DESIGN WORLD OCTOBER 2020

www.designworldonline.com

October 2020

inside: MOTION CONTROL: Updating the old rules of inertia matching

p. 74

3D CAD: Beyond additive manufacturing: Generative design shapes for milling too

p. 90

THE ROBOT REPORT: CropHopper robot takes novel approach to field monitoring

p. 62

All-in-one vs. separates for motion control page 82

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What geopolitical issues will most affect manufacturing?

At the recent National Fluid Power Association’s International Economic Outlook Conference — this one held virtually, due to the Covid-19 pandemic, Sam Potolicchio of Preparing Global Leaders Forum, spoke about some of the key geopolitical trends likely to impact business in the coming months and years.

Potolicchio explained that the upcoming U.S. presidential election will clearly constitute the top geopolitical event this year and will affect trade issues and business in general. And no matter what either political party wants you to believe, he said that the question o en comes down to the “beer question” — who would you rather have a drink with? The issue of personality and charisma is important to voters.

Potolicchio also said that so much of our elections will be determined by a head nod or an off-key comment, because we’re so on the knife edge of being split 50/50 in this country. As an example, he said that he thinks the small-at-the-time moment of Hillary Clinton slipping when getting into an SUV was a moment magnified in some voters’ heads and likely contributed to her loss more than many people would think. He also said that “anyone who tells you they know who is going to win President is full of bunk.”

Advantages that Biden has include: He is not Hillary Clinton, Elizabeth Warren, or Bernie Sanders. Biden is dominating among voters who disliked both Trump and Clinton. He also has the Obama advantage, and will try to make this an extension of the Obama years. What’s more, Trump has not found a way to encapsulate Biden; the Sleepy Joe nickname is not hitting with voters in the way that Crooked Hillary did. What’s more, the pandemic has completely transformed things. Reagan asked: Are you better off now than you were 4 years ago? That will be a tough thing for Trump to battle.

Trump’s advantages are: Never Trumpers are now firmly into his camp. It’s going to be difficult to see people switching sides. Biden is an establishment candidate, and they rarely win for the Democrats.

Additionally, “Washington” candidates usually lose. Trump is actually not that historically unpopular as a president. He stays in a 42-43% popularity range, which means it will likely be a tossup. Voters who are more likely to vote to him are not as likely to vote for a third-party candidate.

The big question remains — Will a second wave of the pandemic hit in October? We don’t know what voter turnout will be, and Potolicchio noted that higher turnouts generally mean a Democratic victory. But if it’s reduced to all mail-in voting, that could push down Democratic voting.

Republican votes are generally more successful by about 5%, which could be a huge X factor. (continued on page 6)

4

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October 2020

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I n s i g ht s (continued om page 4)

Potolicchio said that the #1 risk for business is that we may see an electoral banana republic come November. At the state level, a lot of the swing states are controlled

by Republicans although some have Democratic governors. The Speaker of the House will become President if battles over ballots go to the courts.

This could affect faith in the U.S. globally.

He thinks that Biden will likely win by about 100 electoral votes. A razor thin win by Biden may cause Trump to fight it.

Four other issues to consider 1 Potolicchio said that China is definitely a serious competitor to American hard power, even if they don’t match us with so power. The main areas of dispute between the U.S. and China are: trade war, Huawei spying claims, claims of blame for the Coronavirus, new Hong Kong laws, Uighurs human rights issues, contested territories in the South China Sea, closure of consulates such as Houston, and Tiktok ownership arguments.

Toughness against China will likely be a commonality between Democrats and Republicans. Relations will continue to deteriorate between the two countries, no matter who wins in November. However, om a general population standpoint, the pandemic has accentuated our poor feelings toward China.

Potolicchio is optimistic though; he thinks it’s going to be difficult for the two countries to decouple om each other. “We are too closely entangled with each other. … ultimately, it is going to be more brinksmanship than a head-on collision with fatalities both militarily and economically,” he said.

6

October 2020

DW.Insights.10-20_Vs3.LL.indd 6

2 The pandemic has put a magni ing glass on some serious structural issues that we have not just in the U.S., but globally. Before everything hit, even with an uninterrupted bull market with steady incremental global growth and steady U.S. growth, 53% of Americans lacked emergency savings. 28% of Americans did not have adequate health insurance. 21.3 million Americans lacked broadband WiFi access. 33.6 million Americans did not have paid sick leave.

There is an economic cataclysm that is occurring on Main Street, Potolicchio told the audience — but it hasn’t affected Wall Street and our stock portfolios in the same way. This Achilles heel is the inequity … he noted that breakups of countries generally happen when the richest state is 5-6 times wealthier than the poorest state. It’s been that way with the Soviet Union, Yugoslavia, or the EU before Brexit.

3 There’s a mental health experiment going on and no one’s talking about it, Potolicchio said. Toxic stress is increasing by about 100%, according to some studies. This impacts people’s ability to function at high levels in the professional workspace. He thinks the pandemic is with us for 2-3 years and we are not going to have a vaccine that is going to wipe it out; rather it will be a guessing game, similar to the different influenza strains each year. If there’s a vaccine in November or December 2020, there will be a low level of confidence in it, and we will see less than 50% of people willing to get it.

4 Who’s actually in charge? Potolicchio said that the U.S. isn’t engaging in the world order, and we’re seeing other nations flexing muscle, as well as a decline in the general trust of U.S. leadership. At the university level, we may not get the level of talent that we historically have. This may lead to fewer inventions and new products.

And concerning the climate crisis: it will be a miracle if we don’t have at least five enormous environmental events in the next three years that will have continued economic destruction and will cause new refugee flows into already pandemic-weakened systems.

This is a permanent crisis that we are going to have to address.

But bullish on the future?

Still, Potolicchio is bullish about the future. He described a “youthquake” … we are going to see a new generation get into politics. With the new generation will come a new approach to solving problems, and we’ll increasingly see people who are willing to engage with others outside their political party. Potolicchio said that we need to talk to our political counterparts like they are co-pilots and not enemies. The younger generation is more willing to simply look at problems and not worry about party labels. DW

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

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Teschler on Topic Lean manufacturing: Another name for just-in-time shortages?

TV watchers of the Tonight Show may recall this joke om host Jay Leno during a 2006 monologue: In a

remarkable speech over the weekend, Secretary of Health and Human Services Michael Leavitt recommended that Americans store canned tuna and powdered milk under their beds for when bird flu hits. What? This ranks right up there with “duck and cover” during a nuclear attack. In case of radiation wear a hat. Powdered milk and tuna? How many would rather have the bird flu?

A real knee-slapper. But we can’t help but wonder how Mr. Leno’s supply of toilet paper held up during the recent shelter-in-place orders.

The advice to hoard canned goods during the year of the avian flu was largely ignored, partly because most people took the threat of a pandemic about as seriously as Leno did. Today, shortages are no laughing matter.

Reports are that five months a er the first shelter-in-place orders, an average of 21% of household paper products were out of stock at U.S. stores. Similar shortages have been reported in Europe and Asia.

Much of the blame for the scarcities is being heaped on principles embraced

by lean manufacturing. Even engineers whose employers don’t practice lean manufacturing probably know that the main teachings of the discipline include just-in-time delivery of raw materials, devoting precious little space to stored inventory, and operating with almost no slack. Though lean manufacturing principles began to take hold in the 1980s, it is only in recent years that such practices have become standard operating procedure. The Wall Street Journal recently reported that earnings calls of S&P 500 companies last year mentioned the terms “inventory reduction” and “lean” more than 550 times.

You can get an idea of the potential problems by just reviewing the main principles of lean. They generally include eliminating low-value features, organizing work flow, setting up pull-based production, and boosting product quality. The key idea missing om this list is operational resilience.

Critics say the flexibility to handle extraordinary scenarios vanished somewhere in the quest to make 100% use of production capacity and squeeze out every action of a penny of profit.

We’d argue that lean principles aren’t the only source of supply problems. The analytics firm Beroe Inc. pegs the North American market for management consulting at about $109 billion. This figure makes you wonder whether the companies talking up

inventory reduction on earnings calls are the same ones spending significant amounts on high-priced gurus telling them how to run their business. And how much was that advice really worth if it led to five-month-long shortages?

Consider the claims made by the McKinsey & Co. Global Manufacturing Practice: We guide clients through the design and implementation of operational strategies that will stand the test of time, while creating agility and a product portfolio that is commercially and operationally optimized. Reading through one of McKinsey’s white papers, we find that they are big on modeling: Today’s powerful computer systems allow companies to build detailed models of their entire value chain, om procurement all the way to customer demand and final delivery.

Judging by the empty shelves in our local supermarket, we know of at least one scenario that seems have been le out of those modeling effort. DW

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

8

October 2020

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Grace under pressure

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Technology Forward Turning manufacturing scrap into additive manufacturing “gold” Many users of 3D printing/additive manufacturing technology are concerned with its potential impact on the environment. O en the focus is on resin-based prototypes ending up in landfills and taking years to degrade.

But other materials also end up as scrap, such as that om machining and similar subtractive processes.

Several companies are stepping in to address sustainable materials for the additive industry. One is 6K Inc. Aaron Bent, CEO at 6K plans to turn scrap metal om machining, injection molding, le -over metal powder, and prototype or failed additive manufacturing projects into usable powder for additive manufacturing (AM).

“There are two important aspects of sustainability in additive manufacturing,” says Bent. “One is that the powder production itself is typically only about a 30% yield, with a lot of the rest of the powder going into landfills. And then the printing process itself has losses that include used powder support structures and non-conforming parts.”

6K has a process for producing powders that offers 100% yield, for a lot less material in landfills. In addition, the process cuts the costs of the energy needed for transportation, mining, and refining of the original ore.

In the 6K process, scrap is cleaned and sized to an engineered feedstock.

Then, it goes through the plasma system, which creates the right powder

size distribution whether a customer needs something for metal injection molding, a laser powder bed, an E-beam, or a DED system.

The scrap om other manufacturing processes has already been qualified and chemistry certified. So, engineers are assured of mechanical performance. In addition, the “new” powders can have better properties over traditional atomized powders, including better flowability, higher tap density, no porosity, and no satellites.

Bent sees sustainability and cost as being intimately linked. “I think with a better total circular economy approach to both the printing and powder production process, you can have substantial reduction in costs and therefore a faster adoption of AM.” Elementum 3D, a developer and supplier of metal additive manufacturing (AM) materials, offers a patented Reactive Additive Manufacturing (RAM) technology that creates a variety of materials printable by laser powder bed fusion.

Along with bringing new materials to market, RAM technology delivers materials with equivalent and improved mechanical properties compared to traditional wrought alloys.

RAM technology uses micronscale additives blended into powder feedstock that react in situ during printing to form sub-micron inoculants. These inoculants lead to grain refinement and help eliminate

defects like hot tearing in aluminum, a hurdle for many alloys in AM. Elementum 3D’s alloy feedstock for laser powder bed fusion generates light-weight, high-strength AM parts.

Powder recycling is economically and environmentally beneficial, increasing the number of builds performed with the same feedstock.

Powder processing allows blending multiple components for production of materials like metal matrix composites (MMCs).

However, there are concerns about physical and chemical changes that may occur under processing conditions in laser powder bed fusion, along with components segregating during handling. The layer-by-layer building process involves thermal cycling that can lead to loss in chemical composition. Changes in particle morphology can lead to variances in mechanical behavior, while changes in particle size distribution can affect flowability and inhomogeneous powder distribution over the build platform.

Despite these concerns, many alloys retain chemistry, particle size, morphology, and mechanical properties a er multiple builds with the same powder.

Elementum 3D explored and confirmed the quality and performance of the powder feedstock over multiple builds. The resulting consistency of mechanical properties and powder characteristics assure customers of the resilience and reliability of the materials. DW

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

10

October 2020

Tech.Forward.10-20_Vs2.LL.indd 10

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Green Engineering Paul J. Heney

• Editorial Director

What’s the future like for fuel cell electric vehicles?

HRS and FCEVs in countries promoting the hydrogen economy – 2019

*FCEV: includes cars, light-, heavy-duty vehicles, forklifts. | Source: IPHE.

Fuel cell electric vehicles (FCEVs) and battery electric vehicles (BEVs) are considered by the most people to be two competing technologies. Although both technologies power an electric motor, they have different properties and each of them is well suited for some uses more than others.

BEVs market is increasing, with major automotive companies such as BMW and Mercedes starting to introduce into the market an increasing number of electric battery vehicles. This is in parallel to the main BEVs companies like Tesla, and Toyota. FCEVs, on the other hand, are still in the demonstration stage.

In April 2019, Daimler stepped back om the development of the GLC F-Cell, a er many years of investigation of fuel cells technologies. Daimler did not completely abandon the hydrogen powertrain; instead, it mostly shi ed focus to a different application. In fact, a collaboration with Volvo to develop fuel cell heavy-duty vehicles is slated begin in this Fall, which will define a new chapter for the hydrogen technologies.

Although the FCEVs have not reached large scale production, the long-term plan adopted by several countries is to implement the adoption of FCEVs among other applications.

The idea is to develop a hydrogen network, adopting hydrogen

as an energy carrier in different sectors.

In other words, this would be the development of a so-called hydrogen economy.

According to a new report om IDTechEx, “The Hydrogen Economy, Fuel Cells and Hydrogen Production Methods,” many countries are already involved in the development of a hydrogen economy.

The necessity of the hydrogen economy is driven by the requirement of reducing pollutant emissions while achieving a higher energy independence. While many different sectors can be addressed by hydrogen economies, the automotive sector is one of the first to be developed.

Countries like Germany and Japan have already installed a considerable number of hydrogen refueling stations (HRS), besides promoting the adoption of hydrogen technologies.

The main reason behind this choice is to reduce the cost of hydrogen. A largescale adoption of FCEVs, and hydrogen, would facilitate the adoption of hydrogen and related applications. Many countries are involved in this process and is likely that others will join to boost the adoption of green resources. DW

| Adobestock.com

IDTechEx www.IDTechEx.com/Hydrogen

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October 2020

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Contents 10 • 2020

•

vol 15 no 10

•

designworldonline.com

A Supplement to Design World - October 2020 www.designworldonline.com

CropHopper

90

• AI in agriculture: How PyTorch enables Blue River’s robots ............................................54 • Augean Robotics mechanizes food production, from farm to table ......................66 • Building service network for 10,000 autonomous combines ...................................70

ROBOT_REPORT_COVER_10-20_FINAL.indd 53

96 _FLUID POWER

Updating the old rules of inertia matching

The unsung hero of hydraulic systems

82 _LINEAR MOTION All-in-one vs. separates for motion control

PC-based open controllers work well in some machine control systems, while standalone controllers remain the better option for others.

Knowing which style of pressure gauge is right for your fluid power system is critical in ensuring consistent, efficient operation.

102 _MECHANICAL Thin section ball bearings create flexibility in medical application

Healthcare facilities turn to pivoting and articulating “arms” to hold monitors and other equipment used in operating rooms, patient hospital rooms, and dental offices, among other venues. The arms provide ergonomic advantages but, more importantly, they remain functional, where space is at a premium.

Beyond additive manufacturing— Generative design shapes for milling too

Generative designs don’t have to be 3D printed. Other manufacturing methods enter the ay.

October 2020

CONTENTS 10-20_Vs3.LL.indd 14

ON THE COVER A glass bottle manufacturing line, with complex motion control requirements and the need for redundancy, optimizes performance by using separate and | Courtesy of Siemens dedicated controllers.

90 _3D CAD

14

10/2/20 7:55 AM

53-73

74 _MOTION CONTROL

Modern servo drives with advanced tuning capabilities — when paired with performance servo motors having high-resolution feedback — can eliminate load-to-motor inertia-mismatch concerns.

robot takes novel approach to field monitoring page 62

INSIDE:

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

ON THE COVER

www.designworldonline.com

DESIGN WORLD

10/5/20 9:20 AM

Digi-Key 10-20_DW.indd 15 200831_AutoPuls1_DW_US.indd 1

10/1/20 9:59 3:26 AM PM 8/24/20

Precision Control for Your Operations

10 .20

• contents departments 04

Insights

08

Teschler on Topic

10

Technology Forward

12

Green Engineering

20

Design For Industry

31

Design Notes

41

CAE Solutions

46

Internet of Things

106 Product World

Clutches, Brakes and Motion Control Products

112

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CONTENTS 10-20_second.page_Vs2.LL.indd 16

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October 2020

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Made-in-U.S.A.

DESIGN WORLD

North American & Japanese Plugs—

Follow the whole team on twitter @DesignWorld

EDITORIAL

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

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Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com

The 15A-125VAC Japanese plugs and the NEMA 5-15 plugs look similar. Mains power in North America is 125V while Japan runs 100V. The North American AC frequency cycles at 60Hz while Japan’s is 50 to 60Hz depending on location. That difference may cause motors to burn out or electrical shock. The Japanese approval mark has “PSE” on the plug, and in North America “UL” and “CSA” in combinations.

Japanese wires range from 0.75, 1.25, and 2.0 mms, similar to AWG sizes 18, 16, and 13. If shipping to Japan, you must use a Japanese approved plug; if shipping to North America, you must use a North American approved plug. Interpower never cuts corners on quality!

Digital Production Specialist Elise Ondak eondak@wtwhmedia.com

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Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Events Manager Jen Osborne jkolasky@wtwhmedia.com @wtwh_jen Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

CONTACT CUSTOMER SERVICE AT: (800) 662-2290, or at info@interpower.com for more information.

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Design for Industry M a c h i n e To o l

How custom BLDC motors boost performance and lower costs

Ralph Adams

President • Orbex Group

Custom motors can improve the size and performance of machine designs — including AGVs.

From packaging to communications, BLDC servomotors are gaining market share in a variety of industries — and for good reason. They deliver high torque and smooth rotation (with minimal torque ripple) and lend themselves well to cost-saving customization.

Design engineers typically rely on off-the-shelf brushless dc (BLDC) motors as standalone components to work into their designs. But o entimes it makes more sense to order custom motors — especially where it’s impossible to satis application requirements with catalog components.

Stock motors by definition are a “take what you get” proposition when it comes to size and performance. In contrast, custom BLDC motors and motor assemblies can be designed to fit in tight or irregular spaces without sacrificing torque density. Motors can also be customized for demanding operating environments — whether the threat is thermal, corrosive, or electromagnetic.

Another reason to speci custom BLDC motors is to improve cost. One might assume that custom solutions are costly … but in many applications, the opposite is true. That’s because custom motor assemblies allow feature integration that can ultimately minimize the number of components on the bill of materials — and the assembly time necessary for putting all those components together.

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POWER TRANSMISSION

RETAINING DEVICES & maintenance & assembly tools

This is a custom BLDC motor om Orbex Group for an AGV application. The custom motor assembly integrates with a complete gearbox assembly.

BLDC motors versus stepper motors The focus here is on customizing BLDC motors. The high torque and compact size of BLDC motors has meant they’re increasingly common in today’s dynamic servo applications. They can even outperform designs traditionally run by stepper motors — primarily by improving the performance of servo machines ‌ as well as lowering maintenance requirements.

Of course, stepper motors (especially newer closed-loop variations) excel on several motion-axis types. However, motion designs needing advanced position control and high sha speeds as well as space savings o en necessitate BLDC motors. More specifically, many of these torque-dense motors offer power output that’s roughly triple that of equivalent stepper motors. This difference is due to the high number of poles that stepper motors need to deliver precise positioning under open-loop control. BLDC motors on the other hand deliver top precision sans any sacrifice to rotational speed or torque. No wonder BLDC motors are a top choice on everything om robotic arms to packaging machines needing higher-speed motions under closed-loop control.

Example one: Custom BLDC motors on AGV wheels One emerging application for BLDC motor customization is automated guided vehicles (AGVs). AGVs have come to be indispensable in futureproofed factories and automated warehouses. Because BLDC motors deliver reliable performance across various speeds and torque ranges, they’re a good fit for continuously rotating joints in robotic vehicles. Case in point: One new AGV design employs two custom BLDC motors.

The AGV’s first motor is a 2-kW 120-mm- ame motor with integral brake and encoder —as well as an optional wheel and tire.

This motor integrates a compact yet torque-capable roller reducer directly coupled to the motor output. This arrangement increases driveline stiffness — and saves space and cost.

The AGV’s second motor is a similar smaller system based on a 1-kW 80-mm- ame motor. It delivers gear ratios down to 16:1 — which in turn allow speeds to 2 meters per sec. It also boasts high radial load capabilities (for carts with 2,000-lb payloads) and incorporates optional case rotation. That lets engineers center the loads to be carried by the AGV over the motor’s output bearings to minimize moment loading.

DESIGN WORLD

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Design for Industry M a c h i n e To o l

Example two: Custom through-hole table for inspection of heavy workpieces For another machine build in an inspection and sorting process having challenging load, speed, and size requirements, supplier engineers configured and integrated a rotary through-hole table and servomotor.

The through-hole tables leverage the

This custom BLDC motor om Orbex Group has an integral planetary gear reducer.

advantages of servomotors, cam dividers, and direct-drive motors for top precision and rigidity (at a action of the cost of similar tables based solely on direct-drive motor technology). In fact, the complete actuation solution rotates parts weighing up to 40 lb under a sensor array for inspection — and does so at 200 rpm … even while having a low-profile design to fit into existing workcells.

For this design, the supplier engineers combined an Orbex Group HPM60 200 V servomotor with a THT85 through-hole table to outperform other tables based on mechanical rotary indexing as well as direct-drive motors.

Example three: Custom BLDC motor with planetary gear reducer Yet another motion-control application employs a custom BLDC motor with an integral planetary gear reducer. The optimized motor helps the machine meet various speed, voltage, and mounting requirements — and its high-quality

assembly maximizes controllability. More specifically, the OEM for this application needed a brushless gearmotor for a motion-control application requiring: • A short overall length • A planetary reducer with a 25:1 gear ratio • Use of 48-Vdc bus voltage • High-resolution encoder feedback • Commutation signals • Torque output of more than 2.5 Nm at 160 rpm The supplier’s engineering team tackled this application by modi ing a BLDC motor (the Orbex Group EC4260) with a special sha to allow direct mounting to a two-stage planetary reducer. This feature eliminated the need for costly adapter plates and internal couplings — which trimmed cost and overall design length. In addition, the supplier engineers optimized the motor’s winding to run off the 48-Vdc bus voltage as specified.

These modifications let the motor reach high speeds with minimal current draw.

Completing the package is an integrated 16,384-count magnetic encoder. The added resolution allows superior servo control and better stability.

The modifications and preintegration also prevented component overspecification — for a right-sized assembly costing less than $200. DW

Orbex Group www.orbexgroup.com

This compact THT Series through-hole table maintains accuracy equal to or better than 10 arc-sec to excel in various motion control and automation applications. In fact, the THT Series tables come in six ame sizes om 62 to 450 mm — in 62, 85, 130, 200, 300, and 450 models. All THT Series tables (which are based on servomotors rated to 10 kW) exhibit high precision, rigidity, and transmission efficiency. Torque outputs are 5 to 192 Nm and speeds to 200 rpm. One customized table om this series recently installed into a facility moving 40-lb workpieces at 200 rpm for an inspection process needing precision and stiffness typically associated with more costly direct drive motors.

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Design for Industry Medical

Ironhand superpower under control Ironhand, om the Swedish company Bioservo Technologies, is a so robotic glove that strengthens the human grip with help of the company´s patented SEM technology. The gripping force support of the individual fingers is made possible with FAULHABER drives.

Musculoskeletal disorders are a common occupational disease in the EU and North America and are one of the most common causes for long- term absence om work. Work-related upper-limb disorders annually cost 2.1 billion euros across the EU and are responsible for 45% of all occupational diseases. Wearables--clothing enhanced through technology--offer an approach for reducing these injuries. Ironhand, om the Swedish company Bioservo Technologies, is a so robotic glove that strengthens the human grip with help of the company´s patented SEM technology. The gripping force support of the individual fingers is made possible with FAULHABER drives.

At the EU level, repetitive work is the greatest risk factor. 74% of employees in the EU spend at least 25% of their working time performing repetitive arm or hand movements. According to the German Federal Institute for Occupational Safety and Health (Bundesanstalt fĂźr Arbeitsschutz und Arbeitsmedizin), musculoskeletal disorders are the most common cause for limited capabilities on the job, severe disabilities, early retirement and temporary incapacity to work. According to a survey performed by the European Agency for Health and Safety at Work, 45% of those surveyed suffer om painful or fatiguing positions at work, 25% om back pain and 20% om muscle pain. Studies show that, every second worker could be affected by musculoskeletal-related disorders by 2030.

Work-related disorders of the neck and upper extremities affect

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the throat, shoulders, arms, hands, wrists and fingers and cause tingling, numbness, discomfort or pain. The use of vibrating tools or coldness can worsen these problems. The effects are reduced mobility or grip strength. Both can cause additional dangers during work, for example if an employee can no longer safely hold or operate a tool.

Furthermore, demographic change means that society is becoming older as a whole and will remain in active working life longer. Improved ergonomics at the workplace are therefore increasingly important - both for healthy people as well as for those who are already physically disabled. In addition to solutions that make the actual workplace, e.g., the workbench, the desk or the assembly line, more ergonomic, companies increasingly rely on solutions that can be used to augment people.

Exoskeletons which are worn on the body like clothing, are one solution. www.designworldonline.com

More power in the hand Normally, a gripping action is made possible by the muscles in the lower arm and hand. These muscles pull on tendons, thereby moving the fingers.

Ironhand functions in a similar way: pressure-sensitive sensors in the fingertips of the glove detect the gripping action that the user performs with his or her hand. A computer integrated in the system calculates the additional gripping force that is necessary and small servomotors pull thin cables in the fingers. The higher the pressure on the sensors, the more power delivered by Ironhand. The settings of the glove can be adapted according to personal preferences as well as the type of work performed. Data functions enable a digital risk assessment of the hand and the integration of the user in an Industry 4.0 / factory-ofthe-future concept. Grip-intensive applications with high ergonomic risk DESIGN WORLD

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QUICK RELEASE PINS. can be identified by analyzing the data during practical work and users can take appropriate countermeasures.

Individual and versatile The glove is available in four sizes and can be worn by le - and righthanded users. The battery pack, which is worn like a backpack, contains both a computer unit as well as the motors that control the individual fingers.

Users can preset various profiles that contain different combinations of sensor sensitivity, force, finger symmetry and locking tendency. To change the profile, the user only needs to press a button on the remote control, which is located in the chest area.

By means of this profile, it is possible, for example, to flexibly respond to different requirements encountered during the course of the workday.

Such as if a person performs slightly stressful tasks during the morning followed by activities in the a ernoon that place heavy strain on the muscles.

This also allows both male and female users to work with one system. Within milliseconds, the system can provide up to 80 N of gripping force.

The system is designed so as not to impede the wearing of personal protective equipment (PPE), such as gloves, fall-protection devices, helmets or warning clothing. For breaks, it can be put on and taken off without external help. The capacity of the batteries in the power supply is designed for a typical working day.

Powerful drive To control the individual fingers, Bioservo uses dc-micromotors with graphite commutation of the 1741 ‌ CXR series in their Ironhand. The series combines power, robustness and control in a compact form. This is ensured by graphite commutation, high-quality neodymium magnets, and the tried-and-tested winding of the FAULHABER rotor. The powerful neodymium magnet gives the motors a high-power density with a continuous torque ranging om 3.6 to 40 mNm. The impressive performance data and the compact size open up a wide spectrum of possible applications at an optimized price/performance ratio. DW

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LOCATE YOUR DEALER ONLINE! The 1741 ‌ CXR series motor powers the Ironhand. The motor uses graphite commutation, high-quality neodymium magnets, and windings om FAULHABER. The neodymium magnet gives the motors a high-power density with a continuous torque ranging om 3.6 to 40 mNm. DESIGN WORLD

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www.fairlaneproducts.com 800.548.2935 10/6/20 10:37 AM

Design for Industry O f f- H i g h w a y

Rotational speed sensors allow highly sensitive mobile machine control

Holmer Maschinenbau GmbH, a German-based agricultural company, developed the first selfpropelled six-row sugar-beet harvester in 1974. Since that time, the Holmer machines have been in successful operation by customers in over 40 countries world-wide.

Sugar beet harvesters om Homer Maschinenbau require precise data collection, provided by Rheintacho speed sensors.

On its sugar beet harvesters, it requires a precise collection of actual values directly at the place of consumption (propulsion, toppers, and sugar beet transport systems). These data points are an absolute requirement for the optimum balancing of performance requirements of its high-performance harvesters for various consumers. The entire system must react precisely and quickly to the changing demands of the decentralized consumer.

For example, harvesting when the soil is looser requires less power for the harvesting module and driving through deep soil requires more propulsion power.

These parameters can change during a harvesting process, making constant adjustments necessary.

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Rheintacho’s FC-series rotational speed sensor Decentralized collection of the actual, current performance needs allows a precise adjustment to the power production. Rotational speed sensors om Rheintacho are used to record one of the most important performance indicators, namely the rotational speed of the hydraulically-driven operations, in a cost-effective way and without construction restrictions.

The sensor electronics of the fitted FC-series with asymmetric, one-eyed flange is constructed as a two-channel hall differential sensor. This sensor range complies with the standard DIN/ EN 13309 (construction machines, agricultural technology). It is designed to withstand especially high temperatures (up to 160 °C) and pressures thanks to its special brass alloy. The brass sensor complies with protection type IP69K

www.designworldonline.com

thanks to its intelligently designed sealing system.

FC-series sensors withstand especially high temperatures (up to 160 °C) and pressures thanks to their special brass alloy.

The sensors of the FC-series have two equency outputs. The extremely narrow tolerated phase shi of 20° in identi ing the direction of rotation means that the sensor provides a highly precise signal and enables highly sensitive controlling.

The prompt, contact- ee measurement of sha speed in these modern mobile hydraulic control circuits om Rheintacho has become an essential part of the Holmer system to guarantee the best harvesting results with minimal influence om the soil environment. DW

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Design for Industry Semiconductor

Contactless handling of small semiconductor parts

ZS-Handling’s solution includes the MicroLevi Gripper with different gripper tips for the different sizes, which can be easily exchanged using a collet chuck.

Technical progress and the demand for ever smaller and more powerful processors always lead to demanding requirements. New techniques, such as stacking very thin chips, are needed to enable the manufacture of innovative products.

Especially the properties of thin wafers and chips pose an additional challenge in handling. The materials are flexible, agile, and wavy, and o en also have specially treated surfaces (e.g. with adhesive).

With the help of the patented ultrasonic bearing om ZSHandling, substrates can float evenly on an air film generated by vibrations and therefore be held without contact during handling.

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Conventional handling systems o en have problems, for example particle contamination in air bearings caused by the air turbulence of compressed air (e.g.

Bernoulli grippers). Other systems without air supply, e.g. vacuum grippers, can leave traces such as marks or scratches on the substrate during handling. With the help of the patented ultrasonic bearing om ZS-Handling, substrates can float evenly on an air film generated by vibrations and therefore be held without contact during handling. Through a combination of negative pressure and ultrasound, attracting and repulsive forces act simultaneously on the workpiece, thus keeping it at a distance even when gripping om above.

The ultrasonic movement of the so-called sonotrode creates a supporting gas film (air or process gas) between the sonotrode surface and the substrate. The substrate floats on the resulting gas film at distances of 10 - 150 Âľm, depending on the application. In special cases, higher hovering heights can also be achieved. By using buoyancy forces due to vacuum, handling om above is also possible. In this way, any www.designworldonline.com

DESIGN WORLD

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mechanical surface contact is avoided.

The physics of the ultrasonic bearing results om flow dynamics and not om acoustic principles. The gas pressure in the gap between the workpiece and the vibrating surface increases due to the cyclic compression and decompression of the thin gas film. It is therefore necessary to realize a uniform oscillation pattern in order to generate constant floating forces over the entire sonotrode. The vibrations are not transmitted into the substrates and do not lead to any impairment of the substrate material.

With the repulsive forces of the ultrasonic bearing, the substrate can be moved without any iction even at very high speeds. In combination with vacuum, attractive forces can be applied simultaneously, which allows handling om above. In addition, flexible materials can be “smoothed� without contact by this technique, i.e. they can be kept in an TL Design World V1.pdf

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even, centered position.

For very small components (up to approx. 12 x 12 mm), the self-centering effect is effective when the gripper tip is precisely adjusted, which means that no side stops are required even for very precise positioning.

The force profile of ZS-Handling handling systems is similar to that of a conventional air bearing, but no compressed air supply is required. This means, for example, that in a clean room environment the laminar air flow - unlike with Bernoulli grippers - is not disturbed by high flow velocities and no particles can penetrate through external air or via pipes. Also, in new production lines the costs for the compressed air supply can be saved.

By avoiding surface contact and without dynamic turbulence in the ambient gas, no damage, micro-scratches, micro-cracks, or

contamination can damage the substrate.

Handling on machined or coated surfaces is possible without contact, allowing more degrees of eedom in process and machine design. During handling, a high level of flatness of the substrate is achieved as well.

The systems can be used in all atmospheric processes and in up to 20% partial vacuum processes. This requires fewer resources, such as energy or compressed air, than a standard air bearing.

This has a positive effect on the energy and cost balance for the handling systems of ZS-Handling.

In a clean room environment of ISO 6, dies of different sizes (10 x 10 mm, 5 x 5 mm and 5 x 12 mm) are to be separated om a cut wafer (ø 300 mm) attached to a sawing foil with a contactless gripper. A er that, the dies should be placed for the subsequent bonding process.

ZS-Handling’s solution includes the MicroLevi Gripper with different gripper

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Design for Industry Semiconductor

to facilitate contact- ee separation.

The die li ed in this way is picked up by the gripper tip without contact and moved to the next process step at high speed, where it can be placed easily and precisely by switching off the vacuum. DW

tips for the different sizes, which can be easily exchanged using a collet chuck.

With ultrasound and vacuum at the same time, the die can be gripped om above and held and swiveled without contact. Due to the self-centering effect at the gripper tip, the die can be gripped and placed down precisely even at rapid accelerations of over 2g. In order to achieve an optimal centering effect, the gripper tip must be adapted exactly to the format of the die, therefore three different gripper tips are necessary for this application. The gripper can be connected to any robot or axis system by an adaptable flange. Gripper and housing are made of anodized aluminum, the tip of the gripper is made of titanium.

In the application described here, the dies to be separated are pushed upwards by pins under the wafer to reduce the adhesive force on the adhesive film and

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Design Notes

Camera system helps metalworkers keep an eye on the fire Edited by Mike Santora • Associate Editor Metalworking furnaces and smelters operate at temperatures up to 2,900° F (1,600° C).

Metalworkers in primary and precious metal processing plants operate 24/7 in harsh environments where worker safety, the reliability and durability of the systems, and process automation top a long list of priorities. For optimal production, they must closely control the speeds, feeds, controls, additive consumption, labor allocation, and energy consumption of the melting process.

A key challenge they face is how to best monitor this process, which is contained within closed metallurgical vessels, typically involves toxic additives and happens at extreme temperatures (steelmaking, for example, is approx. 2,912 °F / 1600 °C). Direct visual observation of a melting process is impossible with modern safety standards.

Metalworkers have long relied on a heuristic time-based approach to manage their furnaces and smelters because there were no means to see what was happening inside.

Metallurgical Sensors Inc. (Metsen) has developed an industrial camera system called the EVCamX to bring direct human observation safely back into the smelting process. This technology helps metalworkers “keep an eye on the fire.” The hightemperature-rated vision system keeps workers out of harm’s way and provides a direct line of sight into an extreme DESIGN WORLD

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Design Notes environment that is not physically accessible. Now operators can watch the effects as oxidizing or reducing agents are introduced into the process.

Instead of guesswork, operators can now react rapidly to changing situations discerned om the continuous close-up observation of reactions inside the smelter. In the steel industry, for example, downtime can cost upwards of $10,000 per hour — seconds count. If enhanced vision can shave 15 seconds off a critical process, over $100K can be saved each month by not having to slow down the machines (realizing a production increase of 1.4%).

Other industries that also have noxious encapsulated environments such as petrochemical, aggregates, food and beverage, and pharmaceutical, would benefit om integrating this technology to safely monitor their processes.

The EVCamX design has a unique composite of copper and stainless steel. The most noteworthy element is the protective technology designed into the camera’s optics to keep it clean.

The ultra-high thermal conductivity of the materials, combined with a proprietary gas-cooling rocket-nozzle design, protects the camera viewport om being fouled by the molten splash and debris that regularly defeat conventional high-temperature camera systems. The near-supersonic flow of industrial gas or air creates an almost impenetrable barrier to protect the optics.

Camera shown on top of a pilot-plant metallurgical test furnace which operates at temperatures around 3074 °F / 1690 °C for measuring the reaction rates of additives.

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The camera’s ultra-high thermal conductivity composite metal rocket nozzle viewport flash freezes molten splatter into flakes that mostly fall-away for simplified maintenance.

The second purpose of the protective technology is to keep the camera system cool. All high-temperature The EVCamX software camera work requires a cooling and imaging provides realsystem. Once smelting operations time data for better start, the furnaces typically run decision-making and continuously for weeks or months optimized production. at extremely high temperatures without shutting down. The structures surrounding the furnace become heat soaked, up to 575 °F (300 °C), which is hazardous to workers.

Water can also be used as secondary cooling in environments where air-cooling alone is insufficient. This additional and information systems to provide water cooling ensures the camera and its real-time data for better decisioncomponents remain safe for human touch making and optimized production. It can during any maintenance. be customized to meet an operator’s The EVCamX system features highspecific needs. It also includes a database definition optical camera sensors and can historical viewer that continuouslybe customized with optional LiDAR profilers, archives the digital imagery streams, spectrometers, and a variety of thermal the customer’s level-1 and level-2 data, measurement devices. The system is and any other custom ancillary subdesigned to be a platform for synchronized systems such as acoustic and vibration multi-sensor fusion for advanced data to provide an innovative means of monitoring and control of applications in synchronized process visualization. extremely harsh environments.

Choosing the right visualization system for use in harsh and highImagery helps accelerate process temperature production environments improvements requires careful consideration. A solution The camera system is supported by a that can run for an extended period so ware and imaging package that can be with no adverse effect on the furnace or fully integrated into the operator’s processes DESIGN WORLD

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smelter requires technology with process engineering knowledge built into its design. It should also be constructed in suitable, durable materials, supported by a so ware and imaging package, and backed by a service agreement to ensure optimal system performance, care, and maintenance throughout the product lifecycle. DW

Metallurgical Sensors metsen.com

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Design Notes

MSC So ware ensures the VEGA launchers structural integrity

Edited by Mike Santora • Associate Editor

The Vega launch. | Image credit: Arianespace

While the race to Mars is making headlines, there is another ongoing space race that will shape the digital era and the way the world is connected: satellites.

Satellites are essential for many of the services we use every day, om locationtracking GPS to high-speed communication with 5G networks. Over 2,000 active satellites have been deployed in space, many of which live very close to the Earth’s surface in Low Earth Orbit (LEO).

In the last decade, there has been increasing demand for LEO satellites due to a need for faster networks and greater connectivity. For example, Earth observation programs, such as the European Space Agency’s (ESA) Copernicus, need to be able to take continuous and high-quality images to provide accurate information for ground-monitoring use. LEO satellites are crucial for supplying this data in real-time to observatories, and their launches are also less expensive and require less fuel than other satellites operating further away.

Launching into this orbit requires a great deal of technical precision, however.

ESA’s satellite launch vehicle, VEGA, was specially designed by Avio using simulation

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tools provided by MSC So ware, which is part of Hexagon’s Manufacturing Intelligence division, to send small satellites into LEO. Since its maiden flight in February 2012, the small and flexible VEGA launcher has successfully carried over 20 spacecra into orbit. The next phase of the VEGA launcher, VEGA-C, has been approved and is now undergoing reviews.

The Acoustic Challenge Among the many technical challenges in designing VEGA, the most important of all was to ensure the integrity of its structure and provide a safe environment for its cargo: the satellite payloads. Launchers are subjected to severe conditions at DESIGN WORLD

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Interstage response map.

li -off, om blazing heat to immense atmospheric pressure, but the acoustic load is most critical. The noise generated by the launcher during ignition, li off, and flight can cause vibrations and lead to electronic and mechanical components malfunctioning in both the launcher and its cargo.

To ensure this doesn’t happen, engineers at Avio used a computational approach to predict how sound affects the structure at li -off. With the help of computer-aided engineering (CAE) solutions, MSC Nastran, and Actran, they were able to create accurate Finite Element Analysis (FEA) platforms for structural simulation. These simulation tools are used across nearly every kind of industry, om aerospace to medical technology.

Avio used Nastran to compute the natural motion of VEGA’s structure and applied Actran to model both the acoustic environment and acoustic load

of that structure.

The Avio VEGA and VEGA-C launchers are made of multiple stages, each playing a critical role and requiring extensive tests before being flown. The payload fairing, installed within the launcher’s upper stage, is responsible for protecting the spacecra . It is a cone made of composite carbon fiber reinforced polymer sheets that protect the spacecra om the impact as launch. It shields it om atmospheric turbulence and heat while the launcher passes through the Earth’s atmosphere, protecting it and the payload om the damaging soundwaves during take-off.

To assess VEGA’s upper stage’s complete structural response, experimental acoustic tests were conducted at ESA’s Large European Acoustic Facility, which can simulate the noise at li -off. During the test, the payload fairing’s interior acoustic environment was measured, and MSC Nastran was used to create a Finite Elements (FE) model of the entire upper stage structure.

External and Internal The first step was to assess the acoustic domains with the payload fairing’s relative microphones and general behavior measurement points. while it endured | Image credit: Avio exterior acoustic load.

A study was performed to assess the different simulation opportunities provided by Actran and the required computational time when developing new launchers.

In the first simulation, a Diffuse Sound Field (DSF) excitation was applied directly on the exterior structure, using data

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acquired by the acoustic measurements, to test the spacecra ’s structural integrity during launch when subjected to acoustic pressures.

This quick and useful numerical strategy provided insight into the structural vibrations, but it was not able to model the sound pressure inside the structure and how that affects it, as the fairing’s interior and exterior acoustic environments were not modeled.

To overcome this limitation, a second simulation was performed to explore the internal acoustic cavities. The FE models of the fairing cavities were added to the entire structures, and two possibilities were investigated: a hybrid solution with the structure as modal components and the cavities as physical components, and a fully modal solution with both structural parts and acoustic cavities as modal components. The latter solution proved to be more flexible and versatile.

A final simulation was conducted to provide a very detailed reconstruction of the test launcher. This extensive simulation allowed the external and internal environments to be accurately modeled. Still, it was very demanding in terms of memory, (RAM) capability, and computation time due to the degrees of eedoms involved in the analysis.

The new VEGA-C launcher Once VEGA was validated using these tests, the same acoustic simulation methodology was implemented to evaluate the vibro-acoustic response for the new VEGA-C structures. VEGA-C will be able to accommodate larger payloads such as Earth observational satellites of over two tons.

Engineers at Avio analuzed its most sensitive parts: the interstages between the solid rocket motors and the upper stage.

Interstage structures connect the various parts of a multistage rocket. They are also responsible for the separation of the stages a er launch. These structures are susceptible to vibro-acoustics because they contain much of the rocket’s electronic equipment, so the

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Design Notes

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same combination of MSC Nastran and Actran was used to evaluate their response.

One example of interstage structures is payload adapters, which connect the satellite to the launch vehicle. Both VEGA and VEGA-C launchers are extremely flexible thanks to their ability to accommodate different payload adapters, allowing them to carry multiple payloads at a time according to different configurations. However, as payload adapters contribute to the overall stiffness of the launch system, they can be heavily affected by resonances in the fairing cavity, so it is important to a predict the vibration they will be subject to.

Therefore, the analysis took the internal payloads into account, simulating them coupled with the launcher structure and the acoustic cavities.

Testing new modeling capabilities In addition to the above FE approach, Avio’s engineering team also performed a statistical energy analysis (SEA) of the payload fairing using Actran’s Virtual SEA approach. This method allows engineers to predict how sounds and vibrations pass through a structure, especially at higher equencies where noise can be more penetrable. Relying on previous FE models, the Virtual SEA approach implemented in Actran enables efficient vibro-acoustic analysis om existing FE models by extending them to higher equencies without needing specialist SEA expertise. Furthermore, as the Virtual SEA approach relies on existing low equency FE models, SEA results are valid at both low- and mid- equencies and provide a smooth transition between mid- and high- equency results.

When the available physical measurements and Actran Virtual SEA results on the fairing structure were compared, the engineers found that both results were similar, demonstrating the potential of this new approach to tackle such analysis. Moreover, Actran and the Virtual SEA approach provide a unified environment in which engineers can address their vibro-acoustic challenges across the complete equency range, and use multiple tools for low, mid- and high- equencies analysis. The approach has since been used for further structural analysis on VEGA-C. Using MSC So ware’s solutions — MSC Nastran and Actran — engineers at Avio were able to predict the effect of noise vibrations on the structural integrity of its launchers, VEGA and VEGA-C, ensuring the vital components of these launchers were able to withstand the extreme pressures of launch and li -off. DW

MSC So ware | mscso ware.com 36

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Design Notes

Heavy-duty ring and track system delivers under pressure Edited by Mike Santora • Associate Editor

Bishop-Wisecarver’s HepcoMotion HDRT (Heavy Duty Ring and Track) Systems are specifically developed for high-performance applications. HDRT guidance systems are characterized by their ability to carry very high loads — moving reliably and accurately with very little wear. At Eurocylinder Systems AG the HDRT guidance system has proven itself in a demanding production environment with large amounts of contamination and residues.

Eurocylinder Systems AG is a medium-sized company in the metal processing industry and a high-pressure steel cylinders manufacturer. These cylinders are used to store and transport compressed, liquified, and dissolved pressure gas used in technical, fire protection, diving, beverage, and medical applications. Each cylinder is made om a steel tube, cut into casings between eight and twelve meters. The wall thickness varies om three to nine millimeters, with six different diameters — 140, 172, 178, 204, 229, and 267mm. At the plant, around 1000 casings are cut per day. Every year, Eurocylinder Systems produces approximately 500,000 high-pressure steel cylinders. The plant is predominantly operated in rolling shi s or in three-shi operation and is in operation for over 300 working days per year.

Historically, the cutting of the casings was done using two bandsaws. For this, the supplied tubes were cut into casings of the required lengths with vertical cuts (perpendicular to the tube axis). This was a lengthy process taking up to five minutes per cut. Eurocylinder Systems wanted to optimize this complex process. In 2009, the bandsaws were replaced by a plasma cutting machine. The cutting head of the plasma system has two plasma torches. They are placed opposite each other and rotate during the cutting process on a circular path 180° around the steel tube. One cutting head is responsible for the upper half of the pipe, the other for the lower half of the pipe. Eurocylinder Systems needed to ensure reliable, low-maintenance guided motion of these critical cutting head elements.

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The time saving using the HDRT and plasma cutter system is therefore about 60 to 70%, if the tube length, diameter, and wall thickness are the same.

Requirements: no wear and low maintenance To guide the plasma cutting heads along a prescribed circular path, a ring-shaped high-performance guide system was required that can meet the required operating times ee of faults. The main requirement was to install a guide system that can be wear- ee and low-maintenance in operation.

Additionally, the rings need a high load-bearing capacity to support the entire cutting head (approximately 330 lbs. or 150 kg in total) and operate at the required rates. The plant is in a hall subject to ambient temperatures. Therefore, the guide must, be resistant to contamination arising om the production process and withstand the external influences — in particular, the temperature variations. This means that the plant and the guides must be operable with minimal downtime during any weather, in any season, with temperatures between 77 and 104 °F.

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The cutting head of the plasma system has two plasma torches.

They are placed opposite each other and rotate during the cutting process on a circular path 180° around the steel tube. One cutting head is responsible for the upper half of the pipe, the other for the lower half of the pipe.

Challenges: deposits and impurities Due to the plasma cutting process conditions, large amounts of combustion residues and contamination are produced during this production step.

During the cutting process, the burnt material is carried into the interior of the pipe casing by the plasma jet,

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which causes problems later on in the processing. Therefore,the casings must be cleaned following the plasma cutting.

Guide systems also become polluted with slag splashes and fine dust deposits om the plasma fumes.

To withstand the demanding environment, the solution consisted of

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two HDRT (Heavy Duty Ring and Track) ring systems to hold the cutting heads and guide the circular paths. These rings feature vee guide technology that delivers a self-cleaning action, which means that any contamination is wiped away by the vee bearings as they run along the track. Eurocylinder Systems installed a special housing with a felt ring seal for the HDRT rings that protect the HDRT rings om external influences such as dirt and dust to further combat the slag splashes and material deposits.

In this application, each ring has a 786 mm diameter and is made om hardened, high-quality tool steel with precision-ground running surfaces. The two parallel rings each use four 95 mm diameter eccentric vee bearings for the high loads. Lubrication is provided by four lubrication blocks (two per HDRT ring). The blocks are made of impact-

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Design Notes resistant plastic including, a springtensioned, lubricant-soaked felt wiper for low- iction lubrication and high load capacity and lifetime. The lubrication blocks have now been in service for more than seven years without being refilled.

The main aim of Eurocylinder Systems was the optimization of their plasma cutting process while at the same time accelerating and automating the cutting process. Using the bandsaw, up to four pipes were cut simultaneously, depending on the diameter. The bandsaw required five minutes, just for the cutting.

With an overall cycle time of about six minutes, that means 90 seconds per casing. The plasma cutting system only needs five to ten seconds for one cut, depending on the tube diameter and thickness. The total cycle time amounts to about 30 seconds per casing. The time saving using the HDRT and plasma cutter system is about 60 to 70%, if the tube

length, diameter, and wall thickness are the same.

Self-cleaning HDRT vee rings provide low-maintenance guided motion The system of plasma cutting heads and HDRT guidance has been in use since 2009. Since then, the system has required no maintenance and has resulted in no errors or faults. The angled geometry of the HDRT system expels soot and slag debris as the vee guide wheel runs along the matching vee ring surface. Both the plant and the HDRT

system are exposed to these harsh environmental conditions, but the system has proven reliable, running without any maintenance or failure for over a decade. DW

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CAE Solutions

A new 3D approach to remote design engineering Karl Maddix • co-founder and CEO, Masters of Pie

The coronavirus pandemic has forced almost every business to adapt to new ways of working. In many cases, conferencing services have saved the day – enabling remote teams to collaborate on projects when they can’t be in the same room. But two-dimensional (2D) conferencing is a poor substitute for engineers trying to work together remotely on complex 3D data to design the latest motor vehicle or jet engine.

And trying to untangle complex problems remotely om thousands of miles away is aught with difficulties – even when using products like Microso ’s Remote Assist. The expert o en has to resort to waving their hands around on a screen to communicate to the technician which part of a machine they should be fixing – and which parts should be le alone.

Real-time immersive 3D collaboration is now adding a new dimension to such problem solving – users can share live, complex 3D files such as CAD data, interact with them and reveal ‘hidden’ parts deep within a machine that may be causing an issue. The technology also transforms

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day-to-day collaboration between remote engineering team members. Design reviews, for example, can be brought to life, with participants ‘walking through’ a model, no matter where they are in the world.

The fundamental problem at the root of many of these issues until now has been that enterprise teams have lacked the ability to effectively collaborate in real time using live, complex 3D data. The solution lies in purpose-built

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The key to enabling true real-time collaboration is to start where the data ‘sits’ and ensure that this original data ‘truth’ is the same for everybody when working together, no matter where they are located or what device they wish to use. This way, everyone in the team has the correct and most up-to-date information available.

Whether it is a CAD package, PLM so ware, an MRI scanner, robotic simulation so ware or a laser scanning system, many industries are becoming increasingly dependent on spatial data types and digital twins. These complex data formats are usually incompatible or just too cumbersome to use ‘as is’ in existing collaboration platforms such as Webex, Skype, Google docs or Slack – all built primarily for 2D data formats such as video, text or images.

Moreover, the legacy so ware generating the data itself is unlikely to have any in-built real-time collaboration functionality – forcing enterprise users to resort to one of two methods. One option is to manually export the data, carry out a painful and time-consuming reformatting process, then manually import the newly crunched data into some type of third-party standalone collaboration package. The alternative is to ignore the spatial nature of the data entirely and instead screengrab or render out 2D ‘flat’ images of the original 3D data for use in a basic PowerPoint presentation or something similar.

Neither of these methods allows teams to efficiently collaborate using a live data truth – i.e. the original data itself instead of a reformatted, already out-of-date interpretation of it. So, both methods only compound the root collaboration problem instead of helping to solve it.

The latest generation of real-time immersive 3D collaboration technology is integrated directly into the host so ware, grabbing the original data at source before efficiently pushing it into a realtime environment which users can access using their choice of device (VR, AR, desktop, browser or mobile) for instant and intuitive collaboration.

End-to-end encryption ensures that even the most sensitive data may be confidently shared across remote locations.

The integration into the host package provides not only a live connection to the data but also a bi-directional connection, meaning that users are

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still connected to the host software package running in the background. The advantage of this over standalone applications is that it still gives access to core features of the host package – enabling accurate measurement of a CAD model using vertex or spline snapping to the original B-Rep held in the CAD package, for example. All the underlying metadata from the host package is also available to the immersive experience – and annotations, snapshots, action lists or spatial co-ordinate changes can be saved back into the host package.

The new post-pandemic requirement to have a distributed workforce – in conjunction with the rollout and adoption of key technology enablers such as serverside rendering and high-capacity, lowlatency connectivity – is set to accelerate the adoption and integration of real-time immersive collaboration solutions. In the future, 5G technology will also open up the potential to stream to immersive AR and VR devices – untethering the experience and facilitating factory-wide adoption of immersive solutions. For example, as ‘Industrial Internet of Things’ (IIoT) data streams from smart devices in the factory, it will be overlaid via AR glasses in the physical space. And as cloud service providers build out features such as spatial anchoring to support ever-larger physical spaces, these new services will be used within collaborative environments rich with real-time data.

Factory workers, for example, will have the ability to ‘dial an expert’ directly from a virtual panel on a smart factory device. This offsite expert will appear as a holographic colleague and bring with them live 3D data for that individual machine. Both users will have real-time IIoT data overlaid intuitively on the fully interactive 3D model to facilitate a more effective diagnosis and maintenance process.

Empowering shop-floor workers with hands-free AR and detailed 3D data will dramatically improve assembly line efficiency, with an intuitive environment where product data is fully interactive. Users will be able to move, hide, isolate and cross-section through parts, while using mark-up and voice tools to create efficient instructions for the assembly or disassembly of complex products. These

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CAE Solutions instructions will be recorded and delivered as holographic guides via AR directly on the assembly line.

The next generation of real-time immersive 3D collaboration technology is even set to enable you to have a scaleddown hologram of your latest engine design sitting right in ont of you on your desk. As you work on the design and refine it using your CAD so ware, the changes will be dynamically loaded into the hologram so that you can see the effects immediately and make any further necessary adjustments.

Meanwhile, digital sleeving – with 3D images overlaid on physical designs – will enable you to check how two parts of the engine come together, even when they are being designed by different teams in different locations. Similarly, you will be

able to see how, for example, cabling will fit inside your latest aircra seat design or where best to put the maintenance pockets for easy access.

This kind of approach adds a new dimension to the handoff between design and manufacturing.

If adjustments need to be made to a fan assembly design, for example, the relevant part can be isolated within an immersive design review – and speechto-text notes can be added to the part number and automatically become part of the change request. It’s all a far cry om endless design iterations, spreadsheets and printouts – or CAD screen shares using a 2D representation of a 3D problem.

In the post-pandemic remote world, conferencing is bringing people, video

and documents together. Collaboration is now adding the fourth dimension of 3D immersive experience to complete the picture. DW

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CAE Solutions

Market for CAE/Simulation So ware will reach $6.1 bn this year

Cambashi, a leading global industry analyst and market consulting firm, together with partner intrinSIM announced its latest COVID-adjusted CAE/Simulation market data & forecast, which indicates the CAE (computeraided engineering) market has been growing in double-digit figures and will continue on that path excluding 2020.

“These growth rates illustrate the beginning of the Simulation Revolution, which will continue to grow as more organizations realize that Engineering Simulation is a Key Driver to the Business Drivers that enable increased competitiveness,” said Joe Walsh, intrinSIM. “While 2020 will present lower growth rates, and Cambashi expects negative growth om e.g. the automotive industy, growth overall is still expected to be positive,” said Petra Gartzen, Senior Consultant, Cambashi.

Going forward, the trends that were driving adoption of simulation have not gone away because of COVID-19. The need to develop new, greener versions of any kind of product will accelerate, especially in industries generating vapor trails.

And COVID-19 is also opening up new opportunities especially DESIGN WORLD

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around modeling air flow, people movement, and space organization in any kind of building – be that a factory, a museum, an office, transport, etc.

– where people spend significant amounts of time in close proximity. The need to provide a safe working environment to get industries back to some kind of normal situation could also result in new linkages between CAE and BIM vendors and CAE and IIoT/Connected Application technology providers. DW

Cambashi www.cambashi.com/CAE

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Internet of Things

System monitors the performance of more than 40 machines.

BETA site: Virtually every machine on the Castiglione d’Adda site is equipped with Werma signal towers and SmartMonitor.

The “plug and play” system simply requires a transmitter unit to be added to the signal tower which will then monitor the status change of the machine or equipment, including optionally, the output count.

To reduce unplanned machine downtime, improve response time to down time, and to ee up latent machine capacity, BETA Utensili installed a low cost and retrofittable machine monitoring and data collection system at its plant in Lodi in Italy. Signal towers indicate machine status and transmit this information wirelessly to a PC workstation where it gives a transparent overview of the operation. The easy to install wireless monitoring system provides the tool manufacturer with the required data to analyze and optimize the production process.

Davide Negroni can view the status of all machines in his office in real time.

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BETA Utensili is Italy’s leading manufacturer of professional working tools and instruments – om pliers to screwdrivers, hammers, cutting tools and instruments for measurement and test, even down to personal protective wear equipment.

Davide Negroni is one of 600 staff employed at the company. He manages production at the site at Castiglione d’Adda close to Lodi. “I am responsible for the complete production process,” says Negroni “and we make several million tools per year, half of which are

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sold in Italy, the other half sold on the international markets.”

The search for the right solution “In the past we had a constant battle with machine downtime which went either unnoticed or were uncovered far too late” says Negroni. “In addition to which I could never see the productivity of our machines in real time, which also affected the response time, so we had to find a solution.”

Through a Google search the 50 year old Production Manager found the

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monitoring and machine data collection system SmartMonitor om Werma.

“Unlike the other systems I was able to install SmartMonitor by myself, simply quickly, and intuitively. I was able to install the transmitter units onto our existing Werma signal towers and with the system being “plug and play” contact the receiver to the PC and away we go!” reports Negroni. The Production manager was pleased and impressed: “I found it especially good that I was able to install the trial kit live in our production and test it. This means that it is all no longer theoretical but you can check the heartbeat of the machines yourself.”

SmartMonitor consists of wireless transmitters, a wireless receiver and the so ware. The tried and tested system transmits data on 868 MHz and the networked transmitters roam continuously looking for the optimum route to send data back to the receiver. A wireless transmitter unit is simply added to an existing Werma signal tower and monitors constantly status changes of the machine, equipment or manual work-station and, if selected, the count of the output.

Status changes are transmitted wirelessly to the receiver unit and saved to a SQL database which is an integral part of the so ware supplied.

Signal tower acts as the interface The monitor offers an alternative to monitoring machines and work-stations and collecting data in an uncomplicated and simple way.

The intelligent networking of signal towers provides the basis for a cost-effective, simple and retrofittable alternative to more complex traditional monitoring systems. Type of machine or age is not important as the WERMA signal tower serves as the interface for the system.

At the Castiglione d’Adda site of BETA machine tools, presses and other special machines which are all networked on the SmartMonitor system. Negroni says; “our production facility is extensive, with many different types of machines, some of which are out of line of sight. This system offers the best

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Internet of Things The software displays the networked signal towers fitted to a machine. Productivity can be analysed and error statuses reviewed in order to increase the productivity and efficiency of the machine.

possibility to see machine stoppages and error statuses immediately enabling speedy responses. During night shi when there is no supervisor on duty I can be informed of machine status change by e-mail and can see immediately if the machine is operating correctly. This enables the response time to issues to be minimized and avoids lengthy stoppages.”

Once the initial test phase was completed Negroni ordered more units.

“We have now installed SmartMonitor

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on more than 40 machines,” he says. Dr. Vismara who runs the BETA site in Milan has also installed the Werma system. “We use SmartMonitor at our site to check the performance of the facility and analyze downtime and the causes of unplanned stoppages.”

BETA is happy with the system and already planning to expand its use. “We will install the system on the rest of the machines in use already and then on future purchases.” DW

Werma | www.werma.com

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10/5/20 11:41 AM

Gateways link the world of serial communication to IoT

With the 2019 acquisition of the business of Comtrol Corporation, a US-based pioneer in industrial Ethernet communication and IO-Link masters, Pepperl+Fuchs expanded its portfolio of Industry 4.0 solutions. Enhancements include DeviceMaster gateways, which have been fully integrated into the Pepperl+Fuchs’ product line.

With serial and industrial Ethernet translation capabilities, DeviceMaster makes it possible to integrate networks and systems otherwise isolated by separate protocols into the IoT world without investment in major equipment upgrades. The intelligent, rugged, and easy-to-use family of gateways ensure that the right information is available at the right time, paving the way for Industry 4.0.

DeviceMaster industrial Ethernet gateways support the range of modern and legacy equipment available on the market. They can be used to link Ethernet-based controllers, SCADA systems, and HMIs with field-level devices such as barcode scanners, RFID read heads, weigh scales, vision systems, printers, encoders, and sensors.

DeviceMaster servers and gateways are available with 1 to 32 serial ports with DB9 or terminal block connectors for DIN rail, panel, and

DESIGN WORLD

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rack mounting. They support RS-232/422/485, MODBUS RTU, and ASCII for device connectivity and MODBUS TCP, EtherNet/IP, and PROFINET for interfacing with PLCs and industrial Ethernet networks. An integrated web server makes it easy to configure network settings and port parameters for communication with TCP/IP and industrial Ethernet systems, while Windows and Linux drivers support PC-based applications.

For large-scale applications that require many DeviceMaster gateways, the ee configuration and management so ware, there is PortVision DX. It allows serial devices to be managed, network settings to be configured, and module configurations to be cloned or saved as backup. This speeds up system configuration and ensures productivity. DW

Pepperl+Fuchs www.pepperl-fuchs.com

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Internet of Things

Making industrial data accessible and actionable

The Mendix low-code application development platform helps customers build contextual and personal solutions for data-driven decision-making processes. With the general availability of Mendix Data Hub and Mendix for Industrial Edge services, customers can achieve an end-to-end view of their plants, factories, and systems and provide domain experts with actionable insights through solutions developed with the right data om across the organization.

The Mendix platform extends the Xcelerator portfolio with the ability to build multi experience apps and share data om any location, on any device, on any cloud or platform, to more quickly realize the benefits of digital transformation.

A goal for digital transformation is factory automation, which can be slowed down by distance - both physical and organizational - between operational technology (OT) and organizations co-located at factory locations, and IT organizations housed at corporate headquarters. The Mendix for Industrial Edge platform empowers factory operators to create custom applications on the Mendix low-code platform that run locally as Edge Apps to collect data, have access to insights in near real-time and provide optimal user experiences to a variety of end users. The low-code platform is designed to abstract much of the complexities and

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expand the talent pool for IoT application development, further empowering OT leaders to address pressing issues with limited IT intervention. Business developers, domain engineers and plant operations staff can create Apps for Siemens Industrial Edge without programming skills. When combined with Siemens’ MindSphere, the industrial IoT as a service solution, and other Xcelerator cloud solutions, customers can realize the benefits of an integrated edge to cloud experience.

Disparate legacy systems, containing data in various formats and heritage DESIGN WORLD

10/5/20 11:43 AM

that supports complex physical models can challenge companies in providing developers and engineers secure access to the right data. To help organizations discover, understand, use, and curate data om across the enterprise, and employ it in so ware development, business intelligence, and other data-rich applications, Siemens announced availability of the Mendix Data Hub. In conjunction with the Mendix low-code development platform, the Mendix Data Hub can help organizations realize a dramatic decrease in application delivery time, as developers no longer waste time searching for the right data, seeking the right data owner, minding API calls, and securing access to the data they need.

Initially, the Mendix Data Hub will connect to the most common industrial data sources, such as Teamcenter so ware and SAP, with future releases expanding support for other common data services and databases, and industry-specific applications.

The Mendix Data Hub can also be extended by eQ’s eQube Data-as-a-Service, as part of a newly expanded partnership between Siemens and eQ Technologic, with a rich set of over 60 smart connectors, providing support for industrial data and system integrations. DW

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A Supplement to Design World - October 2020 www.designworldonline.com

CropHopper

robot takes novel approach to field monitoring page 62

INSIDE: • AI in agriculture: How PyTorch enables Blue River’s robots ............................................54 • Augean Robotics mechanizes food production, from farm to table ......................66 • Building service network for 10,000 autonomous combines ...................................70

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The Robot Report

AI in agriculture:

How PyTorch enables Blue River’s robots The PyTorch open-source machine learning library has helped guide weeding robots.

Chris Padwick | Blue River Technology

How did farming affect your day today? If you live in a city, you might feel disconnected from the farms and fields that produce your food. Agriculture is a core piece of our lives, but we often take it for granted.

Farmers today face a huge challenge — feeding a growing global population with less available land. The world’s population is expected to grow to nearly 10 billion by 2050, increasing the global food demand by 50%. As this demand for food grows, land, water, and other resources will come under even more pressure.

The variability inherent in farming, like changing weather conditions, and threats like weeds and pests also have consequential effects on a farmer’s ability to produce food. The only way to produce more food while using less resources is through agricultural robots that can help farmers with difficult jobs, offering more consistency, precision, and efficiency.

Agricultural robots use PyTorch At Blue River Technology, we are building the next generation of smart machines. Farmers use our tools to control weeds and reduce costs in a way that promotes agricultural sustainability.

Our weeding robot integrates cameras, computer vision, machine learning, and robotics. The intelligent sprayer drives through fields using AutoTrac to minimize the load on the driver and quickly targets and sprays weeds, leaving the crops intact.

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A 2017 prototype of the See & Spray precision weed-control machine. | Source: Blue River Technology The machine needs to make real-time decisions on what is a crop and what is a weed. As it drives through the field, high-resolution cameras collect imagery at a high frame rate. We developed a convolutional neural network (CNN) using PyTorch to analyze each frame and produce a pixel-accurate map of where the crops and weeds are.

Once the plants are all identified, each weed and crop is mapped to field locations, and the robot sprays only the weeds. This entire process happens in milliseconds, allowing the farmer to cover as much ground as possible, since efficiency matters.

To support the machine learning (ML) and robotics stack, we built an impressive compute unit, based on the NVIDIA Jetson AGX Xavier System on Module System On Module (SOM) AI on the edge computer. Since all our inference happens in real time, uploading to the cloud would take too long, so

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we bring the server farms to the field.

The total compute power onboard the robot just dedicated to visual inference and spray robotics is on par with IBM’s Blue Gene supercomputer (2007). This makes this a machine with some of the highest compute capacity of any moving machine machinery in the world!

Building weed-detection models My team of researchers and engineers is responsible for training the neural network model that identifies crops and weeds. This is a challenging problem because many weeds look just like crops. Professional agronomists and weed scientists train our labeling workforce to label the images correctly.

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The Robot Report Field operations specialist Alex Marsh with a large self-propelled sprayer. | Source: Blue River Technology

In the image below, the cotton plants are in green, and the weeds are in red.

Machine learning stack uses PyTorch for training On the machine learning front, we have a sophisticated stack. We use PyTorch for training all our models. We have built a set of internal libraries on top of PyTorch.

This allows us to perform repeatable machine learning experiments. The responsibilities of my team fall into three categories: • Build production models to deploy onto the robots • Perform machine learning experiments and research with the goal of continually improving model performance • Data analysis/data science related to machine learning, A/B testing, process improvement, software engineering We chose PyTorch because it’s very flexible and easy to debug. New team members can quickly get up to speed, and the documentation is thorough.

Before working with PyTorch, our team used Caffe and Tensorflow extensively.

In 2019, we made a decision to switch to PyTorch, and the transition was seamless.

The framework gives us the ability to support production model workflows and research workflows simultaneously.

For example, we use the torchvision library for image transforms and tensor transformations. It contains some basic functionality, and it integrates really nicely with sophisticated augmentation packages like imgaug. The transforms object in torchvision is a piece of cake to integrate with imgaug.

Let’s look at a code example using the Fashion MNIST dataset. A class called Custom Augmentor initializes the iaa.

Sequential object in the constructor, then calls augment_image() in the call method.

CustomAugmentor() is then added to the call to transforms.Compose(), prior to ToTensor(). Now the train and val data loaders will apply the augmentations defined in CustomAugmentor() when the batches are loaded for training and validation.

In addition, PyTorch has emerged as a favorite tool in the computer vision ecosystem. (Looking at Papers With Code, PyTorch is a common submission.)

Would you have distinguished cotton plants from weeds at a glance? | Source: Blue River Technology

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This makes it easy for us to try out new techniques like Debiased Contrastive Learning for semi-supervised training.

On the model-training front, we have two normal workflows: production and research. For research applications, our team runs PyTorch on an internal, on-prem compute cluster. Jobs being executed on the on-premise cluster are managed by Slurm, which is an HPC batch job-based scheduler. It is free, easy to set up and maintain, and provides all the functionality our group needs for running thousands of machine learning jobs.

For our production-based workflows, we utilize an Argo workflow on top of a Kubernetes (K8s) cluster hosted in AWS. Our PyTorch training code is deployed to the cloud using Docker.

Deploying models on field robots For production deployment, one of our top priorities is high-speed inference on the edge computing device. If the robot needs to drive more slowly to wait for inferences, it can’t be as efficient in the fields. To this end, we use TensorRT to convert the network to an Xavier optimized model. TensorRT doesn’t accept JIT models as input, so we use ONNX to convert from JIT to ONNX format. From there, we use TensorRT to convert to a TensorRT engine file that we deploy directly to the device.

As the tool stack evolves, we expect this process to improve as well. Our models are deployed to Artifactory using a Jenkins build process, and they are deployed to remote machines in the field by pulling from Artifactory.

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To monitor and evaluate our machine learning runs, we have found the Weights & Biases (W&B) platform to be the best solution. Their API makes it fast to integrate W&B logging into an existing codebase. We use W&B to monitor training runs in progress, including live curves of the training and validation loss.

SGD vs. Adam Project As an example of using PyTorch and W&B, I will run an experiment and compare the results of using different solvers in PyTorch.

There are a number of different solvers in PyTorch -- the obvious question is “Which one should you pick?”

A popular choice of solver is Adam. It often gives good results without needing to set any parameters and is our usual choice for our models. In PyTorch, this solver is available under torch.optim. adam.

Another popular choice of solver

| Source: Blue River Technology

for machine learning researchers is Stochastic Gradient Descent (SGD). This solver is available in PyTorch as torch. optim.SGD. Momentum is an important concept in machine learning, as it can help the solver to find better solutions by avoiding getting stuck in local minima in the optimization space.

Using SGD and momentum, the question is this: “Can I find a momentum setting for SGD that beats Adam?”

The experimental setup is as follows.

I use the same training data for each run and evaluate the results on the same test set. I’m going to compare the

F1 score for plants between different runs. I set up a number of runs with SGD as the solver and sweeping through momentum values from 0–0.99. (When using momentum, anything greater than 1.0 causes the solver to diverge.) I set up 10 runs with momentum values from 0 to 0.9 in increments of 0.1.

Following that, I performed another set of 10 runs, this time with momentum values between 0.90 and 0.99, with increments of 1. After looking at these results, I also ran a set of experiments at momentum values of 0.999 and 0.9999.

Each run was done with a different

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The Robot Report Figure 1: On the left side, the f1 score for crops is shown on the X axis, and the run name is shown on the Y axis. On the right side, the f1 score for plants as a function of momentum value is shown. | Source: Blue River Technology

random seed, and was given a tag of “SGD Sweep” in W&B. The results are shown in Figure 1.

It is very clear from Figure 1 that larger values of momentum are increasing the f1 score. The best value of 0.9447 occurs at momentum value of 0.999 and drops off to a value of 0.9394 at a momentum value of 0.9999. The values are shown in the table below.

How do these results compare to Adam? To test this, I ran 10 identical runs using torch.optim.Adam with just the default parameters. I used the tag “Adam runs” in W&B to identify these runs.

Table 1:

I also tagged each set of SGD runs for comparison.

Since a different random seed is used for each run, the solver will initialize differently each time and will end up with different weights at the last epoch. This gives slightly different results on the test set for each run.

To compare them, I will need to measure the spread of values for the Adam and SGD runs. This is easy to do with a box plot grouped by tag in W&B. The results are shown in graph form in Figure 2, and in tabular form in Table 2. The full report is available online too.

You can see that I haven’t been able to beat the results for Adam by just adjusting momentum values with SGD. The momentum setting of 0.999 gives very comparable results, but the variance on the Adam runs is tighter, and the average value is higher as well. So Adam appears to be a good choice of solver for our plant segmentation problem!

PyTorch visualizations With the PyTorch integration, W&B picks up the gradients at each layer, letting us inspect the network during training.

W&B experiment tracking also makes it easy to visualize PyTorch models during training, so you can see the loss curves in real time in a central dashboard. We use these visualizations in our team meetings to discuss the latest results and share updates.

As the images pass through our PyTorch model, we seamlessly log predictions to Weights & Biases to visualize the results of model training. Here we can see the predictions, ground truth, and labels. This makes it easy to identify scenarios where model performance isn’t meeting our expectations.

Here we can quickly browse the ground truth and predictions and the difference between the two. We’ve labeled the crops in green and the weeds in red. As you can see, the model is doing a pretty reasonable job of identifying the crops and the weeds in the image.

Table 1: Each run is shown as a row in the table above. The last column is the momentum setting for the run. The F1 score, precision, and recall for Class 2 (crops) is shown. | Source: Blue River Technology

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Reproducible models Reproducibility and traceability are key features of any ML system, and it’s hard to get right. When comparing different network architectures and hyperparameters, the input data needs to be the same to make runs comparable.

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Table 2:

Table 2: Run table showing f1 score, optimizer, and momentum value for each run. | Source: Blue River Technology

F-Score 0.940

0.920

Often, individual practitioners on ML teams save YAML or JSON config files.

It’s excruciating to find a team member’s run and wade through their config file to find out what training set and hyperparameters were used. We’ve all done it, and we all hate it.

A new feature that W&B just released solves this problem. Artifacts allow us to track the inputs and outputs of our training and evaluation runs. This helps us a lot with reproducibility and traceability. By inspecting the Artifacts section of a run in W&B, I can tell what datasets were used to train the model, what models were produced from multiple runs, and the results of the model evaluation.

A typical use case is the following.

A data-staging process downloads the latest and greatest data and stages it to disk for training and test, with separate data sets for each. These datasets are specified as artifacts.

A training run takes the training set artifact as input and outputs a trained model as an output artifact.

The evaluation process takes the test set artifact as input, along with the trained model artifact, and outputs an evaluation that might include a set of

metrics or images.

A directed acyclic graph (DAG) is formed and visualized within W&B. This is helpful since it is very important to track the artifacts that

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Figure 2: The spread of values for Adam and SGD. The Adam runs are shown in the left of the graph in green. The SGD runs are shown as brown (0.999), teal (0–0.99), blue (0.9999), and yellow (0.95). | Source: Blue River Technology

| Source: Blue River Technology

| Source: Blue River Technology

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| Source: Blue River Technology

are involved with releasing a machine learning model into production. A DAG like this can be formed easily: One of the big advantages of the Artifacts feature is that you can choose to upload all the artifacts (datasets, models, evaluations), or you can choose to upload only references to the artifacts. This is a nice feature because moving lots of data around is time consuming and slow.

With the dataset artifacts, we simply store a reference to those artifacts in W&B. That allows us to maintain control of our data (and avoid long transfer times) and still get traceability and reproducibility in machine learning.

Leading ML teams Looking back on the years I’ve spent leading teams of machine learning engineers, I’ve seen some common challenges:

• Efficiency: As we develop new models, we need to experiment quickly and share results. PyTorch makes it easy for us to add new features fast, and Weights & Biases gives us the visibility we need to debug and improve our models.

• Flexibility: Working with our customers in the fields, every day can bring a new challenge. Our team needs tools that can keep up with our constantly evolving needs, which is why we chose PyTorch for its thriving ecosystem and W&B for the lightweight, modular integrations.

• Performance: At the end of the day, we need to build the most accurate and fastest models for our field machines. PyTorch enables us to iterate quickly, then productionize our models and deploy them in the field. We have full visibility and transparency in the development process with W&B, making it easy to identi the most performant models.

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The ground truth, predictions and the difference between the two.

Crops are shown in green, while weeds are shown in red. | Source: Blue River Technology

I hope you have enjoyed this short tour of how my team uses PyTorch and Weights and Biases to enable the next generation of intelligent agricultural machines! RR

About the author: Chris Padwick is the director of computer vision and machine learning at Blue River Technology. The company was acquired by John Deere in 2017 for $305 million.

www.therobotreport.com

THE ROBOT REPORT

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The Robot Report

CropHopper robot

takes novel approach to field monitoring Part drone, part legged robot, CropHopper jumps across fields to scan crops and identify weeds and diseases.

Eugene Demaitre | Senior Editor, The Robot Report

Robots can perform many functions in agriculture, om monitoring crops and livestock, to applying fertilizer and pesticide, to harvesting uits and vegetables. While most farm automation involves wheeled robots or aerial drones, HayBeeSee has taken a different approach with its CropHopper robot.

Part drone, part legged robot, CropHopper is designed to move across fields and monitor crops, identi weeds and insects, and watch for signs of disease. It can also conduct mechanical weeding and spot spraying, said the London-based company.

CropHopper can provide better information for farmer decision making than periodic aircra surveys or slower ground-based robots, claimed HayBeeSee.

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Understanding agricultural needs “I studied aerospace engineering and was looking for the next big thing in 2013,� recalled Fred Miller, founder and CEO of HayBeeSee. “Both led to agriculture and robotics, and in 2015, we looked at quadcopters in agriculture.� “People didn’t understand early on what problems in agriculture to solve,� Miller told The Robot Report.

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HayBeeSee is currently working on making its CropHopper robot more rugged, sealing it for dust, and testing different foot designs. | Credit: HayBeeSee “When you talk to agronomists, they view farming as a system. You could use a waterfall chart to show the contribution of things like cultivation, the choice of crop-rotation strategy, and different applications of herbicides. A lot comes down to timing.”

“The problem is that robotics startups were going with a stand-alone model, but it’s not like washing a car. You have to stay on it,” he said. “If you only go out once in a while, you have to waste a lot of time mapping, and with no data to start, you don’t know how effective a spray is. Farmers need something that visits the field very frequently, not simply technology to make one or two scans at the end of the season.”

“A tractor can’t scan every few days, a UAV can’t scan close to the ground, and a satellite can’t provide enough data for decisions,” said Miller.

“At 14 kph [8.6 mph], a tractor for spraying or

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harvesting moves too quickly to detect weeds.

CropHopper is more than a remote-control airplane or pre-existing vehicle base for cameras.”

CropHopper designed for daily monitoring HayBeeSee said its lightweight robot is designed to quickly and efficiently leap as part of an integrated, full-season management strategy. Two carbon fiber arms are key to the hybrid design. The arms are tightened, using a winding mechanism, and then released, bouncing the robot into the air. Its four propellers then engage to propel CropHopper forward as its camera captures field images.

To extend drone flight times, Miller’s team considered using solar cells, but that was not

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The Robot Report

To extend its flight times, HayBeeSee considered using solar cells, but that was not practical. CropHopper needs to recharge every three hours, and it can cover 29.6 acres per hour.

The goal is for it to cover 172.9 acres per day. | Credit: HayBeeSee

practical, he said. CropHopper needs to recharge every three hours, and it can cover 12 hectares (29.6 acres) per hour.

The goal is for it to cover 70 hectares (172.9 acres) per day.

“I already knew from aerospace that it’s hard to optimize for lift and weight, so a jumping mechanism is more efficient,” said Miller. “We hired a Ph.D. student who was a jumping robotics expert. We then put flex legs on a quadcopter.”

“Depending on where you are in the world, the average field is 15 hectares [37 acres],” he said. “CropHopper currently works best in smaller fields, but since it is designed to run for three years without replacing parts, you could have a different strategy with multiple robots for larger fields.”

“When we thought about vehicle missions, we started out thinking about the field as a rectangle, but we soon realized that farmers just need representative samples,” Miller explained.

“CropHopper can accelerate from point to point faster than a wheeled robot. Also, it weighs only 3.5 kg, or 7 lb., and can move across terrain and over obstacles more like four-legged robots for the military, which provides some flexibility and doesn’t compact soil.”

“At the beginning of 2018, we built a device that could jump, control itself, and land,” added Tomasz Wierzchowski, chief technology officer at HayBeeSee. “We’ve

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been polishing it up with computer vision and conducting trials.”

More data could yield better farm returns Last year, CropHopper mapped 30 hectares (74 acres) of fields for an estimated 60% in chemical savings.

HayBeeSee is currently working on making its robot more rugged, sealing it for dust, and testing different foot designs.

While CropHopper’s current height of 70 cm (27.5 in.) is suitable for wheat and barley, foot extensions could make it useful for taller crops such as soybeans and corn, Wierzchowski said. Most legged robots have been designed for more open terrain, he noted.

“We initially focused on weed killing, because CropHopper can cover a lot of land and fly between patches of weeds and crops, but it has gotten much bigger than that,” Miller said. “Agronomists like that it can work all season long, and no other robots can go to the field every day and do the job of killing bugs or applying fertilizer.”

“Image quality, accounting for the robot’s motion, and understanding what you want to measure and at what height are more things that people need to understand,” he said. “There has been a bottleneck of data and technology.”

CropHopper sends data to a Webbased portal where farmers can plan www.therobotreport.com

modifications. HayBeeSee said it could help increase yields by 10% to 30% and triple profits.

In addition, the company said its hopping robot can reduce environmental impacts by cutting carbon emissions and improve sustainability with a lower impact on soils.

HayBeeSee said that all of its test farms, plus an additional 20 more, have requested the product when it is ready.

Agbotics ready for growth HayBeeSee has received angle funding from ESA Business Incubation Centre UK, Innovate UK, the London Co-Investment Fund, and Newable. The company is looking for seed funding.

“In agriculture, there has been some resistance to investing in innovation, but European policies are now driving change,” Miller said. “There is now a lot of interest in farm management platforms, but there’s still a need for new hardware.

We need to go from Ph.D. specialists to the wider knowledge base of industry and engineers.” RR

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Augean Robotics

mechanizes food production, from farm to table Recent automation demonstrations show both the promise and challenge of the agricultural market.

Oliver Mitchell

Back at CES in January, many people may have wondered why a tractor was taking up more than 120 feet inside the already overpacked robotics section of the Las Vegas Convention Center.

Ever since its acquisition of artificial intelligence startup Blue River Technologies for $305 million, John Deere has been betting its future on data-driven agriculture. Hence the enormous green combine on the show floor.

“It’s a great chance for those in the tech industry to visit with them and to learn more about how their food is produced and the important role technology plays and will continue to play in putting food on their tables,” explained Laurel Caes, public relations manager at John Deere.

I hosted Charles Andersen, CEO of Augean Robotics, at RobotLab to dig into the agritech market. He grew up with the industry in a family with generations of farmers. After business school, Andersen worked at John Deere’s largest competitor, Case New Holland (CHN).

After analyzing Blue River and the wider unmanned marketplace for CHN, Andersen concluded that “autonomy is a force for new market disruption within agriculture, meaning that it is a force best commercialized by startups, so I decided to start a robotics company focused on agriculture.”

Augean Robotics, one of The Robot Report’s 2019 Startups to Watch, has one of the few systems actually working in the fields, while other upstarts are still tinkering indoors.

“Roughly 2 million U.S. farms produce about $400 billion in revenue annually,” he noted. “On a revenue basis, half of output is crops, and half is livestock.”

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The Burro agricultural robot.

Specialty crops ripe for disruption Livestock and grain production are already on track to becoming fully automated, Andersen claimed.

“Livestock production is often fairly mechanized and in some cases automated -- robotic milking parlors for example,” he said. “Meanwhile, about one quarter of U.S. farm output is grains -- corn, soybeans, wheat, and other field crops like cotton. These crops are very mechanized, with little in the way of labor in their production. This is where Deere, CNH, Kubota, AGCO, and others focus their marketing and R&D dollars building bigger and better tractors, combines, sprayers, etc.”

This leaves specialty crop production such as berries, orchards, and vegetables,

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| Source: Augean Robotics

which account for 88% of labor, as the literal low-hanging fruit for disruption.

Andersen painted a portrait of aging farmers struggling with increasing overhead and razor-thin margins, forcing many owners to sell their family estates and move production to Central and South America.

“Overall, there is rising demand for food with growing global population. The irony of rising population is that as we have more people on the planet, we have fewer farmers and fewer people looking to work for farmers,” he said. “Thus, inputs across the board, from labor to water to fertilizer to machinery, are increasingly expensive and scarce, and generally speaking, growers are looking to do more with less.”

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The Robot Report

A data-driven tractor at CES 2020.

| Source: John Deere

Based on Andersen’s remarks, robotics is more than the newest equipment; it could be the savior of the U.S.’s agrarian economy.

While many financial analysts have projected uber growth for agritech, the present reality is stymied by long sales cycles and difficult operating environments.

“On the challenges side, the average age of a U.S. farmer is 58, and these rising ages correlate with consolidation and an ever-smaller number of larger operators,” Andersen said. “Simultaneously, the conditions

are often very challenging for autonomy, with the lighting, weather, field variability, and harshness that robots must face and handle consistently over and over again.”

At the same time, the opportunities could be larger than for other areas of autonomy, as unmanned farm vehicles are able to immediately navigate around workers without regulations, pedestrians, or other obstacles.

Augmenting farming with mobile robots Rather than replacing humans, Augean Robotics’ approach is to alleviate today’s agronomy inefficiencies by augmenting

farmhands with mechanical donkeys called Burros.

“We are doing something different,” boasted Andersen, “taking a stepped or phased approach towards full autonomy, beginning with a collaborative robotic platform called Burro that helps people work more productively today, collects tons of data, over time can be modularly expanded towards fully autonomous farming in a variety of different settings, and which we can get into the market today, not five years from now.”

After observing how table grapes were picked and collected, Andersen launched a self-driving wheelbarrow to autonomously steer through vineyard rows as a shopping cart for harvesters.

“We’ve found that, like Kiva systems in Amazon warehouses, if you automate in-field transit, you can enable people doing high-value/high-dexterity work like picking to be much more productive,” Andersen said. “A crew of 10 people harvesting table grapes with one of our robots running them back and forth can pick 40% more fruit per day, and the payback on one of our robots is accordingly just 30 and 40 days.”

In the long term, Andersen said he hopes to translate his success in table grapes to other labor-intensive crops such as berries and orchard fruits.

In fact, his biggest worry for Augean Robotics being a startup is scaling his

The Burro robot can use a machine leraning detection and tracking model to follow a designated person, remote-free, through any setting.

| Thee Source: Augean

Robotics

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A preview of foodservice automation The vision of Augean Robotics’ Charles Andersen

A self-driving wheelbarrow for table grapes. | Source: Augean Robotics

team to keep up with demand.

“Every grower that buys our robots starts asking about five other use cases, o en in different crops, that we didn’t imagine our Burros going in to, and we have to ensure that our autonomy functions consistently and reliably everywhere,” he said.

Andersen said he imagines a robotic herd eventually forming a complete farming logistics platform.

“In five years, I see our Burro robots forming the core API for many of the future autonomous tasks people would like in specialty crops,” he said. “By mastering the process of moving om A to B in complex farming settings with a powerful and modular autonomous platform, I believe we are building a tool-carrying platform that can enable autonomous picking, pruning, weeding, spot spraying, and a host of other tasks.” RR

is embraced by many other roboticists who see a convoy of logistical solutions om the farm to the table. Also at CES 2020, I was introduced to RoboJuice, a tasty invention by juice bar proprietor Mikalai Sakhno.

“I realize that the automation of the food is an inevitable future, and I wanted to participate in the change,” said Igor Nefedov, CEO of RoboJuice.

“Our smoothies will be cheaper, higher-quality, and [require] little wait.”

In light of the recent spate of robo-downturns, including Zume Pizza, Creator, and CaféX, society might not yet be ready to turn over the kitchen to the bots. Nefedov disagreed, arguing in favor of more humanoid robots.

“We’re using human-like robots because it’s scientifically proven that people prefer robots that look like them,” he said. “People will eventually create an emotional connection -- that will drive repeat customers.”

RoboJuice is still in building mode and planned to open a first kiosk to showcase its anchise concept later this year. In the meantime, on a busy evening at CES, I passed a completely empty automated bar, Tipsy Robot. I asked the hostess what was good, and she directed me to the casino’s nightclub, “as the bartender there makes a mean mojito.”

About the author: Oliver Mitchell is a Venture Partner at ff Venture Capital.

Augean Robotics is a portfolio company of ff Venture Capital.

Tipsy Robot’s robot-run bar at CES 2020. | Source: Oliver Mitchell

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Building service network for 10,000 autonomous combines Russian firms to sell, install, and maintain autonomy systems for harvesters, tractors, and sprayers.

Eugene Demaitre | Senior Editor, The Robot Report

For agricultural robotics to be more widely adopted, farmers will need services to help maintain and repair intelligent systems. EkoNiva Holding Co. and Cognitive Pilot have signed a three-year agreement to outfit farm machinery with the C-Pilot autonomous driving system and create a service network across Russia.

Moscow-based Cognitive Pilot is a technology joint venture of Sberbank and Cognitive Technologies Group. The company’s customers include Hyundai Mobis, Russian Railways, Transport Systems PC, and major Russian and international vehicle makers. It recently launched a pilot project to install the Cognitive Agro Pilot so ware and hardware in 242 combine harvesters used by Rusagro Group LLC.

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EkoNiva is the largest partner of farm equipment manufacturer John Deere in Russia. Under the agreement, the Russian-German agricultural holding company will sell the Cognitive Agro Pilot system, as well as install, set up, maintain, and provide engineering support for it. The operations will cover 35 regions of Russia and more than 10 climate zones.

THE ROBOT REPORT

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Supporting Russian agbotics development Cognitive Agro Pilot uses a convolutional neural network to analyze data from a single video camera to understand the types and positions of objects, build trajectories, and send commands to perform maneuvers. Many other agricultural systems use more expensive suites of sensors, according to the company.

C-Pilot is intended to provide autonomy to equipment such as grain harvesters, tractors, and sprayers, freeing operators to focus on the quality of harvesting, claimed Cognitive Pilot. The system can operate safely in harsh weather conditions, with any light intensity, and without GPS, it added.

The partnership between EkoNiva and Cognitive

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Pilot also includes the creation of new smart farming systems. The project is a part of the digital ecosystem of Sberbank, a multinational institution that is working to build up the Russian agricultural technology sector.

“The combination of the unique technological solutions of Sberbank’s Cognitive Pilot subsidiary and EkoNiva’s expertise in sales and services in the regions will position us to improve the quality of customer interactions using the Cognitive Agro Pilot system and help enhance the service level,” said Anatoly Popov, the deputy chairman of Sberbank’s executive board.

www.therobotreport.com

EkoNiva, the largest partner of farm equipment manufacturer John Deere in Russia, will outfit farm machinery with the C-Pilot autonomous driving system. | EkoNiva

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C-Pilot uses AI to analyze camera data. | Cognitive Pilot

Training and nationwide support Cognitive Pilot said it is already training EkoNiva engineers on how to install and set up its autonomy systems. The company plans to train its partner‘s entire service department, from the Leningrad region to Novosibirsk.

“The large-scale work to service combine harvesters across such a vast territory is expected to enable EkoNiva and Cognitive Pilot to amass the world’s most comprehensive video image database for further training of neural networks that combine harvesters already use in Russia, as well as in the U.S., Latin America, China, and other countries,” stated Olga Uskova, the CEO of Cognitive Pilot. “The cooperation between the companies will not only allow us to expand Cognitive Agro Pilot’s sales network in Russia, but also provide our customers with high-quality and fast local services.”

“EkoNiva’s service network will provide a full range of work, including installation, adjustment, repair services and maintenance, as well as consulting of agricultural enterprises about the Cognitive Agro Pilot system,” she told The Robot Report. “All the measures and work meet the highest level of the ‘basic dealer standard’ requirements introduced by John Deere and supported

by Cognitive Pilot.”

“Service engineers will monitor the condition of the Cognitive Agro Pilot hardware and will provide the necessary technical advice,” Uskova said. “In case of any nonstandard technical situations,

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a specialized technical support team will come to the farms to solve complex technical issues in the shortest time. The satellite navigation system allows the dispatcher to identify the nearest engineer to the breakdown site and send him to the client.”

Autonomy for 10,000 combines Under the terms of the three-year contract, technicians will install C-Pilot on up to 10,000 combines from different farm equipment manufacturers.

“Covering the introduction and maintenance of artificial intelligence systems for agricultural enterprises, this agreement is among the largest ones in the world,” said Bjorne Drechsler, first deputy CEO of EkoNivaTekhnika-Holding.

“Fitting our customers’ equipment with autonomous motion systems should improve the efficiency of harvesting and cut the cost of grain for them by 3% to 5%.”

EkoNiva’s “vast geographic footprint and an extensive network of modern service centers will let it quickly scale up the use of artificial intelligence technology in Russia and reinforce its position as a smart agriculture leader,” he said. RR

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Robotics Robotics THE ROBOT REPORT

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| AdobeStock.com

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Updating the old rules of inertia matching

Modern servo drives with advanced tuning capabilities — when paired with performance servo motors having high-resolution feedback — can eliminate load-to-motor inertia-mismatch concerns.

The accepted principle of matching motor to load inertia

The Kollmorgen engineering staff

is no longer pertinent with today’s faster motion-control processors and advanced control algorithms. This outdated inertia-matching method of optimizing system dynamics increases costs and adds unnecessary mass in applications where load inertia is high and the continuous torque requirements are low.

The truth is that motor inertia is only one consideration when developing an optimally performing solution delivering good bandwidth and servo stiffness.

As we’ll explore in this article, two elements are key to building highperformance motion systems: • Mechanisms that are designed to be stiff • Application components that are suitably sized for the application

The dynamics of precision multi-axis laser-cutting machines benefit from newer and more innovative design approaches that emphasize inertia reduction and stiffness maximization.

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Compliance creates delayed response times — in turn reducing system bandwidth. If a design engineer introduces a large inertia mismatch into such a system, the problem of compliance is only magnified.

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Inertia matching was believed to address the stable control of a driven load connected to a servo motor.

During the 1970s when brush-type servo motors began to replace hydraulics in the machine-tool world, designers calculated the load inertia, torque, and speed requirements based on the expected performance of the machine.

Then when selecting a motor to meet the needed torque and speed requirements, if the motor to load inertia wasn’t close to a 1:1 match, engineers used one of two options: • They’d swap in a motor having higher inertia • They’d use a gearbox to reduce the reflected inertia seen by the servo motor Both of these approaches work but increase the system cost. Though optimal power transfer does occur when inertias are matched, that doesn’t guarantee an

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K

Jmtr

Jload

As the ratio between Jload and Jmtr increases Je will approach Jmtr so if Jmtr decreases then Je decreases causing the resonant frequency to go up.

Increasing K also causes frequency to go up. The anti-resonant frequency will not change because load inertia is constant but will increase with an increase in stiffness. Note frequency ƒ is in rad/sec for these equations.

A1 Series: Standard Servo Cylinder

efficiently operating system.

Ideally, total system inertia should be reduced to expend less energy. However, a larger motor increases the torque required to accelerate the added motorrotor inertia.

There are still other considerations to application sizing. During the initial transition of hydraulic to electric motors, quick analysis of complete mechanical and control systems was limited by available technology.

Of course, the construction of closedloop servo systems includes components that can dramatically affect machine performance — including the motor, attached feedback device, coupling to the load, and the capabilities to tune the servo loops. Today’s systems can provide good performance by letting design engineers tune the servo loops to operate within the target bandwidth and servo stiffness, which in turn optimizes the

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BODE PLOTS — GAIN AND PHASE GAIN MARGIN ≈ 9.2 dB BANDWIDTH ≈ 11 Hz AMPLITUDE of an IDEAL SYSTEM

The MP4U from ACS is an 8-axis modular EtherCAT drive module that lets system designers tailor the specific drive for each axis. Different drives can be selected for each pair of axes as well as the power supplies.

PHASE MARGIN ≈ 48°

response to controller commands … even while minimizing overshoot.

In these systems, the servo motor is controlled by a servo drive using current, velocity, and position loops. Each loop is tuned to create an enhanced system response by ensuring: • System stability • Quick reactions to torque or velocity disruptions • Smooth operation.

In contrast, the tuning systems of the past forced design engineers to tune servo loops using discrete components and potentiometers. That meant engineers had to adjust loop gains largely through experimentation. Limited analytical tools and processing power combined with

PHASE of an IDEAL SYSTEM

discrete components demanded a close inertia match between motor and load.

Unfortunately, even as processors and analytics improved (and digitally tuned servo loops were developed) the old demand for a 1:1 match continued to perpetuate.

Technological advancements first brought (limited) changes

With the advent of brushless motor technology, high-energy NeFeB magnets, and digital tuning loops, the inertiamatching protocol met with new complications. High-energy magnets located on the rotor made for motor inertias that were far smaller than those of comparable brush-type motors. So, motors meeting the application’s needed

Bode plots contain important information about bandwidth, phase and gain margins, resonances, and anti-resonance points. In a perfect system, we expect the amplitude plot to be a straight negative slope, -20 dB/decade. The phase plot should start at -90° and drop at a negative slope from the point the amplitude crosses zero dB.

continuous and peak-torque capabilities had higher load-to-motor inertia mismatches.

It’s true that servo-drive digital tuning loops made it considerably easier to adjust gains and filters to provide stable control.

However, the low processor speeds, lowresolution feedback devices, and other limiting factors of the time often led to the development of brushless-motor options with excessive inertia.

Increased processing power allowed the complex analytics to create accurate mathematical modeling and simulation of system responses.

So now, advanced tools integrated into today’s servo drives create interactive analytics of complex mechanical systems.

For design engineers, that simplifies the process of optimizing servo systems.

Axis

Original Jm (kg-cm2)

New Jm (kg-cm2)

Load inertia (kg-cm2)

Original inertia mismatch

New inertia mismatch

Increase

Cost savings

X

120

67.7

256.75

2.14

3.79

77%

17%

Y

17

4.58

9.56

0.56

2.09

273%

34%

Z

121.6

80

29.4

0.24

0.37

54%

17%

This chart illustrates the improved performance and cost savings when engineers stop using the old inertiamatching approach in favor of using increased mechanical stiffness and reduced inertia.

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Advanced analytics also let machine builders understand (in detail) the precise fingerprint of the mechanical system … and how to best address performance limitations.

Compliance — the menace of high-bandwidth solutions

Compliance in mechanical systems is the natural springiness of the powertransmission components between the driven load and the motor. This compliance creates delayed response times — in turn reducing system bandwidth. What happens if a design engineer introduces a large inertia mismatch into such a system?

Well, the problem of compliance is only magnified.

Case in point: Consider a motion design having a small motor capable of output torque sufficient to move an exceptionally large load … but the motor and load are connected via a coupling.

When the small motor quickly applies torque to the large load, the larger load will hesitate to respond, because an object at rest tends to stay at rest. The delay is a result of coupling compliance between the motor and load that introduces windup before the load begins to move.

Unfortunately, as the load eventually syncs up with the motor, the large inertia overshoots the target speed … causing the smaller motor to adjust by slowing down.

When the system adjusts the large inertia’s overspeed, the target speed is again passed — triggering the small motor to adjust once more. This continued cycling creates resonance and an unstable system.

Most mechanical systems can be mathematically modeled and simulated using various excitation frequencies to quickly identify the frequency response — the frequencies at which a resonance occurs. System bandwidth can never exceed the initial anti-resonance point of the system.

The goal of increasing bandwidth is to push the initial resonance frequency higher by identifying and addressing the cause of the resonance. In a compliant system, as the compliance or springiness increases, the frequency of the initial resonance point

is at a relatively low Hertz (Hz) value — which in turn decreases system bandwidth.

In contrast, when the driven load is directly coupled to the motor to minimize compliance, the mismatch is mitigated — increasing the initial resonance frequency and creating a higher-bandwidth system.

Increased stiffness and reduced system inertia

As mentioned earlier, mathematical models representing a mechanical system show that the ultimate solution for a higher bandwidth and cost-effective system is to increase the mechanical stiffness … and to reduce total system inertia.

Consider a direct-drive solution in which load directly couples to the motor with nearzero compliance. Precisely controlling the system with good bandwidth can be wachieved even with inertia mismatches exceeding 1,000:1.

In an extremely stiff (non-compliant) system, the servo system should be sized to provide the necessary torque to move the system inertia in the manner needed by the specific application. Of course, because direct-drive solutions are not suited to all applications, most motion system designs will include power-transmission components that do in fact introduce some compliance.

But advanced analytical tools on some of today’s servo drives readily identify the compliant elements that reduce system performance.

Bode plots of motion system designs

The Bode plot is a powerful analytical tool consisting of two charts illustrating the frequency response of an injected signal to identify the amplitude and phase lag of the system.

Bode plots also provide clues about a system’s inertia mismatch, number of connected bodies, and friction levels … and can identify the system’s open and closedloop bandwidths, phase and gain margins, and resonance frequencies. This information is invaluable for tuning the system to deliver optimal performance. Usually such optimization is done through adjustments to loop gains, the installation of various digital filtering modes, and (in some cases) slight

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design changes to the system’s mechanics.

Refer to the Bode plot example accompanying this article. Using this Bode plot, we can determine the open and closed-loop bandwidths … as well as the associated gain and phase margins. The bandwidth is represented by the frequency at which the open-loop plot reaches 0 dB — here at about 11 Hz. The phase margin is the number of degrees above -180° (about 48°) and the gain margin is the amplitude measurement corresponding to a phase of -180° — about 9.2 dB. Just consider one real-world application example illustrating how to successfully optimize performance along with cost by applying improved system stiffness to the solution — without concern for inertia mismatch …

A three-axis laser-cutting machine was initially designed (and its axes’ motors selected) using the inertia-matching approach. A redesign aimed to reduce the machine’s cost and boost its performance.

A review of the application requirements showed that alternate motor solutions could increase the system resonance point to allow additional gain and phase margins and improved stability.

The new servo motor used in the improved version of the laser-cutting machine reduced the total system inertia, provided higher power density in a smaller package, and increased the stiffness of the machine axis having a large shaft diameter — the one having a high resonant frequency. This increased shaft stiffness reduced compliance which improved performance. DW Kollmorgen | kollmorgen.com

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All-in-one vs. separates for motion control PC-based open controllers work well in some machine control systems, while standalone controllers remain the better option for others.

Kevin Wu | Siemens Industry Machine automation is progressing and evolving, as are options for deploying motion control. System subcomponents that used to operate independently of each other are becoming increasingly connected, and data interdependency among these components is growing. The data revolution and connected devices are letting manufacturers achieve previously unattainable production results, but these intricately integrated systems require more thorough application planning than in the past.

Traditionally, machine automation system architectures have included a motion controller to command servo and stepper drives, a separate logic controller (PLC), and a standalone human-machine interface (HMI). But recently, OEM machine builders have recognized it can be advantageous to integrate the functions of these three devices into a single unit for 82

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A glass bottle manufacturing line with superimposed software emulation.

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OEMs have options when it comes to automation system architectures, enabling them to better equip their systems for application optimization. certain applications. In response to OEM demands, automation vendors now offer a combined device that’s a hybrid personal computer (PC)-based open controller, combining motion and standard logic control with an HDMI output to a monitor.

The open controller concept simplifies data exchange and the network architecture because there are fewer separate devices to specify, install, and integrate. However, standalone controllers have their advantages in more complex and specialized applications.

In either setup, OEMs can take advantage of modern data-interdependent optimization.

PC-based open controllers An open controller combines the functions of a standard logic controller, drive controllers, and HMI software with an HDMI output into a single PC-based platform. This consolidation of devices simplifies access to data because the open controller becomes the single repository for tag storage, and it eliminates the need for data exchange among multiple controllers and a separate HMI. In addition to tag storage, open controllers can host the same types of algorithms end users and OEMs typically use with standalone logic and motion controllers. Available programming languages include ladder logic, function block diagram, and structured text routines—as well as high-level program code such as C++.

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The Siemens ET200SP Open Controller 1515SP PC2 T combines automation and drive controller functionality with an HDMI output to a monitor in a single PC-based device. The TF model adds the capability for machine safety programming as well.

In stride with this fusion of functions, open controllers also integrate a PC-based operating system (OS) for running complex applications and algorithms, while using an independent partition for cyclic logic

and motion controller program functions.

OEMs can run high-level program code in the PC-based half, or as instructions on the cyclic execution side, depending on the requirements of the application.

To mitigate reliability concerns, open controllers are designed to continue cyclic program execution for basic automation and motion control independent of the OS, including uninterrupted execution during

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The Siemens SIMATIC family of automation and motion controllers and industrial PCbased HMI is well suited for designers to customize controls to unique requirements.

OS shutdown or reboot. This enables continuous runtime for mission-critical machine components and safety devices regardless of the OS state, while providing the ability to update PC-based apps and user interfaces while continuing machine production.

Open controllers typically support communication with industrial IoT devices, and they can be used to control multiple machines and plant operations in a distributed configuration. They’re connected to their I/O modules—including safety, communication, and motor starter modules—via an integrated backplane bus, providing flexibility to fit a variety of control cabinet spatial layouts. Because open controllers are versatile and work with many machine types, they are often strong candidates for use in plant expansion projects, and for integrated control among multiple cell areas.

Standalone motion controller, PLC, and industrial HMI By contrast, OEMs have a host of customization options for machine architectures using separate devices.

Standalone logic and motion controllers are available with varied levels of capabilities, and they can be specialized to perform specific functions, such as failsafe operation or high-speed multi-axis motion control.

Separates are especially advantageous when an application calls for highly complex logic control but simple motion control, or vice versa. By using a separate controller for each function, a manufacturer can invest in a high-end device where complex requirements exist and a basic controller where the needs are simple. Such an approach allows designers to focus on the capabilities most important for an application in the most cost-effective way.

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Controller redundancy requirements present another case where separates thrive.

Some high-end controllers are designed to accommodate hot-failover redundancy, providing uninterrupted operation in the event one of two controllers in a redundant configuration fails.

Standalone industrial HMIs—both runtime terminals and PC-based units—also vary in function and form from device to device. Runtime terminals are typically constructed with purposefully simple interfaces for quick programming and operational learning curves. They’re built for reliable and cost-effective operation without an overwhelming number of bells and whistles.

Conversely, PC-based HMIs are highly customizable, compatible with multiple apps and PC applications, and capable of communication over various protocols. They offer added functions related to data storage and visualization directly on the device, useful for troubleshooting and maintenance planning. But, this expanded set of capabilities at a user’s fingertips comes with a tradeoff in terms of cost and complexity as compared to basic HMI terminals.

Comparison OEMs and their end-user customers are ultimately concerned with creating system architectures to enable the most efficient production possible. In the controller

A vertical stacking and counting device involved in producing plastic cups and lids uses an open controller that combines several motion, logic, and safety controllers into a single processor with remote I/O.

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selection realm, this boils down to choosing the simplest hardware to meet all present and future demands of the application.

For fairly simple to moderately complex machine configurations, an open controller is often the best fit, providing a wide range of functions to cover most automation, motion, and safety functions. All data

across the plant floor is centrally located, reducing development efforts and network cabling requirements—and minimizing cabinet space because of consolidation in an open controller’s small form factor.

Open controllers are also advantageous for integration with PC-based applications and industrial internet of things (IIoT) devices. They’re highly versatile for

connecting to many types of equipment and sensors, and for blending PC OS functions with real-time control, while maintaining failsafe operation where required. Unlike many systems configured using separates, it’s possible to program automation, motion, and visualization from the same development software interface because all functionality is consolidated.

Table 1 – Comparison of open and standalone controllers Open Controller

Standalone PLC

Standalone Motion Controller

Complex algorithms and control tasks, including PID control

4

4

4

Quick program execution cycle times, fast I/O scanning

4

4

4

Reusable code libraries

4

4

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4

Function

Highly specialized process control algorithms Ability to run high-level language code (such as C++) directly in cyclic execution partition

4

Simple to moderately complex motion control

4

Standalone Industrial PC/HMI

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4

Highly complex motion control

4

Cross-controller synchronous motion control

4

Failsafe operation

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some

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some

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some

Capacity for highly-complex, memory-intensive PC applications and algorithms

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Store large sets of historical data

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some

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Motor control expansion I/O via backplane

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Remote-I/O capable

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some

Integrated USB interfaces for direct connection of external devices

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some

some

some

Common programming software for all standard automation control, motion control, and HMI visualization

4

some

some

some

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For highly specialized applications, open controllers may not deliver the required capabilities, requiring the use of separate controllers. With separates, users can select their preferred balance of simplicity and feature set, allowing them to dedicate more attention to the necessary functionality of a particular system or machine. By comparison, an open controller offers a uniform level of capability across automation and motion control functions, a level sufficient for many applications, but not for the most complex.

Table 1 lays out a direct comparison of capabilities between open controllers and separates to help OEMs decide which controller architecture is best suited for their applications.

Open controllers for thermoforming machines An open controller architecture was the best choice for a plastic thermoforming OEM upgrading its outdated, siloed automation system, with the following requirements:

• Synchronize multiple axes in a tight space with a high production rate • Centrally view and control all machine components • Minimize control panel space usage • Store machine data in a central repository with IIoT-connectivity • Integrate failsafe control into the primary automation system • Monitor and analyze drive forces and vibrations during punching Plastic thermoforming requires fine precision and efficient production. It involves heating a plastic sheet to a pliable forming temperature, molding the sheet to a specific form, and trimming excess to create a usable product. In the case of this food storage container manufacturer, machine demand was 50,000 plastic cups and lids per hour.

Using an open controller enabled consolidation of several motion, logic, and safety controllers into a single processor

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with remote I/O, eliminating complicated data exchange, minimizing wiring and cabling, and requiring minimal space inside panels.

Furthermore, consolidating to a single controller and synchronizing all stepper and servo drives across the machine improved operability, and integrating machine-wide data at a central IIoTconnected point gave operators a better sense of equipment health.

Separates for glass bottle manufacturing While consolidation of functions is enticing for plastic thermoforming manufacturers, a glass bottle manufacturing line performs optimally using the separates approach.

Glass manufacturing is a carefully calculated process that relies on precise process control of chemical compounds, along with mechanical machine control. While sensor and equipment communication are of high importance, a glass bottle manufacturing line doesn’t rely heavily on external data. A clear communication pathway between each sensor and its controller is generally sufficient, not requiring heavy runtime data exchange throughout the plant, or with cloud-based applications.

To create glass, raw materials and coloring chemicals are mixed together and delivered to a furnace, where they’re heated at a temperature up to 1,600 °C (2,912 °F). As can be imagined, electrical system failures are highly possible due to high temperatures, creating the need for redundant furnace processing PLCs. Coupled with complex motion control requirements at other parts of the line, the redundancy requirement renders separate and dedicated controllers a better choice for this glass bottle manufacturing line.

handled by a standalone motion controller.

Another application may demand a dedicated safety controller for code compliance. In either of these cases, the separates route makes sense.

In cases when specialization is not critical or IIoT connectivity is a central component of the application, choosing an open controller can be a better fit. It combines multiple functions into a single controller, reducing system network and data exchange complexity.

OEMs must consider multiple facets when selecting controllers for an application. Whether an open controller or separates route makes the most sense—they should consider the planning, development, and operational difficulties likely to arise—and select products to address these challenges.

This consideration might manifest in selection of products with an integrated environment for programming all devices.

Similarly, ongoing operations are more manageable with fewer software packages and interfaces, and data consolidation and cloud connectivity are quickly becoming must-haves for machine control solutions.

By carefully selecting the ideal machine automation architecture for an application, OEMs can reduce time to market and improve system performance. DW Siemens Industry www.siemens.com

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Options to optimize OEMs have options when it comes to automation system architectures, enabling them to better equip their systems for application optimization. Sometimes an application may call for a large amount of highly complex motion control, best

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Beyond additive manufacturing— Generative design shapes for milling too Generative designs don’t have to be 3D printed. Other manufacturing methods enter the fray.

There are those that say generative design ensures the best product design possible. Engineers enter the specifications a product needs to meet, and the tool responds by creating a number of potential designs that fit the bill. It even recommends potential materials to be used.

Jean Thilmany Senior Editor

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Now, the resulting designs can be manufactured in a number of ways.

Increasingly, CAD software makers, such as Autodesk, are building manufacturing preferences into their topology optimization and generative design tools, meaning generative design can take into account a particular manufacturing method. The engineer enters the manufacturing method as one of the design constraints. The resulting generatively created designs depict products that can be made according to that method and that meet other desired specifications, says Kim Losey, Autodesk’s head of marketing for Fusion 360. www.designworldonline.com

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MJK recently turned to generative because weight, strength, and style were all necessary considerations for the triple clamps it makes for motorcycles.

On motorcycles, stanchions from the telescopic fork are attached to the triple clamp, and sliders at the other end are attached to the front-wheel spindle. The clamps are part of the fork that connects the motorcycle’s handlebars, steering stem, and shock absorbers.

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Autodesk’s generative design technology developed parts for conventional 2.5- and 3-axis milling and set Fusion 360 to design parts that could be made exclusively through those methods.

Using that input, the CAD and CAM product quickly returned a range of designs that are lightweight and fully machinable.

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Two years ago, Autodesk released generative design to subscribers of its Fusion 360 Ultimate product development software. Autodesk moved to marry generative design with manufacturing methods when it announced late last year that PowerMill, PowerShape, and PowerInspect would become part of the company’s Fusion 360 solution.

Now, Autodesk says, CAD and CAM reside on the same Fusion 360 platform.

The inclusion of CAM brings manufacturing considerations to the front of the generative engineering process, saving engineers and manufacturers time and money.

The generative technique is a completely different approach to design. The design concept allows engineers to define design parameters: such as material, size, weight, strength, and cost constraints--before they begin to design. Then, using artificialintelligence-based algorithms, the software presents an array of design options that meet the predetermined criteria, Losey says. www.designworldonline.com

By calling upon advanced software and computing power the generative system runs through many possibilities, each meeting the engineers’ design specifications. It presents the best designs to engineers, allowing them to pick the optimal design. Engineers are involved at the beginning and at the end of the design process. If they don’t feel any of the returned designs meet their standards, they can tinker with inputs and cue the generative-design system to start again.

The computer-generated (“generative”) designs might be unorthodox, new, and unexpected, with geometries that wouldn’t naturally occur to the designer. No matter how different, if the design is shown to work, it can be created by additive manufacturing, also called 3D printing, Losey says.

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organic, nature-like forms that were commonly created did not lend themselves well to processes such as machining, casting or fabrication, she adds.

But that led many people to assume the designs could be produced only through additive-manufacturing techniques.

Now, the scope of generative-design automation is expanding to include traditional manufacturing processes, such as milling, die casting, and even water milling.

Today, you can input traditional manufacturing constraints into Autodesk Fusion 360 and use its generative-design functionality to produce optimal design solutions that can be manufactured according to one of several predetermined methods, she adds.

Autodesk’s generative design software, part of its Fusion 360 platform, includes capabilities to sort through the design

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possibilities reflected by particular manufacturability considerations. This enables engineers to compare how easily, quickly and cost-effectively components can be produced via different manufacturing methods, Losey says.

By applying constraints that sort design possibilities according to selected processes, design options can be evaluated in a new light. Both engineers and manufacturers are often surprised at the results, she says. Multi-axis machining might be the best choice, as it turns out, even for a very elaborate part, when certain constraints are in place.

And bringing manufacturing to the front of the decision-making process underscores the role generative design has to play in the choice of product, Losey adds.

Estimating manufacturing costs PowerMill 5-axis CAM software provides

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expert CNC programming strategies for complex 3- and 5-axis subtractive, highrate additive, and hybrid manufacturing.

Meanwhile, PowerShape is CAD software that creates complex 3D geometry to better control CAM software such as PowerMill. It works with any combination of surface, solid, or mesh data and quickly creates damage and collision-free toolpaths for large, complex parts, Losey says.

A recent video from Autodesk, in reference to questions to keep in mind while populating a prospective generative design, asks: “Will you deviate from the traditional design scope to include manufacturing constraints? Will you use 5-axis, 3-axis or even 2.5-axis milling?

What about die casting? Can your design be water milled? Or does additive manufacturing provide the best value and performance?�

Clearly, the manufacturing process is a big influence on the type of geometry produced, Losey says.

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While generative design can provide results optimized for your manufacturing method of choice, how do you evaluate the tradeoffs between performance and the cost to make your part?

Autodesk includes software—the aPriori Cost Insight Engine—as part of its generative design package. It generates a manufacturing cost estimate for each design alternative created.

“It interrogates a model for features or tolerances that would be costly based on certain manufacturing methods,” she says.

“It allows engineers to fully explore costs and to strike balance between performance and cost.”

Another way generative design reduces manufacturing costs: the generative process can result in a single, solidmesh body that can replace multibody components, such as a welded assembly.

This reduces a manufacturer’s need to spend money on jigs, fixtures, welders, and welding material. And single-body parts can be made via additive manufacturing, which also reduces the need to design and manufacture tooling.

Also, generative design allows engineers to replace small assemblies with a single component to reduce manufacturing costs and bill-of-materials complexity.

Milled motorcycle parts MJK Performance had shied away from the generative design method because Phil Butterworth, MJK designer and co-owner, felt the visual style evoked through generative design wouldn’t fit his company’s style. The company, of Calgary, Canada, produces aftermarket parts for Harley Davidson motorcycles.

“It always made me think of those spiderlike, organic, alien models,” he says.

“I just thought it’d give us the same style only blockier, covered in intricate little pieces and looking silly.”

But MJK recently turned to generative because weight, strength, and style were all necessary considerations for the triple clamps it makes for motorcycles and Butterworth knew the method could help with weight reduction.

On motorcycles, stanchions from the telescopic fork are attached to the triple

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clamp, and sliders at the other end are attached to the front-wheel spindle. The clamps are part of the fork that connects the motorcycle’s handlebars, steering stem, and shock absorbers.

“Our clients want the look of a 200-pound race bike for their 1,000-pound Harley,” Butterworth says. “As a result, we need to make our parts as light and strong as possible but also stylish. Every part has to look like it belongs on a hundredthousand-dollar bike.”

But the triple clamps are large and bulky, leading Butterworth and his fellow designers to attempt to reduce their weight. With an additional factor: The clamps had to be fully machinable on a 2.5axis mill because the company makes all its parts at its small, four-machine shop.

Butterworth says he was surprised to learn that generative design might be the answer to his needs. He’d assumed generative design was mostly limited to additive manufacturing.

He soon discovered that Autodesk’s generative design technology could develop parts for conventional 2.5- and 3-axis milling and set Fusion 360 to design parts that could be made exclusively through those methods. Using that input, the CAD and CAM product quickly returned a range of designs that are lightweight and fully machinable, Butterworth says.

Not only that, “when the model came back, it looked like something I would buy immediately. I was blown away. It looks racy; it’s got all the cool geometry. It has all the cool stuff generative does but in a style people understand and recognize,” he says.

After studying the potential designs, Butterworth selected one and then spent approximately 20 minutes editing it to suit the characteristic MJK Parts style.

Through use of generative design, engineers went from computer model to a prototype within a few hours. And the weight of the triple clamp was reduced by 23% compared to a similar triple clamp designed by an engineer rather than the generative program. Nor did the generative design sacrifice safety, Butterworth says.

Normally, this process would take one or two days to complete. But with generative design MJK was able to www.designworldonline.com

accelerate this process. They went from a computer model to a prototype in a few hours. Fusion 360 can easily be set to produce designs for 2.5-axis milling, he says.

Within JPL, its Atelier division is the team charged with trying new approaches and processes, and its recommendations are passed on to teams working on specific missions. This division is collaborating with Autodesk to evaluate generative design for the proposed lander.

Topology optimization joins in Capabilities are also changing fast in topology optimization, which differs from generative design. When using topological optimization, an engineer defines loads within a 3-D space and the program removes material to attain a shape that uses the least amount of material while still retaining required stiffness and density.

The method also creates parts with odd shapes, though it typically gives fewer results than does generative design.

Additive manufacturing, with its capability to create never-before-seen shapes, seemed a natural for both.

But, to give you an example of the move to find methods beyond additive has quickened, take the example of the following two engineering journal submissions.

An October 2016 paper in the journal “Advances of Engineering Software” stated that: “Despite being an effective and a general method to obtain optimal solutions, topology optimization generates solutions with complex geometries, which are neither cost-effective nor practical from a manufacturing perspective.” That paper was written by Sandro Vatanabe and his coauthors.

In it, Vatanabe, now an engineering professor at the FEI University Center in São Paulo, Brazil, and his colleagues proposed techniques to restrict the range of solutions for the optimization problem. The paper was entitled Topology optimization with manufacturing constraints: A unified projection-based approach.

Three years later, a paper entitled “Topology optimization for multi-axis DESIGN WORLD

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machining” presented a topology-optimization approach that incorporates restrictions of multiaxis machining processes. In it, author Matthijs Langelaar posits that particular cutting tool shapes and maximum insertion lengths can be included in topology optimization without much additional computational effort. He then shows examples of how to generate optimized, machinable, three-dimensional parts. Langelaar is an associate professor of structural optimization and mechanics at Delft University of Technology in the Netherlands.

Langelaar set out a formulation developed for 5-axis processes, though the technique also covers other multi-axis milling configurations, 2.5-axis milling and 4-axis machining by including the appropriate machining directions. In addition to various tool orientations, user-specified tool length and tool shape constraints can also be incorporated in the filter.

So, while a generative design or topology optimization study can result in interesting new designs, perhaps previously unfathomable designs, engineers needn’t limit themselves to 3-D printing to manufacturing the design of their choosing.

Butterworth says generative design has opened up countless new avenues at his company.

“Before I even start programming a mill, I know my part is going to pass any performance test,” he says. “Whatever the weight optimization in the simulation does, the 2.5-axis generative design just gave us a solid model right away.” DW

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P o w e r

Knowing which style of pressure gauge is right for your fluid power system is critical in ensuring consistent, efficient operation.

The unsung hero of hydraulic systems Carl Dyke | Contributing Editor | info@lunchboxsessions.com

Pressure gauges are unsung heroes in many hydraulic systems. As they are neither directing flow nor controlling pressure, they may not attract a lot of attention. In fact, if the pressure gauge is damaged or goes missing, the machine may continue to operate as though the pressure gauge was never even required.

Even though a good pressure gauge should have no effect on its hydraulic system, it shouldn’t be ignored. Gauges represent a first line of diagnosis and detection, and are invaluable in a well-executed preventative maintenance program. A pressure gauge is your glimpse inside of an otherwise opaque system. It provides quantitative information about how the system is operating, and whether that operation is within normal limits.

The best gauge Like nearly everything else in hydraulics, asking “what’s the best pressure gauge” is almost guaranteed to get you the unsatisfying answer, “it depends.” And indeed, this is a case of one size never fitting all. Gauges that excel at repeatable and accurate high-pressure measurements almost universally will be inaccurate in low pressure systems. A bourdon tube type of gauge might be perfect for your needs —until you take into account the

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The Bourdon tube with gear movement is popular and capable for a broad range of fluid power pressure measurements.

coarse and corrosive media you need it to measure.

And a diaphragm gauge might seem like the right answer, until you learn that pressure spikes are not well tolerated, and temperature swings make the readings less accurate. To make a good choice for your system, you’ll need to know a bit about the different kinds of gauges available and understand their specific mechanics and limitations.

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A typical pressure gauge The typical analog pressure gauge features an indicator needle that rests at approximately a 7 o’clock position and sweeps around to a 5 o’clock position. Throughout the range of the sweep, the needle points to the current pressure value on a printed scale with units as desired. This is all that is visible and evident from the outside.

Behind the dial and inside the case is where the clever action takes place. Like an analog wristwatch the typical pressure gauge features a movement. This precision mechanism of gears and springs amplifies the small total travel of the primary sensing element and transfers this motion to the large sweep of the gauge needle.

A tiny motion from the sensing element is translated to a full dial sweep by a gear movement.

The ‘C’ shaped Bourdon tube straightens as pressure increases, with linked motion to the gear movement.

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Bourdon tube Typical sensing range: 600 mbar up to 6000 bar (10 to 87,000 psi) The primary sensing element for so many fluid power pressure gauges is a Bourdon tube. Named after Eugene Bourdon’s 19th century invention, a Bourdon tube is a C-shaped or helical shaped tube that tends to straighten as the fluid is pressurized. While this straightening may be minor (and in fact very subtle if viewed by the eye), the motion can be linked to a geared movement to create the full sweep of the needle, around the dial.

The Bourdon tube tends to be a simple C shape and made of a copper alloy for pressures below 60 bar (870 psi) where a stronger stainlesssteel helical tube with a few complete wraps is necessary for the higher pressure ranges. The Bourdon tube is typically crimped, soldered or brazed to the socket which is the entry point for the pressurized fluid and also the fitting where the gauge is physically connected to the pneumatic or hydraulic system. While the Bourdon tube is not the only type of sensing element for pressure gauges it is economical and effective for many applications.

Diaphragm gauge Typical sensing range: 0 to 40 bar (0 to 580 psi) From the outside, a diaphragm pressure gauge looks the same as a bourdon tube gauge, with the typical circular housing and an indicator needle that sweeps along a dial. The difference is found in the sensing element.

Instead of a Bourdon tube deforming

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according to pressure, the membrane in a diaphragm gauge flexes against spring resistance. This deflection drives the indicator needle around the gauge face, via mechanical linkage.

The large surface area of the diaphragm lends itself well to low pressure measurements. Small pressure changes are picked up easily. However, the diaphragm is vulnerable to high pressure. Exposure to a pressure spike beyond its rating may rupture the membrane. You’ll know if this has happened — the indicator needle will sit at the bottom of the scale and never move again.

Diaphragm gauges are also adaptable to different media mixtures. The diaphragm can be coated with one of several materials to resist abrasion or corrosion from unusual media. And unlike a winding Bordon tube, the diaphragm has a large surface area, which provides lots of clearance. Challenging media full of particulate is less likely to clog this gauge. You can even purchase flange-fit gauges, which locate the diaphragm right at the interface point, making it nearly impossible to clog.

Bellows Typical sensing range:0.03 to 5 bar (0.5 to 75 psi).

A bellows-type gauge is typically used in low pressure applications, but it can be specially constructed to tolerate higher pressure instead.

The diaphragm gauge is well suited for low pressure ranges.

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Some bellows gauges measure through the expansion of the bellows.

The measured liquid is channeled into the bellows element, and as pressure increases, it pushes the bellows to expand.

Alternately, a bellows gauge might direct the measurement liquid into the cavern around the bellows element to compress it.

In either arrangement, it is the movement of the bellows that slides the mechanical linkage driving the indicator needle. Like the diaphragm and bourdon tube gauges, the needle is mechanically linked to the sensing element.

Housing ABS plastic is generally the standard housing material for all three of these gauge types. This plastic is light and inexpensive, but it won’t survive much rough treatment.

Consider the installation conditions. Will this gauge be permanently mounted in a

relatively protected location? Or will it be carried around by millwrights, or located where an object may fall on it? The housing can generally be upgraded to stainless steel, which will fare better in adversity than the ABS plastic.

Liquid fill Gauges might be referred to as “dry,” or they can be liquid-filled. The liquid fill option provides dampening against environmental vibration. It can also provide lubrication for the movement mechanism.

Many liquid gauges are hermetically sealed, but some have a small valve at the top.

Glycerin and silicon are two popular liquid-fill options for hydraulic pressure gauges.

Glycerin is typically used for indoor installations. It offers good dampening within a temperature range of –4° and 140°F (-20° and 60°C).

Silicone maintains a low viscosity even at colder temperatures and is often preferred for colder climate applications.

Look for good dampening between -40° to 140°F (-40° to 60°C).

Maintenance and care There aren’t really any serviceable parts in a typical gauge, but there are some requirements for long life and reliable accuracy. Often times, a pressure gauge is installed in a system with an on/off valve in place at the entry fitting. This valve allows the gauge to rest on the pin at zero until a reading is needed. The gauge stays calibrated longer when left in this state. The viewer of the gauge opens the valve when a reading is needed. Later, when the system is shut down and the needle rests at zero, the valve is closed once again.

Some liquid filled gauges used as portable diagnostic instruments may

It’s not a web page, it’s an industry information site So much happens between issues of R&D World that even another issue would not be enough to keep up. That’s why it makes sense to visit rdworldonline.com and stay on Twitter, Facebook and Linkedin.

It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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include a small on/off venting valve at the top of the case. This valve may need to be open to the atmosphere for an accurate reading, but it will allow the liquid to leak out if not closed once again before the valve is tilted. If the fluid leaks out, the life of the gauge may be shortened.

Temperature vulnerability All three analog gauge types we’ve looked at — Bourdon tube, diaphragm and bellows — will demonstrate some inaccuracy with temperature changes, whether they are changes within the measured fluid, or the ambient temperature around the gauge.

This is due to fluid expansion, as well as the properties of the metals and materials used in the gauges and sensing elements themselves. To limit inaccuracy, try to take readings at roughly the same system temperature and ambient temperature.

When that’s not practical, at least note the temperatures so that they can be considered when evaluating the reading.

Impact shock If your gauge is not going to be permanently mounted to one location, consider adding a protective boot to cushion against accidental impact. In our own classroom environment, we’ve found that unprotected bourdon tube gauges can lose calibration after only 1 or 2 drops. Needless to say, all of our gauges are now covered with protective boots.

Pressure shock Pressure spikes can ruin calibration, or even destroy the delicate sensing mechanism of bourdon tube, diaphragm, and bellows gauges. If your system suffers an overpressure event, make sure to examine the gauges for signs that they have lost calibration. If your gauge is the type with an on/off valve, this is another reason to leave

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the gauge shut off from the system unless you intend to take a reading. When the valve is off, it should isolate the gauge from pressure spikes.

Losing calibration If you are convinced that the hydraulic system is completely shut down and depressurized, but the indicator needle does not rest on the zero pin, the gauge has gone out of calibration. It may be able to be recalibrated if it has not been damaged, but it’s more likely that the gauge will need replacement.

Differential piston gauge Up to 680 bar (10,000 psi) Let’s finish up with a look at a slightly different style of gauge. A pressure gauge with two connection points is often required to determine the level of clogging in a full pressure filter element, or to measure the margin pressure in a load sense hydraulic system. Differential pressure gauges compare the pressure between two different fluid zones. All of the gauge styles we’ve seen so far — bourdon tube, diaphragm and bellows — can be adapted for differential measurements, but the piston gauge departs from these in a few significant ways.

tolerate even a minimal amount of mixing between the two ports, a different style of differential gauge might be your best choice, or you may select a piston-type gauge with a separating diaphragm to prevent bypass flow.) The pressurized fluid on both sides of the gauge simply pushes on either side of the piston, with a spring working to hold the piston centered.

Magnetic linkage Instead of a mechanical linkage, a magnet on the piston carries the needle indicator along as it shifts. There is no delicate mechanism and no spring to become overflexed or deformed by an extreme pressure spike, so expect a long and reliable life from your differential piston gauge. DW

Bypass flow Piston gauges can have a small amount of bypass flow from the highpressure side to the low-pressure side. (If your application cannot

The gauge with two connections is used to measure the difference in pressure between two zones.

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Thin section ball bearings

create flexibility in medical application Healthcare facilities turn to pivoting and articulating “arms” to hold monitors and other equipment used in operating rooms, patient hospital rooms, and dental offices, among other venues.

The arms provide ergonomic advantages but, more importantly, they remain functional, where space is at a premium.

Edited by Mike Santora

In the operating theater, a surgeon can grab the monitor and move it; the monitor remains where it was last positioned. The monitor, or display, is then pushed back, reclaiming the space. That is the ideal scenario, of course.

However, for one manufacturer of these arms, who was modifying an existing arm design to hold more weight — two monitors, a problem arose: Heavier loads resulted in erratic, non-repeatable movement of the arms, and caused them to drift and sink out of position when at rest. “It made it very hard for the doctors and nurses to move the arm and position the display for optimum viewing,” said Jeff Fergus, Chief Applications Engineer of AST. The existing setup was using sliding bearings, which worked adequately when tasked with light loads. But for these heavier loads, especially for arms that have multiple pivot points, movement became imprecise and unpredictable — unacceptable conditions in an operating room, surgical suite, or other clinical 102

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environments where medical staff need to focus on patient care.

AST engineers got to work evaluating performance and life requirements.

Movement consistency and repeatability were key, even after thousands of movements. The manufacturer insisted that the design life should exceed ten years.

Additionally, and perhaps the greatest challenge, the re-design criteria established by the manufacturer did not allow for changes to any of the existing components used in the arm assembly. Only minor modifications were permitted, ones that did not require new tooling or changes in the supply chain.

With the load, operating conditions, and general dimensions somewhat fixed, the engineering team worked to come up with a solution: thin section ball bearings with a full complement of balls, or an airframe control bearing. These bearings were wellsuited for the duty cycle experienced by the wall mount arms — highly repetitive combined with a relatively short range of movement.

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With their thinner cross-section than a single row, deep groove ball bearing, thin section ball bearings are well-suited for applications with space restrictions — such as on mounts or articulating arms.“With their thin cross-section, the bearings can have a large outer diameter and a somewhat larger inner diameter, too,” Fergus said. “You can pass wires or mechanical components through their center. For articulating or robotic arms, the thin section bearings allow you to run wires or fiber optics from a central processor to a remote device on the end of the arm with minimal obstruction.”

Thin section ball bearings are designed for applications where low friction and high accuracy are required and space is at a premium. The airframe type selected is used when loading is predominantly in the radial direction. However, they can also support limited axial (one direction) and reversing loads. These attributes made the bearings especially suitable for the manufacturer of the monitor arms.

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These bearings were well-suited for the duty cycle experienced by the wall mount arms — highly repetitive combined with a relatively short range of movement.

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Heavier loads resulted in erratic, non-repeatable, movement of the arms and caused them to drift and sink out of position when at rest. “It made it very hard for the doctors and nurses to move the arm and position the display for optimum viewing,” said Jeff Fergus, Chief Applications Engineer of AST.

“The larger size of the bearing with the thin section and full complement of balls allows us to carry the weight,” Fergus said. “Once we determined the bearing size and proper pre-load, we developed a prototype concept where we simply modified the bearing mounting surfaces at the end of the arms. As each joint had (typically) two bearings, that provided the necessary stiffness and stability.”

AST has nearly 300 different types of thin section ball bearings, organized into the following series: SR (formerly our E Series) series: Inch dimensional series with bore sizes ranging from 3/8 to 1 5/8-in. The Torque Tube Series: Inch dimensional series with bore sizes ranging from 5/8 to 2 5/16-in. (for nonmilitary/aircraft applications without cadmium plating). The 6700 series: Metric dimensional series for limited space applications and light loads.

In a similar but separate application, the user was seeking to re-design an existing product. A modified setup was applied to this second manufacturer whose monitor arm was required to hold two monitors with a light at its endpoint.“They had an existing lighting system in the operating room, and they needed to introduce a brighter light — a fixture with additional light heads attached,” Fergus said.

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which required the ability to precisely position the arm. But with the additional lights and weight, the load was too heavy for its existing arm.

The engineering team again recommended thin section ball bearings.

Its 6700 series assemblies are very thin, a suitable configuration for the existing arms, and its dimensional constraints (the manufacturer was unwilling to redesign the monitor arm).

After exhaustive testing for both clients, the thin section bearings proved successful and durable. “Testing was critical, because the healthcare settings required thousands of cycles,” Fergus said. “It’s extremely expensive to make a service call into a surgical room or hospital.”

The AST team has developed a global network of partner manufacturers who will produce customized designs, ensuring the optimal performance of its customers’ products. DW AST Bearings astbearings.com

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

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w w w. d e s i g nw o r l d o n l i n e . c o m / M C 2

Lisa Eitel

C

Conveyor functions serve specific applications

Conveyors for discrete product transport benefit om customization to satis requirements — including chain and belt size, morphology and material; support ames; controller, drive, and motor or motors; mode of engagement with the drive; encoder, vision, and switch feedback; tracks, bumpers, and gates; and HMIs and plant-level IT integration.

Consider warehouse automation where the objective is ultra-fast sorting and tracking. Such applications need conveyors with servomotor functionality integrated with inspection stations fitted with machine vision.

Or consider pharmaceutical manufacturing — CONTROLLER now a trillion-dollar industry, even while standards such as FDA CGMP regulations are more stringent than ever. Here, conveyors must deliver top-notch warehouse automation functions and have stainless SENSOR FEEDBACK and aluminum parts to pose no risk of contamination ENCODER to expensive pharmaceutical products such as pills.

FEEDBACK Likewise, medical-device manufacture must adhere to FDA regulations that dictate equipment-sterilization schedules so conveyors in these applications withstand harsh washdowns.

In the conveyor installment of Design World’s MC² we’ve written and collected more than a dozen references that detail these and other types of discrete material handling with conveyors.

Educational installment brought to you by:

SENSOR FEEDBACK ENCODER FEEDBACK

Topics include the basics of conveyors and conveyor-selection criteria • Customizing belt conveyors • All about knife-edge conveyor units • Maintaining conveyor systems • What is pitch in the context of conveyors • Chain-on-edge conveyors and where they’re used • Pallet conveyors • and power and ee conveyors.

Check it out at designworldonline.com/conveyors-classroom — and access the full MC2 library at www.designworldonline.com/MC2.

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Product World Modular industrial displays for industrial applications

Platinum safe servo drives boost servosystem performance

Emerson Emerson.com/IndustrialDisplays

Elmo Motion Control elmomc.com/contact-us Elmo Motion Control, a manufacturer of motion control technologies, now offers a new line of servo drives — the Platinum series of servo drives with advanced servo functionality and functional safety.

An evolution of Elmo’s Gold line of servo drives, the new line of servo drives is designed to meet OEMs’ growing needs for safer, smarter, smaller, and faster servo drives. It provides unmatched solutions for medical, robotics, material handling, semiconductor, laser processing, printing, and inspection applications needing the highest-quality motion.

The Platinum line has EtherCAT networking and processing for faster cycling and higher synchronization along with negligible jitters and near-zero latency. The higher processing power enables faster data handling, a larger memory, and an endless real-time recorder to support high-performance applications.

Additionally, Platinum servo drives hold the highest-level

This new portfolio of RXi industrial display and panel PC

functional safety certifications (IEC 61800-5-2 SIL-3, Cat4 PL-e)

products are for monitoring, visualizing, and enhancing everyday

and have a comprehensive set of smart functional safety features —

production processes in life sciences, metals and mining, power

including over-the-network safety and optional rich safety I/Os. The

and water, and manufacturing and machinery. A modular design

Platinum line includes one of the world’s smallest Functional Safety

is foundational to the industrial display platform, it lets users

and Functional Safety over EtherCAT (FSoE)-certified servo drives.

select the right configuration based on application needs — minimizing cost through flexibility, serviceability, and field upgradeability. Also, vivid and responsive displays improve an operator’s capabilities to make better decisions.

RXi industrial displays are designed to work with Emerson’s programmable logic control (PLC), programmable automation control (PAC) solutions, and third-party control systems. The RXi industrial display portfolio has standardized physical designs to minimize the variety of enclosure cutouts required for OEM applications. This makes each display easily replaceable and upgradeable in the field.

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

groov EPIC firmware version 2.0

GigE Vision line scan cameras

Opto 22 opto22.com

Omron automation.omron.com

Opto 22 has announced

The FS Series GigE Vision line scan cameras are now available in 2K,

the second major version

4K, and 8K resolutions. With single-line monochrome and upcoming

of its firmware

dual-line monochrome and color formats, these cameras are new

for groov

additions to the GigE Vision line. F-Mount, C-Mount, and M42-Mount

EPIC, the edge

lens configurations are available.

programmable

GigE Vision is a global camera interface standard that uses the

industrial controller

Gigabit Ethernet communication protocol to provide fast image

for automation

transfer with cost-effective standard cables over long distances. This

applications, and the

updated FS Series incorporates this technology along with Power

industrial internet of things

over Ethernet (PoE), which lets users supply power and transfer image

(IIoT). The groov EPIC 2.0 firmware includes updates

data on a single Ethernet cable to help reduce system costs and

to both of groov EPIC’s real-time control engines and

simplify installation and setup.

provides an under-the-hood refresh to many ecosystem

Another essential feature of the new cameras is the Precision

components. This update also increases the control

Time Protocol (PTP), which enables more precise multi-camera

platform’s reach with support for groov RIO, Opto 22’s

triggering over an entire system by lowering the latency when

new industrial edge I/O module, which supports 61,260

multiple cameras on the same system are triggered simultaneously.

unique I/O combinations in a standalone unit.

The new cameras’ compact design and 58 x 58 mm frame make them

With groov EPIC 2.0, Opto 22’s PAC Control, a

suitable for a wide variety of applications, including optical scanning,

flowchart-based, multi-tasking control engine, is updated

waterfall sorting, web, and print inspection, flat panel inspection, and

to version R10.3a; and 3S Software’s CODESYS Runtime,

pick-and-place.

an IEC 61131-3 compliant runtime engine, is updated to version 3.5.15.10. Both control options can execute userconfigured, high-speed, closed-loop control programs for process control, manufacturing, and OEM machines. In combination with the jointly updated design software — PAC Project Suite 10.3 and Opto 22’s CODESYS Library Package 2.0.0.0, which is compatible with the CODESYS Development System v3.5 SP15 — these updates allow the number of groov EPIC I/O points to be expanded with an unlimited number of groov RIO remote I/O modules.

Each groov RIO module is an independent edge I/O unit that can sense and control various traditional wired I/O signals or devices from anywhere on a connected Ethernet network.

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Product World Industrial gear units for mixer applications NORD NORD.com MAXXDRIVE industrial gear units are a suitable choice for use in large mixers. NORD’s new SAFOMI (Seal-less Adapter for Mixers) adapter has a flange with an integrated oil expansion tank, increasing operational reliability and requiring less routine maintenance over the lifecycle of the gear unit. MAXXDRIVE units have been part of the NORD product range for more than ten years and have proven themselves in countless applications worldwide. They offer output torques from 132,000 – 2,250,000 lb-in. and operate reliably under demanding conditions.

NORD MAXXDRIVE industrial gear units are FEM-optimized and have a compact design that enables efficient operation under high external loads. MAXXDRIVE units have

IO-Link Capacitive Proximity Sensors Carlo Gavazzi GavazziOnline.com

extensive modularity, providing many options for tailored solutions without the need for costly custom component design. When equipped with a SAFOMI-IEC/NEMA adapter,

These Capacitive Proximity Sensors with Integrated IO-

MAXXDRIVE industrial gear units combine the functions of standard IEC/NEMA adapters

Link communications build upon Carlo Gavazzi’s existing

with an oil expansion tank in a single, integrated component.

range of sensors. These new sensors are housed in durable AISI316L stainless steel housings or PTFE Teflon housings for high chemical resistance.

Based on 4th generation TRIPLESHIELD sensors,

Four-megapixel high-speed camera

the CA18, and the CA30 Series sensors are suitable for industrial automation equipment in applications where the sensing performance needs to be constantly and accurately monitored and logged.

Vision Research phantomhighspeed.com

Besides the full range of technical features provided by these capacitive sensor families, the IO-Link

The Phantom T1340 is a high-resolution camera that captures images up to 13 Gpx/ second, doubling other 4 Megapixel cameras’ capabilities in its class. The 2048 x 1952 low-noise sensor, combined with a compact form factor, are suitable for demanding measurement applications such as object tracking, flow visualization, microscopy, and modern imaging techniques, like Digital Image Correlation (DIC). A binned mode is included to provide higher throughput and a sensitivity boost at 1 Megapixel and below.

Workflow features of the T1340, which are suitable for applications in outdoor range environments, include Phantom CineMag V compatibility for an ultra-fast and secure

communication mode enables additional advanced functionalities such as QoR (Quality of Run), QoT, (Quality of Teach) and diagnostic parameters. With IO-Link, each sensor becomes fully programmable and customizable, allowing more than half a million setting combinations.

Feature: • M18 and M30 in AISI316L stainless steel or PTFE housings

workflow. The CineMag also supports direct recording for long-duration events. A 10Gb

• Programmable sensing distance and hysteresis

ethernet option is available for fast file downloads, enabling users to continue shooting

• Sensing mode: single point, two point, and

with reduced downtime in any environment. The on-camera controls, video outputs, and CineMag compatibility enable a standalone operation.

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windows mode • Logic functions: AND, OR, XOR, and “Gated SR/FF”

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Product World High-accuracy inclination sensor ASM Sensors asmsensors.com The new high-accuracy inclination sensor positilt PTM27 in an ultra-compact housing is suitable for applications where high robustness and accuracy are required. It can also replace rotary angle sensors.

This new inclination sensor is robust, comes in an ultra-compact housing, and provides high accuracy. The positilt PTM27 sensor measures inclination in the range of +/-180° with one axis, and in the range of +/-60° with two axes. In contrast to conventional sensors of this type, the sensor offers a very high measuring accuracy with a linearity deviation max of 0.05° and a resolution of 0.005° over the measuring range 360°. The

HMI software platform Adisra adisra.com SmartView V4.0 Service Pack 1 (SP1) is now available for immediate download. ADISRA SmartView is a complete HMI and supervisory control and data acquisition (SCADA) package, designed specifically for machine builder OEMs and discrete part manufacturers to develop effective interfaces for monitoring and analyzing machine operation and overall status. SP1 adds a host of development and usability features, making it even easier for users to create applications with greater flexibility.

SmartView already delivers a comprehensive and easy-to-use development environment.

New developments include templating functionality supporting the re-use of advanced graphic objects and screens across multiple applications — adding the flexibility of using tags to adjust the file and pathnames for recipes and reports. The display resolution of an application is now easily changed to match any target deployment.

sensor is based on MEMS technology.

This technology works on a contactless principle without any moveable components and is wear-free and shock and vibration resistant. Inside the housing, the sensor electronics are completely encapsulated and protected against moisture, dust, and dirt. Also, an integrated water block prevents capillary moisture ingress along the cable. The sensor has protection class IP67.

Tube clamp connectors range consistently extended JW Winco jwwinco.com The monitor mounts GN 197, including VESA adapter plates and locking slide units GN 134.7 and GN 147.7, open up new possibilities offering the right solution for diverse user needs.

The use of touch screens, panels, displays, and monitors on production machines has become common practice and is defined by the VESA standard for mounting monitors. Winco uses this standard to create a practical interface in the form of a monitor mount coordinated with the existing portfolio. The monitor mount is focused on the core functionality. The connection stud makes it simple to fasten the mount to all tube clamp connectors according to the given installation situation. Combining rotary or flanged joints, it is possible to realize any number of degrees of freedom and adjustment options.

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10/5/20 2:33 PM

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New DC/DC converter for extreme environments Wago wago.com

Digital and analog interface benefits combined with Dual Channel Baumer baumer.com

The 12 to 24 VDC DIN Rail mountable converter for extreme conditions has a conformal coating, which provides increased effectiveness against harsh environments. It can also be used in a range of temperatures from -40 to +70 °C and is suitable for extreme applications.

Additional Features: • Reverse polarity and short circuit protection- preventing problems with miswiring • 95% efficiency at full load-reducing energy loss and providing full ampacity without derating • These converters are useful in environments that require extreme testing procedures and can provide up to 3 A

Single and three-phase SR35 Series soft starters

Pressure sensor PP20H and conductivity sensor CombiLyz AFI now add on the Baumer portfolio

AutomationDirect automationdirect.com

of process sensors with digital communication interface. Digital communication opens up many opportunities — but only sensors that

More fully digital soft starters have

deliver precise measured values offer real added

been added to the AutomationDirect

value by IO-Link. Both pressure sensor PP20H

drives and motor controls lineup.

and CombiLyz AFI conductivity sensor excel in

STELLAR SR35 series full-

measuring performance and IO- Link interface, but

featured solid-state soft starters

now they offer even more interesting features

are available in three frame sizes to

such as simple and fast parameterization — even

control both 1-phase and 3-phase AC induction motors with 24VDC control voltage (optional 110-230 VAC). Designed for 17-361 full-load amps at 110-240 VAC (1-phase) or 200-600 VAC (3-phase), the SR35 soft starters are fully digital and use thyristors on the A and C phases for controlled reduced voltage motor starting and stopping.

SR35 soft starters provide full motor overload protection and built-in SCR failure protection. The fully programmable units have an easy-to-navigate menu structure for quick application set up and feature integrated Modbus RTU communications and programmable digital inputs and relay outputs for remote control. An optional remote

during operation. This way, secondary data like different process data output simultaneously, or diagnostic data only accessible this way, can be communicated from sensor to controller or even retrieved from the sensor memory if required.

Further to the digital interface, the sensors also provide one or more conventional analog outputs for maximum user flexibility.

keypad is available.

DESIGN WORLD

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Ad Index

SALES

Accumold ................................................ 81

Fixtureworks ......................................... 25

AllMotion ...................................................4

GAM ......................................................... 52

Altech Corporation ........................ 18,19

Interpower ...............................................17

Aurora Bearing Company ............... 32

J.W. Winco, Inc. .................................... 32

Automation24, Inc. ................................11

Keller America .........................................9

AutomationDirect .............................. IFC

Keystone Electronics Corp. ........ 3,85

Bansbach Easylift .............................. 48

Maple Systems ................................... 47

Bay Associates Wire

Nason ..................................................... 44

bcrowley@wtwhmedia.com 610.420.2433

Jim Dempsey

Jami Brownlee

jbrownlee@wtwhmedia.com 224.760.1055

Mike Caruso

Courtney Nagle

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

mcaruso@wtwhmedia.com 469.855.7344

Bill Crowley

LEADERSHIP TEAM

Publisher Mike Emich

Technologies, Inc. ........................ 30

NSK ........................................................... 43

Bishop Wisecarver .............................. 13

Opto 22 ....................................................77

Bodine Electric Company ................ 36

PBC Linear ............................................ 27

Boker’s Inc. ............................................ 42

PM B.V. ................................................... 39

Canfield Connector ............................ 42

Smalley Steel Ring ............................. 40

Carlyle Johnson ................................... 16

Smart Products USA ....................Cov,7

mference@wtwhmedia.com 216.386.8903 @mrference

CGI Inc. ................................................... 23

Sorbothane .......................................... 95

Chieftek Precision .............................. 93

Spartan Scientific ............................... 95

Mike Francesconi

Clippard ..................................................BC

Tormach ................................................. 84

Del-tron .................................................. 76

Trim-Lok ................................................. 29

DeviceTalks ...........................................101

TTI, Inc. ......................................................5

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

Ultra Motion .......................................... 78

mfrancesconi@wtwhmedia.com EVP Marshall Matheson 630.488.9029 mmatheson@wtwhmedia.com 805.895.3609 Neel Gleason @mmatheson ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

Dorner ...................................................... 51

Wago USA ............................................. 37

Jim Powers

ebm-papst Inc. ........................................ 1

Whittet-Higgins .................................... 21

Encoder Products Company ..........86

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

jdempsey@wtwhmedia.com 216.387.1916

Michael Ference

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

FAULHABER MICROMO ...................IBC

The Robot Report

A Supplement to Design World - October 2020 www.designworldonline.com

CGI Inc. ....................................................... 61 Parvalux ..................................................... 65

FOLLOW US ON

CropHopper

robot takes novel approach to field monitoring page 62

INSIDE: • AI in agriculture: How PyTorch enables Blue River’s robots ............................................54

Follow the whole team on twitter @DesignWorld

• Augean Robotics mechanizes food production, from farm to table ......................66 • Building service network for 10,000 autonomous combines ...................................70

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