about 30 to 35% efficiency.”

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Design Notes 10-17_Vs4.LL.indd 26

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Design Notes Drilling pipe is the lifeline of the oil and gas industry. Vallourec, a global supplier of drill pipe for energy companies has a presence in 20 countries.

For a permanent solution, Vallourec realized it needed outside expertise.

Before becoming engineering manager at Vallourec Drilling Products, Klun worked in the automotive industry. That’s where he got to know the system integrators from JR Controls. The company – a Rockwell Automation Recognized System Integrator – has specialized in materialhandling controls since 1984.

At Klun’s request, JR Controls’ engineers arrived in Houston to analyze Vallourec’s production problems. Collaborating closely with Klun, they designed a new controls platform for the line, and engineered

a programming blueprint tailored to address its particular issues.

To implement the solution, JR Controls specified a suite of Rockwell Automation hardware and software. The Logix control platform formed the foundation of the new system.

“We replaced 19 PLCs with one master Allen-Bradley ControlLogix control system, creating tight integration between the programming software, controller and I/O modules,” Klun said.

“JR Controls then installed remote racks in cabinets on the floor and connected everything with Ethernet I/O. Now that

the system is networked, we have one point to plug into. And I can access the entire line from one spot.”

Operators on the floor also gained better visibility and control of the welding process after 16 new AllenBradley PanelView operator terminals were installed at stations on the line.

Previously, these controls were manual push button boxes which provided no feedback to the operators. Through the use of the PanelView capabilities we were able to integrate the push button boxes into the PanelView and then provide feedback letting the operators know if things were okay or not.

The new control platform and the customized programming concept were augmented by a synchronized combination of proximity sensors from Rockwell Automation, replacing the old ultrasonic type.

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With the memory of ControlLogix controllers, the plant was able to store and retrieve recipes for each size pipe for the first time.

“The values of all the position sensors are saved. When we do a changeover, we just call up the size we’re going to run and all the registers change,” Klun said. “Now we don’t have to re-zero and reset everything up, and put a new value in manually.”

The automated precision enabled by the new control platform and specialized programming has significantly increased production on the line.

“We went from only being able to run 35 drill pipes per shift to 110 per shift,” Klun said.

The new controls system also is easy to operate and troubleshoot.

Klun especially appreciates the timing

function within the programming logic of the Logix platform.

“Their programs are so easy to follow because of the way they apply step logic,” Klun said. “If a fault occurs on the line, we can simply track back through the sequential steps in the process to identify it. Then we can go directly to the source.”

Once the problem is solved, the new control system enables operators to pick up a program exactly where it stopped. DW

Rockwell | rockwellautomation.com

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Design Notes Edited by: Mike Santora • Associate Editor

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The alpha prototype of Gatan’s IPrep installed next to a scanning electron microscope.

Controller helps bring microscope component into focus

Gatan Inc. is a manufacturer of specimen preparation equipment that recently designed an alpha prototype of its next generation automated specimen preparation tool. The IPrep prototype is mounted directly to a Scanning Electron Microscope (SEM) and shuttles a sample back and forth between the processing chamber and a receiving dock on the SEM. The processing chamber is where two broad beam ion guns are used to polish the sample at low angles.

Using an automated transfer mechanism, the IPrep allows the use of a variety of SEM-related imaging techniques resulting in a 3D reconstruction of specific areas of the sample with a high level of slice thickness control.

The IPrep tool uses two different AllMotion controllers for critical functions. One controller commands the end effector of a transfer arm to open and close in an accurate and repeatable way. The end effector picks up and drops off the sample carrier at the two distinct locations—the polishing chamber and the SEM. The second controller is used as part of

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Design Notes

a kinematic mounting system located on the receiving dock inside the SEM. High-reliability stepper motors were used for the end effector and receiving dock, and were made by two different manufacturers.

Both of the AllMotion controllers used were EZHR23EN48V controllers. The fully intelligent controller+drivers measure only 2.25 by 2.25-in. and can be bolted to the back of the stepper motors they control. These EZHR23EN48V controllers use a single four-wire bus, containing two power wires and two communication wires. Simple commands are made via any serial terminal program or from the EZStepper Windows application.

Because every operation the IPrep performs occurs in a vacuum chamber, it is impossible to hear or see when things go wrong. Because of this fact, Gatan has chosen to rely entirely on sensor data—the EZHR23EN48V is pre-wired for OptoSwitch inputs—to understand if a problem has somehow occurred within the chamber, at which time workflow would need to be halted for maintenance purposes.

The main specifications for the system lie in the repeatability of placement in the SEM. 3D reconstruction only works with very low shift and rotation between placements. “Our tolerance for shift between images in the SEM (after transferring) is on the order of several nanometers,” said Thijs Hosman, Project Manager and Research Scientist for Gatan. Further, some of the shift between images can be compensated for by incorporating shift detection algorithms, but the mechanical placement accuracy still has to be on the order of 1 micron.

The tolerance for rotation is about 0.05 degrees between images. The distance between the preparation chamber and the SEM is on the order of 1 meter.

There is no doubt that making a high vacuum compatible (E-6 Torr) receiving dock with a kinematic mechanism that allows the sample to be mounted with an accuracy of <1 micron every time it is dropped off proved very tricky. Also, having a workflow that consists of tens of very specific operations that all have to be handled reliably thousands of times

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October 2017

Design Notes 10-17_Vs4.LL.indd 32

The AllMotion EZHR23EN48V controller+drivers have selectable step resolution from ½ to 1/256th step, and up to 20 million microsteps per second.

has proven to be challenging. As with any design, there were tradeoffs. For example, time versus accuracy, speed versus reliability, and, in the case of stepper motors, speed versus torque. In the latest IPrep version Gatan focused on proving that the technique was highly reliable. DW

AllMotion | allmotion.com

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Design Notes Edited by: Mike Santora • Associate Editor

3D printing lightens the load on metal tool production

Assembling an electronic component using a 3D printed fixture produced in anti-static ABS plastic on the Stratasys Fortus 900mc Production 3D Printer improves manufacturing efficiency.

Ricoh Japan is replacing traditional metal tooling with custom, lightweight 3D printed jigs and fixtures for its Production Technology Center assembly line. The tooling is printed on a Stratasys Fortus 900mc Production 3D Printer. The assembly line, located in the northeast branch of Ricoh Industries in Miyagi prefecture, Japan, is dedicated to manufacturing large-format printers.

By producing the tools in durable ABS thermoplastic on its Stratasys 3D Printer, Ricoh can customize each tool according to the part geometry while reducing the tool’s weight. This capability helps Ricoh accelerate the manufacturing process in which an operator typically handles more than 200 parts each day.

Ricoh develops and manufactures office equipment such as copiers, fax machines and projectors. Electronics industry competition led the company to look for new ways to accelerate product launches while maintaining or lowering production costs.

“Because we are producing an enormous number of parts, it takes a lot of time and effort to identify the right jigs and fixtures for each one. This manual process has become lengthier as the number of components grows, requiring that an operator to examine the

34

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Design Notes 10-17_Vs4.LL.indd 34

shape, orientation and angle of each part before taking out a tool and placing it back in its original fixture. The operators were occasionally annoyed with the many different tools, and we were looking for a way to accelerate tooling to match our manufacturing schedule,” said Taizo Sakaki, Senior Manager of Business Development at Ricoh Group. “Now we can customize the tools according to the part and produce them on demand, which is helping us restructure and modernize our production process.”

Prior to 3D printing, Ricoh outsourced machine cut tools, which could take two weeks or more. Now, Ricoh’s operators determine the shape and geometry of a fixture that corresponds to its associated part through 3D CAD software and 3D print it in one day. This leaves the workers more time to attend to other stations. Moreover, new hires can adapt to the tools and the workstations in two days when previously a new worker spent at least one week to learn all the tools.

DESIGN WORLD

9/29/17 11:57 AM

Ricoh’s 3D printed jigs and fixtures boost assembly line productivity, produced on the Stratasys Fortus 900mc Production 3D Printer using ABS plastic.

The jigs and fixtures are also much lighter so that workers can use them for a prolonged period of time without fatigue.

“The Stratasys Fortus 900mc 3D printer lets us realize designs that are difficult for conventional cutting methods to replicate, such as hollow interiors, curves or complex shapes. The material used to 3D print the tools is very strong and antistatic which is important due to the large number of electronic components we are assembling, adding to the advantages of Stratasys 3D printing,” explained Sakaki.

Ricoh’s large-format printer assembly plant has pioneered the adoption of digital manufacturing, and the company continues to explore areas where 3D printing can be applied to expedite workflows, such as molding and low-volume production– releasing more resources and expanding its scope for its diverse customer base. DW

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Ethernet switch for rugged environments

Power-over-Ethernet (PoE) technology has become popular and there are many devices that are PoE ready: PoE cameras, VoIP phones, wireless radios, and access controllers. These technologies have been widely adopted in industrial markets that include automation manufacturing, security surveillance, power/utility, water wastewater treatment plants, oil/gas/mining, and transportation industries. The LNP-2804GN-SFP-T works well in wide temperature environments that require rugged Power Source Equipment (PSE) networking equipment with high-density Ethernet port connectivity, long distance data transmission, and reliability.

The LNP-2804GN-SFP-T is a rackmount industrial Gigabit PoE+ managed Ethernet switch that offers twenty-four full Gigabit Ethernet ports with a PSE maximum of 30 W per port and four combo ports featuring four SFP fiber slots for long distance connectivity or four 10/100/1000 twisted pair ports. This product series has an IP30 rated metal casing design that can be mounted in a 19 in. rack.

The device provides a dual redundant power input range of 46 to 57 Vdc with an overload current and reverse polarity prevention, as well as high EFT surge and ESD protection. Additionally, there is a built-in relay warning

function to alert maintainers when power failures occur on one of the two power sources. Each unit is built to withstand industrial networking hazards like shock, drop, vibration, electromagnetic interference (EMI), and temperature extremes (-40°C ~ 75°C). The unit dimensions are 438 mm (W) x 259.2mm (D) x 43.6mm (H) and a unit weight of 8.37 pounds. DW

Antaira Technologies | www.antaira.com

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Internet of Things

Unmanaged 8 port gigabit switches

In each of these industrial unmanaged 8 port gigabit switches, the RJ-45 ports support 10/100/1000Mbps speeds with autonegotiation and auto-MDI-/MDX detection.

Housed in compact enclosures of 50 mm, these devices reduce the footprint of the control cabinet. They each have an operating voltage of DC 9 to 57 V and two LEDs per port for flexible and easy-to-use operations. The 8521112 economical style industrial switch is DIN rail mounted and is powered with 24 Vdc.The 852-1102 industrial switch offers dual power feeds for redundant power capabilities as well as operations over a wide voltage range and a monitoring alarm relay. DW WAGO | www.wago.us

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Internet of Things

Easier, faster setup of network backbones The EKI-9600 series are L3 managed Gigabit switches that support static routing and network address translation (NAT) features, enabling an easier and faster setup for network backbones at a lower cost.

“As connectivity demands continue to grow in the IoT era, constructing a robust network architecture has become a complex task for information and operations technology professionals,” says Frank Tseng, Product Manager at Advantech. “The new EKI-9000 series switch is designed to address the issue of growing network bandwidth requirements head-on by providing mission-critical

capabilities to help users build proper network segmentation to achieve better network performance at a lower cost.”

With the support of static routing, the EKI-9600 series can provide routing between different segmented networks, which not only helps prevent network traffic over-flooding but also maximizes the performance of each network. In addition, with NAT capability, users can better manage their IP resources, increase IP management efficiency, and further ensure network security.

The EKI-9600 series consists for two models, the EKI-9612G and the EKI-9628G. The EKI-9612G is a DIN-

rail L3 managed switch that comes with eight Gigabit ports and four SFP (miniGBIC) ports, while the EKI-9628G is a rackmount L3 managed switch offering up to 24 Gigabit ports and four Gigabit combo ports. Both models are equipped with Advantech’s Gigabit X-Ring Pro redundancy technology, which offers an ultra-high-speed recovery time of less than 20 ms, thus ensuring network stability. DW

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Internet of Things

Power over Ethernet switches

Stride PoE+ switches allow Ethernet network cables to also carry electrical power. Normally two connections are required, a network connection and a power connection. PoE reduces the time and expense of having electrical power cabling installed.

Two versions of Stride PoE+ switches are available: 10/100 Mbps and GbE. Both have one standard RJ45 Ethernet port and four PoE+ RJ45 ports (30 W on each port). Using Powered Device (PD) Detection, the PoE switch port will detect the presence of a PoE enabled device before sending power. If a non-PoE device is detected, power will not be sourced on that port but Ethernet communications will be permitted.

Power input requirements are 54-58 Vdc for PoE+ (30 watts per port) and 48-58 Vdc for PoE (15.4 watts per port). The switches provide broadcast/network storm protection and have redundant power inputs.

With IP30 metal cases, these PoE switches have a wide -40 to +75°C (-40 to +167°F) operating temperature range and are approved for HazLoc environments. The switches are DIN rail mounted and an optional panel mounting bracket is available.

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Internet of Things News

Networking all of production As part of the Industry 4.0 area at EMO 2017 trade show, HEIDENHAIN will present its Connected Machining system of production in which all work steps are networked - from the design to the deliverable component – through the company’s TNC control. It can access all order-related information in a company network, enabling efficient exchange of data. Partner companies in the areas of CAD/CAM, machine tools, tool measurement and tool management will collaborate in the demonstration.

HEIDENHAIN’s premise is that a workpiece is produced on a machine tool, so all information should be consolidated there and data on the status and quality of a workpiece must flow back into the production IT system. The machinist, who is responsible for the quality of components and for staying on schedule, needs to have access to all this data.

In the scenario to be presented, calibrated tools are already in the machine magazine, the operator having scanned a code on each tool holder when loading it, so the TNC 640 knows which cutters are available. Using the control’s Remote Desktop Manager software, the CAM system can be accessed directly, while the CAM software interrogates the tool database during program creation.

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In the Batch Process Manager, the operator schedules execution of the production job on the machine.

NC programs and the position of the clamped workpiece on the pallet are linked with respect to the order and sorted into a list according to priority.

The TNC operator can schedule several production orders simultaneously.

The control supports this by comparing the tools required to run the program

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with the cutters actually available in the machine, reporting any tools that are missing. The operator can then, for example, output a list of new tools that need to be prepared to execute the job.

Information on the estimated machining time can be used for further order planning and, together with information from the tool management system, for ordering new tools.

New StateMonitor software supports the operator, capturing data from connected machines, presenting a realtime view of machine status and sending messages to computers throughout the company as well as to mobile devices.

The software can send a message to the tool presetting station if the life of a tool is approaching a critical value. Based on stored data, new tools can be preset, a unique code added to the holder for unambiguous identification and the data sent back into the network so the CAM system and virtual machining software are able to access it.

Automatic workpiece measurement on the machine delivers important data for quality assurance, which can be archived or evaluated. The data is centrally available to all other systems, meaning that from the NC program to the tool presetting station, all links in the process chain can be optimized.

Core components of Connected Machining are the DNC interface, the Remote Desktop Manager and the StateMonitor software. The interface establishes a connection to enterprise resource planning systems and production control systems and links StateMonitor to the company network.

Remote Desktop Manager provides access to all Windows applications.

Furthermore, functions for data presentation such as viewers for PDFs and graphics files as well as for CAD files in STEP or IGES format are a standard feature. A browser is installed on the control, enabling simple Ethernet connection to a company network. DW

HEIDENHAIN CORP. | www.heidenhain.us DESIGN WORLD

9/29/17 12:36 PM

Internet of Things News

CLPA hosts

workshop at ARC Forum

ELECTRIC!

Robert Miller Director of the CLPA-Americas

Following its 15th Anniversary, the CCLink Partner Association (CLPA) was a corporate sponsor of the ARC Industry Forum 2017 in Sitges, Spain. The Forum is one of a series of annual events organized by ARC. With Industry 4.0 placing a huge emphasis on increasing the ease of communication between devices, the CLPA hosted a workshop at the Forum that explored the benefits that CC-Link IE’s gigabit Ethernet performance can bring to companies deciding their Industry 4.0 strategy.

The session included a panel discussion lead

by ARC’s analysts and participation by other industry leaders such as Hilscher, Mitsubishi Electric and the OPC Foundation.

CLPA-Europe general manager John Browett commented, “Implementing Industry 4.0 capabilities is one of the main challenges facing automation manufacturing companies today.

The CLPA believes that because of its unmatched gigabit bandwidth, CC-Link IE is a natural choice to deliver the necessary open network performance and capacity to these applications.

We were pleased to be able to communicate this message to the industry leaders facing these challenges and hold high level discussions on how our technology can help. DW

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CAE Solutions

The merging of design and manufacturing Additive manufacturing, the Internet of Things, and other technologies are smashing through the wall that used to separate design and manufacturing. A number of programs being launched this year promise to merge design and manufacturing into one function.

One of those programs is SOLIDWORKS 2018, which includes new tools and enhancements to help

engineers get their designs to manufacturing faster. The user interface, for example, lets engineers use a pen or their finger on the touch screen rather than a mouse to design objects. This more natural approach can speed up design.

CAMWorks lets users integrate design and manufacturing through its rules-based machining and automatic feature recognition.

SOLIDWORKS 2018 includes tab and slot features for self-fixturing of parts for welding and tools to easily create or flatten corners that include three bends.

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SOLIDWORKS CAM for CNC machining CAMWorks, now part of SOLIDWORKS CAM, lets users seamlessly integrate design and manufacturing. It has rules-based machining and automatic feature recognition to streamline and even automate CNC manufacturing operations.

Mesh data Engineers can work with mesh data similar to how they work with surface or solid geometry. Combine, intersect, split, move/copy, cut with surface, and check for interference. In addition, quickly fit surface bodies to regions of mesh models.

More flexibility with 3D Interconnect Users can seamlessly work with such file formats as ACIS, STEP and IGES, and automatically update designs whenever new files are received. In addition, 3D Interconnect now supports internal file information like custom properties, materials properties and reference axes.

Refined sheet metal design tools SOLIDWORKS 2018 includes tab and slot features for self-fixturing of parts for welding, a normal cut feature to ensure clearances are included for manufacturing, and tools to easily create or flatten corners that include three bends.

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Efficient collaboration Speed up design detailing while also streamlining and automating downstream manufacturing tasks, such as CNC programming and inspection, by importing 3D models along with PMI from all major CAD formats, as well as STEP 242.

Electrical routing Routing is fast with greater detail Users can drag and drop in-line connectors and support shrink- wraps and boots. Users can also flatten a route in drawing with support for clips and disjointed routes.

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CAE Solutions

Generative design for better part geometry The SOLIDWORKS Simulation Topology Study tool can help users automatically optimize the shape of a design based on weight, function, and manufacturing criteria. This features takes into account simulation data and manufacturing constraints.

SOLIDWORKS inspection support for MBD Users can create inspection documentation directly from 3D models with Production Manufacturing Information, as well as from 2D drawings, PDFs, and TIFFs. SOLIDWORKS Inspection is now integrated with SOLIDWORKS PDM, and supports SOLIDWORKS part and assembly files (*.sldprt, *.sldasm), as well as non-native 3D CAD formats.

Project and process management SOLIDWORKS Manage provides data management, project management, and process management all in one package. It adds powerful project, process, and item management capabilities to SOLIDWORKS PDM Professional.

Design branching and merging Users can investigate different design approaches without affecting approved files with the new features in SOLIDWORKS PDM. The software also helps to streamline the process of working with external users.

Automated PDF creation for SOLIDWORKS drawings SOLIDWORKS PDM Standard can automatically create PDFs from SOLIDWORKS drawings through workflow transitions. This feature eliminates the manual creation of PDFs.

The SOLIDWORKS Simulation Topology Study tool can help users optimize a design based on weight, function, and manufacturing criteria.

Create inspection documentation directly from 3D models with Production Manufacturing Information. This program also lets users create documentation from 2D drawings, PDFs, and TIFFs.

Automatic revision table update SOLIDWORKS PDM manages and automatically updates SOLIDWORKS revision tables.

Cloud-connected SOLIDWORKS Empower desktop computers with cloud convenience through online licensing. SOLIDWORKS Online Licensing makes using your license on multiple machines effortless. The SOLIDWORKS login moves custom content and settings to any machine on which SOLIDWORKS is installed. The SOLIDWORKS Admin Portal allows easier management of SOLIDWORKS products and services. DW

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Software helps you design cool

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Thermal issues are at the root of many product failures in electronics designs. Modern products are more complex, smaller, require more power, and operate in more extreme environments. The more complex the design, the greater the thermal strain on the components.

Sherlock Automated Design Analysis software uses a Physics of Failure approach to indicate when thermal temperatures are too hot for integrated circuits and solder joints. The thermal-analysis feature helps users quickly run thermal-mechanical analyses, eliminating timeconsuming data-entry.

Users can explore options to reduce thermal issues, including changing component type, material parameters, and or layout to minimize loads during thermal expansion. Understanding the interaction of mounting points and components during thermal expansion assures a more reliable PCB layout under thermal-mechanical stresses.

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ca i r e m A 3 4. n i e d a ince 19 m Y s VER

The software captures system-level effects on solder joint reliability during temperature cycling. Examples of system-level effects include:

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M o t i o n

C o n t r o l

Using a dedicated pulse control LSI vs. a CPU for motion control

Pulse control LSIs specialize in motion control, and feature high operational reliability.

Jerame Chamberlain | Nippon Pulse

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In motion control, acceleration and deceleration are central to the move profiles used to control a motor. Good acceleration and deceleration control ensures quick

For instance, consider a basic tin-can stepper motor tasked with moving a heavy load. If the expectation is that the stepper will be able to generate enough force to move the load at a high speed right out of the gate, it will not be able to perform that movement and will fall out of step. This would be akin to trying to start a carâ&#x20AC;&#x2122;s manual transmission in fifth gear. What happens instead is that the car starts in first gear, then slowly works its way up to fifth gear.

Similarly, in order to move a heavy load with a small, standard motor, the speed must be ramped up slowly.

Likewise, if a heavy load is moving at a fast speed, inertia prevents it from stopping instantaneously. The load must slow down before coming to a stop from the slower speed.

If the deceleration is too quick, it can cause damage to equipment or the workpiece due to impact or shock.

There are several types of acceleration/deceleration movements that are commonly used in motion control. Linear acceleration/deceleration is the simplest to generate, but there is a jolt at the beginning and end of any speed changes. Using S-curve acceleration/deceleration is gentler and there is less impact to the load when changing speeds. Linear and S-curve motion profiles can be used in tandem to provide less shock to the load while lessening the

Motion Control 10-17_Vs3_MB.LL.indd 51

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

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| istockphoto.com

and accurate positioning, and fast settling without damaging equipment or materials.

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M o t i o n

C o n t r o l

Developing software for a CPU can also be labor-intensive, and the features and performance of the CPU may determine by how much the pulse cycle can be shortened. demand on the motor. For delicate loads such as semiconductor wafers or electronic chips, S-curve acceleration/deceleration helps mitigate the risk of damage.

What is a pulse control LSI/ASIC chip?

To operate any motor, what’s needed is a device or circuit that produces a speed and direction signal. In many cases, a CPU or FPGA device is used to create movement, because technically these devices can be programmed to generate pulses. However, no serious engineer should consider using these for important motion control applications, unless they are okay with a “good enough” mentality when it comes to their application’s movement.

Another option is to use an LSI (large-scale integration) pulse control IC. A pulse control LSI is a dedicated chip that’s specialized for motor control.

Manufacturers have different names for these kinds of controllers – motion control IC, motor control LSI, pulse generator, ASIC chip, etc. – but they are all essentially the same thing. Using a convenient motion control-specific tool like a pulse control LSI makes it easy to design programs.

Choosing a pulse control LSI lets engineers easily write setting data and

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techno

10/3/17 9:49 AM

M o t i o n

The flowchart shows the steps in the pulse control LSI programming development process.

C o n t r o l

This graph of linear acceleration/deceleration shows that every time speed changes, the motor “jerks” because the motion profile is not smooth.

commands for both linear and S-curve acceleration/deceleration without overloading the CPU. When CPU and engineering resource costs, ease of use, and speed of development are considered, the end user benefits greatly from the specialized motion control option.

Is pulse control with a CPU difficult?

Creating pulse signals only using a CPU has a few drawbacks. For starters, one has to create a program that uses counters or timers to turn the port on and off. It’s easy to control at a constant frequency, but it can be quite troublesome to create a program that features a constantly changing acceleration/ deceleration rate. An inexpensive CPU is also easily burdened by processing motion control demands, so it will have a hard time performing other commands simultaneously.

This means that a high-performance CPU would be necessary for even basic linear acceleration/deceleration.

As speed increases, the pulse period becomes shorter. There are two general

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With an S-curve acceleration/deceleration motion profile, the transition points are curved resulting in smoother motion.

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M o t i o n

C o n t r o l

Nippon Pulse’s PCD46x1A series is ideal for engineers that worry that pulse control LSIs are too expensive compared to just a CPU for their motion control applications. The PCD46x1A series features three chips ranging from single axis to 4-axis control. They’re suitable for engineers who haven’t used pulse control LSIs before, and for those who need basic, uncomplicated motion control functions.

Using the interrupt method of stair-step acceleration raises a lot of factors to consider.

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methods of acceleration/deceleration: 1) using a CPU to gradually shorten the pulse period, which is taxing for the CPU, or 2) using the interrupt method of stair-step acceleration/ deceleration.

When using a CPU to shorten the pulse period, there are lots of factors to consider: How many pulses should be output in total?

At what point does the motor need to start decelerating? If decelerated to the initial speed (FL speed), can it be stopped exactly there? Since the current position cannot be managed by setting only the number of pulses to be outputted, is an absolute value counter also necessary? If the motor and/or controller can be forcibly stopped with a signal from the outside, what should be done with that signal processing?

Developing software for a CPU can also be labor-intensive, and the features and performance of the CPU may determine by how much the pulse cycle can be shortened.

Development of the acceleration/ deceleration programs is much easier with a pulse control LSI. There is an easy flow from the beginning of the program to the completed operation. Not only can one easily program linear and S-curve acceleration/deceleration,

A pulse control LSI, also known as a motion control IC, motor control LSI, pulse generator, or ASIC chip, is a dedicated chip that’s specialized for motion control.

DESIGN WORLD

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M o t i o n

C o n t r o l

but determining current positioning is easier thanks to the up/down counter values.

Because the CPU is able to leave the LSI unmonitored, the LSI transmits an interrupt signal to the CPU when the operation is completed. An external dedicated terminal can also forcibly stop a pulse control LSI if necessary.

The hours required for development are greatly decreased, and high-frequency output pulses are possible regardless of the CPUâ&#x20AC;&#x2122;s speed because the chips are not burdened by the CPUâ&#x20AC;&#x2122;s speed or capability limitations. Pulse control LSIs specialize in motion control, so they have high operational reliability. DW Nippon Pulse | www.nipponpulse.com WHAT DO YOU THINK?

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Shorten the cycle little by little.

Shortening the cycle time gradually is one method of deceleration.

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DESIGN WORLD

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Servomotor .... .. couplings: Stiffness, damping, hunting, and stabilization considerations Here we address considerations when specifying a servomotor coupling to satisfy servo requirements â&#x20AC;&#x201D; ever-evolving conditions that become more demanding all the time.

Tetsuya Niwa | Director of product planning and development Kei Yamada | Product Manager â&#x20AC;&#x201D; Product planning and development Hiroki Goto | Engineering specialist Paulo Castelo | Technical solutions supervisor NBK America

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Flexible couplings fasten machine drive shafts and transmit torque while allowing for multiple forms of misalignment such as lateral, angular, and axial. Various flexiblecoupling types have been developed to satisfy application demands.

Case in point: Couplings used in servo systems with feedback mechanisms are often

selected for their static torsional stiffness and backlash-free features — integral requirements for high-precision and high-speed applications. Here, design engineers often select disc couplings for their static torsional-stiffness. But new technological improvements in servomotors have spurred dramatic improvement in speed response frequency. The catch is that vibration (also called hunting) tends to arise when designers apply increased gain settings to servo systems and use high-static-torsional-stiffness couplings such as disc or bellows-type couplings.

Semiconductor, robotics, medical, automation, and other precision-machinery industries use equipment with the latest servomotor technology possible to satisfy performance criteria. But as gain settings increase, precision accuracy and speed are critical ... and coupling technology must advance to ensure peak servo system performance.

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Ideally, axes that pair servomotors and ball screws move in exact accordance with servomotor commands. But realworld setups often take time to stabilize after each move. Couplings address this issue with high gain ... and some address hunting as well.

Torsional rigidity of the entire system

Disc coupling

Torsional rigidity of coupling: Kc (N·m/rad) Ball screw groove diameter in mm

450

High-gain rubber coupling 240

7.8

7.8

Support bearing - Nut distance (mm) Torsional rigidity of ball screw Kbs in N·m/rad Torsional rigidity of entire system K in N·m/rad

300 96

300 96

79

68

Torsional rigidity of the entire system is 1/K = 1/Kc + 1/Kbs.

Shown left to right here are disc type, bellows type, and high-gain rubber type couplings. Design engineers tend to use disc couplings for their static torsionalstiffness. But hunting tends to arise when gain settings are applied to servo systems that use high static torsional stiffness couplings such disc or bellows types.

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One way to resolve hunting in servo systems under high gain settings is to use couplings with vibration-damping technology. As we’ll explore, high-gain rubber couplings in particular excel in servo systems for semiconductor-manufacturing equipment and other precision automation — which are systems that need to have high response.

Stabilization time — and its effect on productivity Integrated damping in couplings can dramatically reduce stabilization time — and that in turn increases machine-axis speed and general productivity.

Just consider the interplay between a feed-screw machine, ball screw, and servomotor system. Ideally, axes that pair servomotors and ball screws move in exact accordance with servomotor commands.

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But real-world setups often delay execution of commands — a factor in errant positioning called stabilization time.

Higher servomotor gain and highresponse operation are needed to minimize stabilization time — but substantial gain increases actually spur the counterproductive phenomenon of hunting. This hunting effectively distorts machine-operating equilibrium and hampers servomotor control. So increasing gain while suppressing hunting requires systematic adjustments to servomotor parameters — including mechanical coupling characteristics.

Tests show when a servomotor drives a design through a disc or bellows coupling, raising the gain tends to readily cause hunting. So here, the conventional approach is to switch to a coupling with higher torsional stiffness as a way to boost the entire rotating axis’ rigidity. However, whole-system DESIGN WORLD

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torsional rigidity depends on torsional rigidity of the ball screw.

The table in this feature titled, “Torsional rigidity of the entire system” shows calculated torsional-rigidity values for a complete example system incorporating various couplings. The torsional-rigidity value of the disc coupling in this example setup is 450 N·m/rad compared to a high-gain rubber type coupling value of 240 N·m/rad. Only examining these values, one would conclude that disc couplings have 1.9 times higher torsional-stiffness values. In fact, total-system torsional rigidity is 79 N·m/rad for the former and 68 N.m/rad for the latter — so the actual difference is only about 1.2 times.

In fact, the torsional rigidity of the ball screw is the more dominant determining factor affecting system torsional rigidity — not the coupling.

That means simply changing the coupling to one with inherently higher torsional stiffness values may insufficiently improve system torsional rigidity ... and may not protect against hunting, either. But technical advancements in servomotors (especially in response-frequency speed) have increased the need for vibration damping (as a way to avoid hunting). Ultimately, vibration damping plus adequate torsional stiffness allows for accurate position repeatability — especially useful on axes for positioning.

In fact, we conducted extensive tests to verify the relationship between a coupling’s static torsional stiffness and the positioning repeatability of an actuator.

The testing methodology we detail in this feature adheres to JIS B 6192 protocols; the testing equipment included three different coupling types from the manufacturer.

Stop-position accuracy was measured seven times. Then spreads between maximum and minimum values were calculated and respective values compared and reported in test results. Refer to the charts that accompany this feature for those. The origin of position is set at both the center and edge for the maximum-range linear stroke.

Maximum values as testing parameters are expressed as ± values.

Notice from the test results that static

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Equipment in test setup

Part numbers

Manufacturer

Note

Actuator

KR30H

THK

Positioning repeatability to ±0.005 mm Position accuracy to 0.1 mm

Motor

HF-KP013

Mitsubishi Electric

XGT-25C-6×8

NBK

XBW-25C2-6×8

NBK

MJT-20C-RD-6×8 NBK XL-80

RENISHAW

torsional stiffness doesn’t gravely impact positioning repeatability on actuators. In fact, the sub-micrometer variations that we reference in our results likely arise from the actuator’s precision limitations.

High-gain rubber coupling construction High-gain rubber couplings — those with hydrogenated nitrile butyl rubber (HNBR) — have an integrated structure that includes aluminum hubs on both sides molded with a vibration-reduction rubber that prevents backlash — yet remains flexible. An internal claw-like structure lined with HNBR optimizes torsional rigidity and damping.

Bode plots illustrate why high-gain rubber couplings increase servomotor gain well beyond the capacity of comparable disc couplings with higher torsional stiffness values. Gain width between 0 dB and the point at which there’s a phase delay in the Bode plot is -180° — and this is called the gain margin. General guidelines for servo systems recommend gain margins between 10 and 20 dB. As the servomotor gain is

Testing conditions for one motion axis Motor speed

3,000 rpm

Acceleration deceleration

50 msec

Positioning location

20, 170, 350 mm

Loaded object

3 kg

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SERVOSYSTEMS DEMAND EVER-HIGHER RESPONSE SPEED RESPONSE FREQUENCY (HZ)

Laser displacement sensors

Here are some industry changes in servomotor speed response frequency. Note that these are based on a survey of servomotor-speed response frequencies listed in manufacturers’ catalog values.

STABILIZATION TIME FOR SERVOSYSTEM

MOTOR REVOLUTION

Coupling

Static torsional stiffness: 170 Nm/rad Static torsional stiffness: 850 Nm/rad Static torsional stiffness: 55 Nm/rad

ACTUAL POSITION

COMMANDED POSITION

COMMAND TIME TO REACH STOP POSITION

STABILIZATION

COMMAND TIME TO REACH ACTUAL STOP POSITION

This plot illustrates the difference between commanded and actual axis position.

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The test equipment detailed in this feature used NBK America XGT high-gain rubbertype couplings; XBW disc-type couplings; and flexible couplings from a discontinued line of MJT products.

Accuracy of stop position was measured seven times.

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increased, gain margin decreases. When the gain margin falls below 10 dB, hunting tends to occur.

Compare the limit gain (which is the servo gain at which hunting occurs) of the disc-type coupling to the gain margin of the high-gain rubber-type coupling. Notice that the high-gain rubber-type coupling at 17.40 dB surpasses the disc-type coupling’s 9.90 dB value. Because the gain margin is above 10 dB, the servomotor gain of the high-gain rubber type can exceed that for the disc coupling — thus shortening stabilization time and increasing throughput.

The table titled, “Difference in stabilization time according to coupling type and servomotor gain” which can be found online at couplingtips.com (by searching on “Kei Yamada” and NBK) shows stabilization-time deviations by coupling type and servomotor gain. If servomotor

Here is how the test installation we detail in this feature was setup.

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BODE PLOTS OF THE SYSTEM BODE PLOTS OF THE SYSTEM

M o t i o n

HIGH

gains are equal, there’s no difference in the stabilization time due to the difference in couplings. However, when comparing the servomotor limit gain, stabilization time is 12 msec for the disc-type limit gain (25) and 3 msec for the high-gain rubber-type limit gain (32). High-gain rubber types that suppresses hunting and improve servomotor gain more effectively minimize stabilization time.

We performed additional testing on an actual system including an axis running off a ball screw with a shaft diameter of 15 mm and a 100-W servomotor. The test was run with the motor at 3,000 rpm; the acceleration and deceleration time was 50 msec; workpiece load was 3.0 kg; and the ratio of moment of inertia of load: 3.5. Refer to the tables for specific results.

In short, rubber has durability ... and rubber as a subcomponent in couplings

DISC TYPE

LOW

HIGH-GAIN RUBBER TYPE

These are Bode plots of the system with different couplings. Note how the high-gain rubber couplings have a larger gain margin than the disc-type couplings. This allows for higher servomotor gain settings. The disc-type couplings have a comparatively smaller gain margin that increases the risk of hunting.

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HIGH-GAIN RESPONSE

LOW-GAIN RESPONSE

TIME (MSEC)

This diagram shows time required for axis stabilization with changes in that value due to gain.

RESULTS AFTER 108 TESTS

ANGLE (RAD)

RESPONSE WITH HIGH-GAIN RUBBER COUPLING AND DISC-TYPE COUPLING DISC TYPE

ACCELERATION (M/SEC2)

HIGH-GAIN RUBBER TYPE

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

ANGLE (RAD)

These are the results of 108 drive tests. In short, rubber has durability ... there’s no degradation of performance due to deterioration in couplings that include the material. Plus rubber in couplings effectively imparts damping properties.

NBK America | nbk1560.com/en-us

WHAT DO YOU THINK?

AFTER

BEFORE TORQUE (N·m)

effectively imparts damping properties. Data on the material’s durability has accumulated since the advent of high-gain couplings in 2007. Plots of torque versus angle show that even after 108 drive tests, there’s no degradation of performance due to rubber deterioration in couplings that include the material.

Know that in the future, servomotors will need ever-higher frequency response — along with demand for higher precision and higher speed. So industry will continue demanding coupling technology that melds high torsional rigidity and high-level damping properties to maintain peak servosystem performance.

For more information — including actual exported results from coupling tests detailed in this feature — visit couplingtips.com and search on “Kei Yamada” and NBK. Also refer to Atsushi Matsubara’s 2008 piece, “Design and Control of Precision Positioning and Feed Drive Systems” and Nabeya Bi-tech Kaisha technical data in the 2017 NBK General Catalog. DW

COMMANDED POSITION

TORQUE (N·m)

This is the internal structure of high-gain rubber type coupling.

MOTOR SPEED (RPM)

STABILIZATION TIME t₁ (HIGH GAIN) AND t₂ (LOW GAIN)

TIME (SEC)

TIME (SEC)

This is a performance comparison of two leading servocoupling types.

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small and mid-size companies need cad too Small to medium-sized companies are adopting CAD and other engineering technologies to bring new innovations to market and, in some cases, to found entirely new market sectors.

Jean Thilmany | Contributing Editor

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Zipline used CAD to design autonomous drones that deliver medical supplies up to four miles to reach remote villages in developing and war-torn countries. It uses Siemens products to design and simulate the drone’s mechanical features as well as its electrical and software systems and to tie them all together into a complete virtual product. | Courtesy of Zipline

| Courtesy of Hall Designs

| Courtesy of Kimball International

While small and medium-sized companies (SMBs) may employ only a handful of engineers, they’re demanding access to the same engineering software tools, including CAD and analysis systems, their larger counterparts rely upon.

And SMBs are using these systems for more than product design and analysis. The changing marketplace and the increasing adoption of the industrial internet of things (IIoT) demand new ways to use already-established engineering technologies, says Bob Jones, Siemens executive vice president of global sales, marketing, and services.

The tools are also needed to keep up with ever increasing time to market speeds as well as the integration of mechanical, electrical, and software components within products that even a few years ago were considered strictly mechanical, says Ricardo Espinosa, research and development engineering manager at medium-sized furniture-maker Kimball International of Jasper, Ind.

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Hall Designs relies on CAD to help design components for trophy trucks. The trucks are off-road racing vehicles. | Courtesy of Hall Designs

The company’s leaders hope to eventually use CAD and other engineering technology to create chairs customized to—pardon the pun—mold exactly to your unique seat, Espinosa says.

Kimball began its business using mostly paper, and two-dimensional engineering processes, he adds.

But companies smaller and less established than Kimball are using

engineering tools from the get-go to create entirely new markets, Jones says.

Take the example of Zipline, which has designed autonomous drones that deliver medical supplies up to four miles to reach remote villages in developing and war-torn countries. These places are hard to reach by vehicle, Jones says.

“The Zipline drones can deliver medical supplies to an area in 15 minutes rather than

the four hours it would take for trucks to get there,” Jones says.

The 60-employee company headquartered in Half Moon Bay, Calif., uses Siemens products to design and simulate the drone’s mechanical features as well as its electrical and software systems and to tie them all together into a complete virtual product.

Engineers use analysis software to simulate how the drone would perform under certain

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Craig Hall, who founded Hall Designs three years ago, says his business wouldn’t be possible without use of CAD. conditions and—if they find performance wouldn’t be up to par—they make needed design adjustments before simulating again.

All this is done before the first physical prototype is made.

The company is now at work on methods to extend drones’ battery life, so they can travel more than 46 miles without requiring a recharge, Jones says.

“Zipline is disrupting its industry and engineering digitalization is driving that disruption,” he adds. “The size of company doesn’t dictate type of problems they’re solving.”

Or take the example of the classic SMB--with only a few employees—able to enter the marketplace thanks to affordable engineering software.

Craig Hall, who founded Hall Designs three years ago, says his business wouldn’t be possible without use of CAD, which he relies on to help design components for trophy trucks. The trucks are off-road racing vehicles. Hall has competed in and even won some of these races.

The CAD technology, in this case Solid Edge, allows him to import and directly edit customers’ and suppliers’ files, adjust them, and make changes in seconds, he says.

Hall often needs to design and deliver new and revised components within the

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six-to-ten week window customers have between races. Speedy design and revision is important because fabricating the components themselves might take four weeks, Hall says.

“With Solid Edge, you can provide the customer with a 3-D model of the chasis and the suspension moving and they can view it and rotate it and get a real-time view into what the part will look like without the customer having to spend any money to get a prototype part,” Hall says. “To have that finished part done in time for that next event is huge.”

After 20 years spent working at a fabrication business and shop job, opening his own custom design shop was “very scary,” Hall admits. “That cuts my time spent recreating those parts by hundreds of hours,” Hall says. “I want to get that done at work so I can separate my work life from my home life.”

Fashionable Furniture Though Kimball employs 80 engineers, much more than Hall or Zipline, the alreadyestablished company turns to engineering software to keep up with the needs of a quick-changing industry, Espinosa says.

Ironically, though there’s a slim chance you have a piece of Kimball furniture in your home, odds are quite high you’ve sat on one of their chairs or worked at one of their desks within the past month, even the past week. You may even be reading this from the luxury of one of those chairs.

The company produces furnishings across several product lines. Its furnishings are sold under three brands: Kimball Office, National Office Furniture, and Kimball Hospitality. The latter encompasses hotel and motel furniture. The company also designs and manufactures special orders for nonstandard furnishings not available in its catalogs.

Espinosa is responsible for Kimball’s “digital strategy,” that is, the way it calls upon engineering software now and in the future to drive revenue and growth.

In addition to the 80 Solid Edge CAD users, about 200 other employees have access to pertinent engineering software to track engineering and process changes and to help with finance and marketing.

“In the past we’ve had to do a lot of manual work and repeat the same thing over and over with physical testing to get where we want,” Espinosa says. “Now we’re digital

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and we’ll be even more so in the future, so we don’t have to keep repeating everything and can shorten time-to-market.”

“We’re not doing digital because we like it but because the market is taking us there,” Espinosa says frankly.

Like other industries, institutional furniture has undergone many changes in the past decade. For example, the desks and lamps in hotel rooms often include electrical components into which users can plug their laptops. Hotel guests have driven demand for the integration, which is harder for furniture-makers to pull off than the straightforward-looking furnishing implies, he says.

Keeping on top of market trends also plays a role in Espinosa’s digital strategy, he adds.

Like other industries where the fashion is a passion, furnishings must be redesigned quickly to keep up with changes in the

marketplace or risk looking outdated, Espinosa says.

“As soon as we finish a product and distribute it we have to create a new one because innovations by our competitors, designers and architectures are moving really fast,” he says.

The Future of Sitting In the late 1990s, Kimball primarily relied on manual methods and a two-dimensional design system to design, track, and build furniture. At the time, product life was 10 years, meaning a piece of furniture engineers had spent two or three years designing could be sold for 10 years, Espinosa says.

By 2020, product life will be around three years with time to develop that product around three months, Espinosa says. By then, the company will have a fully digital engineering process.

The company implemented Solid Edge around 14 years ago. After tracking engineering and process changes through back-and-forth emails, Kimball next integrated CAD with Teamcenter, Siemens PLM software.

Teamcenter offers daily, monthly, and yearly views into engineering processes and design projects.

The program allows the company to revise and track its offerings and offer its clients a mind-boggling array of furnishings customized to their needs, by fabric, color, and construction.

Kimball still produces one physical prototype producing a furniture model.

The prototype is necessary to meet the regulatory standards set by BIFMA, the trade association for business and institutional furniture manufacturers, he adds.

In the near future, Espinosa expects the company will be able to further customize its

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furniture—perhaps right down to the seat—and include more software and electronics into its lines. Currently, the company uses 3D scanning methods to scan people. The digital data helps engineers design for ergonomics, Espinosa says.

“But we envision customized chairs; like today you’d go to a tailor to get a custom suit made,” he adds. “This will be the future of sitting: to capture a person’s body shape and weights and create such a chair.”

Customers might even be able to use a cell-phone app to scan themselves and to automatically transfer that data to Kimball, he adds.

“Our digitalization strategy will help us get to the customizable chair,” Espinosa says. “We’ll be able to put that scan information directly into Solid Edge and go to 3D printing or another technology to create models and parts.”

Future plans also call for the sensors that drive IIoT to be incorporated into Kimball offerings. Through sensor feedback, your chair will send you notification that you’ve been sitting too long, for example, to get up and move, he adds.

IIoT feedback could also be used to automatically adjust levers that raise and lower the height of the furniture, Espinosa says.

The sensors could determine and then remember the desk height, tilt, and other specifications. For those who share offices, their desk, chair, and other furniture would automatically adjust to their specifications the minute the person appeared in the office, he adds.

Far from remaining stagnant, SMBs are creating whole new industries and redefining already-existing industries.

Engineering tools, including CAD, allow small business owners to go out on their own, to explore innovations, and to keep up with their larger competitors, Jones says.

Perhaps your office chair will thank you for these innovations and the technology that aids them, in just a few years. DW

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Optimizing battery performance in extreme temperatures Sol Jacobs | VP and General Manager | Tadiran Batteries

Demand for industrial grade primary lithium and rechargeable lithium batteries continues to grow. Even though such batteries use nearly identical in chemistry, quality differences exist that will affect product design. Here are factors to keep in mind to maximize long-term lithium battery performance.

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E n v i r o n m e n t s

Side-by-side comparison

As anyone who drives in the winter knows, the typical batteries function best at

room temperature, as cold temperatures increase the internal

of a miniaturized hybrid lithium pack designed for use in a GPS/ice buoy. The original battery pack (left) was made of 380 alkaline D-size cells (54 kg) while the hybrid LiSOCl2 battery pack (right) uses just 32 D-size lithium thionyl chloride cells and 4 hybrid layered capacitors (3.2 kg).

resistance and reduce the available capacity and the voltage.

This is why a lead acid car battery that provides 100% of its capacity at 27°C (80°F) will deliver only 50% of its capacity at –18°C (0°F). Alkaline batteries also use a water-based electrolyte that can freeze.

Similarly, consumer grade Lithium-ion (Li-ion) batteries perform optimally at 20°C (68°F). If charged and discharged at 45°C (113°F), their cycle life is cut in half. Consumer grade Liion batteries also face degraded performance at temperatures below 0°C, with no ability to be discharged or recharged at very low temperatures.

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Exposure to extreme temperatures reduces both battery life and voltage under pulse.

Meanwhile, the advent of the Industrial Internet of Things (IIoT) has created dynamic opportunities for industrial grade battery-powered remote wireless devices to find their way into virtually every industrial sector, from smart infrastructure to smart agriculture, environmental monitoring, asset tracking, machine-to-machine (M2M) and system control and data automation (SCADA) applications, to name a few.

Self-powered wireless devices can prove highly cost effective for these industrial applications by eliminating all the labor,

logistical, and regulatory expenses associated with installing a hard-wired device, which can cost upwards of $100 or more per foot, or far more in remote hardto-access and environmentally sensitive locations.

Downsizing without compromising Exposure to extreme temperatures reduces both battery life and voltage under pulse.

If a wireless device is to be deployed in an extreme environment, the historic tendency has been to specify an oversized

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battery to compensate for expected capacity losses. However, this approach defeats the purpose of product miniaturization and adds unwarranted expense, which is becoming a greater issue in light of increasingly restrictive UN and IATA battery transport regulations.

Designing a miniaturized remote wireless device requires a compact and lightweight power source. Reducing size and weight increases the productivity of people working in remote places, from utility linemen who have to carry line fault sensors up and down

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Bobbin-type LiSOCl2 batteries also feature the widest temperature range of all commercially available chemistries (-55°C to 125°C) and can be modified for use in the cold chain, where frozen tissue samples, transplant organs, drugs and pharmaceuticals must be continually monitored at -80°C.

utility poles, to simplifying the transport of scientific instruments designed to monitor ice flows in the Arctic.

The vast majority of remote industrial wireless devices are powered by 3.6 V bobbintype lithium thionyl chloride (LiSOCl2) batteries that feature high capacity and high energy density to support product miniaturization, as twice as many 1.5 V cells are required to deliver the same voltage as a single 3.6 V cell.

Bobbin-type LiSOCl2 batteries also feature the widest temperature range of all commercially available chemistries (-55°C to 125°C) and can be modified for use in the cold chain, where frozen tissue samples, transplant organs, drugs and pharmaceuticals must be continually monitored at -80°C. Bobbin-type LiSOCl2 batteries can also handle extreme heat, making them ideal for use in medical asset tracking RFID devices that need to withstand autoclave sterilization temperatures of up to 125°C without having to remove the battery.

Bobbin-type LiSOCl2 cells also feature a very low annual self-discharge rate of less than 1% per year, thus permitting the battery to last as long as the device.

How a battery is manufactured and the quality of the raw materials can strongly influence its annual self-discharge. For example, the highest quality bobbin-type LiSOCl2 battery features a self-discharge rate as low as 0.7% per year at ambient temperature, thus able to retain over 70% of its original capacity after 40 years. By contrast, a lower grade LiSOCl2 battery can have a self-discharge rate as high as 3% per year, thus losing 30% of its capacity every 10 years, making 40-year battery life unachievable, especially at extreme temperatures.

Wireless communications and the IIoT The IIoT has created fast-growing demand for remote wireless devices capable of delivering high pulses to power two-way

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A standard bobbin-type LiSOCl2 battery can be modified to deliver periodic high pulses with the addition of a patented Hybrid Layer Capacitor (HLC).

communications and remote shut-off capabilities.

Standard bobbin-type LiSOCl2 batteries are not designed to deliver periodic high pulses, as they can experience a temporary drop in voltage when first subjected to this type of pulsed load: a phenomenon known as transient minimum voltage (TMV).

To overcome this challenge, a standard bobbin-type LiSOCl2 battery can be modified to deliver periodic high pulses with the addition of a patented Hybrid Layer Capacitor (HLC). The bobbintype LiSOCl2 battery and the HLC work in parallel, with the standard battery supplying background current in the 3.6 to 3.9 V nominal range, while the single-unit HLC works like a rechargeable battery to store and deliver high pulses. As an added bonus, the HLC features a unique end-oflife plateau in its voltage curve that can be interpreted to issue ‘low battery’ status alerts.

Supercapacitors can also be used to store high pulses. While popular for use in consumer devices, supercapacitors are ill-suited to most industrial applications due to drawbacks such as bulkiness, high self-discharge rates of up to 60% per year, and a limited temperature range. Power supplies that use multiple supercapacitors also require balancing circuits, which draws additional energy and adds to the expense.

Consumer alkaline batteries can deliver high pulses, but cannot support long-term deployments due to their low voltage (1.5 V), limited temperature range (-0°C to 60°C), and a very high self-discharge rate that reduces their life expectancy to months, not years.

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Energy harvesting demands industrial grade rechargeable Li-ion batteries A growing number of remote wireless applications are being deployed using energy harvesting technology to extract energy from solar, wind, thermal, motion, and RF/EM signals, with the harvested energy being stored in rechargeable Lithium-ion (Li-ion) batteries.

Consumer grade Li-ion cells have major drawbacks for industrial applications, including a limited temperature range, an inability to deliver high pulses required for advanced two-way communications, and a limited lifespan of approximately 5 years and 500 full recharge cycles. If the wireless device needs to operate beyond 500 recharge cycles, then additional cells may be required to reduce the average depth of discharge per cell, which adds cost and bulkiness.

Fortunately, an industrial grade rechargeable Li-ion battery has been developed that can deliver up to 20-year battery life with up to 5,000 full recharge cycles. These robust batteries feature an extended temperature range of -40°C to 85°C, including the ability to be recharged and discharged at very cold temperatures.

Industrial grade Li-ion cells can also deliver the high pulses required for advanced twoway wireless communications.

grade primary lithium and rechargeable lithium batteries. Each application is unique, so design engineers need to be careful about specifying the right battery, mindful that major quality differences can exist between competing batteries produced using virtually the identical chemistry. Careful due diligence is required throughout the battery specification process to maximize long-term performance and reliability while reducing the total cost of ownership. DW Tadiran | www.tadiranbat.com

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The gravity ofprecise boom control

Recent changes in valve technology have allowed engineers to drastically improve the operator’s control of a telehandler boom—and the efficiency of the overall hydraulic system in the process.

Eko Prasetiawan | Chief Hydraulics Engineer | JLG Industries Inc.

Telescopic handler (telehandler) operators have been searching for a solution that would give precise boom control when paired with a boom suspension (ride control) system.

Traditional load hold valves have limitations due to high pilot pressure requirements and techniques used to improve stability—such as pilot damping schemes—that interfere with precise control for machines equipped with a ride control accumulator.

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JLG launched the 1644 telehandler at IFPE this year. It offers a 15,600 lb lift capacity and is one of the first to showcase JLG’s precision gravity and SmartLoad technology systems. | Courtesy of JLG Industries, Inc.

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With the demand for machines to be more productive and energy efficient, gravity lowering allows for increased speeds and precise movements.

A few of the challenges encountered with previous technologies include:

• Delayed or aggressive initiation of a lift down function after a lift up function

• Aggressive initiation behavior of the lift up function after lift down function is selected

• Imprecise stopping when lowering the cylinder

To address these challenges, a system is required that gives operators the precision they desire. With recent changes in valve technology, engineers have discovered breakthrough performance in

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JLG’s 742 telehandler line offers a 7,000-lb maximum lift capacity, and is one of the first machines to use the | Courtesy of JLG Industries, Inc. precision gravity lowering system.

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Figure 1. This circuit shows how gravity lowering works on JLG’s new telehandlers.

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hydraulic circuitry through gravity lowering that improves the operator’s control of a telehandler boom and the overall efficiency of the hydraulic system on both ride control and non-ride control equipped telehandlers.

What Is gravity lowering?

With the demand for machines to be more productive and energy efficient, gravity lowering allows for increased speeds and precise movements. Similar technology has previously been seen on aerial work platforms, specifically boom lifts, but is beginning to make its appearance on telehandlers with a new feature to enhance lift down capability.

A gravity lowering circuit is applied on the lift cylinder of a telehandler and works in harmony with the main control valve (MCV). In the circuitry, shown in Figure 1,

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valve (1) is the holding device that opens with a proportional control signal applied to port “Pil” and fed from the MCV control pressure chamber. The relationship between the opening of valve (1) and the shifting of the MCV spool are carefully designed to provide the required flow and back pressure for smooth control. Similarly, valve (3) is sequenced to open with the pilot signal at “Pil” and permit oil recovery—that is, exhaust oil from the bore side of the cylinder can cross over and refill the rod side. In this manner, the MCV spool and pump are partially alleviated from providing flow to the lift cylinder’s rod side and therefore flow is available to perform other hydraulic functions. Valve (4) is provided such that if during a lowering function there is insufficient pressure in the bore for lowering

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Figure 2. Self-compensating valve helps control boom down velocity. As the lift load increases in weight, lift down time picks up speed but can even itself as the load continues to increase.

by gravity, as in back dragging bucket work, the recovery circuit is shut off and the flow delivery from the pump and MCV spool to the rod side immediately begin to pressurize the rod side to provide down force at a reduced rate of speed. Finally, valve (2) is a relief valve that serves as a circuit over pressure protection.

Because the pilot pressure for opening valve (1) is aligned with the MCV spool shifting pressure, the pressure required is low and provided from a stable source, unaffected by vehicle dynamics or load sense oscillations. Gravity, pressing down on the lift cylinder piston bore, provides the energy to exhaust oil from the cylinder and the rod side and is no longer required to have high pressure to perform lift down. In this way, the potential to trap pressure in the rod side, and in turn over-compress the bore side due to pressure balance about the cylinder piston is eliminated. The challenges with aggressive initiation and imprecise boom control on ceasing motion are eliminated at the source; not storing excess energy in the rod or bore side of the cylinder keeps the cylinder in perfect force balance, and during command transitions there is no excess energy to rebalance forces quickly or to manage carefully with damping schemes.

This results in the initiation and termination of functions quite precisely.

Benefits By introducing gravity lowering to telehandlers, the system offers many advantages

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Gravity, pressing down on the lift cylinder piston bore, provides the energy to exhaust oil from the cylinder and the rod side and is no longer required to have pressure to perform lift down.

October 2017

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to both the hydraulic system designer and the machine operator. There are three major benefits that are easy to see, but more will come to light as the technology increases in application.

The first of those benefits is energy savings. In a traditional holding valve, a parasitic load is created in the cylinder function due to the high pilot pressure requirement for opening. This results from a setting for the main element that is usually

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| Courtesy of JLG Industries, Inc.

Side view of JLG’s 1732 telehandler’s engine and hydraulics system. The 1732 was also launched at IFPE, offering a lift capacity of 16,750 lb.

HALF THE SIZE. TWICE THE TORQUE.

25-30% above the maximum potential load. While the traditional load-holding valves come with a pilot ratio, which reduces the amount of energy consumed during lowering, a significant energy loss remains for the majority of load cases. This energy will then become a direct heat load and it must be removed by the system cooling circuit.

Another benefit is increased speed. Powered flow from the system pump is not required to lower the boom with gravity lowering, which allows for the power to be directed to other functions. The speed of combined function movements is greatly increased.

Gravity lowering also gives the operator increased precision, which assists increased cycle time. As mentioned earlier, the gravity lowering valve is not developed from the pressure in the rod side of the cylinder. Instead, it is taken directly from the operator control input, giving the operator more control. The machine system and machine control system now have unlimited opportunity to determine how much and how fast the pilot pressure to the gravity lowering valve is developed in relation to the operator input request.

In addition to increased precision, some manufacturers include a valve that self-compensates for changes in load, which allows for the velocity of the boom down function to stay controlled no matter what the load is. This compensation works by trying to make a standard lift down time. As shown in Figure 2, as the lift load increases in weight, lift down time begins to pick up speed but can even itself out as the load continues to increase.

Other benefits include a reduction in noise level and increased operator comfort. Due to no power being demanded from the system to lower the boom at high speeds, operators can achieve the same (or

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faster) cycles at lower engine speeds, which allows for reduced noise and fuel consumption.

When one considers lower noise levels, faster movements, and increased precision contributing to the machine operator achieving the same work with less effort, the machine becomes easier to operate and provides more operator comfort.

Conclusion This past March, at CONEXPO 2017, JLG Industries revealed to attendees a glimpse at the future of their telehandler line. The 742 telehandler, which offers a 7,000-lb maximum lift capacity, also introduced the precision gravity lowering system to the family. With the systemâ&#x20AC;&#x2122;s incorporation, the telehandler can rely on hydraulic power to raise the boom and gravity to lower it, thus providing the operator with more precise control as well as increasing the machineâ&#x20AC;&#x2122;s efficiency. JLG plans to incorporate the gravity lowering technology across its entire line of telehandlers later this year.

Ultimately, gravity lowering removes inefficiency from the hydraulic system.

Productivity will greatly increase due to the benefits gravity lowering provides the system and operators can feel more confident in landing loads at height. DW JLG Industries Inc. | www.jlg.com

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M e c h a n i c a l

The 3 bearing questionsmanufacturers hear most

Key factors can simplify your bearing choice. Here are questions application engineers like Matt McCormack of SKF hear frequently, and his recommendations.

Edited by Mike Santora | Associate Editor

How do I determine which bearing to use?

The first and most basic question: Which one? Determining basic bearing parameters is usually not the challenge. Going through the multitude of specialized features that differentiate a suitable bearing from the bearing can be a challenge.

There are as many as 40 different ball bearing types, roller bearing types, plane bearing heads, journal bearing heads, and bushing types. And thatâ&#x20AC;&#x2122;s just the basic families. 40 different types! Dig a little deeper and you will find variations of those types and, of course, the different sizes. There are hundreds of thousands of different bearings to choose from. And this is just a small portion of whatâ&#x20AC;&#x2122;s out there on the market.

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The following diagram shows available choices and in the center, of course, is bearing selection.

Several influencing factors surround this central question. These aren’t all the factors, but these are some of the most common used.

Begin with how much load the bearings need to support; this will influence the style of bearing to use. With a light load, for example, a ball bearing might suffice. If it’s a heavy load application, a different approach is needed. Of course, how fast is the bearing going to go?

Additionally, what kind of contamination is this bearing going to see? If this is a food and beverage plant application, contamination will be high from a washout cycle at the end of a shift. The different caustic detergents, the cleaning and killing of bacteria: that can easily get inside the bearing and damage the seal, damage the lubricant, and corrode the bearing.

Does there need to be a common misalignment? If there is some inherent misalignment in the system, the bearing choice will need to handle misalignment as opposed to a freebase style bearing that won’t tolerate that misalignment.

Accuracy: how accurate must the bearing be? If it’s going into a shopping-cart wheel, accuracy is not an issue. An inexpensive bearing will suit. But if it’s going into a CNC machine making parts every day at high volume, then a higher accuracy bearing is needed.

Consider size and temperature. If it’s going into a dentist’s drill, a bearing the size of a popcorn kernel is required. If it’s going in a wind turbine, a bearing that’s several feet or even meters in diameter is needed.

What kind of temperatures will the bearing be exposed to? Is it going into an Alaskan offshore drilling platform that needs to live in -50° F or is it going into a desert environment?

Lastly, there is bearing life. How long, how many cycles must this bearing last? Some need a bearing that will last a month or two, others need a few years just to get through the warranty period, and then there are others that want a bearing to last for the lifetime of the device, upwards of 40 years, so they don’t have to worry about it.

This is by no means a comprehensive list of the different influence factors in bearing selection but these are some of the major concerns. These questions help narrow down the bearing selecting process. The process is actually fairly complicated, which is one of the reasons it’s always good to consult with application engineers. Looking at the whole picture is generally something that takes years of experience to get through the selection process and make sure you are getting the right bearing.

How do I determine the loads on a bearing?

It is easy to think of what the weight of a component is on the bearing (weight of the shaft for example) and ignore other influencing loads. In general, the bearing loads to consider should be the reaction load at the given position.

Take a shaft and a ball bearing, for example. The radial load is the load that is perpendicular to the shaft. It doesn’t matter if the shaft is going towards vertical. The radial load will always be perpendicular to the actions of the shaft. The axial load and the thrust load will be parallel to the axis. And if those situations are ever combined, then they can be both radial and axial.

A large industrial fan is another example. An application like this will have a large cylinder portion where a fan blade is located and at the top there will be a box where the buffer is attached to the fan to move the air through it. All of this is being driven by an electric motor. The electric motor is belt driven from the fan shaft, so there is a buffer to cut between the pulley and the belt.

Internally, there is a pulley system, a belt, and then two bearings supporting this fan shaft.

In the following fan shaft image, the fan is on the left-hand side followed by the shaft, drive pulley, and two pillow block bearings supporting.

There are as many as 40 different ball bearing types, roller bearing types, plane bearing heads, journal bearing heads, and bushing types.

And that’s just the basic families.

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When considering bearing loading, think of the three different loading components that make up this application. Consider the rotor assembly weight: the shaft is going to weigh a given amount, the fan collar is going to weigh a given amount, and the pulley system is going to weigh a given amount. Just as an example, let’s say this shaft weighs 150 pounds and is cradled between the bearings.

The last loading is coming from the work that the collar is doing.

This fan is pushing a large amount of air with great force to get it through the ductwork to make it go throughout a building. Any force this fan collar is pushing, there’s an equal reaction force that’s happening on the bearing.

Those are the three basic load components on the bearing. Also consider the weight of the component, the force and the drive forces. In this example, it was a belt, but it could be chain driven or gear driven.

There are also other loads infrequently considered. For example, in the case of the fan, there might be imbalance loads. If the fan is not in balance, perhaps it wasn’t balanced properly when it was first installed, or if it becomes imbalanced over time, those imbalances will increase the load behind the bearing, and create misalignment.

If the pulley was misaligned or the belt was misaligned during initial setup, that can cause misalignment to load down the bearing. These are just a few considerations to think of when sizing the bearing. It’s important not to just think of the weight. There are other options that need to be considered.

What’s the best seal design for my bearing application?

There are always pros and cons to consider during seal or lubrication selection. Just as there is no one perfect bearing for all applications, there isn’t one perfect seal type for all either. When looking at bearing

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Visit us at www.usafgrp.com for a full list of capabilities.

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M e c h a n i c a l

selection and seal selection, some bearings are only offered open, for example. Below we have a double row spherical roll bearing and there are rubber lip seals on either side of the bearing.

Because the primary function of the seal is to protect the bearing from contaminants, it is important to keep the bearing clean when taking it out of the packaging so it isn’t contaminated from handling. Make sure the bearing retains the lubricant. It’s important to retain the supply to the bearing inside so it doesn’t leak out leaving the bearing to run dry. When selecting a seal, weigh the pros and cons, advantages and disadvantages, and try to balance the sealing efficiency on one side.

This is the ability of keeping out contamination like dirt and water plus the efficiency of retaining the grease inside the bearing so there are no leaks. Additionally, there are also concerns with eliminating the need for removal of the bearing.

That’s what we want out of the one side of the seal. On the opposite side, because of the rubber lip that is making contact with the inner ring, have the rubber rubbing on the inner ring of the bearing increase the friction. The result is a bearing that will not be as free rotating as it once was. This is also going to add some torque to the bearing and it could end up reducing the speed capability of the bearing. We have to balance two trade-offs here, sealing efficiency and then the friction related to it.

If you had a bicycle wheel, for example, you would want that bearing to be as free spinning as possible.

We don’t want to reduce the speed capability of the bearing. If there’s a spindle going 20,000 RPM, lowering the speed could influence the bearing selection and eliminate it as an option.

As for sealing efficiency, to goals is to match the efficiency to the application.

In a food plant mixing flour, a seal that will keep all that contamination out will be needed. And what if the engineering team wants to lubricate the bearing as well? Perhaps a sealed for life bearing solution might be necessary.

There are near limitless application questions centered on the bearing of a motion system design. These are just a few of the most common. Whether checking on the selection of a catalog component or looking for a custom solution, when in doubt, it’s best to check with the applications engineers at the bearing manufacturer. DW

SKF | skf.com

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Product World Electromagnetic actuated clutches Miki Pulley mikipulley-us.com CS Clutches connect a motor and a load providing low inertia, minimal drag and quiet operation. They use the magnetic force generated by the energized coil providing engagement of input and output members of the clutch.

Available with three different armatures, these clutches have a clutch stator,

rotor and armature assembly. They also have an integrated bearing design making mounting fast and easy while ensuring application concentricity. CS Clutches operate well in temperatures from +14 to +104°F (-10°C to +40°C). Available in bores ranging from 10 to 15 mm, with brake torques ranging from 3.687 to 236.02 ft-lb (5 Nm – 320 Nm). The CS Clutch uses corrosion resistant materials, and is RoHS compliant.

Micro PLC with PAC power IDEC IDEC.com/usa THE FC6A MicroSmart is a PLC with up to 520 I/O. It has the power of a PAC (programmable automation controller) in a low-cost controller with a small form factor, making it a suitable fit for demanding applications. Basic instructions can be executed in 0.042 microseconds, and program memory is 640 kB. There are 1,024 timers, and six of the 512 counters are high-speed at rates up to 100 kHz. These features are combined with data and bit memory, double the capacity of a typical micro PLC.

Three MicroSmart PLC models are available, each with 24 Vdc or 100-240 Vac input power. The 16 I/O model

has 9 inputs, and 7 relay or transistor outputs. The 24 I/O model has 14 inputs, and 10 relay or transistor outputs.

The 40 I/O model has 24 inputs, and 16 relay or transistor outputs.

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IP67-rated servo motors for washdown environments Kollmorgen kollmorgen.com The AKM Washdown and Food Grade Servo Motor is for applications with strict hygiene regulations. The AKM Washdown and Washdown Food series comes in a range of standard lengths, windings, feedback systems and connection technologies. This motor incorporates AKM electromagnetics within a housing protected by an FDA-approved 2-K coating and IP67-rated seal configuration.

Features • Frame sizes 2 through 6 • Static torques from 1 to 25 N-m • IP67 seal design • PTFE shaft seal • Stainless steel shaft, connectors and hardware

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Product World Advanced digital signal conditioner Kaman kamansensors.com With its new graphical user interface (GUI) for easier setup and connectivity,

Right angle hypoid gearing brushless dc gearmotors Brother Gearmotors brother-usa.com/gearmotors

and cloud-based data access/monitoring, the digiVIT digital variable impedance

This portfolio of brushless dc gearmotors

transducer has an array of networking

are suitable for environments requiring

capabilities suitable for Industrial Internet

maintenance-free operation and accurate

of Things (IIoT) applications. It is a good

speed control as well as operation over a

choice for position, vibration, and proximity

wide speed range. They are also desirable for

sensing, part sorting, process control,

settings where brush dust contamination is

laboratory testing, engine dynamics

to be avoided or brush contact arcing could

testing, condition monitoring, and more.

affect electronically sensitive equipment.

This self-configuring system is capable of performing with

nearly any sensor, from any manufacturer, as well as any conductive

Features

target. The transducer also has simple pushbutton calibration,

• Maintenance free; lubricated and

temperature compensation, and zeroing.

sealed for life • Configurable; several shaft configurations and custom options

Non-spill quick disconnects

available

CPC cpcworldwide.com

quiet helical and hypoid gearing

• High efficiency, further enhanced with • Safe, 12-48 Vdc motors with a wide speed control range

The LQ Series is now easier to connect and has more robust non-spill connectors for high-performance computing and data center applications.

LQ2, LQ4 and LQ6 Series quick disconnects now all have swivel configurations and an integrated thumb latch for easy, one-handed operation in confined spaces like the server racks of large data centers.

In addition to the swivel joints, CPC reduced the forceto-connect by more than 20%. The LQ4 and LQ6 QDs also can handle twice the original side load force and feature a 38% higher burst pressure rating than before, offering additional protection from rough handling or use.

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Infrared temperature sensor with IO-Link Balluff balluff.com This BTS infrared temperature sensor with IO-Link interface and two switching outputs can monitor temperatures between 250 and 1250 °C even in inaccessible or hazardous areas. It can also detect hot objects in motion and record temperature values - all without contact.

The pyrometer in the M30 stainless

steel housing with IP67 protection is the first in this form factor with a multifunction display with plain text information and automatic display orientation like with a smartphone. In addition to two switching outputs, this pyrometer has an IO-Link interface for remote parameter setting and direct data exchange with the controller or control panel.

3-Phase monitors with enhanced noise immunity Gavazzi GavazziOnline.com These three-phase monitoring relays provide protection against phase loss and improper phase sequence. The DPA52 and DPB52 offer versatility and ease of use, including a wide input voltage range, multi-color LED indicators for visual status, and a relay contact output. They conform to global standards such as UL 508, CSA C22.2 and EN 60947-5-1. They can also be used globally in applications/markets where it is necessary to monitor phase presence, sequence, and value, such as HVAC, lifts and escalators, material handling, water treatment, and others.

DESIGN WORLD

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Magnetic spindle encoder with functional safety Heidenhain heidenhain.us The new ERM 2200 and 2400 series of magnetic modular angle encoders now permit mounting to include a mechanical fault exclusion of these encoders, a key requirement in making a machine functionally safe.

These changes include deeper, more robust fastener mounting holes

in the reader head and fastener holes in the scale drum itself. While making these changes, Heidenhain also consolidated the reader head designs into a single, smaller footprint so the new heads will drop into the old designed space.

Oil for high-speed can closing machines Kluber klueber.com KlĂźberfood NH1 M 4-150-NE is a fully synthetic oil for high-speed can closing machines.

These machines require its circulating oil to be stable for extended periods of time.

Depending on the machine type, the oil must have the ability to quickly hold or separate water. KlĂźberfood NH1 M 4-150-NE is specifically formulated from a new chemistry, resulting in improved solvency, helping to keep machines clean. Additives help prevent residue/deposit formation and allow the oil to have more resistance against oxidation.

Finally, an emulsifier enables the oil to efficiently hold water.

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Product World Epoxy for die attach applications Master Bond masterbond.com EP17HTDA-1 is a one component epoxy that can also be used for bonding and sealing. EP17HTDA-1 has a suitable viscosity and flow for die attach applications. It has a high glass transition temperature (Tg) and also has electrical insulation properties, even at elevated temperatures and low exotherm upon curing. This system also has a die shear strength of 24-27 kg-f and can be used in a typical die size ranging from 4-400 mm2.

EP17HTDA-1 has temperature resistance with a service temperature range of -80 to +600°F [-62 to +316°C] and a Tg of 195-205°C. This compound boasts thermal conductivity of 9-10 BTU•in/

ft2•hr•°F [1.30-1.44 W/(m•K)]. It withstands a variety of chemicals including acids, bases, salts, fuels, oils and many solvents. As a one part system, EP17HTDA-1 does not require any mixing for use and is curable in the temperature range of 300-350°F in short durations.

Low Backlash

Spiral Bevel Gearboxes Tandler Spiral Bevel Gearboxes provide the highest quality, lowest backlash, and most durable products available. With the widest range of ratios and specialty models, maximum performance and versatility are assured.

Helical Gearmotors WATT Drive Helical Gearmotors are offered in 4 models, featuring high performance right angle and inline designs with an extensive range of sizes, ratios, mounting and output options. We have the drive that meets your needs.

Inline Helical

Hollow Shaft

Parallel Shaft Custom Designs Standard Design

• 8 sizes 1-250 HP

• High Speed Options

• 15 Single Stage Ratios

• Wash Down Options

• 1-75 HP Capacity

• Multi-Stage Ratios

• Shaft Mount Designs

• NEMA, IEC, or servo motor adapters

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Standoff fasteners hold printed circuit boards securely PennEngineering pemnet.com New PEM SMTSSS ReelFast SNAP-TOP standoff fasteners hold printed circuit boards securely in assemblies without requiring mating screws or other loose threaded hardware to complete attachment.

Unlike loose parts with

handling issues, PEM SMTSSS standoffs are supplied on tape and reel compatible with existing SMT automated installation equipment. Without a need for secondary installation operations that may inadvertently be performed improperly, board damage and costly scrap can be avoided. PEM SMTSSS standoffs are manufactured from carbon steel and are available in unified lengths of 0.250 or 0.375-in.

Teflon coatings ™

and metric lengths 6 mm, 8 mm, or 10 mm. They will install reliably in boards and panels as thin as 0.060-in. and 1.53 mm.

Improve part performance

with unique properties of Teflon™ coatings!

Coatings can be applied to: • metals • elastomers • ceramics • composites • rubber • glass

Split hub clamps Stafford Manufacturing staffordmfg.com These split hub clamps are available in

As a licensed industrial applicator, Donwell...

one and two-piece clamp-style designs machined from a variety of materials with special features such as wider slots, stress

• provides custom coating services to

relief holes, and balancing flats. Suitable

• coats both small and large parts to

your specifications.

for both stationary and rotary applications, these split hub clamps are non-marring and can be manufactured to precise OEM design requirements.

close tolerances in quantities from 1 to 1,000,000.

• has over 50 years of high-performance coating application expertise.

Easy to adjust, the split hub clamps can be machined from aluminum, steel,

stainless steel, brass, titanium and other alloys. Sizes can range from 1/4 to 6-in.

I.D. with unlimited customization including heavy duty construction, balancing options, and external modifications.

1-800-864-2702 www.donwell.com For FREE Coating Sample

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Use of the Teflon™ mark requires a direct trademark license.

Customers and distributors of Donwell can only resell LICENSEE’s product as licensed with the Teflon™ mark.

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Ad Index

SALES

Tom Lazar

ACE Controls .....................................................6

ITT Enidine ...................................................... 39

Aignep USA ............................................... 35,41

IXYS ...................................................................40

All Motion ...........................................................4

J.W. Winco, Inc. .............................................. 73

Allied Electronics .......................... Cover,3,57

John Evansâ&#x20AC;&#x2122; Sons, Inc. ............................... 56

Allied Moulded Products, Inc. ..................68

Keller America Inc .........................................69

Altech Corporation ..........................................1

Keystone Electronics Corp. ...................... 47

Aurora Bearing Company ......................... 35

Mach III Clutch Inc. .......................................48

AutomationDirect ................. Gatefold,Insert

Maryland Precision Spring ........................ 38

Bison Gear .....................................................IBC

Master Bond ................................................... 41

Bodine Electric Company ..........................86

Memory Protection Devices, Inc. ............ 55

jeast@wtwhmedia.com 330.319.1253 @wtwh_MsMedia

Caplugs ............................................................ 27

NBK America LLC .......................................... 52

Carlo Gavazzi .................................................64

OKW USA ......................................................... 95

Michael Ference

Carlyle Johnson Machine

ON Semiconductor ...................................... 33

Company .................................................. 16 Centritec Seals -

PBC Linear ................................................28,29 PHD Inc. ........................................................... 43

A Carlyle Johnson Company ........... 70

Prince Manufacturing Corp. ..................... 63

Century Spring Corp. ................................... 91

Proto Labs ....................................................... 13

Chieftek Precision USA ......................17,19,21

ROSS Controls ...............................................89

Clippard Instrument

Rotor Clip Company, Inc. ............................ 93

Laboratory, Inc. .....................................BC

Smalley Steel Rings ..................................... 10

CS Hyde Company ....................................... 30

Solenoid Solutions ....................................... 32

Del-tron Precision, Inc. ................................. 61

Sorbothane .......................................................6

Design-2-Part Shows ................................ 100

Southern New Hampshire

DieQua ......................................................76,102

University ...................................................7

Digi-Key Electronics ...................................... 15

Sunstone Circuits ........................................ 77

Donwell Company .......................................103

Tadiran Batteries ........................................... 71

Dorner Mfg Corp ...........................................88

Tensility International

Dunkermotoren ............................................. 45

Corporation ................................97,99,101

Elesa USA Corporation ........................ 20,78

THK America, Inc. .............................................5

Encoder Products Company .................... 82

Tolomatic, Inc ................................................. 23

Equipto ............................................................. 73

Trim Lok ............................................................ 24

Fabco-Air, Inc. ................................................ 87

Turck Inc. ...................................................83,85

Fischer Connectors ...............bellyband, 36

USA Fastener ................................................94

Fluid Metering, Inc. .....................................103

Weintek USA ................................................... 31

Helical Products Company ..........................9

Whittet-Higgins ............................................. 25

igus Inc. ............................................................84

Xcentric Mold & Engineering .................... 72

Indium Corporation ......................................49

Zero-Max, Inc. ...................................................2

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

Jessica East

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Michelle Flando

mflando@wtwhmedia.com 440.670.4772 @mflando

Mike Francesconi

tlazar@wtwhmedia.com 408.701.7944 @wtwh_Tom

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director

mfrancesconi@wtwhmedia.com Scott McCafferty 630.488.9029 smccafferty@wtwhmedia.com 310.279.3844 David Geltman @SMMcCafferty dgeltman@wtwhmedia.com 516.510.6514 EVP @wtwh_david

Marshall Matheson

Neel Gleason

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Ag & Construction

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